Stud welding is a high-speed process used to connect a metal fastener to another piece of metal. It is widely used to assemble metal structures, enclosures, equipment, signs, and other components. Stud welding is highly versatile because it is compatible with a variety of metals and a range of options for fasteners, called weld studs.
Midwest Fasteners is a trusted name for reliable stud and pin welding systems, weld studs, and insulation fasteners in the entire U.S. market and beyond. With over 40 years of industry experience, our team can provide recommendations and products for your specific application. Learn more about stud welding equipment, the benefits of stud welding, and some common examples of its use in different industries.
About Stud Welding Equipment
Stud welding is a complete, one-step fastening system performed with a tool called a weld gun and weld studs. Stud welding equipment and systems can be hand-held or incorporated into CNC and automated machines. Weld studs come in a variety of designs, such as with or without threads, curved or bent, eye bolt shaped, internally tapped, and more.
There are two types of stud welding: capacitor discharge (CD) stud welding and arc stud welding. In both types, the gun holds the fastener above the workpiece as the space between them is heated and melts. Then the gun pushes and holds the fastener down to form a solid weld. While they are very similar, these two types of stud welding are not identical and are not usually interchangeable. It’s important to know which method is appropriate for a given application so that the correct gun and studs are used.
CD Stud Welding Equipment
CD stud welding is generally the choice for welding small-diameter fasteners to thin pieces of metal. The fasteners used for this process usually have a special tip that helps guide and control the weld. Midwest Fastener offers several CD stud welder options:
Arc Stud Welding Equipment
Arc stud welding is used for large-diameter fasteners and thicker metal components. The fastener and a ceramic ferrule are placed on the gun, then an electrical arc melts the fastener end and a small portion of the workpiece. The ferrule contains the molten metal against spreading during heating, and can be broken off after the weld is completed.
Benefits of Stud Welding
CD welding and Arc welding are both fast and efficient, and both can be used with many types of metals and fastener configurations. Another advantage is that the welding operation is performed on one side of the workpiece, so it is suitable for many limited-access applications, such as the outside of a tank or enclosure.
The Benefits of CD Welding
The top benefits of CD welding include:
- Can achieve up to 20 manual welds per minute
- Weld thin metals and/or dissimilar metals
- Leaves no marks or distortion on the reverse of the weld
- Requires 110-volt power
- Compatible with fastener thread sizes up to ⅜ in.-16 and M10
The Benefits of Arc Stud Welding
The top benefits of arc stud welding include:
- Provides structural strength without drilling
- Full penetration of the weld zone
- Compatible with fasteners up to 1 ¼ in., and with thicker base materials
- Requires direct current 220 or 440 volt power
- Ceramic arc shields contain the material it melts
Applications of Stud Welding Equipment
Stud welding has applications in almost every industry for assembly, structural support, and general fastening.
Common CD stud welding applications include:
- Stainless steel equipment: restaurant, medical, and laboratory
- Signage: architectural, aluminum, and metal
- Electronic and electrical enclosures: including NEMA, control panels, etc.
- Insulation fastening: thermal and acoustical, including high temperature
Arc stud welding is the most commonly used stud welding process. Some typical examples include:
- Power and process industry equipment, tanks, and enclosures
- Steel fabrication
- Steel structure erection and construction
- Industrial manufactured metal fabrications
- Marine equipment, vessels, and containers
Stud Welding Equipment from Midwest Fasteners
Selecting the right stud welding equipment is essential for successful results. Low-quality construction, subpar fasteners, and accessories that don’t fit your gun produce unreliable results and cost more in the long run. Instead of settling, trust the experts at Midwest Fasteners. We’re your single-source stud welding specialists for all your equipment, accessory, and fastener needs. Contact us today or check out our stud welding equipment catalog to learn more about us and our products.