Depending on the heat input, various processes and process variants with different significance have developed. The different processes of drawn arc stud welding can be differentiated according to:
Type of arc ignition
Both processes differ in the ignition geometry of the bolts, the process sequence, the equipment technology and (partly) in the field of application. Both processes use direct current - but different energy sources, see Figure 2.
Type of energy source used
the length of the welding time
or the welding pool protection used
Depending on the customer, component, material and process requirements, different stud welding processes can be used and their decisive quality criteria can be used. The optimum working ranges of the different stud welding processes differ, among other things, in the diameter of the welding element, in the materials and component surfaces used, the sheet thickness and working position, the required connected load and the process requirements (automation, quality and reproducibility, workshop or construction site conditions), etc.
Hubzündung |
Kurzzeithubzündung |
Spitzenzündung |
|
ISO 4063 |
783 |
784 |
786 |
Power Source |
Transformer |
Transformer |
Capacitor Discharge |
Stud Diameter d |
M6 – M24, Ø 3 – 25 mm |
M3 – M10, Ø 3 – 10 mm |
M3 – M8, Ø 3 – 8 mm |
Stud Weld Base Geometry |
Ignition Angle 22,5° |
Flange |
Ignition Tip, Flange |
Stud Type ISO 13918 |
PD (MD) / RD / UD / ID / SD |
PS / US / IS |
PT / UT / IT |
Min. Base Material Thickness s |
0,25 d; > 1 mm |
0,125 d; > 0,6 mm |
0,1 d; > 6 mm |
Welding Current I-max [A] |
300 - 3.000 |
2.000 |
10.000 |
Welding Time t [ms] |
> 100 |
< 100 |
1 - 3 |
Electrical Connection |
400V, 32 to 125 AT (slow blow) |
400V, 32 to 125 AT (slow blow) |
230 V |
Weld Base Protection |
Shielding Gas (SG) / CF |
none (NP) / Shielding Gas (SG) |
None (NP) |
Base Material |
Steel, Galvanized Steel |
Steel, Galvanized Steel |
Steel, Galvanized Steel |
Criteria |
Stud Welding |
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Drawn Arc |
Capacitor Discharge |
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with ceramic ferrule |
with shielding gas |
Short-Cycle / SC |
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Stud Diameter |
||||
Ø Stud ≤ 8 mm |
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Ø Stud 8 - 12 mm |
max. M10 |
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Ø Stud > 12 mm |
max. M16 |
max. M12 |
||
Base Material |
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Unalloyed Steel, Mild Steel |
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CrNi-Steel, |
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Aluminium / AlMg3 |
max. M10 |
SC-Studs |
max. M6 |
|
Brass / CuZn37 |
max. M6 |
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Base Material |
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Rust Film, Scale, Primer |
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galvanized |
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Base Material Thickness s |
||||
Sheet Metal |
s > 1/4 x d |
s > 1/8 x d |
||
Sheet Metal |
s > 1/4 x d |
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Heavier Plate Material |
Surface |
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Requirements |
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High Process and Quality Requirements |
Automotive |
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Connection 230 V |
max. M8 |
max. M8 |
max. M8 |
|
Construction Site Use |
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precisely shaped |
max. M10 |
With Shielding Gas |
Spatter Ring |
|
Thin Material no rear side marking |
||||
Automation |
||||
well suited |
The stud diameter, stud base ignition geometry, application and weld pool protection determine the welding process. |
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suitable with limitations |
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not suitable |
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