Welding Guns

Depending on the application, different stud welding methods and stud diameters may be used. Therefore, you should clearly clarify before making a purchase:

- WHAT you expect from the welding stud as a joining element,
- HOW or with which stud welding process you will work,
- WHERE welding will take place.

By specifying the welding elements, the welding process, the weld pool protection and other parameters, you will arrive at the "WOMIT", i.e. the suitable welding gun.

Depending on the stud dimensions (diameter and length) and type of weld pool protection, accessories such as stud holders and stands may be required in addition to the stud welding gun. It is best to order these at the same time in order to be equipped in the best possible way right from the start.

Important distinguishing features are:

- the diameter of the welding elements in the welding area,
- the stud materials used,
- the plate thickness,
- the working position,
- the required welding power cable dimensions and guides, and
- the process requirements (shielding gas, ceramic ring).

The welding gun must not only fit the intended use, but also your stud welder. Ideally, both should come from the same manufacturer. On the one hand, the use of third-party guns or improper use could lead to the loss of the manufacturer's warranty or guarantee. On the other hand, you benefit from the advantages of an optimally coordinated overall system.

A distinction is made between welding guns for capacitor discharge stud welding with tip ignition (gap or contact method) and for drawn arc stud welding (short-time drawn arc or drawn arc with ceramic ring or shielding gas).
Important influencing variables for the gun selection for stud welding with tip ignition are the spring preload (contact method) and lift (gap method) as these parameters influence the welding time.
In some cases, the welding guns for the gap method are identical to those for drawn arc welding (control of solenoid). In both cases, the stud passes through the same movement profile: lifting - holding - lowering.

The short welding times of only 1 to 3 milliseconds require, in addition to the manufacturer's coordination of cable length and cross-section, the exact coordination of the gun movement and the discharge process. A cable extension would cause a higher inductance, which would throttle the welding current and extend the discharge time. It should therefore be avoided, as should winding the cable into a coil.

For an optimum welding result, the piston of the welding gun must move precisely and without friction over time. Otherwise, quality problems such as binding errors, droplet short circuits or "cold plunging" can occur. Lockable or latching parameter settings prevent unintentional adjustment and thus ensure high movement precision and faster acceleration of the piston mass.
Many inexpensive welding guns are fitted with plain bearings for piston guidance. These react sluggishly due to their design. Welding guns with ball linear guides work faster and more precisely.

Besides the technical structure, ergonomic points are also important such as:

- Gun weight,
- dimensions,
- grip,
- handling and
- balance.

Unhandy, heavy welding guns that are poorly adapted to the work processes make work more difficult and can lead to overstraining of the arm, back and shoulder muscles in the long term. If the gun lies comfortably in your hand and the distance and angle between your finger and the probe are optimally selected, you will have to expend less energy and will not tire as quickly.