Professional stud welding covers the reliable joining of steel, stainless steel, aluminum, and galvanized sheet metal. bsk + BTV GmbH can assist you in selecting the right welding elements and processes.
Key guidelines, such as DVS Information Sheet 0901, as well as the fundamentals of arc stud welding, form the foundation. Suitable stud welding equipment, such as that used for the CD gap method with aluminum, is available.
Can you weld bolts to stainless steel?
Yes, studs can be welded to stainless steel. Stainless steel—or CrNi steel—welds well using all three methods. Bolzenschweißtechnik bsk + BTV GmbH provides consulting services on stud welding to help you select the right process and equipment.
Can you weld bolts to aluminum?
Yes, studs can be welded to aluminum. The most suitable methods are the CD-slit process, which welds aluminum without shielding gas, or arc welding with shielding gas. Bolzenschweißtechnik bsk + BTV GmbH can advise you on the correct process and equipment selection.
Can you weld studs onto galvanized sheet metal?
Yes, galvanized sheet metal can be welded, up to a certain coating thickness. The CD machines from Bolzenschweißtechnik bsk + BTV GmbH can process zinc up to about 15 µm, while the higher-end machines can handle up to about 20 µm.
What is the best method for fastening bolts to aluminum?
The CD gap welding process is suitable for stud welding on aluminum because the very short welding time allows aluminum to be processed even without shielding gas. Alternatively, arc welding with shielding gas is possible. Bolzenschweißtechnik bsk + BTV GmbH provides advice on selecting the correct process and equipment.
Can you weld bolts onto coated or painted sheet metal?
Coated or painted sheet metal can be welded, preferably using the contact welding method with a slightly longer welding time. The best results are achieved on a clean, bare metal surface. Bolzenschweißtechnik bsk + BTV GmbH provides advice on selecting the correct process and equipment.
Can brass bolts be welded?
Yes, brass studs can be welded. However, because zinc has a low boiling point, it can evaporate; therefore, precise welding parameters are important. Bolzenschweißtechnik bsk + BTV GmbH supplies welding elements and provides advice on material selection.
Can aluminum bolts be welded?
Yes, aluminum studs—for example, those made of AlMg3 (EN AW-5754)—can be welded. The CD gap welding method or lift welding with shielding gas are the most suitable techniques. Bolzenschweißtechnik bsk + BTV GmbH supplies aluminum studs and the appropriate equipment.
What materials are used for weld studs?
Welded studs are available in steel, stainless steel (A2 or A4), aluminum (such as AlMg3), and brass. The choice of material depends on the application and corrosion requirements. Bolzenschweißtechnik bsk + BTV GmbH supplies all standard materials.
What is the permissible carbon content for welded studs?
Unalloyed welding studs are considered suitable for welding if the carbon content in the melt analysis is 0.20 percent or less; in practice, a value below 0.18 percent is recommended. For sheet metal, the maximum should be 0.22 percent. Higher strength grades are achieved not through higher carbon content, but through cold forming. Bolzenschweißtechnik bsk + BTV GmbH supplies suitable welding elements.
What is annealed steel, and why is it important in stud welding?
During production, aluminum or silicon is added to killed steel to bind reactive nitrogen. This makes it age-resistant and fine-grained, and less prone to embrittlement during rapid cooling. Unkilled steels are unsuitable for this purpose.
Why are free-cutting steels unsuitable for stud welding?
Sulfur and lead are added to free-cutting steels to make them easier to machine. During welding, these elements form films at the grain boundaries, which significantly reduce the strength of the joint and lead to hot cracks. Therefore, they are unsuitable for use as bolts or sheet metal. “For more details, please see our technical information on stud welding.”
What is a black-and-white connection, and how do you resolve it?
A black-and-white joint refers to the joining of unalloyed steel with stainless steel. When a ceramic ring is used, the weld metal becomes brittle, especially at thicknesses over 10 to 12 mm. Solutions include tip ignition, gas shielding, the short-time process, or friction-welded dual-material studs. Bolzenschweißtechnik bsk + BTV GmbH can advise you on the right solution. For quality assurance, we use the criteria of the DVS Association, as set forth in the DVS Information Sheet 0901 from DVS Media .
Which shielding gas is suitable for stud welding on aluminum?
Only inert gases are suitable for aluminum. Argon-helium mixtures containing approximately 75 percent argon and 25 percent helium have proven effective, as has pure argon for small diameters and thin sheets. Gases containing reactive components such as CO2 or oxygen are unsuitable and cause porosity.
Why can’t aluminum be welded without any pores at all?
Aluminum absorbs moisture, which turns into hydrogen in the arc, and the weld pool solidifies very quickly due to its high thermal conductivity. The hydrogen cannot escape and forms pores; a porosity of about 30 percent is typical. This is compensated for by the flange on the bolt, ensuring that the joint remains secure.
What should I keep in mind when stud welding on galvanized sheet metal?
Zinc vaporizes at around 900 degrees and interferes with the welding process. Thin galvanized coatings can be easily handled using the contact method with tip ignition; for thicker coatings, the short-cycle method and the use of flange bolts are recommended. For M10 or larger sizes, or when high standards are required, the zinc is removed locally—preferably with a drill or milling cutter rather than an angle grinder. Zinc fumes are harmful to health, so be sure to use a fume extractor.
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.
