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13 Checking the Quality of the Weld
You don’t need to test all studs.
It is sufcient to carry out stud tests on several production samples that are
picked at random.
Bending Test
Type of fracture Possible cause Corrective actions
Base material buckling Correct parameters none
Fracture in welding element above
ange
Correct parameters none
Fracture in the weld metal Weld energy too low Increase weld energy
Plunging speed too low Increase plunging speed
Unsuitable stud/base material
combination
Replace welding element or
workpiece
If the strength of the joint is inadequate, then:
check the setting of the stud welding unit.
check whether the surface of welding element and base material are clean and
electrically conductive.
They must be free from scale, oil, paint, oxide layers.
Grind off hardened workpiece surfaces (e.g. roll hardening).
Check the piston of the welding gun for ease of movement.
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