Testing the Strength and Integrity of Welding Studs Attached to Sheet Metal

The Mountz Weld Stud Test Tool is designed for use during the production of sheet metal products to test the strength and integrity of welds used to attach threaded studs to the sheet metal.

Application Story # 1
A company that manufacturers popcorn machines, conveyor ovens, and toasters in Missouri wanted the capability to test welds on the products before the assembly process was completed. The company was experiencing issues with studs that were welded. The studs were breaking after the manufacturing process was finished. It was costing the company time and money in rework, which ultimately affected their bottom line. With a quality improvement mindset, the company searched for a solution.

When evaluating the problem, the breaking point for the studs was unknown. There were also 4 different size studs that were being welded into place. Each stud had its own engineering specification. The manufacturer selected both the Mountz WSTT (Weld Stud Test Tool) and TorqueLab torque tester. After implementing this equipment, the manufacturer performed a destructive test evaluation. Upon further testing and analysis, the engineering team was able to develop specifications for all the different size studs being welding.

The Weld Stud Test Tools proved to be a successful solution and reduced failures. The manufacturer continues to use the tools for quality sample auditing tests. They color coded the tools and placed a set in a cart system. The system used on all their production lines throughout the facility.

The Weld Stud Test Tools are sent to the calibration lab once a week to be tested and verified on a torque analyzer, to ensure the tools are operating in peak performance.

Application Story # 2
A manufacturer needed a verification process to test the integrity welds being placed on metal enclosures. Their current system was to test the welds using a metal chip approximately 4"x4" and doing a test weld. They were using various metal thickness, so several chips were being used at one time depending on the thickness of the enclosure. This process was time-consuming and very costly in material expenses.

The solution was to set up test parameters for all metal thicknesses used in the manufacturing of their metal enclosures using the WSTT (Weld Stud Test Tool). Once these parameters were developed, the manufacturer learned the type of welds needed for each metal thickness. Then the welder could check each weld on the enclosures using the WSTT device. This test method provided an instant verification if the welded stud passed or failed the quality test. It also saved them money by eliminating the need to constantly purchase the metal chips for the old testing process.

Get Easy Test Results
A simple way to test the shear torque of weld studs. Apply a straight pull of the WSTT wrench (no side load). When the wrench breaks-over and the weld stud is still attached then it passed. If the weld stud breaks off - then it failed.