Abstract: Stud-welding device and procedure to mold a stud to a workpiece, adapted to weld studs with different dimensions, changing continuously, using an automatic stud-welding device, the device being mechanically fed studs in a stud holder, individually and in the correct position, and the stud holder being held by the stud-welding device, guided to the welding position, and the stud is welded to the workpiece, after which the stud-welding device returns the stud holder to the transfer position, in order to take on another stud and to achieve such several stud holders are assigned to the stud-welding device and alternatively connected to the stud-welding device in accordance with a selectable call-up program, so that a given stud-holder, equipped with a stud and connected to the stud-welding device, is separated from the stud-welding device after the weld has been performed thereon and the transfer position has been reached and held in that location, the operating sequence being controlled electrically or electroni

Abstract: A method and apparatus for improved percussive arc welding is disclosed. In this technique a test arc of a voltage no greater than the initiating voltage of the percussive arc welding is first applied across the pieces to be welded. The welding cycle is then performed if, and only if, an arc is detected responsive to the impressing of the test voltage.

Abstract: The disclosure concerns an electrical stud-welding device with a welding head and a stud holder fastened thereto in a detachable manner. The stud-welding device is of the type that can be regulated with respect to various welding parameters, such as charging voltage, capacitance, plunge velocity, weld current, weld time, and plunge damping and providing means for weld studs of different dimensions without the need to perform test welds, thus also allowing automatic change of the stud holder, by designing the stud holder as a data carrier for several specific, variable welding-parameters, and data-acquisition units which can be acted upon by the stud holder arranged on the stud-welding device and a central, device-specific data-processing unit associated with the stud-welding device, and provided for the acquired data, which unit sets the controlled variables in accordance with the data that were determined.

Abstract: Apparatus and methods for replacing or repairing missing or damaged abrasion resistant wearbars utilized in high velocity cyclone boilers. A retrofit wearbar having an aperture therein is utilized in conjunction with an end weldable stud wherein the wearbar and stud are placed in position over a damaged wearbar or against the boiler tube in the case of a missing wearbar and the stud end welding technique utilized to fuse the wearbar and stud in place with the damaged wearbar or boiler tube in the case of a missing wearbar in situ. An arc shield is utilized which has a projection from the weld fillet cavity thereof which cooperates in conjunction with the aperture of the retrofit wearbar to provide alignment of the stud in the wearbar and prevent shorting of the stud to the wearbar during the welding cycle.

Abstract: A stud arrangement on casehardened studded chains for motor vehicles, wherein the studs consist of a steel body which is permanently welded to a chain link and provided with a centrally disposed hard metal pin. The hard metal pin is inserted into the steel body such that it is covered on all sides by steel material of a thickness which at least corresponds to the casehardening penetration depth. In a method for producing such studded chains, an inwardly converging blind hole is cut out from one end of the steel body. The hard metal pin, of a shape corresponding to the conical hole, is forced into the hole, the pin being shorter than the blind hole so that a skirt is formed outside the pin. The edge of the skirt is beveled, and the steel body with the metal pin therein is joined to the chain by resistance welding in a machine for welding studs onto chain links, the body with the pin being moved gradually toward the chain link as the beveled edge melts and flows radially outwards.

Abstract: The present invention is directed to an improved method and apparatus for effecting spot welds between superimposed sheets of galvanized metal. In accordance with the method, one of the electrodes is comprised of a consumable tip component, preferably a steel ball, whereby predictable and repeatable welding conditions are effected at each welding cycle. The invention is further directed to a method of effecting spot welds between galvanized sheets which includes the step of interposing between a conductive carrier electrode and the metal surface a consumable metallic increment having reduced contact area adapted to engage the galvanized sheet, the consumable component being compatible with the ferrous subtrate beneath the galvanized layer.

Abstract: A stud welding device having a collet for holding a stud to be welded, is provided with a guide member which positions the stud on a stepped surface, as in the window frames of automobiles.

Abstract: A fastener is provided for securing an article to a support without making a hole in the support and wherein access can be gained to only one side of the support. The fastener is welded to the accessible surface of the support and the article is clamped to the support by setting the fastener with a blind-riveting tool.

