TuffStudds Wear Protection System
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Superb wear and abrasion protection for material handling plants and earth moving equipment.
TuffStudds are chromium carbide-laden, wear-resistant alloy studs that are readily applied onto alloy castings or plate. The applied pattern becomes embedded with mineral debris, causing a dead bed effect over 70% of the area, which enhances wear protection. TuffStudds reduces costs in many ways, including less downtime, reduced labor for maintenance and lower overall cost of component replacement. |
TuffStudd Specifications
 Series 58 (Base Diameter 5/8") |
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 Series 68 (Base Diameter 3/4") |
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 Series 78 (Base Diameter 7/8") |
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TuffStudds are applied using a stud welding system that employs a stud gun powered by a transformer/rectifier with solid state weld timing and amperage control. For field applications requiring maximum portability, an AC generator with a minimum capacity of 85 kW can power the DC welding system. Each TuffStudd takes only 0.6 to 1.2 seconds of arc time to apply. Simply load a TuffStudd and a ceramic arc shield (ferrule) into the stud welding gun, position on the work surface and pull the trigger.3
Stud welding gun
Load a Tuffstudd
Load an arc shield
Position on the Workpiece and pull trigger.
1) A TuffStudd is positioned in contact with the work surface.
2) The welding gun trigger is pulled, initiating the welding arc and automatically lifting the stud.
3) The main welding current melts a portion of the stud and the work surface. Within a second, the Tuffstudd is plunged into the molten pool.
4) The ceramic arc shield (ferrule) retains the molten metal in the weld area for maximum strength and safety, and the Tuffstudd is metallurgically bonded to the work surface at the weld interface.
WELDING PARAMETERS
Following are the stud welding parameters for each of the three size studs:
| Welder Settings | ||
| Stud dia. | Time (seconds) | Current (amps) |
| 5/8" | .60 – .70 | 900 – 1,100 |
| 3/4" | .70 - .85 | 1,000 – 1,250 |
| 7/8" | .85 – 1.0 | 1,150 – 1,750 |
EQUIPMENT OPTIONS
Below are two common equipment options depending upon certain criteria.
 HBS IT 1002 |
PROWELD 1850 |
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| AVAILIBLE POWER
Power required (3 phase) |
460/480V | 230/460/580V |
| PORTABILITY
Weight of welder |
64 lbs. | 500 lbs. |
| TUFFSTUDD SIZES TO BE
APPLIED Maximum size of Tuffstudd capable of being welded |
3/4" | 7/8" |
| NON-STUD WELDING
CAPABILITIES Stick welding |
yes | yes |
| Arc air gouging | no | yes |
TuffStudd Applications
Applications for Tuffstudds are extensive and can by used in any setting where
material comes in contact with the equipment, causing abrasion and impact issues.
Click on each image below to view examples.
 Aggregate Plants |
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 Asphalt Equipment |
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 Asphalt Plants |
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 Loader Buckets |
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 Misc. Equipment |
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 Rock Saws |
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 Waste Handling |
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