Stud welding expertise: comparisons & practical tips

This section brings together in-depth stud welding expertise and practical comparisons, including stud welding versus screws or rivets, selection of diameter and current, and common errors and how to avoid them.

Sound technical knowledge is the key prerequisite for economical joints in modern sheet metal processing. Bolzenschweißtechnik bsk + BTV GmbH supports you as an experienced partner in selecting the optimal process and monitoring it in operation. To control automated processes in accordance with standards, all welded joints must meet strict criteria. An overview of relevant regulations can be found on our information page about DIN standards in stud welding . Reproducible results require process selection, welding execution and inspection tailored to the application. Thermal effects depend on materials, geometry and welding parameters.

Stud welding, screws or rivets – which is better?
Welding is faster and less expensive than screws when there are many identical fastening points, because drilling and tapping are eliminated. Unlike mechanically interlocking rivets, a weld creates a metallurgical bond between the materials themselves.

What is the difference between CD and ARC processes?
The CD process (capacitor discharge, tip ignition) uses extremely short discharge times (1–3 ms), making it suitable for thin sheets where the reverse side must remain unmarked. The ARC process (drawn arc welding) uses a pilot arc and longer times for thick components and large diameters.

How do you select the correct diameter, sheet thickness and current?
Sheet thickness, stud diameter, material and welding process are matched to the application. The DAI-1300 is intended for studs up to M16. Welding current and welding time depend on the application. Clean surfaces and appropriate weld pool shielding using shielding gas or a ceramic ferrule are important. Alongside the designations UF, PF and RF, we supply ceramic ferrules under the product designation MF.

What common errors occur and what safety guidance applies?
Common errors such as lack of fusion or distortion can be avoided through correct parameters and trial welds. The required protective measures are determined by the risk assessment and the manufacturer’s instructions. For questions about your application, contact the team at Bolzenschweißtechnik bsk + BTV GmbH at info@stud-welding.de.