1、Recommended Practices for StudWelding ANSI/AWS C5.4-93 An American National Standard second printing, January 2010550 N.W. LeJeune Road, Miami, FL 33126 ANSI/AWS C5.4-93 An American National Standard Approved by the American National Standards Institute June 28, 1993 Recommended Practices for Stud W
2、elding 3rd Edition Supersedes ANSI/A WS C5.4-84 Prepared by the American Welding Society (AWS) C5 Committee on Arc Welding and Cutting Under the Direction of the AWS Technical Activities Committee Approved by the AWS Board of Directors Abstract These recommended practices for stud welding, prepared
3、by the Subcommittee on Stud Welding of the AWS Committee on Arc Welding and Cutting, are intended to serve as a basic guide for those interested in attaching fasteners by arc and capacitor discharge stud welding. The variations of the process, stud design, equipment, welding procedures, quality cont
4、rol, and safety precautions are discussed. The information presented will guide the designer and the shop in the utilization of studs in many fields including automotive manufacture, boiler and building construction, farm and industrial equipment, railroads and shipbuilding, aircraft and aerospace,
5、metal furniture, and other metal working industries.ii ANSI/AWS C5.4-93 International Standard Book Number: 0-87171-418-3 American Welding Society 550 N.W. LeJeune Road, Miami, FL 33126 1993 by American Welding SocietyAll rights reserved Printed in the United States of America Errata: 2nd Printing,
6、January 2010 Photocopy Rights. No portion of this standard may be reproduced, stored in a retrieval system, or transmitted in any form, including mechanical, photocopying, recording, or otherwise, without the prior written permission of the copyright owner. Authorization to photocopy items for inter
7、nal, personal, or educational classroom use only or the internal, personal, or educational classroom use only of specific clients is granted by the American Welding Society provided that the appropriate fee is paid to the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923, tel: (978)
8、750-8400; Internet: .iii ANSI/AWS C5.4-93 Statement on the Use of American Welding Society Standards All standards (codes, specifications, recommended practices, methods, classifications, and guides) of the American Welding Society (AWS) are voluntary consensus standards that have been developed in
9、accordance with the rules of the American National Standards Institute (ANSI). When AWS American National Standards are either incorporated in, or made part of, documents that are included in federal or state laws and regulations, or the regulations of other govern- mental bodies, their provisions c
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11、tract or other document that invokes the AWS standards. Where this contractual relationship exists, changes in or deviations from requirements of an AWS standard must be by agreement between the contracting parties. AWS American National Standards are developed through a consensus standards developm
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19、chnical requirements of this standard may only be obtained by sending a request, in writing, to the appropriate technical committee. Such requests should be addressed to the American Welding Society, Attention: Managing Director, Technical Services Division, 550 N.W. LeJeune Road, Miami, FL 33126. W
20、ith regard to technical inquiries made concerning AWS standards, oral opinions on AWS standards may be rendered. These opinions are offered solely as a convenience to users of this standard, and they do not constitute professional advice. Such opinions represent only the personal opinions of the par
21、ticular individuals giving them. These individuals do not speak on behalf of AWS, nor do these oral opinions constitute official or unofficial opinions or interpretations of AWS. In addition, oral opinions are informal and should not be used as a substitute for an official interpretation. This stand
22、ard is subject to revision at any time by the AWS C5 Committee on Arc Welding and Cutting. It must be reviewed every five years, and if not revised, it must be either reaffirmed or withdrawn. Comments (recommendations, additions, or deletions) and any pertinent data that may be of use in improving t
