While stud welding is a very simple process, unlike other forms of resistance welding or WIG/TIG or MIG welding that relies more on welder skills and understanding of correct technique, there are some mistakes that commonly made.
When used correctly, a stud weld gun will create a uniform, precise weld time and time again. With capacitor discharge systems, the actual weld time is so brief, with the process from arc to plunging down on the stud weld just fractions of a second, that issues with pooling, splashing or uneven welds a non-issue.
With the use of drawn arc systems, the stud weld gun is loaded with the stud that is complete with a ferrule. This is ceramic collar or disc that sits on the weld site, restricting the movement of the molten material and allowing for a uniform, complete seal with the weld.
Just like any tool or piece of equipment, failure to maintain the stud weld gun as per the manufacturer’s instructions will result in poor quality welds. Often, due to the nature of the welds, these are very hard to determine just by visual inspection.
The results of poor maintenance of the hand-held tool or even a fixed mount tool may not be noticed until there are part and component failures. By following routine cleaning and maintenance, this issue can be avoided.
Not Changing the Settings
Different types of stud welding applications will need different settings on the power source to allow the stud weld gun to work effectively with the given base metal or the type of weld stud.
When these settings are not adjusted to reflect these factors, the welds may be incomplete, inconsistent or simply fail. Always check the settings on any power source and hand-held tool before using to ensure they are correct.