Safe, simple, efficient: stud welding technology

Stud welding technology is an efficient method of setting welding studs on all kinds of metallic, weldable surfaces. The stud welding devices are so safe and easy to use that semi-skilled workers can quickly achieve good results.

Definition of stud welding

Stud welding technology describes the setting of welding studs using welding guns. Connected stud welding devices provide the required welding current. Depending on the diameter and material of the studs, drawn arc or tip ignition is used. However, this hardly makes any difference for the handling of the welding elements.

How the stud welding process works

Welding studs are welded using the arc welding process. To do this, the bolts and the base material are put under high current. There is initially a small gap between the bolt and the base material. The arc jumps over in this gap and generates such a high temperature on both surfaces that the materials melt. After melting, the welding gun moves the stud into the base material. The so-called "melt pool" is created, in which the liquefied metals flow into one another. After switching off the welding current, the weld pool cools down and solidifies. The welding stud is now firmly seated on the base material.

Areas of application from stud welding

Stud welding is used wherever two components are to be firmly connected to one another. It has established itself in practically all metalworking areas. It is particularly popular in general steel construction, mechanical engineering, shipbuilding, body construction and in refractory technology. Since stud welding technology can be used for practically all metal thicknesses, it is suitable for machining thick sheets made of steel as well as thin sheets made of aluminum or copper.

Weld studs for drawn and tip ignition

The question of tip or drawn ignition depends on the following factors:

  • Diameter of the welding studs
  • Sheet thickness of the base material
  • Desired speed of processing

The drawn arc process is suitable for all stud diameters. However, depending on the strength of the studs and the type of stud welding equipment, it is comparatively slow. The tip ignition process is characterized by a very high welding speed. This is only 1 to 3 milliseconds. This not only enables automated welding processes with very short cycles. This process can also be used to process welding elements with thin walls, small diameters and materials with low melting temperatures. Special welding guns are available for this purpose, which are optimized for processing aluminum or steel sheets.

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Written by

Markus Neuse



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