Implementing Production Line Practices into the Stud Welding Process

The stud welding process is a widely used group of operations in the manufacturing world. Because the process has so many applications, manufacturers find it highly advantageous to be able to automate stud welding on a production line. Streamlining stud welding into an automated production line process allows manufacturers to increase speed, precision, quality, and efficiency for any fabrication project. If you are working with stud welding as a contract manufacturer or professional welder, you can greatly increase your output without compromising quality by implementing production line practices in your facility. At Northland Fastening Systems (NFS), we provide a broad range of tools to automate your stud welding process as well as tools, studs, accessories, and expert services to support your current non-automated stud welding operations.


Whether or not you have the facility accommodations to integrate a fully automated stud welding process, you can always implement elements of a production line in certain ways. Handheld stud guns and other units can be effectively used in a production line setting, although the most efficient process in many cases is automated.


Non-Automated Production Line

The general structure of a production line is designed to operate in stages, with each step of the fabrication process occurring at its own stage. When it comes to non-automated stud welding, forming a production line is entirely possible. An example of an effective non-automated production line process might include these steps:


  1. The surface of the base material is cleaned or otherwise prepped.
  2. Any shielding gas that will be used in a drawn arc process is prepped.
  3. The gun tip is prepped, including any ferrules, fluxes, and stud that might be used, depending on the weld type and the necessary stud dimensions and material.
  4. The weld is performed.
  5. Ferrules and other waste materials are removed.
  6. The weld is inspected for quality.


In this scenario, the majority of the process will be performed by a welding technician, and likely one weld will be performed at a time. When it comes to automation, there are a few key differences that make a production line more efficient.


Automated Production Line

Automated stud welding processes are typically used in sheet metal construction where a large base material can be fed through a conveyor system, but there are some other applications that can feed smaller components that are not necessarily in sheet form through an automated system. Automated production lines often use stud welding tools controlled by a software system. Each step of the process can be done in bulk, including the performance of the weld with multiple stud welding tips. In some facilities, up to 40 studs can be welded in one step, and the software used in a welding process can be calibrated to highly specific results. This can include intricate patterning of the studs with precise placement.


To learn more about integrating an automated or non-automated production line stud welding process into your facilities, contact Northland Fastening Systems at (651) 730-7770 or request a quote online today.