Precision and Power with Arc Stud Welders

Precision and Power With Arc Stud Welders

Dependence and efficiency in industrial machinery depend upon strong, secure attachment provided by drawn arc stud welding - thus justifying its popularity for this application area.

An adjustable spring tension holds the stud fastener in place while its ends are protected from melting by ceramic ferrules in a welding gun, creating an effective electric arc weld that bonds both ends of the fastener together as well as parts of its base metal - producing high quality fusion welds.
Precision

The drawn arc stud welding process provides fine control over time, heat and pressure requirements to create high quality welds. Unlike contact welding, which necessitates drilling holes into workpieces before welding can begin, drawn arc stud welding does not create holes that detract from structural integrity or the aesthetic appeal of finished products.

A weld gun begins by initiating a controlled electric arc to melt both ends of the stud as well as some base metal, then forging back spring force forces it back into this molten weld pool to form a permanent weld with full cross sectional penetration and no leakage.

Single-sided fastening processes like this one-side fastening method are well suited to intricate applications like badges, emblems and jewellery due to a minimal heat-affected zone and no unsightly spatter that create a clean appearance. Furthermore, this fastening method is widely used as it offers more secure fastening methods than traditional screwing.
Power

Stud welding can replace tedious secondary operations like drilling, tapping and punching with its fast, efficient method for connecting metal parts together - saving significant labor and equipment costs while eliminating holes that lead to corrosion issues in workpieces.

Capacitor discharge (CD) stud welding can join virtually all metals together - even dissimilar materials. When the trigger is pulled, the gun solenoid is activated, drawing an arc that melts both ends of the stud and surrounding base material before an arc shield - usually made of ceramic ferrule - contains and concentrates heat to protect the surrounding environment and keep molten metal within an enclosed pool for easy plunging into. Once in this molten pool, merging all three metals produces an effective weld that brings all their full strength together.

Aluminum stud welding requires the use of a shielding gas, typically 100% Argon; however, He/Ar mixes may provide superior arc ionization energy that accelerates weld penetration rates and speeds. Welded welds should also be strong enough to support weight of workpiece and reduce vibration-related damage.
Speed

Drawn arc (contact) stud welding is a fast welding method that produces welds within four to six milliseconds, making it an efficient means of joining metal surfaces together and forming new shapes. Furthermore, its single-sided process removes the need to drill a hole through sheets or base material and provides secure fastening solutions with tamper-proof fastening capabilities.

With this technique, a metal stud is loaded into the gun with an external ferrule and then planted onto the surface of a plate to be joined. When activated by the trigger, DC supply activates an internal lift system which draws pilot arc to melt one end of stud while ceramic ferrule shields it from arc, concentrates heat, and contains the weld zone.

Once the arc time has expired, the gun solenoid de-energizes and its spring plunges the weld stud down into the pool of base metal, where an instantaneous weld bond forms to connect fastener to parent metal and create strong one-sided weld bonds.
Safety

Stud welding does not usually require hot work permits; however, you will still need to follow proper safe operating procedures for both equipment and work area safety - including taking all appropriate fire control measures and inspecting after every weld.

Capacitor discharge stud welding is one of the most widely employed fastening techniques using arc welding tools, offering high-quality welds without penetration from either side. This makes capacitor discharge stud welding ideal for leakproof fastening on applications like transformers and ships/tankers.

By employing this method, the stud and ceramic ferrule are loaded into a gun under spring tension before being released when receiving a signal (such as trigger pull or an email from PLC or Robot), freeing stored energy through its "timing" tip into a pool of molten metal that solidifies to form welds.