ArcStudWelding.pdf
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384 KB
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Pobierz
003 338C
2012−01
Arc Stud
Welding
Fundamentals
Visit our website at
www.MillerWelds.com
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
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1
1-1.
Symbol Usage
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1
1-2.
Arc Welding Hazards
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1
1-3.
Additional Symbols For Installation, Operation, And Maintenance
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3
1-4.
California Proposition 65 Warnings
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3
1-5.
Principal Safety Standards
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4
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SECTION 2 − ARC STUD WELDING (SW) GUIDELINES
1-6.
EMF Information
4
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5
2-1.
Process Description
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5
2-2.
Typical Uses Of The Arc Stud Welding Process
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5
2-3.
Equipment
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5
2-4.
Arc Stud Welding System
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6
2-5.
Power Source
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6
2-6.
Stud Welding Controls
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6
2-7.
Volt/Ampere Curve - Constant Current (CC) Power Source
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7
2-8.
Duty Cycle - Power Source For Constant Current (CC) Welding
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7
2-9.
................................................................
2-10. Pistol Grip Stud Gun Components
Arc Stud Welding Guns
8
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8
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SECTION 3 − STUD WELDING PROCESS
2-11. Selecting Cable Length and Size
9
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10
3-1.
Stud Welding Sequence
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10
3-2.
Recommended Procedures And Techniques
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10
3-3.
The Welding Stud
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11
3-4.
Arc Shields (Ferrules)
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11
3-5.
Different Types of Weld Studs And Ceramic Ferrules
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11
3-6.
Stud Specification Chart
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12
3-7.
Recommended Settings For Stud Welding Of Steel
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12
SECTION 4 − WELD INSPECTION/TROUBLESHOOTING
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13
4-1.
Inspecting Welded Studs
...............................................................
13
4-2.
Performing AWS Bend Test
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14
4-3.
Performing AWS Torque Test
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15
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2011−10
7
Protect yourself and others from injury —
read, follow, and save these important safety precautions and operating instructions.
1-1.
Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex-
plained in the text.
NOTICE
− Indicates statements not related to personal injury.
Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
bols and related instructions below for necessary actions to avoid the
hazards.
1-2.
Arc Welding Hazards
Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section
1-5
. Read and
follow all Safety Standards.
When making input connections, attach proper grounding conduc-
tor first − double-check connections.
Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Only qualified persons should install, operate, maintain, and
repair this unit.
Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
Turn off all equipment when not in use.
During operation, keep everybody, especially children, away.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
ELECTRIC SHOCK can kill.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Do not touch electrode holders connected to two welding ma-
chines at the same time since double open-circuit voltage will be
present.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Do not touch live electrical parts.
Wear a safety harness if working above floor level.
Wear dry, hole-free insulating gloves and body protection.
Keep all panels and covers securely in place.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on
unit.
Additional safety precautions are required when any of the follow-
ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoid-
able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt-
age. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
SIGNIFICANT DC VOLTAGE exists in inverter weld-
ing power sources AFTER removal of input power.
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
HOT PARTS can burn.
Do not touch hot parts bare handed.
Allow cooling period before working on equip-
ment.
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
Properly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
Page 1
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
FUMES AND GASES can be hazardous.
Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
Keep your head out of the fumes. Do not breathe the fumes.
After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
Use only correct fuses or circuit breakers. Do not oversize or by-
pass them.
If ventilation is poor, wear an approved air-supplied respirator.
Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watch-
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath-
ing air is safe.
FLYING METAL or DIRT can injure eyes.
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Do not weld in locations near degreasing, cleaning, or spraying op-
erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
Wear approved safety glasses with side
shields even under your welding helmet.
Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
BUILDUP OF GAS can injure or kill.
Shut off compressed gas supply when not in use.
Always ventilate confined spaces or use
approved air-supplied respirator.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).
Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
Wear approved safety glasses with side shields under your
helmet.
Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
NOISE can damage hearing.
Wear protective clothing made from durable, flame-resistant
material (leather, heavy cotton, or wool) and foot protection.
Noise from some processes or equipment can
damage hearing.
WELDING can cause fire or explosion.
Wear approved ear protection if noise level is
high.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
CYLINDERS can explode if damaged.
Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, physical damage, slag, open flames, sparks, and arcs.
Do not weld where flying sparks can strike flammable material.
Protect yourself and others from flying sparks and hot metal.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
Keep cylinders away from any welding or other electrical circuits.
Watch for fire, and keep a fire extinguisher nearby.
Never drape a welding torch over a gas cylinder.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder − explosion will result.
Do not weld on containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).
Use only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
and associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Do not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
Use the right equipment, correct procedures, and sufficient num-
ber of persons to lift and move cylinders.
Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
Do not use welder to thaw frozen pipes.
Page 2
1-3.
Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
BATTERY EXPLOSION can injure.
Do not install or place unit on, over, or near
combustible surfaces.
Do not use welder to charge batteries or jump
start vehicles unless it has a battery charging
feature designed for this purpose.
Do not install unit near flammables.
Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
MOVING PARTS can injure.
Keep away from moving parts such as fans.
FALLING EQUIPMENT can injure.
Keep all doors, panels, covers, and guards
closed and securely in place.
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
Use equipment of adequate capacity to lift and
support unit.
Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
READ INSTRUCTIONS.
Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manu-
ally lifting heavy parts or equipment.
Use only genuine replacement parts from the manufacturer.
OVERUSE can cause OVERHEATING
Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
H.F. RADIATION can cause interference.
Do not block or filter airflow to unit.
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
FLYING SPARKS can injure.
Have only qualified persons familiar with
electronic equipment perform this installation.
Wear a face shield to protect eyes and face.
Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
Sparks can cause fires — keep flammables away.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
STATIC (ESD) can damage PC boards.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
MOVING PARTS can injure.
Keep away from moving parts.
Be sure all equipment in the welding area is
electromagnetically compatible.
Keep away from pinch points such as drive
rolls.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
WELDING WIRE can injure.
Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
Do not press gun trigger until instructed to do
so.
Be sure this welding machine is installed and grounded
according to this manual.
Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
Page 3
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