Keystone Better Mann Catalog

BETTERMANNOBOSTUD WELDING PRODUCTSFASTENING TECHNOLOGIES, INC

K E Y S T O N EK E Y S T O N EK E Y S T O N EK E Y S T O N EK E Y S T O N E

SHORT CYCLECAPACITOR DISCHARGE

DRAWN ARC WELD STUDSPRODUCTION EQUIPMENT

PORTABLE EQUIPMENT

STUD WELDING ACCESSORIES

SHORT CYCLECAPACITOR DISCHARGE

DRAWN ARC WELD STUDSPRODUCTION EQUIPMENT

PORTABLE EQUIPMENT

STUD WELDING ACCESSORIES

Stud Welding TechnologySystems • Studs • Application Engineering

CAPACITOR DISCHARGEThe Process

CAPACITOR DISCHARGE STUD WELDING

Capacitor Discharge (CD) stud welding is an extremely efficient method of welding fasteners to awide variety of metals like mild steel, stainless steel, aluminum, brass, copper, titanium, etc. Theprocess utilizes a powerful bank of capacitors to store energy at a specific voltage determined bystud size and material. When a weld is initiated, this energy is “discharged” through a special“ignition tip” at the base of the stud, creating an instantaneous arc which melts both the base ofthe stud and the adjoining surface on the workpiece. At the same time, the welding gun forcesthe stud into the workpiece, resulting in a permanent bond as the molten material solidifies……..allin 0.004 seconds!

Capacitor Discharge stud welding eliminates drilling, tapping, punching, riveting, gluing, andscrewing, and is especially beneficial when working with thin gauge materials due to theabsence of reverse-side marring or discoloration. This process is suitable for studs ranging insize from #4-40 (M3) thru 3/8-16 (M10).

Several standard handgun models are available from stock to accommodate routine applica-tions, while automated production systems are available on a custom-designed basis for high-volume applications.

Additionally, a complete range of standard US and Metric studs is readily available from stock inmild steel, stainless steel, and aluminum, while non-standard stud designs and alloys are avail-able upon request.



DRAWN ARC & SHORT CYCLEThe Process

DRAWN-ARC STUD WELDING

Drawn-arc stud welding is an extremely efficient method of attaching fasteners primarily to mildsteel and stainless steel by utilizing a constant-current DC power supply, typically a 3-phasetransformer-rectifier, equipped with integral controls to operate a special drawn-arc stud weldinggun. When a weld is initiated, current begins to flow through the stud while the weld gunsimultaneously lifts the stud to “draw an arc”, which melts the base of the stud and adjoiningsurface on the workpiece. Upon completion of the weld time, the gun plunges the stud back tothe workpiece, resulting in a permanent bond as the molten material solidifies…….all in less thanone second.

In general, the drawn-arc process is capable of welding a broad range of stud diameters (up thru1-¼” or 32 mm) and to almost any material thickness above 0.040” (1 mm). To accommodatesuch a broad range, the process is actually split into two categories:Standard Drawn-Arc and Short-Cycle.

Standard drawn-arc is used with studs ¼” (6 mm) diameter and larger, and base material thick-nesses at least 1/3 the stud diameter. This process requires the use of flux-loaded studs andceramic ferrules, included with the studs, to contain the molten material during the weld and forma fillet around the stud base.

Short-cycle is an abbreviated version of drawn-arc for studs 3/8” (10 mm) and smaller, especiallywhen welding to base materials as thin as 1/5 the stud diameter. With this method, the weldcurrent is usually much higher and weld time much shorter (short-cycle), resulting in lighterpenetration and less molten material, thereby eliminating the need for ceramic ferrules and flux-loaded studs, though shielding gas is often recommended.

Several standard handgun models are available from stock to accommodate routine applica-tions, while automated production systems are available on a custom-designed basis for high-volume applications.

Additionally, a complete range of standard US and Metric studs is readily available from stock inmild steel and stainless steel, while non-standard stud designs and alloys are available uponrequest.

