In the automotive industry, stud welding operations are heavily utilized in many applications. From exhaust systems to electrical wire routing, multiple types of stud welding operations are used as fastening systems in various sections of most automotive construction. If you’re working in the automotive industry or any other business that uses stud welding, you can find everything you need to get the job done with Northland Fastening Systems (NFS). We provide stud weld tools for rent or purchase, a complete range of stud types and dimensions, stud welding accessories, and the expert advice of our staff of experienced technicians. For capacitor discharge (CD), drawn arc, and short cycle weld fastening systems, NFS is a one-stop shop.
Stud welding today is used largely for attaching types of steel in composite construction, fasteners, food-grade welding, and more. When it comes to cars and other vehicles, steel is used in many parts of gas-powered combustion engines, chassis, and frames. However, with electric-powered vehicles becoming more and more prevalent, manufacturers are constantly looking for ways to make the end product lighter and powered with less energy while still being safe for drivers.
Using stud welding for fastening systems is a highly efficient technique, so instead of swapping it for an operation that uses lighter materials, more commonly, automotive manufacturers are utilizing aluminum stud welding systems, and broadening and improving the capabilities of those methods. When it comes to selecting a welding operation to calibrate for aluminum, manufacturers usually choose CD over drawn arc resistance welding because of the conductivity of aluminum compared to steel.
CD Welding for Aluminum
CD stud welding forms a connection point by generating a burst of energy from low-voltage electrostatic capacitors with direct current. That burst of energy heats the stud tip, vaporizing it and creating an ionization path that allows complete flow of current through an arc that, in turn, heats the stud and connection point. Applying pressure of the stud to the surface then completes the weld.
The conductivity of aluminum makes CD stud fastening systems more effective than drawn arc welding because the electrical current can move more easily. The arc current in drawn arc welding requires a great deal more energy to weld aluminum, making it less useful for lightweight, rapid welding. CD welds are performed within milliseconds and they leave no marking on the opposite surface. Because of this and the conductivity of aluminum, they are the primary choice in automotive manufacturing for electric cars.
CD stud welding for aluminum can be used extensively in nonstructural automotive construction. For example, CD studs are applied in cosmetic aluminum paneling for the framework, electrical routing, insulation, power-steering columns, heat shields, exhaust systems, lighting, and more.
To learn more about the use of stud welding for aluminum in electric cars and other applications, or about other stud welding fastening systems, call Northland Fastening Systems at (651) 730-7770. You can also request a quote online to get started with us today.