This process welds various size of studs to sheet metal or structure. These studs can be welded to base metal with two different processes. One is resistance welding and other is Arc Welding. Most commonly used process is Arc Welding in Automotive, Construction, and Engineering Industries. Three different types used in Arc Welding are, Drawn Arc Welding, Short Cycle Welding and Capacitor Discharge Welding. Heat Required for welding is generated by DC arc between Stud and base Metal. Welding Current is gained from Mains Transformer. Welding time and Welding Current is controlled by a microprocessor controller as per the combination of Stud to be welded and the base metal. It is very important to select the proper process according to shape of the stud being used. The process and machine capacity is selected depending upon the stud size, strength required and productivity required.
Various Power Sources of different Capacities are used. For higher productivity, auto stud feeders are also used. Special Purpose Automated Machines and Robotic Applications are also available.
DRAWN ARC PROCESS (DA TYPE)
This process is typically deployed in construction and heavy machinery building. Sometimes special studs with Aluminium Balled Tips are used. Ceramic Pheruls are used to contain the spread of arc. Inert gase is also deployed, when the oxidation is strictly to be avoided and when welding very large studs. Stud and Pherul is placed in collet of gun. On positioning the gun on base metal, weld cycle as illustrated above is completed by machine.
SHORT CYCLE (SO TYPE)
This process is similar Drawn Arc, but welding times are very short, typically 10-100 Mili-Seconds.
Due to shorter welding times, use of pheruls is not required.
Peculiar application areas include Automotive and Motorcycle Industries.
CAPACITOR DISCHARGE STUD WELDING MACHINE
An extremely short discharge of capacitor bank enables the welding of ferrous and non ferrous metals up to 10 mm 0 in around 2-3 ms. Studs, un-threaded pins and other fittings can be welded on thin plates with little modification of the painted, zinc or plastic coated surface Digital control with 4 programs that can be stored and recalled by changing the gun. This allows to have up to 4 guns equipped and adjusted for 4 different parameters. LED function and diagnosis indicators with Microprocessor control unit compensating the mains variations. Forced ventilation cooling and Safety device and protection against casual use and failures is available.