Stud welding requires a balanced, precise environment to create a solid weld. Many factors can affect the weld quality, including things like arc timing and the materials you're working with. If you're new to this type of welding work, there are a few things that you should be attentive to before you start your first project, especially if you've chosen CD stud welding over ARC welding.
Don't Create A Center Punch
You might think that creating a center punch for the stud will help you to position the stud for stability. Unfortunately, that punch mark creates a valley in the metal that can alter the quality of the weld. The ignition tip of the welder can end up sitting in the dent, which makes the tip length shorter than it would otherwise be. This shortens an already shortened arc time in CD welding, which can affect weld integrity. Avoid the center punch whenever possible to minimize this, placing the studs directly on the surface instead.
Always Clean The Metal Surfaces
Especially when you're dealing with CD stud welding, you need to have a completely clean surface. CD stud welding is a rapid-weld process, which means that you have much less time to actually melt the metal. If the metal surface is rough or has any kind of contaminants, that will interfere with the weld because it won't have enough time to compensate. The arc time is simply too short to address things like this, which will result in a weak or failed weld.
If you have plated metal, CD stud welding will still work provided that the plating will take a weld. Zinc plating isn't responsive to welding, so avoid using any zinc-plated metals in this process.
Avoid Working With Hard Metals
The short arc time of CD stud welding also poses a problem when you're welding with materials that are too dense. Medium or high carbon steel is dense and extremely difficult to penetrate. That makes it a poor choice for this type of rapid-process welding. If you need to work with a metal like this, you should opt for ARC welding instead.
The right environment and material is essential to any kind of welding, but when you are dealing with short-cycle processes like CD stud welding, it's even more important. With the information here, you'll be able to avoid many of the common problems encountered. This helps you get a more solid, stable weld that you can count on in most any environment. If you're not comfortable with your skills, talk with a local welder for help.