What is Drawn Arc Stud Welding?
Drawn arc stud welding is a process by which a metal stud is joined to a metal work piece by heating both parts with an electrical arc. It permits strong, one-sided welds on base metals with thicknesses starting at 0.048" (1.2 mm), and produces welds in as little as 0.06 seconds, thus tends to be used for heavier stud welding applications, anything generally from 3mm up to 30mm can be possible with this process.
A key factor that differentiates stud welding from other fastening processes is that the fastener is attached to the work piece without marring the other side. This method provides highly reliable fastening for a wide variety of applications and allows almost any size or configuration of a metal stud to be welded quickly to a work piece, while providing maximum weld penetration and reliability.
The process utilizes a DC power supply to create the arc, a stud welding tool, metal fasteners, and in some cases, ferrules.
There are three common techniques:
Drawn Arc Stud Welding – For this technique, a flux loaded stud is loaded into the stud weld tool chuck, and a ferrule (a disposable ceramic shield that contains the molten pool of metal) is placed over the end.
Short Arc Stud Welding – While this process is similar to drawn arc, it does not use a flux load or ferrule. It also offers the shortest welding times of all the drawn arc stud welding options.
Gas Arc Stud Welding – As it employs insert shielding gas with no flux or ferrule, this process is easier to automate, although it provides less fillet control and less depth of penetration in comparison with the drawn arc technique.
ADVANTAGES
Drawn arc stud welding provides excellent welding success under a broad range of conditions. It produces a full cross-sectional weld, forming a bond that is stronger than the surrounding metal.
Improved Quality
Weld Strength – The process produces strong, one-sided welds that are vibration-proof and resistant to breaking, loosening, or weakening.
Aesthetic Appeal – For applications in which quality is measured in part by attractive appearance, this technique offers excellent cosmetic appeal because the reverse side is not marred.
Ample Design Freedom – The one-sided fastening process permits greater design versatility.
Tamper-Proof – One-sided fastening prevents unwanted tampering in that a bolt head is not accessible.
Increased Productivity
Faster, Easier Manufacturing – Compared with other typical fastening processes, this welding process permits faster, easier manufacturing because each weld is achieved in less than a second, and because welds can be achieved with access to only one side.
Fewer Manufacturing Steps – The process eliminates punching, drilling, tapping, and riveting. With special techniques, it permits welding on painted surfaces, eliminating the need for pre-grinding and recoating.
Economic Advantages
Labour Savings – Labour costs are dramatically reduced with the process because through-hole preparation is eliminated and the weld can be completed by a single worker.
Fabrication Savings – Often, an expensive, odd-shaped piece can be duplicated inexpensively by welding several studs to a simple stock shape to form a metal fabrication.
DRAWN ARC APPLICATIONS
A weld produced by the drawn arc process offers a variety of benefits, including high structural integrity, excellent productivity, leak resistance, corrosion resistance, as well as minimized noise and vibration. Our customers have found extensive use in a wide range of applications, including:
Automotive – heat shields, power steering and dashboard components, instrument panels, insulation, exhaust systems, lighting systems, hydraulic/brake/fluid lines, electrical wire routing, and trim
Construction – bridges, building, conduit, and piping
Farm Equipment – fenders, brackets, cabs, spreaders, shrouding, thresher teeth, and wiring and hose management
Highway Equipment – cover plates, non-skid devices, and wiring and hose management
Institutional Apparatus – commercial dishwashers, bottle washers, cooking equipment, and griddle plate assemblies
Furniture – metal household and office furniture, lawn furniture, shelving, and racks
Metal Products – barbecue equipment, enclosures, heating/plumbing apparatus, insulation enclosures, HVAC units, and water storage systems
Industrial – inspection cover plate attachments, enclosures, flow indicators, material handling equipment, and controls
Power Generation, Distribution, and Genset – power transformer tanks and transducers
Shipbuilding – insulation, wire management, and hatch covers
Lawn and Garden – tractors, mowers, and seeders
Electrical/Electronic – electrical enclosures and hydraulic lines
Buying large quantities? Call us free on 0800 975 9710 for unbeatable prices.