Stud welding is a joining technique that applies an electric current between the base of metal fastener and its substrate to create an instantaneous weld, as the fastener plunges into a pool of molten metal and instantly connects.
This completely leakproof, hole-free and decorative joining method boasts several key advantages. These include:
Types
Stud welders come in various forms, such as drawn arc, capacitor discharge and advanced process models. Each type has its own advantages and uses; which you choose depends on the application and materials that will be welded together.
For instance, drawn arc welding can help join metal sheets together quickly and reliably. This process uses short bursts of electricity to melt the pip of each stud into its surrounding base material to form a strong weld between sheets – ideal for construction equipment as well as wiring hoses and cables.
CD welding is a more delicate method used for thinner base materials, employing short bursts of electricity to quickly melt an abrasive tip on the weld stud before plunging it into a pool of base metal in under half a second. Although its bonds are strong but not as durable, CD welding should only be undertaken when necessary.
CD welding uses low-carbon steel as the base metal, as well as several alloys such as copper, cadmium, and nickel to increase thermal and electrical conductivity between weld studs and surrounding sheet metal surfaces. Copper in particular is particularly helpful when working with aluminum bases as it prevents corrosion.
Materials
Based on their application, welding studs may be constructed from various materials. Mild steel is the most frequently used choice, offering grades ranging from low carbon content up to high strength like 302HQ and 30430. Threaded stainless weld studs are also readily available; standard arc weld studs typically feature flux loaded ends to facilitate welding processes while protecting surfaces.
Specialized studs are available for applications that require more precise fastening or higher strength, such as weld studs with fully threaded ends for attaching components to a workpiece base workpiece and applications where fasteners may have exposed backsides.
Capacitor discharge (CD) stud welding is an efficient way of welding smaller diameter studs to thin base metals without using much heat or energy, producing welds in less than one second and making quick work of securely fastening them in place without drilling or tapping required – perfect for thin materials or delicate assemblies.
Sizes
Stud welders use high current electricity to weld metal of all shapes and sizes together securely, without drilling or tapping holes for attachments; creating strong welds. This method of fastening is often preferred since it eliminates drilling/tapping holes altogether while being faster and more accurate than manual welding methods.
Drawn arc welder studs come in various diameters and lengths. Available threaded or unthreaded and threaded or unthreaded for internal threading applications. Collared, reduced base or internally threaded variations allow these welder studs to meet most applications such as fastening in limited clearance areas or cable mounts, while zinc plating provides corrosion resistance; nickel, aluminum or stainless are available upon request as corrosion inhibitors – as are options that come either annealed or fluxed upon arrival.
Capacitor Discharge (CD) weld studs are ideal for welding smaller-diameter fasteners to thin base metals with rapid and automatic welding cycles completed within milliseconds, providing quick welds without distortion or burn-through on the other side of material. They’re great for use in automatic feed stud welding systems as well as short cycle welding applications like gas arc or robotic welding applications. These threaded or non-threaded weld studs may even be threaded for even faster welding applications like robotic welding applications or short cycle gas arc welding applications.
Applications
Welding studs are used widely across industries. Metal name plates, door handles and other fabricated metal products like hinges all require fasteners that won’t deform or distort their face surface; this is where stud welding truly excels – creating strong welds without distortion of holes that requires tapping, drilling or polishing; it’s a cost-efficient method that protects parent material integrity while eliminating secondary operations like tapping drilling and polishing.
Capacitor discharge (CD) equipment allows welders to seamlessly attach studs of any shape or size to virtually any thin base material, including tamper-proof or pre-coated materials, in milliseconds. There’s no significant distortion or burn-through of the base material and welds are uniformly strong and reliable with no burrs or reverse side discoloration from these CD welds.
CD, drawn arc and other specialized equipment can all be utilized for industrial stud welding applications. Common applications for this form of welding include automotive, manufacturing and power generation applications as well as applications involving pipe welding, container fabrication, refrigerated storage units, climate control insulation facades or insulation facades – particularly useful in pipe fabrication, pipe linings and refrigerated storage facilities – plus fabrication metal components like doors, safe deposit boxes or signs.