Stud Welding Calculator
Calculate parameters for drawn arc and capacitor discharge stud welding.
Process Comparison
| Process | Stud Range | Weld Time |
|---|---|---|
| Drawn Arc | 6-32mm | 100-1500ms |
| Short Cycle | 3-12mm | 10-100ms |
| CD Gap | 2-10mm | 1-6ms |
| CD Contact | 2-8mm | 1-3ms |
Stud Welding Fundamentals
Process Selection
- Drawn Arc: Heavy structural studs, full penetration, requires ferrule, most common for shear connectors
- Short Cycle: Medium duty, faster cycle, thinner plates, no ferrule needed
- CD Gap: Light duty, minimal heat input, thin sheet metal, decorative work
- CD Contact: Very light duty, fastest cycle, requires tip ignition
Quality Requirements (AWS D1.1)
- Visual: 360-degree flash collar, no undercut or porosity visible
- Bend Test: 30-degree bend without fracture in weld zone
- Tensile Test: Fracture in stud shank, not weld (production testing)
Common Issues
- Incomplete Flash: Current too low, time too short, or poor contact
- Hang-ups: Stud stuck to ferrule - wrong ferrule size or position
- Porosity: Contaminated surface, wet ferrules, or wrong shielding
- Undercut: Current too high or plunge timing incorrect