Stud welding is a complete one-step fastening system, using a wide variety of fasteners called weld studs. In this welding process a fastener can be end-joined to a metal work piece instantaneously for a high quality, high strength permanent bond.
This process 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.
Weld Studs are used in a wide variety of applications:
The fastener is manually or automatically inserted into the stud welder chuck.
The fastener is positioned into firm contact with the work surface.
The welding gun is activated and the fastener is welded in a fraction of a second. The fastener weld develops full strength instantly.
Installation of flanged aluminum CD studs with Sunbelt Pro-C 1000, VZB Feeder Bowl and PHM-500 Lift / Gap Stud Welding Gun, for rapid, high quality welds.
ARC Stud Welding is generally used to weld large diameter fasteners to rougher and thicker base metals.
ARC Studs may be almost any shape and there are literally hundreds, however, they must have one end of the fastener designed for ARC welding equipment. Mild steel, stainless steel and aluminum are applicable materials for ARC welding.
A fastener and ceramic ferrule are firmly placed against the work surface under spring tension.
Upon triggering, the weld gun automatically lifts the fastener from the base metal and initiates a controlled electric arc which melts the end of the fastener and a portion of the base metal.
A ceramic arc shield concentrates the heat and retains the molten material in the weld area for maximum weld strength and reliability.
At the precise moment the fastener and the parent metal become molten, the fastener is automatically plunged into the work surface. The metal solidifies and a high quality fusion weld is completed.
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, CD Studs can be manufactured in almost any shape.
The fastener is placed against the workpiece. Most CD studs have a special tip which provides precise weld-time control, for consistent, automatic welds.
The weld gun is activated and stored energy is discharged through the fastener melting the full diameter of its base and a portion of the parent material.
Spring-loading forces the fastener into the molten metal.
The fastener is held in place as the molten metal solidifies and instantly creates a high quality fusion weld.