Abstract: Method and apparatus for simultaneously welding by the stud end welding technique a stud having two or more ends. The stud includes at least one elongated relatively thin metallic projection from each end of the stud to be welded. The method and apparatus maintains a current density in a given projection sufficient to disintegrate only a portion of each projection with consequent arc initiation upon contact with the base metal such that the disintegration of a given projection will permit the remaining projections to contact the base metal causing a short to extinguish the one arc which has been initiated and consequent disintegration and arcing of the next tip to strike the workpiece which procedure proceeds randomly from tip to tip until the ends of the stud reach the molten metal pools.

Abstract: Method and apparatus for welding studs to a workpiece are provided. When studs are welded to workpieces using a draw-arc, stud-welding technique, a coating of smut is sometimes deposited on the workpiece around the welded end of the stud. This coating detracts from the appearance and if the workpiece is covered with coating material, such as paint, the smut must first be removed, requiring an extra operation. It has been found that the coating of smut will not be deposited, if, during the welding cycle, fluid is carefully deposited on the weld area around the end of the stud where the weld occurs. This fluid consists of a small volume of low pressure air and an anti-smut liquid.

Abstract: Mobile apparatus for, on site, welding of rail retaining clip studs to existing railroad rail plates which includes a railway car assembly having wheel and axle assemblies and propulsion means to move the railway car assembly along the railway tracks. The railway car assembly further includes two carriage assemblies each of which carries two welding gun assemblies which project downwardly upon each side of the rail plate. The carriage assembly includes carriage actuator means for moving the carriage assembly both longitudinally and transversely of the rail plate to position the welding gun assemblies. A position and sensing control means is provided which includes a rail plate sensor which first senses the position of a rail plate to stop the railway car assembly and properly position the welding gun assembies with respect to the rail plate longitudinally thereof.

Abstract: A method and apparatus for welding studs to a workpiece are provided. When the studs are welded to workpieces using a drawn-arc, stud welding technique, sometimes a coating of smut is deposited on the workpiece around the welded end of the stud. This coating detracts from the appearance of the stud and workpiece. Further, if the workpiece is to be covered with a coating material, the coating of smut must first be removed, resulting in an extra operation. It has been found that the coating of smut will not be deposited if, during the stud welding cycle, gas is directed toward the weld area in a swirling manner around the end of stud where the weld occurs.

Abstract: Both process and apparatus are disclosed for testing arc stud welding guns. The process and apparatus are premised on generating two electric signals, the first of which occurs as a result of a switching action at the beginning of a welding operation. The second occurs when the welding stud impacts it's counter-electrode. The elapsed time between these signals is measured and used as a basis to determine the effectiveness of the arc stud welding gun. Process and apparatus are both disclosed for testing during actual and simulated arc welding.

Abstract: Method and apparatus are provided for welding studs to a work surface wherein a substantially smut free surface is produced adjacent the weld. Apparatus is provided for depositing a thin coating of liquid in spray form onto the work surface adjacent the area whereon the stud is to be welded, prior to the welding operation. Contaminates formed in suspension in the liquid during the welding operation are removed by removal of the liquid suspension which is accomplished in a simple and inexpensive manner.

Abstract: A stud welding gun wherein air pressure is employed to feed a stud into a collet which holds the stud against a work piece is provided with a collet held in a guide bushing and having a plurality of openings at a position wherein air used to feed the stud is forced into a space between the collet and flash shield. The air serves to clean the flash shield and the guide bushing of contaminate material.

Abstract: A stud welding apparatus is provided wherein loading of the studs to the gun is automatically accomplished. The gun is capable of detecting stud supply as well as gun position to perform the welding operation in a reliable and efficient manner.

Abstract: A fastener is provided for securing an article to a support without making a hole in the support and wherein access can be gained to only one side of the support. The fastener is welded to the accessible surface of the support and the article is clamped to the support by setting the fastener with a blind-riveting tool.

Abstract: The disclosure relates to a tube with surface-enlarging elements attached to the inside thereof, which elements are in the form of radially inwardly directed pins welded on the tube wall. A method and apparatus for forming such a tube are also provided, the apparatus comprising a holder for each pin which is movable both longitudinally and radially of the tube.

