Drawn arc stud welding is a process by which a metal stud is joined to a metal
workpiece by heating both parts with an electrical arc. It permits strong,
one-sided welds on base metals with thicknesses starting at 0.048" (1.2 mm),
and produces welds in as little as 0.06 seconds.
A key factor that differentiates stud welding from other fastening processes is that the fastener is attached to the workpiece without marring the other side. This method provides highly reliable fastening for a wide variety of applications and allows almost any size or configuration of a metal stud to be welded quickly to a workpiece, while providing maximum weld penetration and reliability.
The process utilizes a DC power supply to create the arc, a stud welding tool,
metal fasteners, and in some cases, ferrules.
There are three common techniques:
Drawn Arc Stud Welding – For this technique, a flux loaded stud is
loaded into the stud weld tool chuck, and a ferrule (a disposable ceramic shield that
contains the molten pool of metal) is placed over the end.
Short Arc Stud Welding – While this process is similar to drawn arc,
it does not use a flux load or ferrule. It also offers the shortest welding times
of all the drawn arc stud welding options.
Gas Arc Stud Welding – As it employs insert shielding gas with no flux or
ferrule, this process is easier to automate, although it provides less fillet control
and less depth of penetration in comparison with the drawn arc technique.
ADVANTAGES
Drawn arc stud welding provides excellent welding success under
a broad range of conditions. It produces a full cross-sectional weld, forming
a bond that is stronger than the surrounding metal.
Improved Quality
Weld Strength – The process produces strong, one-sided welds that are vibration-proof and resistant to breaking, loosening, or weakening.
Aesthetic Appeal – For applications in which quality is measured in part by attractive appearance, this technique offers excellent cosmetic appeal because the reverse side is not marred.
Ample Design Freedom – The one-sided fastening process permits greater design versatility.
Tamper-Proof – One-sided fastening prevents unwanted tampering in
that a bolt head is not accessible.
Increased Productivity
Faster, Easier Manufacturing – Compared with other typical fastening processes, this welding process permits faster, easier manufacturing because each weld is achieved in less than a second, and because welds can be achieved with access to only one side.
Fewer Manufacturing Steps – The process eliminates punching, drilling, tapping, and riveting. With special techniques, it permits welding on painted surfaces, eliminating the need for pre-grinding and recoating.
Economic Advantages
Labor Savings – Labor costs are dramatically reduced with the process because through-hole preparation is eliminated and the weld can be completed by a single worker.
Fabrication Savings – Often, an expensive, odd-shaped piece can be duplicated inexpensively by welding several studs to a simple stock shape to form a metal fabrication.
DRAWN ARC APPLICATIONS
A weld produced by the drawn arc process offers a variety of benefits, including
high structural integrity, excellent productivity, leak resistance, corrosion
resistance, as well as minimized noise and vibration. Our customers have found
extensive use in a wide range of applications, including:
Automotive – heat shields, power steering and dashboard components, instrument panels, insulation, exhaust systems, lighting systems, hydraulic/brake/fluid lines, electrical wire routing, and trim
Construction – bridges, building, conduit, and piping
Farm Equipment – fenders, brackets, cabs, spreaders, shrouding, thresher teeth, and wiring and hose management
Highway Equipment – cover plates, non-skid devices, and wiring and hose management
