Stud welding overview

Stud welding joins metallic fastening elements to a base material. The joint is formed directly at the contact point between the welding element and the workpiece.

Different processes, materials, welding elements and systems are used depending on the task.

The welding element, base material, sheet thickness, access to the component and production requirements are decisive when selecting a solution.

The detailed technical pages explain the processes, material combinations, mechanical parameters and inspections.

How do capacitor discharge and drawn arc stud welding processes differ?

Capacitor discharge stud welding uses energy stored in a capacitor and short welding times. It is particularly suitable for appropriate thin sheets. Drawn arc stud welding uses a lifted stud and an arc and is also suitable for larger stud diameters and thicker components. Specific applications are explained on the page The three welding processes.

Stud welding processes: when are short-cycle drawn arc welding, shielding gas or ceramic ferrules used?

Short-cycle drawn arc welding uses short arc times and is employed in applications including the automotive industry and automated production. In drawn arc welding, shielding gas or a ceramic ferrule can protect the welding area. The choice depends on the process, stud diameter, material and application.

Stud welding processes: how do contact welding, gap welding and through-deck welding differ?

In the contact process, the ignition tip rests on the workpiece before welding. In the gap process, the stud is first lifted and accelerated before contact. The gap process is used particularly for aluminium. In through-deck welding, a headed stud is welded through a deck sheet onto the base material below; this requires appropriate process design and suitable ceramic ferrules.

Which manufacturer supplies all systems from a single source?

Bolzenschweißtechnik bsk + BTV GmbH supplies welding studs, stud welders and welding guns as well as automated solutions. The team advises on processes, materials and suitable equipment for your application. Email info@stud-welding.de.

Stud welding is used when threaded studs, pins or other metallic fastening elements need to be joined directly to a component. The joint is made from one side. This makes the process particularly attractive for sheets, enclosures, cladding and load-bearing structures.

Typical applications

• Control cabinet construction and the electrical industry: Threaded studs and pins serve as fastening points on sheet metal components. Other applications include ground studs and earthing connections. Depending on the task, capacitor discharge welding may be suitable for thin sheets.
• Vehicle construction: In the automotive industry, ground studs and brackets, among other parts, are welded onto vehicle body components. Short-cycle drawn arc welding is an established process for these applications.
• Steel and composite construction: Headed studs are welded onto steel components using drawn arc welding and create the connection between steel and concrete. Applications include building and bridge construction.
• Machine, vessel and equipment construction: Studs create fastening points on machine components, enclosures and vessel walls. The appropriate solution depends on the material, component geometry and requirements of the joint.
• Facades, cladding and insulation: Studs, insulation pins and disc pins enable cladding and insulation mats to be fastened. For visible sheet metal surfaces, the effect on the reverse side is also a selection criterion.

Further examples can be found under Stud welding by industry and application →.

What are the benefits of stud welding?

• Processing from one side: The component is processed from the welding side. Access to the reverse side is not required for this operation.
• Fastening without a through-hole: The fastening element is welded directly onto the component. There is no need for a hole through the component, as would be required for a through-bolted connection.
• Short welding operation: Welding times depend on the selected process. Capacitor discharge and short-cycle drawn arc welding in particular enable short welding operations for suitable fastening tasks.
• Suitable for thin sheets: With appropriately designed capacitor discharge welding, heat input is low. Fastening elements can therefore be welded with only minor visible changes on the reverse side of the sheet.
• Suitable for manual and automated use: The process can be used with a handheld gun as well as with automatic welding heads and CNC systems. Equipment can thus be adapted to the production task.

From handheld equipment to automated production

For manual tasks, stud welders and welding guns are available. In automated applications, welding heads, feeding technology and CNC systems are coordinated. Information can be found in the section Automation & CNC →.

Which solution suits your application?

The base material, welding element, sheet thickness, accessibility and required joint are decisive. The intended processing of components and the production task also influence the choice. The benefits of a process must therefore always be considered in the context of the specific application.

The overview of the three welding processes and material combinations in stud weldinghelp with preparation. Suitable equipment for your component can then be selected.