Abstract: A percussion welder includes a single acting main cylinder having a ram extending through both ends of the cylinder mounting a spring loaded chuck on one end of the ram and an adjustable return spring on its other end.An automated version includes a hollow ram for the main cylinder through which a stud to be welded is blown from an escapement in a vibratory feeder bowl. The escapement has two spaced guide rails which receive the studs in a single column and a block which slides transversely across the end of the rails to pick off a single stud and move it into alignment with a gush of air which blows the stud head first through a tube to the hollow ram. A chuck having a stationary and a movable clamp is mounted on the opposite end of the ram. An actuator is disposed adjacent the chuck and opens the chuck to permit the stud to pass therethrough and at the same time places a platform beneath the chuck to prevent the stud from exiting the chuck more than a selected distance.

Abstract: A method of making thick-walled heat insulation modules by vacuum accreting ceramic fibers from an aqueous solution onto a mold and the product provided thereby. The dimensionally stable generally rigid modules have a thickness of 3"-8" and a density of 10-12 lbs. per cubic foot and are readily subdivided and/or tailored if desired for overlapping intermeshing assembly to provide a continuous lining for a high temperature chamber withstanding operating temperatures between 1600.degree. and 3,000.degree. F.

Abstract: An improved, relatively permanent operating head for stud welding guns is provided which eliminates the need of ferrule replacement after each welding sequence, thereby greatly speeding up and facilitating the welding operation, and lowering the cost thereof. The head includes an elongated, metallic, notched, dielectric-covered ferrule surrounding the usual stud-conveying chuck provided with the gun, along with air cooling apparatus for directing circumferentially spaced air currents through and exteriorly of the permanent ferrule to extend the life thereof and minimize buildup of slag thereon. In preferred forms, an inner, electrically insulating phenolic sleeve is disposed between the chuck and ferrule, and the work end of the latter is coated with an initial layer of tungsten carbide and an outer layer of tantalum for maximum heat resistance and electrical insulation.

Abstract: A fastener is provided for securing an article to a support without making a hole in the support and wherein access can be gained to only one side of the support. The fastener is welded to the accessible surface of the support and the article is clamped to the support by setting the fastener with a blind-riveting tool.

Abstract: A self-contained, portable, underwater stud welder includes a hand-held welding gun and a battery powered backpack. The welder uses a bank of rechargeable nickel-cadmium batteries which charges a storage inductor, the energy of the inductor being transferred to a bank of capacitors, providing a high efficiency method of charging the capacitor bank so the battery bank is kept small.

Abstract: Apparatus is provided for welding studs to workpieces. The invention is particularly concerned with welding studs to workpieces made of materials having relatively low electrical resistance but covered with layers of other materials having higher electrical resistance, a common example being metal workpieces having painted surfaces. In order for the stud to make effective electrical contact with the workpiece at the beginning of the welding cycle, the paint must be eliminated; in accordance with the invention, this is accomplished by rotating the stud which effectively removes the portion of the paint in contact with the stud. Electrical contact can then be established between the stud and the workpiece to enable the welding cycle to be initiated.

Abstract: An arc welding device is provided, which device is employed for the attachment of studs to a work surface. The device embodying the subject invention allows the operator to weld a stud on an area of a workpiece which has heretofore been inaccessible to prior art welding guns, of the type in common use. The aforesaid is generally accomplished by arrangement of the stud gripping collet relative to the operating elements of the device such that with the stud positioned normal to a work surface, the operating elements are off-set laterally from the stud.

Abstract: A weldable fastener for supporting insulation adjacent to a surface and apparatus for welding the fastener are provided. The insulation fastener is specifically designed for applying insulating material to the outer surface of a wall of a cryogenic container, which walls are commonly made of aluminum. The fastener includes, in the preferred form, an aluminum stud having a weldable end and a recess at the opposite end. A strong plastic-glass fiber rod, which is preferably made by a pultrusion process, is affixed in the recess of the stud and extends outwardly therefrom, coaxially with the stud. After the insulation is placed over the rod and stud and against the surface, a suitable clip or washer is applied over the end of the rod to hold the insulation in place. The apparatus for welding the stud to the surface includes a stud welding tool which operates by a known end-welding technique. The tool has a chuck leg terminating in an offset member holding a chuck at one side of the tool.

