Stud welding Basics

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 welding stud can be end-joined to a metal work piece instantaneously for a high quality, high strength permanent bond.

The base metal and the welded 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.

Two Stud Welding Methods

Two stud welding methods are available – Arc Stud Welding and Capacitor Discharge (CD) Stud Welding. The method used depends on the type of stud fastener needed based on the application and the base metal the fastener will be welded to.

Arc Stud Welding Process

Arc Stud Welding is generally used to weld large diameter fasteners to rougher and thicker base metals.

Mild steel, stainless steel and aluminum are applicable materials for Arc welding.

Capacitor Discharge (CD) Stud Welding Process

Capacitor Discharge Stud Welding is generally used to weld smaller diameter fasteners to thin base metals.

Since the entire weld cycle is completed in milliseconds, welds can be made without pronounced distortion, burn-through or reverse side discoloration. As long as one end of the fastener is designed for CD welding equipment.