About

“What is Studwelding?

A method of applying a single side fastening to a metal component”

Taylor Studwelding Systems Limited with over 35 years in the industry has, by blending professional experience with extensive resources, built up an enviable reputation exporting products worldwide. Simultaneously Taylor Studwelding Systems Limited has developed its position as the UK’s leading supplier, designer and manufacturer of Studwelding equipment and weld studs from hand held, lightweight units to fully automated CNC and robotic Studwelding systems. At our purpose built computerised office and factory complex our service is fast, efficient and friendly. We have over 10,000,000 items – constantly in stock, no order is too complex to fulfil.
Taylor Studwelding Systems Limited strives to create an environment in which all personnel are valued and encouraged to work together to reach their full potential.
We will continue to develop a quality line of Stud Welding equipment from simple hand weld units, through to CNC fully automated systems.
We are determined to provide first class technical and administrative service through ongoing investment in technical and personnel development.

The problems – Fixing & Fastening

Drilling & Tapping

These processes are very slow. Thicker parent material is required. Longer studs are required.

Inserts

They can eventually work loose. They can crack paint and leave unsightly stains. Holes need to be punched and deburred in parent material. The reverse side is not always clean and flat. The parent material is weakened by holes.

Back Welding

The process is slow. Holes need to be punched and deburred in parent material. The excess weld needs grinding off for a clean flat finish. The parent material is weakened by holes.

Through Bolting

Requires two handed assembly and access from both sides . Holes need to be punched and deburred in parent material. Bolt heads are unsightly and stains can come from the bolt holes. The assembly is not leakproof and the parent material is weakened by the presence of holes.

The Solution – Studwelding

The benefits of this system are: Fast attachment. No reverse marking. The welded joint is stronger than the parent material or the stud. Access is only required from one side. No holes hence no leaking or weakening of the sheet. Tamperproof, pre-coated or painted materials can be welded. The equipment is portable and easily jigged, in fact, Studwelding overcomes all of the disadvantages of the previous processes.

Selecting The Best Process

The Capacitor Discharge ‘CD’ Process

The Capacitors are charged to a pre-set voltage to suit the diameter to be welded. The stud pip is placed into contact with the sheet.

Upon triggering, the stored energy is discharged as a high current pulse, melting the pip and producing an arc.

Return spring pressure forges the stud into the molten surface area on the sheet to give complete fusion across the flange.

The Drawn Arc ‘DA’ Process

Current and weld time is pre-set to suit the diameter to be welded. The stud is then placed on the plate.

Upon triggering, a pilot arc occurs as the stud lifts to a pre-set height.

The main arc then melts the weld end of the stud and creates a molten pool in the plate.

Return spring pressure forges the stud into the molten pool. The ferrule contains the molten metal and shapes the fillet.

The Short Cycle ‘SC’ Process

The process is the same as for Drawn Arc ‘DA’ but operates over a much shorter time period – up to 100 milliseconds. Ceramic arc shields (ferrules) are not required with this process but shrouding with gas can improve weld fillet formation especially when welding Stainless Steel studs. Capacitor Discharge studs may be used.

Process

Stud/Material/Power

Advantages

Capacitor Discharge “CD”

Designed specifically for thin gauge materials where reverse marking must be minimal. Sheet surface should be clean and flat. Stud has a weld pip.

Stud Diameter   Low cost equipment, low cost studs, fast to load and weld, easy to jig and automate, small light equipment, no ferrules or shrouding gas required, good weld results with aluminium or brass in addition to mild and stainless steel. Weld is clean and requires no finishing.
1mm – M10
Material Thickness
0.7mm & above
Power Requirements
Single Phase
240/110 Volt
Drawn Arc “DA”

Very strong penetrative welds are achieved with this process. Ferrules required to contain and shape molten metal. Weld end of stud is fluxed.

Stud Diameter  Burns through parent material laminations, tolerates surface curvature and imperfections e.g. light rust, scale, grease and some coatings. Gives neat and controlled weld fillet. The only method of Studwelding large diameters. This process also lends itself to multi-gun applications.
3mm to 30mm
Material Thickness
2mm & above
Power Requirements
Three Phase
415 volt
Short Cycle “SC”

More penetrative welds than “CD” and is suitable for hot rolled/coated materials.

Stud Diameter  This process is more tolerant than CD of uneven or dirty surfaces. Can be easily automated and can utilise low cost “CD” studs. Ferrules are not required however shrouding gas improves weld spatter.
M3 to M8
Material Thickness
1.5mm & above
Power Requirements
Three Phase
415 Volt

Industries Using Studwelding

ELECTRICAL

Industrial Control, Lighting Equipment, Domestic Appliances, Power Generation and Distribution.

ELECTRONICS

Control and Security Equipment, Medical Instruments, Automation, Data Transmission, Communications, Test Equipment.

MECHANICAL

Material Handling and Conveyors, Lifts, Metal Furniture, Transportation, Construction and General Machinery.

HEATING & VENTILATING

Domestic and Industrial Boilers, Air Conditioning and Ventilation Units, Refrigeration Systems.

DECORATIVE & CONSUMER

Signs, Nameplates, Panels, Badges, Emblems, Jewellery, Kettles, Saucepans.

MISCELLANEOUS INDUSTRIAL

Catering & Food Processing, Insulation and Fireproofing.

The Applications

ELECTRICAL

Mounting components on panels and in cabinets. Earthing components. Bonding doors and panels. Fixing wiring looms.

ELECTRONICS

Fixing fascia panels. Mounting switches, push buttons and instruments. Mounting printed circuit boards.

MECHANICAL

Fixing cover plates and maintenance inspection hatches. Attaching machinery guards. Fixing fluid and air lines. mounting handles and other components.

 HEATING & VENTILATING

Attaching flanges, covers and hatches. Mounting fluid chambers. Fixing burners and heating elements. Securing pipes and insulating material.

DECORATIVE & CONSUMER

Fixing of signs, plates, panels and badges. Attaching pins, findings and clasps to jewellery. Attaching feet to kettles and handles to pans.

MISCELLANEOUS INDUSTRIAL

Hygienic fixing of legs, brackets and stiffener strips to counters and table tops. Securing acoustic insulation. Fixing fireproofing material.