Stud welding is a complete one-step fastening system, using fasteners called weld studs. Weld studs come in a variety of designs, threaded, unthreaded, tapped, etc., sizes and shapes for a wide range of applications.
A weld stud can be end-joined to a metal work piece instantaneously for a high quality, high strength permanent bond. (View video demonstration.)
The base metal and the welded stud fastener do not need to be the same material. For example these combinations can be welded together - brass to copper, brass to steel, copper to steel and similar combinations.
Stud welding is less expensive than other fastening methods and can used in locations which do not allow the use of other fasteners. Weld studs can be installed by one man, working on one side of the work piece, in less than a second.
There are many reasons why the stud welding process is superior over other fastening systems.
Stud Welding Equipment
The equipment required for stud welding is composed of the following:
- A direct current Power Supply
- A Controller
- A Weld Gun
- Cables to tie the system components and base metal together
In most systems, the power supply and controller are combined as one component called the "Welder".
Two Methods for Stud Welding
Two stud welding methods are available - Arc Stud Welding and Capacitor Discharge (CD) Stud Welding.
The stud welding method used depends on the type of stud fastener that is needed, based on the application and the base metal the weld stud fastener well be welded to.
Arc Stud Welding Process
Arc Stud Welding is generally used to weld large diameter fasteners to rougher and thicker base metals.
Arc Weld Studs may be almost any shape and there are literally hundreds of designs, however they must have one end of the fastener designed for Arc welding equipment.
Mild steel, stainless steel and aluminum are applicable materials for Arc welding.