The stud welding is part of an arc welding process, where a united body is produced
by heating with an electrical arc between the metal studs or similar parts and base
metals. The heating process is running till the base metal getting molten stage,
after certain time the arc is stopped and stud is feed into the molten zone. Molten
metal is shielded with a ferrule and flux or shielding inert gas. The Argon inert
gas is used for joining the aluminium stud and flux is used for steel stud welding.
Working principle of stud welding
The work or stud is held with collect chuck of welding gun and a porcelain or ceramic
ferrule is placed around the welding zone of stud. The current and controller units
are set for timing control. Now the welding gun is positioned wherein stud to be
weld on the base metal. Then current supply is started and the stud lifted about
1mm to 1.5 mm. the arc is produced between the gap of stud and base metal. The arc
melts the end of stud and base metal where it touches with flux. This flux provides
protecting properties from atmosphere gases in the ferrule boundaries. Now current
source is off as per schedule setting. The another additional spring loaded attachment
is provided for exerted the force on stud during molten stage. This is an automated
solenoid system. It has also setting time for released load after arc is completed.
The end of stud and base metal fused together and solidify inside of the ferrule.
Once welded joints are cooled, the ferrule may removed by breaking. Another one new
ferrule used for new weld joint.