Stud welding
with ceramic ferrule

Details of our welding technology

The process “Drawn arc stud welding” is used for studs of an approximate diameter of 3 to 25 mm, welding current up to 3.000 A and welding times up to 3.000 ms.

In general, the positive pole of the power-source is connected to the workpiece.

The stud will be inserted into the chuck of the stud welding gun and positioned onto the workpiece, possibly by adding a ceramic ferrule.

Initiating the welding process: by means of a lifting mechanism, the stud will be lifted and at first an auxiliary arc (pilot arc) of a low current will be drawn. Then the main arc will be drawn between the tip of the stud and the workpiece.

The main arc of a high amperage must be adjusted to the diameter of the stud.

The cross sectional area of the stud and the opposite workpiece a partially melting.

After the lapse of the adjusted welding time, the stud is moved towards the work piece and both melting zones join tightly.

The power-source turns off, the melting zone solidifies and cools down.

If a ceramic ferrules was used, it will be removed afterwords.

Step 1

The stud is placed against the workpiece.

Step 2

The stud is lifted off, while current is flowing, thus creating an arc.

Step 3

The arc melts the surfaces of stud and workpiece.

Step 4

The stud is plunged into the weld pool.

Step 5

A cross-sectional joint is achived.

Operation Stud welding with ceramic ferrule
Minimum sheet thickness t 1/4 d
Maximum stud diameter d for welding from different positions 25  ↓
  16  ←
  20  ↑
Suitable surface conditions¹) bright metal, rolling skin, primer suitable for welding, surface rust, thin layer of oil
Unsuitable surface conditions¹) hot-dip galvanising, loose layers of scaling, heavily corroded, protective coating
Common applications studs with more than 8 mm ø in steel and boiler construction, and shipbuilding, on surfaces only coarsely cleaned, deep penetration, suitable for field welding
¹) Here, we can give only general hints without any commitment or warranty on our part. The conditions must be tested in each individual case. Basically, a higher degree of surface cleanliness is required for shorter welding times. The best results are always achieved on bright metal surfaces.