Abstract: The apparatus for the automatic introduction of the members to the electrode of a resistance welding machine comprises an arm mounted on the machine frame so as to pivot about a horizontal pin located at the intersection of the horizontal hollow electrode axis and the vertical of the end of the slide for supplying the members to be welded, at least one jack for controlling the rotation of said arm, a finger mounted at the end of the arm so as to slide radially and coupled to at least one control jack integral with the arm, and a gripper mounted at the end of said finger and having two jaws which move under the action of at least one jack.A particular application of the invention is to the fitting of studs to heat exchanger tubes.

Abstract: A stud welding gun having means for automatically feeding studs to the barrel of the gun is provided with a stud receiver which facilitates removal of jammed studs from the device.

Abstract: Apparatus is provided for measuring and indicating the length of time a welding arc exists in a stud welding cycle utilizing a capacitive power source. Heretofore, the arc time of stud welding apparatus employing capacitors for the power source has only been measured in the laboratory with an oscilloscope. The new indicating and measuring apparatus for the arc time is usable with conventional stud welding, contact stud welding, and gap stud welding employing capacitive power sources. The apparatus produces a number on a visual indicator in the form of a meter or a digital read-out device and the operator can note the number when the ultimate weld is produced. The operator can then subsequently adjust the equipment to repeat that number on the indicator to always be assured of optimum weld quality without the necessity of repeating a number of test welds.

Abstract: A part structure adapted for attachment to a metal base by welding, particularly an ornament for attachment to an automobile body. The part structure or ornament is a metallic, electrically conductive member and has at least one weld stud affixed thereto. A resilient seal surrounds the weld stud and effects a seal around the weld stud and the weld produced thereby during welding.

Abstract: Apparatus for welding studs to workpieces by a drawn-arc welding technique is provided. The apparatus includes a stud welding tool having a plunge dampener mounted on the rear end thereof for dampening the plunge stroke of the stud during the welding cycle. The plunge dampener includes a rolling diaphragm which reduces friction. The plunge dampener also incorporates both vacuum and pressure for dampening the plunge stroke of the stud.

Abstract: A clinch weld fastener and method of using the same to effect attachment of a non-ferrous panel, such as an aluminum panel, to a ferrous panel, such as a steel panel. The clinch weld fastener is in the form of a clinch nut blank, preferably of the self-piercing type, with weld projections extending from one end thereof. To effect assembly of the two panels together, the clinch weld fastener is first clinched to the aluminum panel with the weld projections extending outward from one surface thereof and then after placing the aluminum panel with the weld projections in abutment against the steel panel, projection welding the clinch weld fastener to the steel panel thereby securing the aluminum panel to the steel panel.

Abstract: A ferrule for use in end welding a stud to a workpiece and a method of welding with the ferrule are set forth. In end welding a stud to a workpiece, the stud is first placed with an end against the workpiece and is then retracted as a low current pilot arc is formed between the stud and the workpiece. A main high current weld arc is then superimposed between the stud and the workpiece. This arc causes portions of the stud and the workpiece to be molten and the stud is then plunged forward to engage the workpiece. The molten portions join and solidify to securely weld the stud to the workpiece when they return to full contact. Some of the molten metal tends to flow outwardly as the stud strikes the workpiece to establish a fillet between the stud and the workpiece. This fillet under normal conditions is substantially uniformly formed with the aid of a ferrule located around the end of the stud to help control the flow of molten metal and to reduce splatter of the metal.

Abstract: An electronic control unit is disclosed for a stud welding device having a movable electrode mounted on a solenoid armature, for moving the electrode away from the workpiece. The control includes a timing circuit providing a plurality of timer outputs in accordance with the preselected time intervals. A pilot arc circuit and an electrode movement circuit connected to the solenoid are activated by a timer output for establishing a pilot arc between the electrode and the workpiece and for moving the electrode from the workpiece. A welding power circuit is activated by another one of the plurality of timer outputs to establish welding current between the electrode and the workpiece. The electrode movement circuit is deactivated by another one of the plurality of timer outputs to enable the electrode to contact the workpiece by the urging of a spring. Means are provided for terminating the welding current. The control is suitable for use in a direct current welding power circuit.

Abstract: Relates to a method of and apparatus for electric welding through insulation coatings, such as paint, on metallic surfaces by directing a vapor jet of paint solvent upon a selected area of a painted metal surface to first soften and then vaporblast the softened paint away from the area to expose a bare spot of the metal surface for welding. Then, before the softened paint reflows back over the bare spot as a result of the discontinuance of the vapor jet, quickly bringing a metal part into welding range of the bare spot and welding the two metal parts together. Following the welding operation, the softened paint coating reflows over the exposed welded juncture and hardens to form a protective film thereover.

