Drawn arc stud welding

Key Features Three Welding Processes Supports drawn arc, contact and non-contact stud welding. Three Independent Welding Channels One main unit supports up to three welding channels with different gun and process configurations. Post-Weld Tempering Applies a controlled current after capacitor discharge to slow cooling and help reduce thermal stress. Online Capacitor Monitoring Calculates capacitor capacity after each welding cycle to identify aging and support equipment maintenance. Flexible Gun Configurations Compatible with servo and non-servo welding guns, including automatic, semi-automatic and manual servo configurations. Industrial Communication Integrated PROFINET and DeviceNet interfaces, with multiple Ethernet ports for PC, CNC and PLC communication. Welding Data Management Integrated oscilloscope, data logger and WeldNIC group control software support waveform analysis, process monitoring and equipment management. Welding Process and Digital Control The SAW-D9 supports three welding process categories: drawn arc, contact and non-contact welding. Servo-controlled guns provide precise control of stud movement and contact force, while non-servo configurations offer a simpler equipment structure. Its post-weld tempering function maintains a current output of approximately 50–100 A after the main discharge, helping control the cooling process and reduce the risk of cracking under suitable welding conditions. For equipment condition monitoring, the system records discharge voltage and current waveforms at a 100 kHz sampling rate and calculates capacitor capacity using an integration algorithm. This provides ongoing information about capacitor condition. Digital Monitoring and Automation Integration The SAW-D9 incorporates an X86 / Windows-based data logging platform with 1 TB or greater storage capacity and support for more than one million welding-point records. Welding data is stored in a MySQL database and can be exported in CSV format for further analysis. Multiple Ethernet ports provide dedicated communication functions for PC monitoring, real-time data, data logging, Modbus TCP and CNC control. PROFINET and DeviceNet interfaces support integration with industrial automation systems. Through…

Introduction In automotive Body-in-White (BIW), automotive components, and new energy vehicle structural manufacturing, stud welding is widely used for applications such as cable harness fixing, heat shield installation, interior component mounting, and structural part assembly. However, in actual production, issues such as poor weld integrity, porosity, slag inclusion, and incomplete fusion remain key factors affecting stud welding quality stability. In severe cases, these defects can reduce stud strength and even cause stud detachment, affecting downstream assembly processes and product reliability. Based on stud welding principles and practical industrial applications, this article systematically analyzes the formation mechanisms, major causes, and engineering solutions for porosity and slag inclusion defects. 1. Formation Mechanism of Porosity and Slag Inclusion 1.1 Porosity Formation Mechanism: During the stud welding process, the high-temperature arc rapidly melts the welding area and forms a weld pool. If gases (such as H₂, CO, and N₂) inside the weld pool cannot escape before the molten metal solidifies, they will remain trapped inside the weld and form porosity. Porosity is mainly classified into: Surface porosity Internal porosity Among them, internal porosity is more difficult to detect and can reduce the effective strength of the welded joint. 1.2 Slag Inclusion Formation Mechanism: Slag inclusion refers to non-metallic impurities generated during the welding process that fail to escape in time and remain trapped inside the weld after solidification, forming defects. The main sources include: Oxides on the base material surface Oil contamination and foreign materials Coating residues Oxidation products generated during the welding process Slag inclusion reduces the effective bonding area of the weld and creates stress concentration areas, affecting weld joint reliability. 2. Six Root Causes of Porosity and Slag Inclusion 2.1 Workpiece Surface Contamination — The Most Common Cause Insufficient cleaning before welding is the primary cause of porosity and slag inclusion….

The SAW-3600C Drawn Arc Stud Welding Machine is a compact welding power source designed for industrial stud welding applications. With a maximum output current of 1,800 A and support for stud diameters from 3 mm to 12 mm, it is suitable for welding steel and galvanized steel studs. Featuring two independent welding channels, integrated linear servo motor drive and AQC2 Active Quality Control technology, the SAW-3600C provides a flexible and cost-effective solution for mold manufacturing, metal fabrication and other specialized welding applications. Key Features 1. Compact Design With a machine weight of only 65 kg and a compact cabinet structure, the SAW-3600C is suitable for production environments with limited installation space. 2. Dual Independent Welding Channels Two independent channels support connection to different types of welding terminals, including manual and semi-automatic servo welding guns. Both channels can operate independently or work in sequence under the control of the power source. 3. Integrated Linear Servo Motor Drive The integrated drive function supports direct control of linear servo motors, simplifying system configuration for servo welding applications. 4. AQC2 Active Quality Control Equipped with second-generation AQC2 technology, the system offers strong resistance to external disturbances, helping maintain consistent welding performance. 5. Welding Counting and Alarm Functions Built-in welding counting and alarm functions support production monitoring and help operators identify abnormal operating conditions. Applications The SAW-3600C is suitable for a range of industrial drawn arc stud welding applications, including: Mold and die manufacturing Metal fabrication and hardware production Steel component manufacturing Industrial equipment manufacturing Specialized stud welding applications Technical Specifications Item Specification Model SAW-3600C Input Voltage AC 380 V ±10% Input Frequency 50–60 Hz Rated Capacity 90 kVA Inverter Frequency 20 kHz Maximum Output Current 1,800 A Rated Output Current 1,500 A Rated Output Power 90 kW Open-Circuit Voltage 100 V Stud Diameter 3–12…