Welding Range: 4-40 thru 3/8-16(M2.5 thru M10)

Weld Rate: Up to 30 Studs/min.Recommended Materials: Mild Steel, Stainless Steel,

& Aluminum (thru 1/4-20)Dimensions: 7-1/2” x 11-3/8” x 17”

(19.2 x 22.8 x 43) CMWeight: 26 lbs. (12 kg)Input Power: 110 thru 230 VAC

50 thru 100 HzOutput Power: 40 thru 200 VDC, SteplessCapacitance: 110,000 Mfd.Weld Gun: TSK 310 with 15 ft. cable

TS/BS 308 SYSTEM TS/BS 318 SYSTEM

Welding Range: 4-40 thru 5/16-18(M2.5 thru M8)

Weld Rate: Up to 30 Studs/min.Recommended Materials: Mild Steel, Stainless Steel,

& Aluminum (thru 1/4-20)Dimensions: 7-1/2” x 11-3/8” x 17”

(19.2 x 22.8 x 43) CMWeight: 22 lbs. (10 kg)Input Power: 110 thru 230 VAC

50 thru 100 HzOutput Power: 40 thru 200 VDC, SteplessCapacitance: 66,000 Mfd.Weld Gun: TSK 310 with 15 ft. cable

ANALOGTS 308/318 CD Stud Welder

CAPACITOR DISCHARGEEquipment

Stud Welding Systems Include: Twin “Quick Adjust” Ground Clamps

& Precision Handgun

Tri-Pod Foot Twin Leg FootpieceTemplate Adapter

DIGITALBS 308/318 CD Stud Welder



CAPACITOR DISCHARGEWeld Chucks & Accessories

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CAPACITOR DISCHARGEWeld Studs (UNC & UNF)

Flanged CD Weld Studs

Non-Flanged CD Weld Studs

Note: Other sizes, lengths, no-thread pins, and materials are available upon request. Contact Nationwide Sales at 800-659-5972.

Technical SpecificationsFlanged CD Weld Studs

Technical SpecificationsNon-Flanged CD Weld Studs

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Technical SpecificationsMetric Flanged CD Weld Studs

Metric Flanged CD Weld Studs

CAPACITOR DISCHARGEWeld Studs (Metric) PRODUCTION EQUIPMENT

High volume stud welding with a portable system can be monotonousand time consuming where quality and accuracy is sometimessacrificed due to operator fatigue.

All production stud welding systems are designed to save time andmoney producing consistent weld quality, repeatable locationalaccuracy at a fraction of the time. From a small Table-Top System toa fully integrated CNC controllable system, our technical sales staffcan configure a system to suit your requirements.

The SIK-2 Stud Welding Head can be mounted in almost any positionutilizing drop load or an ABZ Stud Feeding System at a welding rate ofup to 50 stud/min. All sys-tems utilize our standard, offthe shelf components, withspare parts readily availableminimizing any downtime.

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Stud Welding Systems Include: “Quick Adjust” Ground Clamp

Precision Handgun

Welding Range: 4-40 thru 1/2-13(M3 thru M14)

Weld Rate: Up to 15 Studs/min.Recommended Materials: Mild Steel & Stainless SteelDimensions: 25-1/2” x 12” x 18”

(65 x 30 x 45) CMWeight: 151 lbs. (69 kg)Input Power: 208/230/460 VAC

Three-Phase 50/60 HzFusing: 50/50/35 ampsOutput Power: 100 thru 900 VDC, SteplessWeld Gun: HP 312 with 25 ft. cable

Welding Range: 4-40 thru 3/8-16(M3 thru M12)

Weld Rate: Up to 15 Studs/min.Recommended Materials: Mild Steel & Stainless SteelDimensions: 25-1/2” x 12” x 18”

(65 x 30 x 45) CMWeight: 105 lbs. (48 kg)Input Power: 208/230/460 VAC

Three-Phase 50/60 HzFusing: 50/25/15 ampsOutput Power: 100 thru 600 VDC, SteplessWeld Gun: HP 312 with 25 ft. cable

DRAWN ARC/SHORT CYCLEThe Process/Equipment

DS 312 Specifications

DS 312

HP 312

DS 310

DS 310 Specifications



DRAWN ARCWeld Studs & Equipment Accessories

Ferrule Grips

Foot Pieces

Weld ChucksShort Cycle Only

Short Cycle Only

Note: All stud lengths are before weld. Typical burn off of 1/8” on studs up to 1/2 Dia. and 3/16” burn off on studs 5/8 Dia. and above. Other sizes are available upon request. Contact Nationwide Sales at 800-659-5972.

Collar Studs

Full Thread Welded

Partial Thread WeldedPartial Thread

Ferrules

Collar Stud WeldedCollar Stud

Full Thread

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KEYSTONE FASTENING TECHNOLOGIES, INC409 PARKWAY VIEW DRIVE • PITTSBURGH, PA 15205

Ph. 800-659-5972 • Ph. 412-787-5970 • Fax. 412-788-6627

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CNC Custom Production EquipmentSPM Manual Support ColumnTS310 or HP312 Weld Gun Sold Separately

Keystone Better Mann Catalog

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Transcript of Keystone Better Mann Catalog