Arc stud welding attaches fasteners to metal surfaces using an electric arc to fuse together their ends and the parent metal surface. A ceramic arc shield concentrates heat and molten material for an optimal welding result.
Drawn arc stud welding can be applied to studs of various diameters; it’s best suited for larger ones — 1/4″ or larger with base material thicknesses up to 1/3 of their diameter.
Templating
Templating ensures accurate weld alignment and stud location for successful arc stud welding. A template made of ebonite or masonite should be used, with bushings added to extend its life and allow different sizes of studs to be welded on one plate. Welds should be visually inspected for 360-degree weld flash, while any that appear questionable must be mechanically tested to confirm their integrity.
Drawn Arc welding produces strong, penetrative welds suitable for many materials with various thicknesses and can be automated for maximum productivity. This process utilizes weld studs equipped with flanges and ceramic ferrules to contain and shape the molten weld pool; automation makes this method even easier as it tolerates uneven surface conditions like light rust, scale and grease accumulations.
Short cycle stud welding offers higher currents and faster welding times compared to drawn arc, as well as more tolerant surface conditions than its counterpart. Furthermore, this process can be automated without using ferrules – making it the only arc stud welding method capable of welding large diameters as well as multi-gun applications.
Argon Gas
Argon gas is a noble gas with many industrial applications. When used for arc welding, argon provides an inert environment to shield the weld pool from elements in the air, protecting against porosity while increasing strength and penetration depth of welds.
Drawn arc stud welding is often utilized for applications requiring leakproof fasteners, including tanks and ships, power distribution systems and electrical enclosures. Furthermore, this method is ideal for creating tamper-proof welds that are difficult to break away or remove.
The drawn arc process can accommodate welding of various stud diameters and base material thicknesses, and with either or without ferrules to contain the molten weld and create a fillet around its base. Furthermore, this welding method makes automation of operations simpler.
Shielding Gas
Stud welding uses an electric arc to produce heat which melts fastener and base metal at one location, using shielding gas to focus this energy at the point of fusion for strong welds with high tensile strength and corrosion protection. Furthermore, an unblemished backside allows aesthetic applications.
Drawn arc stud welding is often the go-to process for larger diameter studs and thick materials (with some exceptions). An arc forms between the stud and base material, producing an extremely strong and tidy weld. It tolerates imperfections as well as curvatures. In addition, cold-rolled or coated materials don’t need ferrules reducing overall equipment and supply costs.
Short cycle stud welding is an excellent solution for applications requiring leakproof fastening of smaller materials or those requiring leak proof fastening, such as leak proof fastening. Similar to the DA process, but without needing ferrules. As well as this cost and productivity benefiting high volume applications; short cycle stud welding also supports more materials and allows use of lower cost CD studs.
Welding Gun
Stud welding guns are used to initiate the welding process. Each one features an ignition tip at its tip that releases stored energy instantly when activated by instantaneously melting one end of a fastener and some material within its immediate surroundings.
Melted metal quickly solidifies to form an excellent and long-term weld that quickly solidifies into an invisible weld, making this welding technique perfect for applications requiring leak proof fastening or invisible welds, such as automobiles and aircraft or containers containing liquid such as transformer tanks.
Arc stud welding can be used with fasteners made of mild steel, stainless steel and aluminum – including inspection cover plate attachments, enclosures, plumbing apparatus and wiring and hose management parts as well as furniture or household products. Arc welding also has various uses ranging from tamper-proof fastening to structural assembly – it even works well when applied tamper-proof fastening applications are involved! Arc welding has proven popular as an industrial joining method. Arc welding also serves fabricated metal products manufacturers who produce inspection cover plate attachments attachments attached by inspection cover plate attachments (such as inspection cover plate attachments attached by screws), enclosures plumbing apparatus parts as well as furniture manufacturers who manufacture household products made out of metal like cabinets made with metal furniture as well.
Welding Flux
Welding flux acts as a protective shield that shields molten metal from atmospheric gases that could otherwise lead to porosity and other defects, helping stabilize the arc and ensure high-quality weld pools.
Cellulosic fluxes are ideal for this form of welding as they don’t produce heavy slag. These usually comprise organic cellulose and lime binder. Unfortunately, however, they don’t offer as much arc stability compared to rutile-based fluxes.
As soon as the trigger is pressed, an electric arc melts both ends of the stud fastener held within its ceramic ferrule in the welding gun; creating an extremely high quality one-sided fusion weld that is significantly stronger than either its base metal or stud fastener components alone. This technique eliminates holes which weaken structures, as well as static or dynamic loads such as compression tension bending torsion vibration resistance and more – and is widely used across many products from construction equipment to appliances to automobiles!