Cause of Stud Welding Fail

There are numbers of cause of Stud Welding fail it can be identify by using the tool 4M analysis.

Man

1.  New Manpower

2. Unawareness of the process

3. Less Skill Level

 

Machine

1. Wrong Weld Parameters

2. Wrong Gun

3. Wrong Machine

4. Shunting

5. Stud Gun Reach ability

6. Contact of Gun with the Sheet

7. Stud Collet Flatness

8. Lifting Mechanism Malfunctioning

 

Method

1. Difficulty to make contact angle

2. Weld Spatter Stick inside the Collet

3. No Method for Spatter Cleaning

4. Earthing Cable Loose/not connected

 

Material

1. Uneven Surface ( 30mm min. flat surface required)

2. Surface Roughness

3. Oil, Dust

4. Base Material Grade variation

5. Base Material Hardness Variation

6. Stud Head Variation

7. Stud Hardness Variation