arc stud welders

Arc Stud Welders

Arc stud welding is an innovative way of attaching various sizes and applications of metal fasteners securely to base materials such as mild steel and stainless steel, in a short process that results in a stronger bond than either material can offer on its own.

An electric arc of electricity is directed between stud and substrate, melting both to form a solid weld. Once completed, welders either use gas to shield their weld or ferrules to concentrate and control heat output.
Safety

Arc stud welding is an efficient, quick method of joining circular parts (studs) to flat metal workpieces using an arc welder. An electric current melts the ends of both components together to form an indestructible bond under low contact pressure - typically taking less than one second per part!

An arc welder features an arc generator to generate electrical current that melts metal, with a ceramic ferrule surrounding the arc to concentrate heat and contain any molten metal that forms, while protecting weld areas from potential damage.

Triggering an arc quickly heats both ends of a stud and its base material, before plunging it into a molten pool for welding - creating an impregnable weld bond stronger than either itself. This process has wide applications; for instance, manufacturers frequently employ it when assembling inspection cover plate attachments, enclosures and flow indicators.
Preparation

Arc stud welding provides connections that are as strong or stronger than their parent material, with single-sided welds eliminating concerns of leakage or staining on the opposite side of sheet metal sheets. With weld times as short as 0.06 seconds, it provides fast connections.

Clean surfaces are critical for producing quality welds. This is particularly important with aluminum which often forms oxide layers which inhibit successful welding. A stainless steel brush or non-VOC cleaner may help remove these oxides more effectively.

Drawn arc stud welding (DASW) is more complicated than CD, yet ideal for thicker materials and uneven surfaces. Ferrules serve as ceramic shields to enclose the weld area and concentrate the heat of the arc, keeping the weld zone clean and producing uniform results with excellent penetrative power. It has many automotive applications such as heat shield assembly, dashboard components assembly and insulation routing while industrial applications include air and fluid lines as well as pneumatic, hydraulic and cooling systems assembly.
Performance

Under proper setup and use of arc welding equipment, stud welding produces welds that are stronger than their respective shanks, along with reduced undercut and expulsion rates, complete flash rings and stable process signals.

Stud welding is an extremely efficient way to weld; one worker can load, position and weld up to 30 studs within one minute using hand guns or more complex production equipment. This speed enables workers to move faster while saving time.

Drawn arc stud welding is an effective solution for creating leakproof connections in hydraulic lines or electrical enclosures in industrial machinery. Additionally, its one-sided welds make them tamper-proof fastening solutions; furthermore they require no removal from their appearance side. With regular maintenance arc stud welders can offer long, reliable service; this includes cleaning out their power source to remove dust that accumulates inside it which traps heat inside electronic components and creating overheat conditions that cause premature failure.
Maintenance

Arc stud welders differ from other welding processes in that they require minimal mechanical components and maintenance, meaning you should periodically blow out your power source to clear away dust or dirt that accumulates within it and causes problems such as heat retention and build-up in its inner components. It's important to clean this off so as to keep welding at optimal performance levels and minimize potential downtime issues.

Arc stud welders are widely used in the automotive industry, such as power steering components, dash components, engine assemblies and insulation. Furthermore, they can also be found used by farm equipment manufacturers for assembly of cabs, heat shields and other parts as well as routing wiring or routing hoses.

Drawn arc stud welding utilizes a weld gun to pull the stud out from its ferrule, melting both its base and any material touching it, to weld to substrate material before solidifying as the molten metal cools - the entire process takes less than one second and cannot be verified through bend testing or torque testing pre-production samples.