“What is Studwelding?

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

The Problems – Fixing & Fastening

Drilling & Tapping

Drilling and Tapping

These fastening processes are very slow; a thicker parent material and longer studs are required.



Inserts can eventually work loose, plus they crack paint and leave unsightly stains. Holes need to be punched and deburred in parent material, weakening it. The reverse side is not always clean and flat.

Back Welding

Back Welding Illustration

This process is slow and requires weakening the parent material from punching and deburring holes. The excess weld needs grinding off for a clean flat finish.

Through Bolting

Through Bolting Illustration

Through bolting requires two handed assembly and access from both sides. 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.

Stud Welding Illustration

The Solution – Stud Welding

The benefits of using a stud welding system include fast attachment with no reverse marking. The welded joint is stronger than the parent material or the stud and access is only required from one side. No holes are made, 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, stud welding overcomes all of the disadvantages of the aforementioned processes.

Selecting The Best Process

The Capacitor Discharge ‘CD’ Process

Capacitor Discharge Stud Welding: Stud Placed on Sheet

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.

CD Stud Welding: Producing an Arc

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

CD Stud Welding: Completing the Weld

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

Drawn Arc Stud Welding: Placing Stud on Plate

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

Drawn Arc Stud Welding: Melting Stud with Arc

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

DA Stud Welding: Stud Melted onto Plate

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

Drawn Arc Studwelding: Stud Welded to 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.




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


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


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


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


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


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


Catering & Food Processing, Insulation and Fireproofing.

The Applications


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


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


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


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


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


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