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.
The stud is placed against the workpiece.
The stud is lifted off, while current is flowing, thus creating an arc.
The arc melts the surfaces of stud and workpiece.
The stud is plunged into the weld pool.
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. |