23、his standard are required and should be addressed to AWS Headquarters. Such comments will receive careful consideration by the AWS C5 Committee on Arc Welding and Cutting and the author of the comments will be informed of the Committees response to the comments. Guests are invited to attend all meet
24、ings of the AWS C5 Committee on Arc Welding and Cutting to express their comments verbally. Procedures for appeal of an adverse decision concerning all such comments are provided in the Rules of Operation of the Technical Activities Committee. A copy of these Rules can be obtained from the American
25、Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126.This page is intentionally blank. iv ANSI/AWS C5.4-93 ivv ANSI/AWS C5.4-93 Personnel *Advisor A WS Committee on Arc Welding and Cutting B. L. Shultz, Chairman The Taylor-Winfield Corporation L. R. Soisson, 1st Vice Chairman Welding Consultants
26、N. E. Larson, 2nd Vice Chairman Praxair, Incorporated W. A. Dierschow, Secretary American Welding Society D. R. Amos Westinghouse Turbine Plant J. W. Barton Hypertherm, Incorporated *E. R. Bohnart Miller Electric Manufacturing Company H. A. Chambers TRW Nelson Stud Welding Division C. Connelly Appli
27、ed Fusion Technology, Incorporated D. A. Fink The Lincoln Electric Company J. R. Hannahs PMI Food Equipment Group *R. T. Hemzacek Consultant G. K. Hicken Sandia National Laboratory J. E. Hinkel The Lincoln Electric Company D. B. Holliday Westinghouse Electric Corporation D. W. Meyer The ESAB Group E
28、. R. Pierre Liquid Air Corporation A WS Subcommittee on Stud Welding H. A. Chambers, Chairman TRW Nelson Stud Welding Division W. A. Dierschow, Secretary American Welding Society R. L. Alley American Welding Society J. Colella L-Tec Welding and Cutting Systems B. W. Folkening FMC Corporation J. C. J
29、enkins Consultant D. E. Kuehn TRW Nelson Stud Welding Division R. W. McClellan Ingalls Shipbuilding C. C. Pease C. P . Metallurgical *B. L. Shultz The Taylor-Winfield CorporationThis page is intentionally blank. vi ANSI/AWS C5.4-93 vivii ANSI/AWS C5.4-93 Foreword This foreword is not part of ANSI/AW
30、S C5.4-93, Recommended Practices for Stud Welding, but is included for informational purposes only. These recommended practices for stud welding are intended to serve as a basic guide for those interested in attaching fasteners by arc stud welding, including capacitor discharge methods. Arc stud wel
31、ding is an alternative method to other welding processes, as well as drilling and tapping through bolting, etc., and provides a one-sided method of attachment. The present document further expands the document published in 1984. Comments and suggestions for the improvement of this standard are welco
32、me. They should be sent to the Secretary, AWS C5 Committee on Arc Welding and Cutting, American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126. Errata ANSI/A WS C5.4-93, Recommended Practices for Stud Welding The following Errata have been identified and incorporated into the current reprin
33、t of this document. Page 3, Paragraph 1.2.1, change from “currency” to “current” in third sentence. Page 19, Table 8, last entry under Stud Base Diameter in inches, change “01.000” to “1.000”. Page 23, Table 10, under Shielding Gas Flow heading, “litre/min.” should read “liter/min.”. Page 23, Table
34、10, under Shielding Gas Flow, CFH heading, change “1” to “15”. Page 23, Table 10, under Shielding Gas Flow, liter/min. heading, change “57.1” to “7.1”.This page is intentionally blank. viii ANSI/AWS C5.4-93 viiiix ANSI/AWS C5.4-93 Table of Contents Page No. Personnel v Foreword.vii List of Tablesxi
35、List of Figuresxi 1. Process Description .1 1.1 Arc Stud Welding1 1.2 Capacitor Discharge Stud Welding.3 2. Selection of Method.4 2.1 Fastener Size .5 2.2 Base Metal Thickness .5 2.3 Base Metal Composition.5 2.4 Capacitor Discharge (CD) Method .5 3. Designing for Stud Welding6 3.1 Base Metal 6 3.2 S
36、tud Design Ratio .7 4. Considerations for Stud Selection7 4.1 Arc Stud Welding7 4.2 Capacitor Discharge Studs11 4.3 Stud Tensile and Torque Strengths12 5. Equipment for Stud Welding12 5.1 Arc Stud Welding Equipment .12 5.2 Capacitor Discharge Stud Welding Equipment 17 5.3 Automatic Feed Systems 17 6
