what is stud welding

Stud welding is a fast, reliable and accurate method of welding a metal fastener to another metal
object. The resultant weld joint is stronger than the stud or parent material. Improved product
design is achieved since reverse marking is eliminated and the area around the stud is flat and
clean.

In order to weld the stud, access is only required from one side which means that component
handling is reduced. Welds are also leakproof and tamper proof, and since no holes are punched
in the sheet, corrosion problems are reduced and the work piece is not weakened.

Stud welding can also be used on single sided pre-coated polished or painted materials. The
fastener can be made from many metals or alloys.

Stud welding benefits: Fast attachment. No reverse marking.

The welded joint is stronger than the parent material or the stud.
Access is only required from one side. No holes hence no
leaking or weakening of the sheet. Tamperproof. Pre-coated or
painted materials can be welded. The equipment is portable and
easily jigged. In fact Stud welding overcomes all of the
disadvantages of the following problems.

problems with alternative fixing and

fastening methods

Drilling and Tapping: These processes are very slow. Thicker parent
material and longer studs are required.

Inserts: They can eventually work loose. They can crack paint and
leave unsightly stains. Holes need to be deburred in parent material.
The reverse side is not always clean and flat. The parent material is
weakened by holes.

Back Welding: The process is slow. Holes need to be punched and

deburred in parent material. The excess weld needs grinding off for a
clean flat finish. The parent material is weakened by holes.

Through Bolting: Requires two handed assembly and access from

both sides. Holes need to be punches and deburred in parent material.
Bolt heads are unsightly and stains can come from the bolt holes. The
assembly is not leakproof and the parent material is weakened by the
presence of holes.

Stud Welding Processes

The CAPACITOR DISCHARGE "CD" Process

The capacitors are charged to a Return spring pressure forges

Upon triggering, the stored
pre-set voltage to suit the the stud into the molten surface
energy is discharged as a high
diameter to be welded. The stud area on the sheet to give
current pulse, melting the pip
pip is placed into contact with the complete fusion across the
and producing an arc.
sheet. flange.

Stud/Material/Power Advantages
Stud Diameter 1mm -
Designed specifically for Low cost equipment, low cost studs, fast to
M10
thin gauge materials where load and weld, easy to jig and automate,
Material
reverse marking must be small light equipment, no ferrules or
Thickness0.7mm &
minimal. Sheet surface shrouding gas required, good weld results
above
should be clean and flat. with aluminimum or brass in addition to mild
Power
Stud has a weld pip. and stainless steel. Weld is clean and
Requirements Single
requires no finishing
Phase 240/110 Volt

The DRAWN ARC "DA" Process

Return spring pressure

Current and weld time is
The main arc then melts forges the stud into the
pre-set to suit the Upon triggering, a pilot
the weld end of the stud molten pool. The ferrule
diameter to be welded. arc occurs as the stud
and creates a molten contains the molten
The stud is then placed lifts to a pre-set height.
pool in the plate metal and shapes the
on the plate
fillet

Stud/Material/Power Advantages
Stud Diameter 3mm to
Very strong penetrative Burns through parent material laminations,
30mm
welds are achieved with tolerates surface curvature and imperfections
Material
this process. Ferrules e.g. light rust, scale, grease and some
Thickness2mm &
required to contain and coatings. Gives neat and controlled weld fillet.
above
shape molten metal. Weld The only method of stud welding large
Power
end of stud is fluxed. diameters. This process also lends itself to
Requirements Three
multi-gun applications.
Phase 415 Volt
The SHORT CYCLE "SC" process

This process is the same as for Drawn Arc, but operates over a much shorter time period - up to
100 milliseconds. Ceramic arc shields (ferrules) are not required with this process, but shrouding
with gas can improve weld fillet formation especially when welding stainless steel studs. Capicitor
Discharge studs may be used.

Stud/Material/Power Advantages
Stud Diameter M3 to M8
More penetrative welds Material This process is more tolerant than CD of
than CD and is suitable Thickness1.5mm & uneven or dirty surfaces. Can be easily
for hot rolled/coated above automated and can utilise low cost CD studs.
materials. Power Ferrules are not required, however shrouding
Requirements Three gas improves weld spatter
Phase 415 Volt

uses & applications

The Industries Using

The Applications
Stud Welding

Electrical Electrical

Industrial Control, Lighting Mounting components on panels

Equipment, Domestic Appliances, and in cabinets. Earthing
Power Generation and components. Bonding doors and
Distribution. panels. Fixing wiring looms.
Electronics Electronics

Control and Security Equipment, Fixing fascia panels. Mounting

Medical Instruments, Office switches, push buttons and
Automation, Data Transmission, instruments. Mounting printed
Communications, Test circuit boards.
Equipment.
Mechanical Mechanical

Material Handling and Conveyors, Fixing cover plates and

Lifts, Metal Furniture, maintenance inspection hatches.
Transportation, Construction and Attaching machinery guards.
General Machinery. Fixing fluid and air lines. Mounting
handles and other components.
Heating and Ventilating Heating and Ventilating

Domestic and Industrial Boilers, Attaching flanges, covers and

Air Conditioning and Ventilation hatches. Mounting fluid
Units, Refrigeration Systems. chambers. Fixing burners and
heating elements. Securing pipes

Decorative and Consumer
Signs, Nameplates, Panels,
Badges, Emblems, Jewellery,
Kettles, Saucepans.
Miscellaneous Industrial
Catering & Food Processing,
Insulation and Fireproofing.
and insulating material.
Decorative and Consumer
Fixing of signs, plates, panels and
badges. Attaching pins, findings
and clasps to jewellery. Attaching
feet to kettles and handles to
pans.
Miscellaneous Industrial
Hygienic fixing of legs, brackets
and stiffener strips to counters
and table tops. Securing acoustic
insulation. Fixing fireproof
material.