Process Description
TuffStudds are carbide-laden, wear-resistant alloy studs that can be readily applied onto alloy castings or plate using a lightweight stud welding gun powered by a transformer/rectifier with solid state weld timing and amperage control. In most applications, the applied pattern becomes embedded with mineral debris, causing a dead bed effect, which further enhances wear resistance. Designed for mining and construction equipment, this wear protection system provides excellent performance for applications such as dragline buckets, front-end loader buckets, bulldozer blades, grader blades, compactors and chutes.

The application of individual studs is rapid, requiring less than a second of weld time, metallurgically bonding the stud to the work surface. A ceramic arc shield (ferrule) retains the molten metal in the weld area for maximum strength and safety. Stud availability in several sizes allows patterns for a variety of applications and areas of different sizes.

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.

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 surfaces