Stud Welding - Everything You Need to Know
Stud welding. What is it? How can it improve my processes? What types of stud welding equipment and fasteners will I need to succeed? These are the types of questions often asked before experiencing stud welding for the first time. The fact is that stud welding has been used throughout the 20th and 21st centuries to manufacture a broad range of products for nearly countless applications.
What is Stud Welding?Stud welding is a technique similar to flash welding where a fastener or specially formed nut is welded onto another metal part, typically a base metal or substrate. The fastener can take different forms but typically fall under threaded, unthreaded, or even a tapped standoff. The bolts may be automatically fed into the stud welder.
The Stud Welding ProcessAn arc is ignited between one end of the stud and the workpiece during stud welding. Both joining partners are melted and then joined under low contact pressure. The stud welding process usually takes less than a second and is used for round and rectangular cross-sections. A critical factor differentiating stud welding from other fastening methods is that the fastener is attached to the workpiece without marring the other side. The four most common techniques that are used for stud welding include:
- Capacitor Discharge
- Drawn arc
- Short arc
- Gas arc
Common Stud Welding MisconceptionsThe stud welding process is often confused with other functions, including resistance and spot welding. Resistance welding and spot welding use electric current (not an arc) and high pressure to bond two items; stud welding does not. There is no high-pressure requirement in drawn arc stud welding.
Stud Welding AdvantagesAre you looking to find the best way to attach studs and other fasteners to sheet metals for diverse manufacturing applications? Stud welding is an excellent method to consider. Some of the benefits associated with stud welding products and manufacturing methods include:
- Enhanced accessibility
- Holes are not required
- Stud welding equipment is portable
- No reverse markings (with some applications)
- Fast attachments
Stud Welding Equipment RequirementsOne of the most beautiful aspects of stud welding is that anyone can do it. All that is required is a few key pieces of stud welding equipment and a desire to learn a few critical steps along the way. The following types of stud welding equipment are required to be successful at stud welding:
- Welding power source
- Welding gun
- Current cables & connections
- Welding element (weld stud)
- Accessories & safety products