{"id":5763,"date":"2018-07-26T08:39:18","date_gmt":"2018-07-26T06:39:18","guid":{"rendered":"https:\/\/wp.www.stud-welding.de\/service\/the-3-welding-processes\/"},"modified":"2026-10-17T11:13:27","modified_gmt":"2026-10-17T09:13:27","slug":"the-3-welding-processes","status":"publish","type":"service","link":"https:\/\/www.stud-welding.de\/en\/service\/the-3-welding-processes\/","title":{"rendered":"The three welding processes"},"content":{"rendered":"<style>html body #brx-content.wordpress{max-width:none;width:100%;padding:0;margin:0}html body #brx-content.wordpress>h1{display:none}<\/style>\n<style>#btv-tech {width: 100%}#btv-tech{width:100%;background:#fff;color:#111a21;font-size:17px;line-height:1.7}#btv-tech section{width:100%;padding:64px 0}#btv-tech h1,#btv-tech h2,#btv-tech h3{font-family:inherit;font-weight:800;text-transform:none;letter-spacing:-.025em;line-height:1.15;color:inherit}#btv-tech .brxe-heading{text-align:left;align-self:flex-start}#btv-tech h1{font-size:clamp(32px,4.2vw,58px);max-width:1000px;margin:14px 0 20px}#btv-tech h2{font-size:clamp(25px,2.6vw,34px);margin:0 0 24px}#btv-tech h3{font-size:22px;margin:28px 0 12px}#btv-tech p{margin:0 0 20px}#btv-tech a{color:inherit;text-decoration:none}#btv-tech a:hover{color:#b92b22}#btv-tech a:focus-visible{outline:2px solid #b92b22;outline-offset:5px}#btv-tech-hero{background:#080e14!important;color:#fff;padding:64px 0 58px!important}#btv-tech-hero>div{width:min(1120px,calc(100% - 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36px)}#btv-tech-layout{display:flex;flex-direction:column;gap:34px;padding:32px 0 44px}#btv-tech-toc{max-height:270px;width:100%;padding:20px;gap:8px}#btv-tech-toc .brxe-text-link{font-size:14px;padding-bottom:8px}#btv-tech-hero .brxe-text-basic{font-size:17px}#btv-tech-overview>section>div>div{grid-template-columns:1fr;gap:16px}#btv-tech-overview article{min-height:0;padding:24px}#btv-tech-topicnav>div{grid-template-columns:1fr 1fr;gap:10px}#btv-tech-topicnav a{padding:14px;font-size:14px}#btv-tech-feature>div{grid-template-columns:1fr;gap:20px}#btv-tech-feature img{height:180px}#btv-tech-contact>div{align-items:flex-start;flex-direction:column}#btv-tech-contact h2{font-size:28px}#btv-tech-article>section{padding-bottom:24px;margin-bottom:26px}}<\/style>\n<div id=\"btv-tech\" class=\"brxe-div\">\n<section id=\"btv-tech-hero\" class=\"brxe-section\">\n<div id=\"brxe-iqvtij\" class=\"brxe-div container-wide\">\n<p><a id=\"brxe-zqmrze\" class=\"brxe-text-link\" href=\"https:\/\/www.stud-welding.de\/en\/technical-information\/\">Technical information \u2192<\/a><\/p>\n<h1 id=\"brxe-yfayds\" class=\"brxe-heading \">The three welding processes<\/h1>\n<div id=\"brxe-utqrrc\" class=\"brxe-text-basic\">Capacitor discharge, short-cycle drawn arc and drawn arc stud welding: process sequences, applications and technical differences.<\/div>\n<\/div>\n<\/section>\n<div id=\"btv-tech-layout\" class=\"brxe-div\">\n<div id=\"btv-tech-toc\" class=\"brxe-div\">\n<h2 id=\"brxe-xjhymw\" class=\"brxe-heading \">On this page<\/h2>\n<p><a id=\"brxe-glyehf\" class=\"brxe-text-link\" href=\"#spitzenzuendung\" data-brx-anchor=\"true\">Capacitor discharge stud welding<\/a><a id=\"brxe-pyvgiw\" class=\"brxe-text-link\" href=\"#kurzzeithubzuendung\" data-brx-anchor=\"true\">Short-cycle drawn arc stud welding<\/a><a id=\"brxe-lwtqak\" class=\"brxe-text-link\" href=\"#hubzuendung-mit-keramikring\" data-brx-anchor=\"true\">Drawn