Abstract: A weldable fastener for supporting insulation adjacent to a surface and apparatus for welding the fastener are provided. The insulation fastener is specifically designed for applying insulating material to the outer surface of a wall of a cryogenic container, which walls are commonly made of aluminum. The fastener includes, in the preferred form, an aluminum stud having a weldable end and a recess at the opposite end. A strong plastic-glass fiber rod, which is preferably made by a pultrusion process, is affixed in the recess of the stud and extends outwardly therefrom, coaxially with the stud. After the insulation is placed over the rod and stud and against the surface, a suitable clip or washer is applied over the end of the rod to hold the insulation in place. The apparatus for welding the stud to the surface includes a stud welding tool which operates by a known end-welding technique. The tool has a chuck leg terminating in an offset member holding a chuck at one side of the tool.

Abstract: A method and apparatus for welding studs to workpieces are provided. The invention is particularly concerned with welding studs to workpieces made of materials having relatively low electrical resistance but covered with layers of other materials having higher electrical resistance, a common example being metal workpieces having painted surfaces. In order for the stud to make effective electrical contact with the workpiece at the beginning of the welding cycle, the paint must be eliminated; in accordance with the invention, this is accomplished by rotating the stud which effectively removes the portion of the paint in contact with the stud. Electrical contact can then be established between the stud and the workpiece to enable the welding cycle to be initiated.

Abstract: In a bolt welding gun, a tubular bolt holder is positioned on the front end of the gun body and is threadedly connected to the tubular front part of a slide-in unit. The position of the bold holder is axially displaceable relative to the front part. A nut is threaded onto the bolt holder for fixing the position of the holder with relation to the front part. In addition, a base ring is mounted on the front end of the gun body and supporting legs for the gun extend outwardly from the ring. The base ring is coaxial with the nut and has a recess into which the nut fits for preventing its rotation. A releaseable lock within the gun body is engageable with the base ring and prevents its rotation and, as a result, the ring holds the nut against axial displacement for securing the position of the bolt holder relative to the tubular front part.

Abstract: Apparatus for indicating the time and welding current of a welding cycle is provided, along with means for monitoring the welding current and for preventing further welding cycles if the current is outside certain preset limits. The invention is used with stud welding apparatus in which a stud is placed against a workpiece, then withdrawn, and at the same time a pilot arc is formed; subsequently, a main welding arc is established which forms pools of molten metal on the stud and on the workpiece, the metal solidifying when the stud is subsequently plunged against the workpiece, thereby completing the weld. The length of time of the welding cycle and the welding current flowing during the existence of the main welding arc have, of course, heretofore been measured under laboratory conditions. However, such has not been accomplished under field conditions with commercial stud welding apparatus and particularly where such is accomplished by measuring both the welding time and welding current on a single meter.

Abstract: A plurality of individual pre-shaped cores or pins are initially positioned in a prearranged orientation upon an outlet surface of a die body by means of a plate of photosensitive glass or glass-ceramic material which has been etched to form a mask with the desired pattern or arrangement of openings for orienting said cores or pins upon said die surface for subsequent securement thereto such as by welding.

Abstract: A welding terminal operable to arc weld to a work piece a stud thereafter drive an element prethreaded to the stud. In one embodiment, the welding terminal may be adapted to cooperate with a guide to facilitate engagement with the prethreaded element, and in another embodiment, the welding terminal may have fluting or ribs to grippingly engage a portion of the prethreaded element. The duration of the arc weld and the sequencing of the welding and driving functions both may be automatically controlled. The normal force imposed on the fixed stud portion and the torque imposed on the movable threaded portion may be substantially automatically limited.

Abstract: Controls for use in end welding a stud to a workpiece by a drawn-arc technique are set forth. In welding a stud to a workpiece, an end of the stud is placed against the workpiece and is then retracted as a pilot arc is established between the stud and the workpiece. A welding arc is then superimposed on the pilot arc which causes portions of the stud and the workpiece to become molten. These portions join and solidify to securely weld the stud to the workpiece when the stud is plunged back to engage the workpiece. The controls include a timer dial on a control panel of the welding apparatus for setting the length of time of the welding arc, and a current dial on the control panel to set the current of the welding arc. Particularly for the control of the current, a unique circuit enables a desired current to be maintained even though the line voltage and the length of the welding cable vary over a wide range.

