How Does An Aluminum Stud Welder Work?

An aluminum stud welder works through either the capacitor discharge (CD) or drawn arc capacitor discharge technique. This type of welding can weld aluminum studs that range in size from 3/16 to ¾ inches in diameter. A special adapter is often attached to the welder so that the shielding gases that occur during the welding process can be more easily controlled.

The Stud Welding Process

Stud welding involves a heating process where a metal stud and metal workpiece are joined together. Stud welding is different from other fastening techniques because the other side is not marred during the stud welding process. Many different types of metal can be used in stud welding, including steel and aluminum, but the aluminum stud welder is becoming the more commonly used tool in welding today.

How Does an Aluminum Stud Welder Differ From a Steel Stud Welder?

Aluminum stud welding differs from steel stud welding in a few important ways. First, aluminum is a good conductor of electricity; as a result, less heat is generated when working with aluminum versus steel. This can negate the quality of the weld and the work itself. To resistance weld aluminum, much more energy is needed. To overcome this difficulty, capacitor discharge welders are used with an aluminum stud welder to provide the needed energy in order to effectively fuse an aluminum stud to a panel.

Second, a natural oxidation barrier will immediately form on any aluminum surface; as a result, one must thoroughly rub down the surface with a stainless steel brush shortly before beginning the welding process in order to create an effective weld.

Industries That Use Stud Welding

There are many industries that use stud welding (steel and aluminum). These industries include electrical companies and their transformers, local municipalities’ bridges and buildings, militaries’ ships and aircraft carriers, and many more.

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