Sunbelt Stud Welding

Sunbelt Stud Welding

Stud Welding Equipment and Supplies
Sunbelt Stud Welding

What is Stud Welding?



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.

Examples of Weld Studs
Examples of Weld Studs

A weld stud can be end-joined to a metal work piece instantaneously for a high quality, high strength permanent bond. (View video demonstration)

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.


Industries using Stud Welding

Weld Studs fasteners are used in a wide variety of industries:

  • Aerospace
  • Appliances
  • Automotive
  • Construction
  • Electronics
  • Forging Process
  • Insulation Installation
  • Light and Heavy Duty Equipment
  • Offshore
  • Petrochemical
  • Shipbuilding
  • Signs and Decorative Trim
  • Toys
  • Transportation
  • Utilities Metalworking

Stud Welding Equipment

The equipment required for stud welding is composed of the following:

  • A direct current Power Supply
  • A Controller
  • A Weld Gun
  • Cables to tie the system components and base metal together

In most systems, the power supply and controller are combined as one component called the "Welder".


Two Methods for Stud Welding

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 well be welded to.


Arc Stud Welding Process

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.


Arc Weld Stud is placed against the work surface

A fastener and ceramic ferrule are firmly placed against the work surface under spring tension.


A controlled electric arc which melts the end of the fastener

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 for maximum weld strength

A ceramic arc shield concentrates the heat and retains the molten material in the weld area for maximum weld strength and reliability.


The metal solidifies and a high quality fusion weld is completed

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 (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, CD Studs can be manufactured in almost any shape.


CD Stud fastener is placed against the workpiece

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

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.


Fastener forced into the molten metal

Spring-loading forces the fastener into the molten metal.


A high quality fusion weld

The fastener is held in place as the molten metal solidifies and instantly creates a high quality fusion weld.


How a Weld Stud Fastener is Installed

Loading Stud Welding Gun


The fastener is manually or automatically inserted into the stud welder chuck.

Postition the Stud Welding Gun


The fastener is positioned into firm contact with the work surface.

Fire the Stud Welding Gun


The welding gun is activated and the fastener is welded in a fraction of a second. The fastener weld develops full strength instantly.


Stud Welding Video Demonstrations

Arc Stud Welding - Video Demonstration

Capacitor Discharge (CD) Stud Welding - Video Demonstration

Stud Welding with an Hand Held Automatic Stud Feeding System - Video Demonstration

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.

CNC - Automated Bench Stud Welder - Video Demonstration