Abstract: An automatic device for feeding and welding T-profile button studs to a surface is provided with a collet for retaining and aligning an individual stud in place adjacent a workpiece. The collet is formed of relatively thin sheet metal and is effective to properly orient the fastener relative to the workpiece surface while minimizing the occurence or arcing in the area between the collet and the arc shield.

Abstract: The welding of studs by a drop technique is provided, including provisions for the rapid feeding of the studs to a chuck. In this type of welding, a stud is held a predetermined distance above a workpiece with an electrical potential established therebetween. The stud is held in a chuck which, in turn, is carried by a ram. The stud, the chuck, and the ram are allowed to drop the predetermined distance to the workpiece, at which time the stud becomes fused thereto. Weights are often applied to the ram and the distance of the stud above the workpiece can be varied to achieve a proper weld for a particular workpiece. Means are provided to rapidly supply studs to the chuck and include a chuck leg forming a loading passage and carrying the chuck at an end thereof. A feed passage communicates with the side of the loading passage and feeds studs thereinto from a remote supply source. A back-up plunger is affixed directly to the ram and extends into the loading passage of the chuck leg.

Abstract: A welding tool is set forth for end welding studs to workpieces. The tool is primarily designed to end weld small studs having precisely-formed tips. The stud is held by a chuck connected to a chuck leg with an electrical coil holding the chuck leg in a retracted position prior to welding. When the coil is deenergized, a plunge spring plunges the chuck leg, the chuck, and the stud back toward the workpiece. With a high voltage imposed between the stud and the workpiece, the stud tip vaporizes when reaching the workpiece and adjacent portions of the stud and workpiece melt to securely weld the stud. To initially move the chuck and chuck leg to the retracted position, a retraction mechanism is provided. This includes a lever pivotally mounted at the front of the tool and engagable with a portion of the chuck leg to retract the chuck leg when the lever is manipulated by an operator. This reduces the retraction effort to increase the rate of welding and to reduce operator fatigue.

Abstract: A head assembly for electrically welding a stud to a metallic substrate. outer portion of the head is formed of a highly conductive material such as copper, and has a bore therewithin which terminates in a conical surface for engaging the underside of the head of a stud to be welded. Disposed within the bore is a nickel sleeve for retaining the shank of the stud, and a magnet for holding the stud in place. In a preferred embodiment the magnet is spring-loaded and coupled to a microswitch which actuates a control mechanism.

Abstract: A welding head is provided having a bore substantially larger than the sh of a rivet to be welded, and having a conical aperture for receiving the stud head. A copper-free sheath is disposed in the bore for receiving and locating the stud shank. In a preferred embodiment an associated magnet and switch are disposed within the welding head. When the stud-bearing head is brought into firm contact with a substrate current flows through the head, welding it to the substrate. The increased pressure upon the stud urges the magnet inwardly, operating the switch to control the equipment which locates the welding head.

Abstract: In combination with conventional apparatus for joining members of aluminum or other electrically conducting material by resistance welding, adjustable supports for arranging the work-contacting electrodes in spaced proximity to the work, and circuitry for inducing an inert gas shielded arc of alternating current across each electrode and the work, the apparatus being operable to effect self-cleaning of the electrodes as well as the work between successive welding operations.

Abstract: A conventional stud-welding gun has been modified to allow it to be used for welding under water. The stud is contained within a water-tight enclosure formed at the end of the gun by pressing the seal at the end against the object to which the stud is to be welded. A water pump evacuates the enclosure and a stream of inert gas is provided to expel water and dry the region where the weld is to occur.

Abstract: In the machine disclosed, two flexible welding cables carry capacitor discharge current from a capacitor bank in a capacitor charging welding set and produce a movable electrical connection between a welding gun and a base material onto which a welding element is to be welded. Both welding cables are fixed with respect to one another. According to one embodiment of the invention the cables are arranged to be equidistant from one another substantially over their entire length. They are arranged as close as possible to each other within the breakdown limits of the insulation. The cables are of a predetermined length.