arc stud welding with a ceramic ferrule<\/a><a id=\"brxe-wgfzox\" class=\"brxe-text-link\" href=\"#schweissbadschutz-mit-schutzgas\" data-brx-anchor=\"true\">Weld pool shielding with shielding gas<\/a><\/p>\n<\/div>\n<div id=\"btv-tech-article\" class=\"brxe-div\">\n<section id=\"spitzenzuendung\" class=\"brxe-section\">\n<h2 id=\"brxe-ndwzmm\" class=\"brxe-heading \">Capacitor discharge stud welding<\/h2>\n<div id=\"brxe-hynsvi\" class=\"brxe-text\">\n<p>Capacitor discharge stud welding with tip ignition is used to weld predominantly pin-shaped metal parts onto sheet metal. Suitable stud diameters and sheet thicknesses depend on the materials, equipment and application and must be confirmed through appropriate welding trials. It is divided into two processes: contact welding and gap welding.<\/p>\n<h3 class=\"\">Contact welding<\/h3>\n<p>The contact process is primarily used for stainless steel and unalloyed or zinc-coated sheets (15 \u00b5m). The welding stud is inserted into the stud chuck and placed on the workpiece surface using the handheld gun or automatic welding head. A compression spring in the welding gun presses the stud, with the ignition tip characteristic of capacitor discharge stud welding, against the workpiece. Pressing the trigger on the welding gun releases the energy stored in the capacitors through a thyristor. The stud&#8217;s ignition tip heats up so intensely that it melts instantaneously and partly vaporises. The resulting arc fully melts the stud end and the workpiece at the weld interface. After a welding time of only 1\u20133 ms and a welding current of up to 15,000 A, the stud and base material are homogeneously joined, with a very small fusion zone of just a few tenths of a millimetre. With suitable materials and coordinated welding parameters, this allows studs to be welded onto thin sheets. Whether marks or discolouration appear on the reverse side depends on the particular application.<\/p>\n<p><img decoding=\"async\" src=\"https:\/\/www.stud-welding.de\/wp-content\/uploads\/2021\/07\/spitzenzuendung_1.jpg\" alt=\"Sequence of capacitor discharge contact stud welding\" \/><\/p>\n<h3 class=\"\">Gap welding<\/h3>\n<p>The gap process differs from the contact process in that, after the trigger is pressed, a lifting solenoid in the gun raises the stud to a preset lift or gap and then a spring accelerates it towards the workpiece. As soon as the stud&#8217;s ignition tip touches the workpiece, the arc ignites. Adjusting the gap changes the arc duration or welding time; this is generally shorter than in the contact process. The gap process is therefore primarily used for materials with a low melting point, such as aluminium or brass. The welding time is a maximum of 1.5 ms, and the fusion zone is even smaller than in the contact process. Particular care must be taken to ensure a clean workpiece surface free of electroplated coatings, oil, rust or scale.<\/p>\n<p><img decoding=\"async\" src=\"https:\/\/www.stud-welding.de\/wp-content\/uploads\/2021\/07\/spitzenzuendung_2.jpg\" alt=\"Sequence of capacitor discharge gap stud welding\" \/><\/p>\n<\/div>\n<\/section>\n<section id=\"kurzzeithubzuendung\" class=\"brxe-section \">\n<h2 id=\"brxe-zdqvsm\" class=\"brxe-heading \">Short-cycle drawn arc stud welding<\/h2>\n<div id=\"brxe-rvcbwz\" class=\"brxe-text\">\n<h3 class=\"\">Applications<\/h3>\n<p>Short-cycle drawn arc stud welding is primarily used for flanged studs 4 to 10 mm in diameter on thin sheets. Electroplated coatings below 30 \u00b5m are also possible. A major application is the automotive industry, where up to 600 studs are used per body-in-white.