Welding Processes

The two major Stud Welding processes are Drawn Arc Stud Welding and Capacitor Discharge Stud Welding

Drawn Arc Stud Welding Process

Drawn arc stud welding is a process by which a metal stud is joined to a metal workpiece by heating both parts with an 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.

During the process, the stud is loaded into the stud weld tool chuck, and a ferrule is placed over the end. Then, the weld tool is placed against the work position. When the trigger is pressed, the DC power supply sends a signal that energizes the weld tool’s internal lift mechanism lifting the stud, drawing the pilot arc.

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.

Drawn Arc 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. This section examines its quality, productivity, and cost advantages, including: improved weld strength; aesthetic appeal; ample design freedom; faster, easier manufacturing with fewer steps; labor savings; and, fabrication savings.

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 creating a joint that is less susceptible to loosen from noise and vibration.

Our customers have found extensive use in a wide range of applications, including:

  • Automotive, including heavy truck
  • Construction Equipment
  • Farm Equipment
  • Highway Equipment
  • Institutional Apparatus
  • Metal Furniture
  • Metal Products
  • Industrial
  • Power Generation
  • Distribution
  • Generators
  • Shipbuilding
  • Lawn and Garden Equipment
  • Electrical/Electronic Enclosures

More information is available on our drawn arc equipment, accessories, and consumables

Capacitator Discharge (CD) Stud Welding Process

CD stud welding, using very short weld times, permits the welding of small-diameter studs to thin, lightweight materials. The weld cycle can be completed in 0.01 seconds on material as thin as 0.020″ (0.5mm). These fast weld times minimize heat buildup, resulting in welds with very little distortion, discoloration, or burning. Therefore, this type of process is often used when appearance is a critical product feature.

The CD stud welding method, used mainly for welding mild steel, stainless steel, and aluminum studs, includes two primary techniques: contact and gap. Both require a specially designed stud with a projection, or ignition tip, on its weld end. This tip provides accurate welding time control with precise repeatability.

CD Advantages

This process creates high integrity welds even on thin gauge materials. Additionally, it allows the welding of dissimilar metals because the weld penetration is so slight that metallurgical problems are prevented.

The quality, productivity, and cost advantages include: attractive appearance with minimal burn, strength in lightweight applications, minimal backside marking, a fast process with fewer assembly steps, labor savings, and fabrication savings.

CD Applications

Providing quick welds on lightweight or thin gauge materials with little to no distortion, CD welding can be used for: jewelry, hardware, cookware, electrical, houseware, electrical/electronic, and doors.

More information is available on our capacitor discharge (CD) equipment, accessories, and consumables.