Stud Welders

Stud welding is a specialised welding process used to join a metal stud or similar fastener to a workpiece, typically a metal substrate, without the need for drilled holes or additional fastening components.
Read our guide to find out more about this versatile metal fastening process.

Using a stud welder involves several steps to ensure proper setup and operation. Below is a general guide on how to use a stud welder:

• Select the right stud welder: Choose a stud welder appropriate for your specific application. Consider factors like the type and size of studs to be welded, the thickness of the base material, and the welding method (e.g., drawn arc stud welding, capacitor discharge stud welding).
• Prepare the workpiece: Clean the surface of the workpiece where the stud will be welded, removing any dirt, oil, rust etc. that could interfere with the welding process.
• Prepare the studs: Inspect the studs, ensuring they are clean, straight, and free from defects. Then insert into the chuck/collet of the stud welder, ensuring they are firmly and securely held in place.
• Set Up the stud welder: Connect the stud welder to a suitable power source, following the manufacturer's instructions and safety guidelines. Then adjust the parameters accordingly, including welding current, welding time, and arc length.
• Position the stud: Position the stud welder over the desired welding location on the workpiece, ensuring that the stud is aligned correctly. Then apply pressure to the stud gun to ensure proper contact.
• Initiate the welding cycle: Activate the stud welder to initiate the welding cycle by either pressing the button, pulling the trigger, or engaging the foot pedal. This will depend on the type of stud welder and welding method. Monitor the process to ensure proper arc ignition and penetration of the base material.
• Complete the weld: Hold the stud welder in position until the welding cycle is complete; a brief period of arc time followed by a forging or cooling phase. Then, release the pressure on the stud welder and remove it from the workpiece, inspecting the end result.

The stud welding process is commonly used in construction, manufacturing, and fabrication industries for applications such as attaching metal studs to steel beams, plates, or structures.

View a demo weld with one of our sold Nelson Nelweld 6000 drawn arc machines.

The price of a stud welder can vary significantly depending on several factors. Things like the type of stud welder, it's power output, welding capacity, brand, and additional features can all affect costs.

As a rough estimate, CD stud welders suitable for light-duty applications start at around £800 for a good quality, used machine, while high-end, heavy duty drawn arc stud welders with higher welding capacities can cost nearly £30,000.00.

Consider factors such as warranty coverage and customer support to help you make an informed purchasing decision.

The stud welding process involves using an electric arc or a high-voltage discharge to melt the base of the welding stud and the surface of the workpiece simultaneously, forming a weld pool that fuses the two together.

Weld studs, also known as welding studs or projection weld fasteners, are specially designed metal fasteners used in stud welding processes to securely attach components to a base material. These fasteners typically have a threaded, pointed, or flat base that is welded to the surface of the workpiece, providing a strong and permanent connection without the need for additional fastening components such as nuts or bolts.

Yes, a stud welder can work on aluminum, but the specific type of stud welder and welding process used may vary depending on the application and the thickness of the aluminum material. 

When welding aluminum with a stud welder, it's essential to consider the following factors:

• Equipment compatibility
• Welding parameters
• Material preparation
• Weld testing and inspection

With the right equipment, welding parameters, and techniques, a stud welder can be used effectively to weld aluminium studs to aluminium workpieces. Providing strong and reliable connections in various industrial applications.