A superb performer, the Tuffstudds Wear Protection System represents an innovative approach for applying wear studs on areas exposed to high abrasion. The Tuffstudds Wear Protection System provides an improvement in the state of the art for hardfacing technology and is especially designed for heavy mining or construction operations. Tuffstudds are carbide-laden, wear resistant alloy studs that can be readily shot onto alloy castings or plate using a lightweight arc welding gun. In many areas the applied pattern becomes embedded with mineral debris causing a dead bed effect which further enhances wear resistance.

The Tuffstudds Wear Protection System has proven to be an outstanding performer in the roughest environments

Features of the TuffStudds™ Wear Protection System
• Provides excellent wear resistance to construction and mining equipment
• Patterned surface is enhanced by the “dead-bed” effect, prolonging service life
• Simple, easy to apply using stud welding system
• Can be quickly applied on site with minimum equipment downtime
• Minimizes heat input to the base material, reducing stress, distortion and warping
• Repair and restud capability on previously studded surface

Typical applications are:

• Dragline buckets and dippers -teeth, adaptors, shrouds, heel bands, drag chain
• Dozers and graders -ripper teeth, shank protectors, blades
• Bucketwheel excavators -lips, adaptors, skid plates
• Compactors, chutes, feeders

The list is as extensive as your imagination. Use Tuffstudds to provide wear protection and reap the benefits of improved performance.

Note:

HCA= For Impact Applications

HCI= For Abrasion Applications

The Process:

Tuffstudds are applied using a stud welding gun with:

A transformer/rectifier with solid state weld timing and amperage control OR

A timer control unit operated with a DC power source

For field applications requiring maximum portability, motor generators can be used with these systems.

• Load a Tuffstudd and a ceramic arc shield into the stud welding gun and position on the work surface.
• Position a Tuffstudd in contact with the work surface
• Pull the trigger and...
  
• A pilot arc is initiated.
  
• Stud is lifted automatically.
  
• 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 arc shield retains the molten metal in the weld area for maximum weld strength and safety.
  
• A metallurgical bond is developed at the weld interface.

The stud welding process: 1) Stud and ceramic shield is positioned. 2) Stud is lifted and the
welding arc initiated. 3) Stud is plunged into the molten weld pool. 4) Stud is bonded to the
surface while the shield retains the molten metal.

Tuffstudds are normally applied in a staggered, close packed pattern oriented to minimize any washing-out of the base metal due to flow of material over the work surface. High wear areas require a coverage factor of 30% provided by 140-5/8" Tuffstudds per square foot. Low profile 5/8" Tuffstudds are recommended for leading edges exposed to high impact shear conditions. The higher profile 3/4" Tuffstudds are best used on areas requiring massive protection.

Recommended Equipment to install these studs

Please give us a call for more information 800-252-1919.