Which Materials Are Suitable for Stud Welding?

From aluminium alloys to Zintec-coated steel, there are several metal materials that are suitable for stud welding applications. These sheet metal stud welding materials, however, require different approaches for the perfect stud welds and types of welding.

Stud Welding Materials: What Works?

Beyond knowing which materials you can use for stud welding, it is also important to know that the thickness of the base material and the diameter of the stud have an impact on which materials and systems are best suited to the task at hand.

In addition, the weld studs Taylor Studwelding manufactures are available in various materials (mild steel, stainless steel, aluminium and brass), which also affect considerations when choosing the right stud welding system. Taylor Studwelding weld studs all conform with EN ISO 13918.

Stud Welding Steels

Both mild steels and stainless steels can be stud welded. In general, steel is great as a stud and base materials as it suits the drawn arc stud welding and capacitor discharge stud welding processes. Using medium or high carbon steels (above 0.25 percent carbon equivalent) usually requires preheating to prevent cracking.

Taylor Studwelding stock low carbon, mild steel weld studs for drawn arc and capacitor discharge stud welding, as these studs provide excellent quality.  Heat resistant steel grades and corrosive and acid resistant materials are also available upon client request.

As for different types of weld studs, we provide threaded, unthreaded and internally threaded studs in mild and stainless steels. You can use these studs on a range of steel base materials (including electro-galvanised steel, Zintec coated steel, and structural steel).

Stud Welding Steel Alloys

Steel alloys require a different approach to stainless or mild steels. Applications for these stud welding materials are generally more limited. When a steel alloy is the base material, drawn arc stud welding is the best method.

Stud Welding Aluminium

Aluminium is another highly viable stud welding material. Aluminium base materials and aluminium studs are a match made in heaven. This is true of pure aluminium and aluminium alloy base materials, though each is best paired with studs of the aluminium alloy material.

Taylor Studwelding stocks aluminium alloy (AlMg3) CD weld studs. Our aluminium CD studs come in threaded and unthreaded forms. We also produce non-ferrous studs made from aluminium of up to 12mm in diameter upon request for DA stud welding processes.

Stud Welding Brass

Lead-free brass can be used for stud welding applications in conjunction with weld studs made from brass, mild steel, or stainless steel. You should only stud weld brass using the capacitor discharge process.

Taylor Studwelding supplies both threaded and unthreaded brass CD weld studs. Brass CD studs are suitable to use with lead-free brass and lead-free copper as base materials.

Stud Welding Copper

Copper base stud welding materials are best with brass weld studs if you are looking to have no marking. Stainless steel and mild steel studs are also options, though this may result in mild marking. Given that copper has a high thermal conductivity, the high speed of capacitor discharge stud welding makes it the ideal process for stud welding copper.

We always strive to meet our customers’ needs when it comes to stud welding in a range of industries. Each of our clients has unique requirements and we can advise them on finding the right stud welding systems, types of arc welding and studs for them. To find out more about our products, you can get in touch with us and we can provide advice.

Resources

Drawn Arc Studs Manual

Capacitor Discharge Studs Manual