Short cycle stud welding
The process “short cycle stud welding” is used for welding studs of a diameter of 3 to 12 mm onto thin sheets.
The minimum thickness of the sheet is 1/8 of the stud-diameter.
This process leads to a flat weld penetration. For this reason, short cycle stud welding is mostly used for welding studs onto thin sheets. Generally, studs with a flange and a flat apex without any addition of aluminium are in use.
In general, the positive pole of the power-source is connected to the workpiece.
The stud will be inserted into the chuck of the stud welding gun and positioned onto the workpiece, possibly by adding a ceramic ferrule.
Initiating the welding process: by means of a lifting mechanism, the stud will be lifted and at first an auxiliary arc (pilot arc) of a low current will be drawn. Then the main arc will be drawn between the tip of the stud and the workpiece.
The main arc of a high amperage must be adjusted to the diameter of the stud.
The cross sectional area of the stud and the opposite workpiece a partially melting.
After the lapse of the adjusted welding time, the stud is moved towards the work piece and both melting zones join tightly.
The power-source turns off, the melting zone solidifies and cools down.
| Process | Short-cycle stud welding |
|---|---|
| Minimum sheet thickness t | 1/8 d |
| Maximum stud diameter d for welding from different positions | 12 ↓ 8 ← 10 ↑ |
| Suitable surface conditions¹) | bright metal, rolling skin, surface rust, thin layer of oil, zinc coating |
| Unsuitable surface conditions¹) | loose layers of scaling, heavily corroded, coating with organic material |
| Common applications | studs from 5 to 10 mm ø without shielding of the weld pool in case of average quality requirements for the shape of the weld collar. In case of high-grade requirements, shielding gas should be used. |
¹) Here, we can give only general hints without any commitment or warranty on our part. The conditions must be tested in each individual case. Basically, a higher degree of surface cleanliness is required for shorter welding times. The best results are always achieved on bright metal surfaces.