37、. Stud Welding Low Carbon and Austenitic Stainless Steels.17 6.1 Base Metal Preparation.17 6.2 Welding Requirements18 6.3 Welding Technique for Steels .18 7. Stud Welding Aluminum Alloys.20 7.1 Base Metal Preparation.20 7.2 Shielding Gas20 7.3 Welding Requirements20 7.4 Welding Technique for Aluminu
38、m .20 8. Stud Locating Techniques.23 8.1 Locating with Templates.23 8.2 Locating with Spacers.23 8.3 Fixed Guns24 8.4 Methods of Ensuring Perpendicularity .24 8.5 Special Accessories.28 9. Quality Control and Inspection28 9.1 Steel Studs.28 9.2 Aluminum Studs .30x Page No. ANSI/AWS C5.4-93 10. Metho
39、d of Manufacture31 10.1 Cold Welds 31 10.2 Hot Welds31 10.3 Stud Hang-Up31 11. Safety Precautions .32 11.1 General 32 11.2 Electrical32 11.3 Fire Protection.32 11.4 Vision Protection .32 11.5 Hearing Protection.32 11.6 Protective Clothing32 11.7 Ventilation .33 11.8 Other33 11.9 Maintenance 33 11.10
40、 References .33 Annex A (Informative)Commonly Used Metric Conversions35 List of AWS Documents on Arc Welding and Cutting.37xi ANSI/AWS C5.4-93 List of Tables Table Page No. 1 Stud Welding Method Selection Chart .5 2 Typical Combinations of Base and Stud Metals for Stud Welding.6 3 Recommended Minimu
41、m Base Metal Thickness of Steel and Aluminum for Arc Stud Welding .8 4 Typical Length Reductions of Studs in Arc Stud Welding .9 5 Weld Flash Clearance for Arc Welded Full Base Studs12 6 Standard Arc Welding Studs Tensile/Torque Strengths.14 7 Approximate Tensile and Torque Strengths of Capacitor Di
42、scharge Welded Studs.15 8 Typical Stud Welding Conditions for Joining Low Carbon and Stainless Steel Studs to Similar Base Metals 19 9 Comparable Rectangular and Round Studs 21 10 Typical Welding Conditions for Arc Stud Welding of Aluminum Alloys23 11 Minimum Required Torque Valves and Tension Loads
43、 for Arc Stud Welding 31 List of Figures Figure Page No. 1A Equipment Setup for Arc Stud Welding of Steel 2 1B Power-Control Type Power Source Setup for Arc Stud Welding of Steel2 2 Steps in Arc Stud Welding3 3 Steps in Contact Capacitor Discharge Stud Welding4 4 Steps in Gap Capacitor Discharge Stu
44、d Welding4 5 Steps in Drawn-Arc Capacitor Discharge Stud Welding 4 6 Commonly Used Studs and Fastening Devices for Arc Stud Welding.8 7 Typical Stud Welds with Shrink Fissures in the Upper Portion of the Weld Flash 10 8 Stud Flash May be Accommodated by Use of Oversized Clearance Holes, Use of Gaske
45、t Material, and Use of a Dog or Hold-Down Clip.12 9 Commonly Used Studs for Capacitor Discharge Stud Welding .13 10 Oscillograph Traces of Current and V oltages in Arc Stud Welding .15 11 Arc Stud Welding Capacity for DC Power Sources .16 12 Effect of Cable Size and Length on Available Welding Curre
46、nt from a 2000A Power Source17 13 Portable Arc Stud Welding Equipment.18 14 Recommended Orientation for Welding Rectangular Studs to a Vertical Surface .19 15 Satisfactory and Unsatisfactory Arc Stud Welds 20 16 Arc Stud Weld with Proper Flash Indicative of a Good Weld 21 17 Examples of Satisfactory
47、 and Unsatisfactory Capacitor Discharge Stud Welds 22 18 Equipment Setup for Arc Stud Welding of Aluminum.22 19 Simple Template Used to Locate Studs Within 1/32 in. (0.8 mm).24 20 Simple Template for Capacitor Discharge Welds .24 21 Template with Hardened and Ground Bushing and Welding Gun Adaptor .
48、24 22 Locating with Spacer 25 23 Locating from Adjacent Studs 25 24 Locating from Nearby Surface and Previous Stud25xii Figure Page No. ANSI/AWS C5.4-93 25 Mounting Gun in a Fixed Position25 26 Bipod Foot Plate Assembly for 1/2 in. (12.7 mm) Diameter and Smaller Studs25 27 Bipod Foot for 1/2 in. (12
49、.7 mm) Diameter and Larger Shear Connector Studs25 28 Bipods for Unusual Surface Contours 26 29 Typical Ferrule Tube Extension Application 27 30 Typical Offset Assembly.27 31 Ferrule Foot Plate27 32 Typical Extension Assembly.28 33 Stud Hang-Up .28 34 Cold Weld .29 35 Hot Weld .29 36 Bend Test of Welded Studs to Determine Acceptable Welding Procedures.30 37 Method of Applying a Tensile Load to a Welded Stud Using Torque a Bolt Can Be Used for an Internal Thread .30ANSI/AWS C5.4-93 1 Recommended Practices for Stud WeldingANSI/AWS C5.4-93 2ANSI/AWS C5.4-93 3ANSI/AWS C5.4-93 4ANSI/AWS C5
