Short-cycle stud welding is a spark-ignition arc process for studs with a diameter of 3–12 mm on thin sheet metal. The short duration of the process results in a shallow penetration. As a rule of thumb, the sheet thickness should be at least 1/8 of the stud diameter (for example, for a stud diameter of 8 mm, the sheet should be at least 1 mm thick).
Key facts at a glance
Application Limits & Reference Values
| Feature | Reference Value / Note |
|---|---|
| Stud Ø | 3–12 mm |
| Minimum Sheet Thickness | At least 1/8 \times Stud Ø |
| Penetration | Shallow (suitable for thin sheet metal) |
| Stud Geometry | Commonly upset flange + Flat cone tip |
| Aluminium Addition | Generally not required |
| Polarity (typical) | Positive pole at workpiece |
| Quality Check | Test weld + Visual inspection; Bend test depending on requirements |
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.
FAQs
For which sheet thicknesses is short-cycle stud welding suitable?
As a rule of thumb, the sheet thickness should be at least 1/8 of the stud diameter (e.g. Ø 8 mm → min. 1 mm sheet). This ensures a stable process with a shallow penetration.
What types of studs are used in the short-cycle process?
Studs with a flanged head and a flat conical tip are typically used. As a rule, studs without an aluminium insert are employed.
What is the advantage of the short-time process?
The major advantage is the shallow penetration: this makes short-time stud welding particularly suitable for thin sheets where distortion or back-side effects need to be minimised.
What is the difference between short-time and tip ignition?
Short-time is a stroke-ignition arc process for thin sheets with shallow penetration. Tip ignition is a capacitor discharge process with very short durations (in the millisecond range) and its own ignition tip. Which method is more suitable depends on the stud diameter, sheet thickness and production requirements.
How do I set the parameters correctly?
Start with guide values, carry out a test weld and inspect the weld visually (and, depending on requirements, perform a bend test). If there are deviations, first check the sheet thickness, surface and contact pressure conditions, then adjust the current and time.