<\/p>\n<p>Drawn arc stud welding includes short-cycle drawn arc welding as well as drawn arc welding with a ceramic ferrule or shielding gas. The suitable stud diameter and workpiece thickness depend on the process variant, material combination and equipment; a single diameter or minimum-thickness range does not apply to every variant.<\/p>\n<h3 class=\"\">Welding sequence<\/h3>\n<ol class=\"btv-method-steps\">\n<li>Insert the stud into the stud chuck of the welding gun or automatic welding head. Support the gun on the workpiece using a positioning tube, support foot or shielding gas attachment.<\/li>\n<li>After triggering, a lifting solenoid lifts the stud away from the workpiece. A pilot arc is ignited.<\/li>\n<li>The welding power source switches on the main current. The arc melts the stud end and the workpiece surface.<\/li>\n<li>At the end of the preset welding time, the lifting solenoid releases. A spring presses the stud into the molten weld pool.<\/li>\n<\/ol>\n<h3 class=\"\">Technical parameters<\/h3>\n<ul>\n<li>Welding time: select for the process, materials, stud diameter and equipment<\/li>\n<li>Welding current: 500 to 1,500 A, depending on the application and stud diameter<\/li>\n<li>Fusion zone: approximately one eighth of the stud diameter<\/li>\n<\/ul>\n<aside class=\"btv-method-note\"><strong>Process reliability<\/strong>Welding time alone does not indicate process reliability. Coordinated welding parameters, suitable materials, preparation of the welding location and inspection of the joint are decisive.<\/p>\n<\/aside>\n<p><img decoding=\"async\" src=\"https:\/\/www.stud-welding.de\/wp-content\/uploads\/2021\/07\/hubzuendung_1.jpg\" alt=\"Sequence of short-cycle drawn arc stud welding\" \/><\/p>\n<\/div>\n<\/section>\n<section id=\"hubzuendung-mit-keramikring\" class=\"brxe-section \">\n<h2 id=\"brxe-xojfsn\" class=\"brxe-heading \">Drawn arc stud welding with a ceramic ferrule<\/h2>\n<div id=\"brxe-frsays\" class=\"brxe-text\">\n<h3 class=\"\">Applications and parameters<\/h3>\n<p>Drawn arc stud welding with a ceramic ferrule is mainly used in structural steelwork and mechanical engineering. Threaded or headed studs 6 to 25 mm in diameter are welded onto thick steel plates or beams.<\/p>\n<ul>\n<li>Workpiece thickness: greater than one quarter of the stud diameter<\/li>\n<li>Welding time: 100 to 1,000 ms<\/li>\n<li>Welding current: 800 to 2,600 A<\/li>\n<\/ul>\n<h3 class=\"\">Purpose of the ceramic ferrule<\/h3>\n<p>The ceramic ferrule shapes the weld pool, stabilises the arc and shields the welding location from the surrounding atmosphere. An aluminium ball pressed into the centre of the stud&#8217;s conical end acts as a flux and deoxidiser.<\/p>\n<h3 class=\"\">After welding<\/h3>\n<p>Each ceramic ferrule is used for one weld only. After the molten metal has solidified, the ferrule is removed by breaking it away from the stud.<\/p>\n<aside class=\"btv-method-note\"><strong>Eye and skin protection<\/strong>The ceramic ferrule does not replace suitable protection against arc radiation.