stud welding

Details of our welding technology

The process “short cycle stud welding” is used for welding studs of a diameter of 3 to 12 mm onto thin sheets.
The minimum thickness of the sheet is 1/8 of the stud-diameter.

This process leads to a flat weld penetration. For this reason, short cycle stud welding is mostly used for welding studs onto thin sheets.  Generally, studs with a flange and a flat apex without any addition of aluminium are in use.

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.

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.

Process Short-cycle stud welding
Minimum sheet thickness t 1/8 d
Maximum stud diameter d for welding from different positions 12  ↓
  8  ←
  10  ↑
Suitable surface conditions¹) bright metal, rolling skin, surface rust, thin layer of oil, zinc coating
Unsuitable surface conditions¹) loose layers of scaling, heavily corroded, coating with organic material
Common applications studs from 5 to 10 mm ø without shielding of the weld pool in case of average quality requirements for the shape of the weld collar. In case of high-grade requirements, shielding gas should be used.
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.