There are two types of stud welding equipment: "Arc Stud Welder" and "Capacitor Discharge Stud Welders." "Arc Stud Welders" require 208, 240, 480, and 560 single phase or three phase AC power or DC type power source with open circuit voltage in the range of 70 to 100V. Arc stud welders are designed to weld studs from 1/8 (3.2 mm) through 1 ¼ (31.8 mm) using ceramic ferrule or gas. The other type is "Capacitor Discharge Welders." These require 110 V single phase power. DC power is produced by a rapid discharge of stored electrical energy. The method uses an electrostatic storage system as a power source in which the weld energy is stored in capacitors. No ferrule or fluxing is required.
ARC Stud Welding involves the same basic principles and metallurgical aspects as any other arc welding procedure. The weld gun lifts the stud a short distance from the base metal and initiates a controlled electric arc from the power source which melts the end of the stud and a portion of the base metal. The ceramic ferrule contains the molten metal into which the stud is thrust automatically and a high quality fusion weld is accomplished.
ARC stud welding is generally used to weld larger diameter studs to thick base metals. ARC studs may be almost any shape and there are literally hundreds, however, they must have one end of the stud designed for ARC welding and must be made of weldable materials. Mild steel, stainless steel, and aluminum are applicable materials for ARC stud welding.
