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Capacitor discharge stud welding is a fast and efficient process that melts the base of the stud and the surface or material to which you are welding the stud. As soon as both of these metals melt, the welding gun pushes the stud into the surface. Then, the molten metal quickly solidifies, and it creates a permanent bond. This process takes milliseconds to complete, which is why it requires great accuracy.
Here are some essential tips to keep in mind the next time you are doing some capacitor discharge stud welding:
1. Clean the welding surface.
If there is debris, dust or dirt on the welding surface, it can disrupt the connection between the two metals. Before you start welding, make sure to clean the welding surface. If it has oily residue, remove it using a bit of dish soap dissolved in water, and dry it thoroughly.
If it has paint or other stubborn residue, use sandpaper to clean the surface before you start welding.
2. Don't use a center punch to mark the welding spot.
A center punch tool can sometimes create a helpful guide when you are putting something together, but if you are welding with the discharge capacitor method, the hole or depression created by a center punch tool can actually make your weld less effective.
When you utilize capacitor discharge welding methods, your welding gun automatically determines the arc of electricity it produces based on the distance between the stud and the base material. Ideally, while you are welding, your ignition tip should be flush with your base material, but unfortunately, if you've used a center punch tool to mark your spot, the depression will prevent your welding gun from obtaining a flush position, and as a result, it won't create the right size of arc.
With the arc out of balance, your metals may not melt thoroughly, and as a result, they won't weld together as firmly.
3. Ground yourself before using the welding tool.
Before you start welding, make sure that you are grounded. If you fail to ground your welding gun, you could electrocute yourself. Even if you don't hurt yourself, if your welding gun isn't properly grounded, some of the electricity may be lost, and without ample amounts of electricity at the weld base, your weld won't have the heat it needs.
To prevent both of these scenarios, ensure you ground your equipment properly. You can ground the clamp from your welding equipment directly to your work surface. Just make sure that the grip is firm.
4. Adjust the spring pressure.
After the discharged current melts the metal of the base material and the stud, it pushes the stud into the base material. Your welding gun relies on spring pressure to perform this task, and you need different levels of spring pressure for different types of studs and base materials.
Before you start welding, make sure that you have the spring tension on your welding gun adjusted properly. In most cases, the larger the diameter of your stud, the more pressure you need.
5. Set your voltage carefully.
On most discharge capacitors, you have a voltage knob that allows you to adjust the amount of voltage released from the welding gun. Ideally, you should adjust your voltage each time that you use your discharge capacitor welder. However, the setting varies based on the diameter of your stud but also depending on the type of metal you are using. Your discharge capacitor welding tool should have the recommended voltages in its instruction manual.
For more tips on using discharge capacitor welding methods, contact a welding supply shop or specialist or visit websites such as http://www.norfas.com.