The Fabricators Choice Since 1970

June 16th, 2022

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 Process

An 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 Misconceptions

The 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 Advantages

Are 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 Requirements

One 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

Stud Welding Fasteners

Resistance welded fasteners are materially binding and can potentially eliminate the need for laborious welding operations. Premium resistance weld fasteners allow for additional components to be attached to an existing metal part while allowing the fastener itself to stay permanently attached. Welding fastener options include:

Differentiating Stud & Spot Welding

Unlike spot welding, stud welding does not require high-pressure equipment, nor does it need access to both sides of the work to be effective. These factors make stud welding a more flexible and economical choice for a range of welding operations, whereas spot welding requires higher production volumes to be financially feasible.

Contact JHP Fasteners for Stud Welding Equipment & Fasteners Today

If you have questions regarding stud welding or are looking for premium stud welding fastener product options, get in touch with the experts at JHP Fasteners. JHP Fasteners is your source for advanced stud welding systems, fasteners, and accessories.