Arc Weld Studs for Wear Protection

TuffStudds Wear Protection System

Superb wear and abrasion protection for material handling plants and earth moving equipment.

TuffStudds are chromium carbide-laden, wear-resistant alloy studs that are readily applied onto alloy castings or plate. The applied pattern becomes embedded with mineral debris, causing a dead bed effect over 70% of the area, which enhances wear protection.

TuffStudds reduces costs in many ways, including less downtime, reduced labor for maintenance and lower overall cost of component replacement.

TuffStudd Specifications

How are TuffStudds applied?

TuffStudds are applied using a stud welding system that employs a stud gun powered by a transformer/rectifier with solid state weld timing and amperage control. For field applications requiring maximum portability, an AC generator with a minimum capacity of 85 kW can power the DC welding system. Each TuffStudd takes only 0.6 to 1.2 seconds of arc time to apply. Simply load a TuffStudd and a ceramic arc shield (ferrule) into the stud welding gun, position on the work surface and pull the trigger.

Stud welding gun
Load a TuffStudd
Load an arc shield
Position on the Workpiece and pull trigger.

The arc stud welding process

1) A TuffStudd is positioned in contact with the work surface. The welding gun trigger is pulled, initiating the welding arc and automatically lifting the stud.
2) The welding gun trigger is pulled, initiating the welding arc and automatically lifting the stud. The main welding current melts a portion of the stud and the work surface. Within a second, the Tuffstudd is plunged into the molten pool.
3) The main welding current melts a portion of the stud and the work surface. Within a second, the Tuffstudd is plunged into the molten pool. The ceramic arc shield (ferrule) retains the molten metal in the weld area for maximum strength and safety, and the Tuffstudd is metallurgically bonded to the work surface at the weld interface.
4) The ceramic arc shield (ferrule) retains the molten metal in the weld area for maximum strength and safety, and the Tuffstudd is metallurgically bonded to the work surface at the weld interface.

Welding parameters and equipment options

Welding Parameters

Following are the stud welding parameters for each of the three size studs:

Welder Settings
Stud dia. Time (seconds) Current (amps)
5/8″ .60 – .70 900 – 1,100
3/4″ .70 – .85 1,000 – 1,250
7/8″ .85 – 1.0 1,150 – 1,750

EQUIPMENT OPTIONS

Below are two common equipment options depending upon certain criteria.

HBS IT 1002 PRO WELD 1850
Available Power
Power required (3 phase)		 460/480V 230/460/580V
Portability
Weight of welder		 64 lbs. 500 lbs.
TuffStudd Sizes to be Applied
Maximum size of Tuffstudd capable of being welded		 3/4″ 7/8″
Non-Stud Welding Capabilities
Stick welding		 yes yes
Arc air gouging no yes

TuffStudd Applications

Applications for Tuffstudds are extensive and can by used in any setting where material comes in contact with the equipment, causing abrasion and impact issues. Click on each image below to view examples.

Aggregate Plants
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Asphalt Equipment
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Asphalt Plants
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Loader Buckets
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Misc. Equipment
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Rock Saws
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Waste Handling
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