ARC Welding

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Electric Arc welding is the most common process and is utilized whenever metal is fabricated. The best bond forms when the base plate is heavy enough to support the full strength of the welded fasteners, but is sometimes used with lighter gauge materials. Using a stud welding gun, the stud is welded to the base plate using a ceramic ferrule to hold the molten metal in place until the bond is formed. This results in a dense, strong weld that will develop the full strength of the fastener and the base plate. Welding currents range from 250 to 3,000 amps and the weld cycles range from 0.1 to 1.5 seconds, depending upon the diameter of the fastener and the materials being joined.

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Short Cycle and Gas Arc processes both offer ferrule-less stud welding. The short cycle process uses studs that do not have flux loads and have blunt weld ends and flange diameters slightly larger than the studs’ diameter to facilitate auto feeding and assure weld strength. Short cycle systems are typically mounted on robots in automotive plants requiring high productivity, but can also be used for low volume hand gun applications. The gas arc process utilizes gas shielding in place of ceramic ferrules to protect the weld metal and arc. Gas can be used to weld mild steel, stainless and aluminum studs up to 3/8″ diameter. The process is used extensively to weld studs to aluminum pots and pans for securing handles and legs.

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