<\/p>\n<\/aside>\n<p><img decoding=\"async\" src=\"https:\/\/www.stud-welding.de\/wp-content\/uploads\/2021\/07\/hubzuendung_2.jpg\" alt=\"Sequence of drawn arc stud welding\" \/><\/p>\n<\/div>\n<\/section>\n<section id=\"schweissbadschutz-mit-schutzgas\" class=\"brxe-section \">\n<h2 id=\"brxe-qioibc\" class=\"brxe-heading \">Weld pool shielding with shielding gas<\/h2>\n<div id=\"brxe-cdlchx\" class=\"brxe-text\">\n<p>This process can be extended by using shielding gas, or shielding gas can replace the ceramic ferrule. This significantly reduces porosity in the molten metal and produces a more attractive fillet-shaped weld collar. For suitable steel applications, a mixture of 82 % argon and 18 % CO\u2082 can be used. Pure argon is used for the aluminium application described here. Gas selection depends on the material and welding process; the gas is supplied through an appropriate shielding gas attachment on the welding gun. Select welding time, current, stud diameter and workpiece thickness for the specific shielding-gas process, material combination and equipment. Confirm suitability and settings through welding trials and the applicable inspection plan. Aluminium materials can only be processed to a limited extent using drawn arc stud welding.<\/p>\n<\/div>\n<\/section>\n<\/div>\n<\/div>\n<section id=\"btv-tech-related\" class=\"brxe-section \">\n<div id=\"brxe-rldejx\" class=\"brxe-div container-wide \">\n<h2 id=\"brxe-xomxwh\" class=\"brxe-heading \">Related to this topic<\/h2>\n<p><a id=\"brxe-idwutx\" class=\"brxe-text-link\" href=\"https:\/\/www.stud-welding.de\/en\/technical-information\/\">All technical information \u2192<\/a><a id=\"brxe-luwuyz\" class=\"brxe-text-link\" href=\"https:\/\/www.stud-welding.de\/en\/service\/material-combinations\/\">Material combinations \u2192<\/a><a id=\"brxe-iollpd\" class=\"brxe-text-link\" href=\"https:\/\/www.stud-welding.de\/en\/service\/din-standards\/\">Standards and DVS technical bulletins \u2192<\/a><\/p>\n<\/div>\n<\/section>\n<section id=\"btv-tech-contact\" class=\"brxe-section \">\n<div id=\"brxe-aktrfb\" class=\"brxe-div container-wide \">\n<h2 id=\"brxe-npzvra\" class=\"brxe-heading \">Your application. Our experience.<\/h2>\n<p><a id=\"brxe-umszjx\" class=\"brxe-button bricks-button bricks-background-primary\" href=\"https:\/\/www.stud-welding.de\/en\/contact\/\">Discuss your application \u2192<\/a><\/p>\n<\/div>\n<\/section>\n<\/div>\n","protected":false},"excerpt":{"rendered":"<p>Capacitor discharge, short-cycle drawn arc and drawn arc stud welding: process sequences, applications and selection for the particular welding task.<\/p>\n","protected":false},"featured_media":5205,"template":"","class_list":["post-5763","service","type-service","status-publish","has-post-thumbnail","hentry"],"_links":{"self":[{"href":"https:\/\/www.stud-welding.de\/en\/wp-json\/wp\/v2\/service\/5763","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.stud-welding.de\/en\/wp-json\/wp\/v2\/service"}],"about":[{"href":"https:\/\/www.stud-welding.de\/en\/wp-json\/wp\/v2\/types\/service"}],"version-history":[{"count":9,"href":"https:\/\/www.stud-welding.de\/en\/wp-json\/wp\/v2\/service\/5763\/revisions"}],"predecessor-version":[{"id":12686,"href":"https:\/\/www.stud-welding.de\/en\/wp-json\/wp\/v2\/service\/5763\/revisions\/12686"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.stud-welding.de\/en\/wp-json\/wp\/v2\/media\/5205"}],"wp:attachment":[{"href":"https:\/\/www.stud-welding.de\/en\/wp-json\/wp\/v2\/media?parent=5763"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}