With new technology and stud weld systems that require limited configuration and adjustments by operators, stud welding for bridge decks and with composite construction on buildings is a relatively trouble-free job.
However, there are some issues that can occur even for experienced operators. These common issues, as well as how to correct issues with welding a shear connector may be as simple as an adjustment of the equipment.
Old Equipment
While every business wants to use equipment as long as possible, when it comes to drawn arc welding, the equipment can often take a substantial beating. This is more likely to occur if the equipment is used by a lot of different employees, some who may not be as careful with the equipment both when in use and when storing and transporting the welder.
Old equipment may simply be failing. This can result in the lift mechanism not working properly, lifting too soon or staying down too long. Issues with the stud plunging too fast can also cause a splash of the molten pool, resulting in a poor-quality weld.
Poor Surfaces
While generally using drawn arc stud welding and the right type of shear connector will provide a durable, reliable and complete weld, issues with the condition of the surface material can be of concern.
This is particularly true if the beam or metal component or plate has extensive rust or flaking on the surface. This damaged surface will result in greater variability in the weld. In turn, this will reduce the weld quality, potentially providing a less durable hold.
It is as possible to use the wrong shear connector with the base workpiece. It is possible to find these connectors made of stainless steel or mild steel, with the option to have custom alloys used as well depending on the application.