Threaded stud welding is a process in which pin-shaped metal parts (e.g. threaded studs) are welded onto metal workpieces. This can be done using processes such as drawn arc stud welding or capacitor discharge stud welding, in which an arc is generated that melts the surface of the workpiece and the stud, creating a permanent connection.

Welding threaded studs offers very high strength, as the stud and the workpiece are connected over the entire surface. The process is also very efficient, as no post-processing is required, and threads can be applied in hard-to-reach places where other fastening methods would fail.

Alloyed and unalloyed steel, aluminium and brass are particularly suitable for welding threaded studs. It generally makes sense to weld similar materials together, but other combinations are also possible.

There are two main methods:

Capacitor discharge (CD process): A very fast process that is particularly suitable for thin sheets as the heat exposure is minimal.

Arc welding (ARC process): Uses drawn arc and is more stressful for the sheet metal, but more flexible to use with different material thicknesses.

Challenges can include warping of the sheet metal due to heat, the need for corrosion protection for different materials and the potentially high cost of the process. It is important to determine the correct parameters in advance, such as tightening torque and strength class, in order to achieve optimum results.

Threaded stud welding is used in many areas of metalworking, including vehicle construction, the electrical industry, apparatus engineering and construction. It is particularly suitable for applications where thin sheets are used or high precision is required.

Yes, the welding of threaded studs can be automated, which is particularly useful in industrial applications to improve efficiency and increase the number of pieces per minute.