Short-Cycle Drawn Arc Stud Welding

As an efficient and stable solid-phase metal joining process, short-cycle drawn arc stud welding has been widely applied in industrial fields including automobile manufacturing, marine engineering and household appliance production due to its outstanding welding efficiency and joint reliability. The welding forming quality and joint mechanical properties of the process are highly dependent on the accurate matching and coordinated regulation of process parameters. Based on the technical specifications of multiple brands of stud welding equipment and combined with on-site commissioning experience, this paper systematically constructs a standardized and implementable process commissioning methodology from four dimensions: process parameter system, standardized commissioning procedure, process window optimization, and root cause analysis of defects and faults. It provides technical support for engineering technicians to quickly calibrate the optimal welding process window and improve welding process consistency and product yield. 1. Process Parameter System and Physical Significance The electrical welding process of short-cycle drawn arc stud welding can be divided into four core stages: short-circuit stage, pilot arc striking stage, main arc welding stage and forging forming stage. Each welding stage is equipped with exclusive corresponding process parameters. These parameters are not independent of each other but have strong coupling correlations, which jointly determine the welding heat input and weld pool forming state, and ultimately directly affect the forming quality and comprehensive mechanical properties of welding joints. Combined with the official technical manuals and process specifications of mainstream equipment brands such as Hongbai SAW-3600 series, PIDS series and Tucker, this paper systematically sorts out and summarizes the core parameter system of short-cycle drawn arc stud welding, as shown in the table below. Parameter Group Parameter Name Physical Significance / Functional Effect Typical Range Commissioning Priority Arc Striking Parameters Pilot Current Generates a stable low-current arc to remove oil contamination and galvanized layers on the workpiece…