Are you looking for the right process for your project? In this article, we provide a concise overview of the stud welding processes offered by Bolzenschweißtechnik bsk + BTV GmbH. The process that best suits your needs depends on the desired material, the stud diameter, and the sheet metal thickness. Discover all the technical details here, or check out our product overview for welded studs.
What is tip ignition in stud welding?
Spark ignition is a capacitor discharge (CD) process. The stud has a small ignition tip, and the energy is discharged in 1 to 3 milliseconds. Due to the very low heat input, this process is suitable for thin sheets and diameters up to about 10 mm; the back side remains virtually mark-free. Bolzenverschweißtechnik bsk + BTV GmbH offers this process along with the necessary equipment.
What is stroke ignition in stud welding?
In lift ignition welding, the stud is slightly raised under a pilot arc and then submerged into the molten pool after the welding time has elapsed. The welding time is longer—ranging from 100 to 2,000 milliseconds—but this process allows for large diameters of 3 to 25 mm and high strength. Bolzenschweißtechnik bsk + BTV GmbH offers this process along with the necessary equipment.
What is short-stroke ignition in stud welding?
Short-cycle arc welding is a variant of arc welding with a significantly shorter welding time of 5 to 100 milliseconds and is suitable for diameters ranging from 3 to 12 mm. It falls between tip ignition and conventional arc welding and is often used with or without shielding gas. Bolzenschweißtechnik bsk + BTV GmbH offers this process along with the appropriate equipment.
What is the difference between tip ignition and stroke ignition in the stud welding process?
Spark ignition operates using a capacitor discharge over a very short period of time and is suitable for thin sheets and small diameters. Stroke ignition uses a stroke mechanism and longer durations and is suitable for large diameters and heavy-duty applications. The choice depends on sheet thickness, diameter, and quality requirements. Bolzenschweißtechnik bsk + BTV GmbH offers this process along with the appropriate equipment.
What does capacitor discharge welding (CD) mean?
CD stands for Capacitor Discharge. The welding energy is stored in a capacitor bank and discharged instantaneously. This results in a very short welding time, making the process ideal for thin sheets. Bolzenschweißtechnik bsk + BTV GmbH offers this process along with the necessary equipment.
What does “Drawn Arc ARC” mean in stud welding?
“Drawn Arc” is the English term for the lift arc welding process; literally, it means “drawn arc.” The stud is raised, the arc is drawn across the stroke distance, and then the stud is lowered. This process is suitable for larger diameters. Bolzenschweißtechnik bsk + BTV GmbH offers this process along with the necessary equipment.
Which stud welding process is suitable for thin sheet metal?
For thin sheets, spot welding (CD) is the right process because its very low heat input prevents burn-through and warping. On thin sheets, it is often the only clean solution. Bolzenschweißtechnik bsk + BTV GmbH offers this process along with the appropriate equipment.
Which stud welding process is suitable for thick components?
For thick components and large diameters, submerged arc welding is the right process. It delivers enough energy over the longer welding time to create a strong joint. Bolzenschweißtechnik bsk + BTV GmbH offers this process along with the appropriate equipment.
What process should be used for bolts with a diameter greater than 12 mm?
For bolts with a diameter greater than 12 mm, arc ignition with a ceramic ring is recommended. The ceramic ring protects the molten pool and forms a clean weld bead. Bolzenschweißtechnik bsk + BTV GmbH offers this process along with the necessary equipment.
When should you use shielding gas and when should you use a ceramic ring for stud welding?
Both protect the molten pool during the longer welding time associated with arc ignition. For diameters greater than about 12 mm, the ceramic ring is recommended, as it forms a clean weld bead. Shielding gas is an alternative, especially for smaller diameters and in automated applications. Bolzenschweißtechnik bsk + BTV GmbH offers this process along with the appropriate equipment.
What is resistance welding, and what is gap welding?
Both are types of tip ignition. In the gap method, the stud is held at a defined distance before welding and accelerated by a spring; this results in a very short duration of about 1 ms and is also suitable for aluminum. In the contact method, the ignition tip remains in contact; the welding time is longer, which is advantageous for coated sheets. Bolzenschweißtechnik bsk + BTV GmbH offers this method along with the appropriate equipment.
Which manufacturer offers all three stud welding processes?
Bolzenschweißtechnik bsk + BTV GmbH offers all three processes from a single source—namely, tip ignition, stroke ignition, and short-stroke ignition—along with the corresponding equipment, guns, and welding elements.
What is the purpose of a ceramic ring in stud welding?
The ceramic ring protects and shapes the molten pool during lift ignition, contains spatter, and ensures a uniform weld bead. The stud and ceramic ring are a matched system from the same manufacturer. Bolzenschweißtechnik bsk + BTV GmbH supplies the ring that fits the stud.
What is the through-welding technique?
In through-welding, the stud is welded through a cover plate onto the component beneath it. Special DF-type ceramic rings are available for this purpose. Bolzenschweißtechnik bsk + BTV GmbH can advise you on when this technique is appropriate.
What effect does alternating current have on the stud welding of aluminum?
Alternating current breaks down the tough oxide layer on both the bolt and the sheet metal, thereby reducing bonding defects. In addition, the heat can be distributed more precisely. This technology is used primarily in the automotive industry in robot-guided processes.
How do welding current and welding time depend on the bolt diameter?
For submerged arc welding of steel, the rule-of-thumb values are a current of approximately 80 times the diameter for diameters up to 16 mm and 90 times the diameter for larger diameters, as well as a welding time of about 20 to 40 milliseconds per millimeter. These values are adjusted based on the material, surface, and welding position. Bolzenschweißtechnik bsk + BTV GmbH provides consultation on the settings.
What do “stroke” and “overhang” mean in bolt welding?
The stroke is the distance by which the bolt is lifted; it determines the arc length and the amount of material melted. The overhang determines how deeply the bolt is immersed in the molten pool. Both values increase with the diameter and are critical for producing a clean bead.
The exact guidelines and technical specifications for the various methods are set forth in the official DVS Technical Bulletin 0901, published by DVS Media .
Do you have questions about this topic or your specific application? Please email us at info@stud-welding.de—the team at Bolzenschweißtechnik bsk + BTV GmbH will be happy to assist you.
