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SECTION 3
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STUD WELDING PROCESS
3-1.
Stud Welding Sequence
Welding sequence of control unit and process is broken down into four steps as shown below.
Gun is properely
positioned and main
gun spring is partially
compressed.
Trigger is pressed and the
stud lifts off the work. An
arc is created and melts the
stud and parent material.
After arcing is complete,
the main spring plunges
the stud into the molten
pool of metal.
Gun is withdrawn
from the welded stud.
The ferrule is broken
away and discarded.
Ferrule
Stud
Chuck
Step 1
Step 2
Step 3
Step 4
3-2. Recommended Procedures And Techniques
After the part has been designed for stud welding and a particular type and size of stud has been selected, follow these
guidelines when stud welding:
1. Have sufficient weld power available for the diameter of stud to be welded. Stainless steel studs require 10% more
power than an equivalent sized carbon steel stud.
2. Have weld cables of sufficient size, reasonable length, and tight connections.
3. Secondary hook-up should be DC straight polarity for steel and stainless steel, and reverse polarity for aluminum
and magnesium.
4. A good ground is essential. Use a “C” clamp type connector and clean contact area of paint and heavy surface
scale.
5. Setup stud gun in accordance with manufacturer’s recommendations. Adjust gun leg(s) so that stud extension
beyond ferrule is as recommended.
6. Select positions of stud placement by layout or suitable templates.
7. Clean area where stud is to be placed. Grind or scrape area to remove any surface contaminants.
8. Stud gun should be positioned perpendicular to the work surface, and depressed until the ferrule is firmly seated
against the work. The ferrule should remain firmly seated until the trigger is actuated.
9. The trigger should be actuated once and released. Do NOT move the gun during welding. Do NOT actuate the
trigger a second time if the stud is attached to the plate. (Damage (arcing) could result to the chuck.)
10. At the completion of the weld time, the gun should be held in position momentarily to allow solidification of molten
metal. Remove the gun, ferrule and inspect weld.
