2026-10-16
Hongbai Technology Technical Column | Professional Series Introduction In stud welding, a small change in current or welding time can make a noticeable difference to the final weld. Too little energy may result in incomplete fusion, while excessive heat can cause spatter, an irregular weld collar, or burn-through on thin sheet metal. On Hongbai Technology’s SAW-3600 series stud welding system, parameters such as pilot current, welding current, and upset time are used to configure the welding cycle. Getting the best result is not simply a matter of increasing the current. The stud, base material, surface condition, lift height, and welding gun movement all need to be considered together. This article looks at how these parameters work, the reference settings available on the equipment, and what to consider when adjusting them for different applications. 1. How the Stud Welding Cycle Works In the servo-controlled welding process described here, the electrical output and the mechanical movement of the stud work together through four stages. Stage 1: Initial contact The stud is positioned against the workpiece, creating the electrical contact required to initiate the welding sequence. Consistent positioning and stable contact help establish repeatable starting conditions. Stage 2: Pilot arc The power source applies the pilot current while the servo welding gun lifts the stud away from the workpiece. This establishes the pilot arc before the main welding stage begins. The pilot stage helps initiate the arc and prepare for the main welding cycle. On coated or contaminated surfaces, the results also depend on the coating, surface cleanliness, and the selected current and time. Stage 3: Main welding arc When the stud reaches the preset lift height, the power source delivers the main welding current for the programmed duration. The arc melts the end of the stud and the corresponding area of the…
