Strength of Complete Fusion in the Stud Welding Process

Since its invention in the early 1900s, stud welding has proven to be an exceptionally useful tool for a wide range of industries. From construction to electronics, stud welding offers a fastening system that connects metals with strong, rapid, and clean operations. When applied correctly, stud welded connections are stronger than the stud and base material put together. In fact, one of the quickest ways to test the accuracy of a weld is by seeing if the stud will fail in a bend test before the connection point fails. If you are working with stud welding, you know the benefits it provides to many manufacturing processes. Stud welding is quick, cost-effective, and powerful. At Northland Fastening Systems (NFS), we provide a complete range of supplies for the drawn arc, capacitor discharge (CD), and short cycle stud welding process. This includes studs for each type of welding, tools for rent and purchase, welding accessories, and even repairs for most welding equipment.

Stud Welding Process

One of the reasons why the stud welding process is advantageous for so many industries is because of the strength a full fusion weld point provides. Stud welding operations completely fuse stud materials to surface materials. This fusion can be done with a variety of metals, including steel, aluminum, and even copper.

What Is Complete Fusion?

Complete fusion requires both metals to reach melting temperatures. Molten metals will fuse together at the weld point and create a complete connection between parts. All layers of stud and surface material should be molten in order to create complete fusion. Because of this requirement for deep penetration, stud lengths will shorten a specified amount when installed, depending on material and weld types.

A homogenous weld point that is completely fused will be clean with no spatter or puddles. Complete fusion eliminates the risk of a cold or porous weld that will likely fail. Any incorrect applications that have incomplete fusion can be revealed with testing. Incomplete fusion issues can be prevented by accurately calibrating welding equipment, using the right power, and performing a weld in the correct duration and positioning. With drawn arc welding, ceramic ferrules and shielding gas also help technicians achieve complete fusion in the welds.


For complete fusion through paint, annealing, and other surface treatments, technicians should adjust accordingly and use grounding clamps on the job site. In facilities where automated stud welding systems are integrated into a production line, complete fusion results are often built into the equipment. Automation parameters for complete fusion can be adjusted when stud dimensions, materials, and other specifications are changed.

If you are working with any kind of stud welding process in any industry, and are looking for supplies, equipment, and more, we can help. Contact NFS at (651) 730-7770. You can also request a quote online to get started with us today.