Process selection depends on four factors: stud diameter, sheet thickness, material and accessibility.
Process selection
- Thin sheet / minimal heat input → Capacitor Discharge (tip ignition) or Short-Cycle
- Larger diameters / load-bearing joints → Drawn-Arc with ceramic ferrule
- Ceramic ferrule not possible → Drawn-Arc with shielding gas
Process Comparison – Key Values at a Glance
| Process | Typical Stud Ø | Welding Time (typ.) | Protection | Typical Application |
|---|---|---|---|---|
| Drawn Arc with Ceramic Ferrule | 3–25 mm | up to 3.000 ms | Ceramic ferrule | Steel construction; Composite construction; General fabrication |
| Drawn Arc with Shielding Gas | 3–12 mm (up to 16 mm) | ms range | Shielding gas | Applications without ceramic ferrule |
| Capacitor Discharge (Tip Ignition) | up to approx. 8 mm | Very short (capacitor discharge) | Generally none | Thin sheet metal; Series production; Automotive / Electronics |
| Short Cycle | 3–12 mm | Short ms range | Generally none | Thin / Coated sheet metal; Low penetration |
Advantages of KÖCO-Stud Welding Technology
By means of KÖCO-Stud Welding Technology, Threaded Studs, plain studs, Tapped Studs, Shear Connectors, Anchoring Studs etc. of diameter 2-25 mm will be cross-sectionally welded onto sheet metal, pipes, profiles etc.
The advantages of KÖCO stud welding technology are obvious:
- A high degree of safety, thanks to cross-sectional joints
- High productivity through extremely short welding time
- Options for various combinations of materials
- Distortion reduced to a minimum through low thermal stress
- Very little or no damage to the reverse side
- Hollow parts remain leakproof
- Access to parts from one side only is sufficient
- Easy to operate for personnel trained on the job
- Conform to international standards: EN ISO 14555 and EN ISO 13918
- Shear connectors officially approved: European Technical Approval ETA-03/0039
- Stud welding equipment and welding studs from in-house production
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.
Overview of the different welding methods
Technical information
Stud welding in accordance with DIN EN ISO 14555
Arc stud welding is a pressure welding process in which stud end and base material are melted by a short burning arc and then joined with low force. In order to achieve perfect results, not only the materials, surfaces and devices must be suitable, but electrical processes must also be coordinated with the mechanical movement.
Safe stud welding in workshops and on building sites...
Arc stud welding is a pressure welding process. Bolt end and base material are melted by a short burning arc and then joined with low force. In order to achieve perfect results, not only the materials, surfaces and devices must be suitable, but electrical processes must also be coordinated with the mechanical movement.
