Stud welding provides a quick and flexible way of permanently bonding fasteners to work pieces quickly and economically without producing any splatter or fumes.
Striking quality and safety standards across industries like automotive, aerospace, and construction contribute to the expansion of WELD STUDS market. Furthermore, advanced welding technologies also play a significant part in this growth.
Capacitor Discharge (CD) Stud Welders
Capacitor Discharge (CD) welding processes are ideal for effortlessly welding fasteners to thin gauge materials with clean surfaces and non-deformed fasteners to studs without leaving behind any evidence of welding seams or imperfections. They work great with low carbon steels as well as certain aluminium alloys. Furthermore, CD welding offers great tolerance to surface curvature, light rust, mill scale grease or coatings on the material surface and produces strong penetrative welds without needing finishing after welding – which makes it ideal for automation purposes!
As part of the CD process, capacitors store energy at high voltage. When activated by electronics in a gun, this energy is instantly released via special weld timing tips on weld studs designed to dissipate this surge of electrical current into an arc that melts both weld stud and substrate material before spring pressure forces its way into this molten zone for weld completion within milliseconds.
When performing CD stud welding, it is critical that both the weld stud size and welder are suitable for welding that size stud. This will prevent reverse side marking issues as well as ensure that weld stud is welded into metal rather than through it. Furthermore, always wear dry gloves in order to avoid contact with electrically “hot” parts of your circuit.
Drawn Arc Stud Welders
Drawn arc welding processes are utilized when aluminum weld studs must be joined to an aluminum base, such as buildings or bridges, among other uses. Applications of drawn arc welding processes typically include insulation of buildings and bridges as well as vibration resistant industrial equipment; it is especially advantageous in cases that must be tamper proof; this approach provides only one side of visible welds for such needs.
Drawing arc welding works by employing an auxiliary pilot arc of low current to melt the base of studs. Once set at an appropriate welding time, a welding gun pulls these studs down into the weld head, creating a lasting connection between it and its target surface.
Drawn arc welding offers numerous advantages over threading and tapping processes, including faster turnaround in production times and increased reliability when fastening material to objects. Furthermore, its joint is stronger than either its component parts alone and offers engineers greater design freedom.
This method of aluminum stud welding also requires less maintenance than other processes. However, it’s important to keep in mind that the system requires a supply of shielding gas – typically 100% Argon (Ar). However, He mixes (25-75% He) or pure He may be more suitable as an arc-starting gas as He provides greater arc ionization energy than Ar.
Production Stud Welders
Stud welding provides an alternative to rivets or screws, which require holes to be punched through metal panels and leave weak points that can act as corrosion traps, by creating strong connections in one step that are leakproof without leaving behind visible holes that require punching out holes in order to attach. Furthermore, their welds look much more visually appealing than rivet or screw holes and don’t place additional stress on parent metal.
Stud welding is an increasingly popular solution across various industries and applications, serving a number of practical purposes in particular. For instance, it is often the only viable choice when attaching flanged studs to thin gauge sheet metal, and its welds are nearly invisible – making this technique perfect for applications requiring high quality aesthetics.
Stud welding is widely employed in electrical or hydraulic lines to form strong and secure connections that ensure effective fluid transmission as well as protect fragile equipment from the elements. These connections help ensure efficient fluid delivery while protecting delicate machinery from external forces.
Stud welding is an increasingly popular choice for attaching handles and hatches to machinery for maintenance staff’s easy access and maneuverability, reducing risks such as damage or injury during operations and maintenance. Stud welding ensures the handles stay securely attached, thus decreasing risk.
Stud Welding Guns
If you need a stud welding gun for manufacturing or fabrication applications, we have several choices that may suit. Our drawn arc, capacitor discharge (CD), short cycle and fully automated feed systems offer various stud guns designed to weld metal studs onto base materials in construction, automotive fabrication and other industrial settings.
Drawing arc stud welding is more complex than CD stud welding, but can also be more suitable for thicker materials like steel. During this process, the fastener is held firmly against the work surface with spring tension before being covered by a ferrule that concentrates the heat of an arc into an instantaneous weld without needing shielding gas for protection.
Our Drawn Arc (DA) welding guns feature different cable sizes to meet different welding applications; our DA 2A gun can accommodate studs up to 19mm while DA 3A fits 22mm studs. In addition, the Lift Gap LG2 gun provides less reverse side marking, capable of creating up to 5mm lift on thin materials. All our guns have been created to fit comfortably in your hand with their neck tapering down away from trigger to reduce wrist strain.