Nelson Stud Welding is offering an Abrasion Resistant ("AR") Stud Fastener for mining and crushing operations, and manufactures of mining equipment, that is proven to be more effective and lower installed cost than traditional hard facing.

The AR studs are cast from a special Chromium Molybdenum Carbide alloy with proven superior impact and abrasion resistance. Typical hardness is 48-53 Rc. Studs are available in either 5/8", ¾" or 7/8" diameters, all being 13/16 long before welding. When welded in a pattern they create a "rock box" effect where the protective layer is continually renewed during operations at no cost.

Deposition rates for stud welded studs are more than 2 times faster than alternate methods. The in-place cost of studs is 43% less than stick electrode. Weld studs can be applied quickly and in areas where hard facing is slow or difficult. As the stud welding process is semi-automatic, unskilled labor can be used to obtain high quality welds at a rate of 4 – 8 studs a minute through the work shift.

Arcing time is less than 1 second, so heat input is minimized resulting in less cracking, distortion, or warpage of the parent material. The stud welding process is operator friendly in that gloves and helmet are not required, and fumes are very minimal. Stud welding can be done on-site with diesel powered generators, or can be done in the maintenance shed with 230V or 480V 3 phase power.

To get the greatest wear protection and the longest life, the stud pattern should be as dense as possible. Staggering or offsetting the rows of studs will give a denser stud pattern and better wear resistance. Typically, with a ¾ inch diameter stud, a Super Dense Pattern will have 124 studs per square foot, while a standard pattern (leaving ferrules in place between welds) will have 106 studs per square foot.

Nelson Stud Welding is available for an on-site demonstration of the process and the application.