Stud Welding Machines

We are manufacturers of stud welding machines, along with we also provide stud welding. This is a fast and economical method of welding studs of various shapes and diameters onto the parent material. Stud welding is used for fixing studs onto the parent material without making holes. Normally for fixing studs and fasteners you will have to adopt operations such as drilling and tapping. By using stud welding you can completely avoid these operations.

There are two main methods of stud welding i.e. capacitor discharge stud welding and drawn arc stud welding. The selection of the process depends on thickness of the parent material, diameter of the stud, weld strength required and welding aesthetics requirement. The capacitor discharge method is used for thinner material and drawn arc method is used for higher diameter studs and heavy parent material.

Capacitor Discharge Stud Welding

In this method a small projection (pip) at the end of the stud makes contact with the work-piece and energy from the bank of charged capacitors is discharged across the contact, melting the stud projection and creating shallow molten pool in the parent plate. At this time the stud is pushed into the work-piece under controlled spring pressure, completing the weld. Energy required for given welding operation is obtained by selection of voltage across the capacitor.

This process minimizes the depth of penetration into the parent metal surface and is used for welding smaller diameter ferrous and non-ferrous studs on light gauge material. The stud can be welded on the reverse side of coated or finished sheet with little or no marking on the finished side.

Advantages

Uniform high weld quality Machine photo
Application on different materials
No blackening on other side of weld
No re-working necessary on the other side of the weld
No additional material necessary, such as flux, inert gas etc.
Elimination of different operations such as drilling, riveting etc.
Possible to weld studs on components with access from one side

Applications

Control panels
Elevator panels
Sound proof canopies
Cookware
Shipbuilding
Super market display
Electro-static precipitators
Insulation
Steel furniture
Cabinets and racks

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Drawn Arc Stud Welding

We provide drawn arc stud welding. In this method studs are welded with the help of either ceramic ferrule or shielding gas. When the gun switch is pressed, low current flows between pointed stud end and work-piece and immediately the stud is lifted drawing an arc. Then the full welding current flows in an arc, creating a molten state in stud end and work-piece. The solenoid is de-energized and the stud is pushed under controlled spring pressure into the molten pool. The whole operation takes fraction of a second. The metal displaced during the movement of the stud into the work-piece is moulded into a fillet form by ceramic ferrule.

Drawn arc stud welding is generally used for higher diameter studs and where higher weld strength is required.

Advantages

Uniform high weld quality
No additional material necessary, such as flux, inert gas etc.
Elimination of different operations such as drilling, riveting etc.
Stud diameter from 5mm to 25mm
No need of skilled workers to use the machine

Application

Transformers
Boilers
Automobile
Heat exchangers
Shipbuilding
Heavy fabrication
Metal Structures
Shear connector welding

Capacitor discharge or Drawn Arc – How to select

Use Capacitor discharge when

Clean welds are required
No marking on reverse side of the weld
Base material is thin
For small diameter stud welding up-to 8mm
When excellent aesthetics are required
Only for studs with projection (pip)

Use Drawn Arc when

High weld strength is required
Possible on slightly oily, scaly parent material
For structural applications
For higher stud diameters
For short cycle studs and drawn arc studs

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