Process control during stud welding

Stud welding is an efficient process for joining studs with different materials. Process control is of high importance to ensure the quality of the welds.

Important terms for process control:

Welding current: The welding current is the electrical current that is set by the operator during the welding process. This current flows through the stud and the workpiece during the welding time to create the welded joint.

Welding time: The welding time is also set by the operator and determines the duration during which the current flows through the stud. It includes the time between lifting and plunging (stroke) of the stud.

Stroke: The stroke is the distance the stud must go when it lifts off the base material. This parameter is also set by the operator.

Tension: Tension is an important process variable that is influenced by various parameters during welding. It affects the energy input and is therefore decisive for the quality of the welded joint.

The stud welding process follows a specific sequence:

  •  Start: The welding process begins
  • Precurrent: In this phase, a precurrent is applied to ignite the arc and start the welding process
  • Welding current: The actual welding current is activated to melt stud and base material
  • Immersion: The stud is immersed into the base material to create the joint
  • End: The welding process is complete

Process control in practice

To ensure the quality of the stud welds, key parameters such as welding current, welding time, voltage and stroke are recorded and compared with reference welds. This enables the early detection of welding faults that can be caused by incorrect operation, electromagnetic influences, or inadequate base material preparation.

identified by process control. For example, bonding defects can be recognized at an early stage if there is little "cold" immersion. This early quality control enables trained personnel to react quickly and avoid further faulty welds.

The documentation of welds, including parameter records and process control analyses, serves as proof of quality, and contributes to traceability.

Process control in interaction with automation

The interfaces of stud welding machines also enable the use of process automation. Special hardware is required for this, such as a drawn arc stud welding machine with welding current and voltage curve documentation and a drawn arc stud welding gun with stroke measurement. This combination enables complete process control and the detection of many possible welding defects.

Overall, process control in stud welding is crucial for ensuring high-quality welded joints, minimizing costs by reducing errors and guaranteeing product quality. By integrating process automation and thorough documentation, the efficiency and reliability of stud welding processes can be significantly increased.

Published on

Written by

Markus Neuse



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