Direct Answer
Shear stud welding inspection per AWS D1.1 requires: visual inspection of all studs (no cracks, no undercut, 360° base flash), bend test on a percentage of studs (4° minimum bend without fracture or cracking), and pre-production qualification tests each shift (studs bent and visually inspected before production begins). A stud that cracks during the bend test requires investigation of the installation parameters and repair of the failing stud.
Full Explanation
Bend test procedure per AWS D1.1 Section 7.6: bend the stud 30° from vertical with a steel ring and hammer (or hydraulic tool). The stud must not fracture and no cracks shall be visible at the base. Pass criteria: 360° base flash (weld metal around the full perimeter), no cracks, no visible porosity at the base, and the stud withstands 30° bend. Test frequency: typically 2–3 studs per start of each day or work shift, plus any stud that fails visual inspection. Failed studs are repaired by additional fillet weld around the base (per AWS D1.1 repair requirements) or replaced.
What This Means for Your Shop
Shear stud installation quality is sensitive to: stud gun calibration, ferrule type, base metal surface condition (must be free of mill scale, paint, and rust at the weld location), and weather (wind, rain affect shielding for the arc). Train your stud welding operators on these parameters and perform daily qualification tests without exception.
Common Mistakes
Not performing pre-production qualification tests each shift. A stud gun that worked perfectly yesterday may be miscalibrated today — the daily qualification test catches this before production studs fail inspection.
Recommended Process
Require pre-production stud qualification at the start of each shift: weld 2–3 qualification studs on a scrap plate, bend them, inspect visually. Log results. Only proceed to production after passing qualification. Document all qualification results.