How New Technology and Better Stud Welding Products Make Industry More Sustainable

Since the beginning of the 20th century, stud welding began to be used more prevalently throughout industries beyond its original applications in shipbuilding. The several wars that the United States and much of the rest of the world faced also played a large role in the expanded use of strong, fast connecting systems like stud welding in manufacturing. Today, stud welding is used in most industries, from automotive to food grade equipment. However, many changes in the way people build are causing stud welding to develop once more to keep up with sustainability and energy-efficient designs. Over the last 10 years, engineers and fabricators have worked to improve the functioning lifespan, weight, and other properties of welded studs. If you are a manufacturer working with drawn arc, capacitor discharge (CD), or short cycle stud welding operations, you can find the high-quality supplies you need at Northland Fastening Systems (NFS). We provide a complete range of stud welding products, including tools for rent or purchase, studs, welding accessories, and our own welding technicians expert advice.

Stud Welding Products

Modern stud welding products already offer some of the most efficient systems for installing quick, powerful connection points and fastening technology. However, fabricators and manufacturing companies are still working to increase the range of those capabilities.

Setting Standards

Two major industries are setting sustainability and cost-saving guidelines for the rest of those who use stud welding on a large or heavy-duty scale. Power plants and shipbuilders have both researched and found ways to improve their use of studs with less waste and for longer use.

Power plants:

Most power plants use studs installed in operating furnaces to act as heat transfers into boiler tubes. These studs are typically made of 430 stainless steel with a refractory coating, and they have to be fully replaced about once a year. The replacement of these studs requires a large factory shutdown, which is both expensive and time-consuming. Some newer kinds of studs made from an iron and aluminum alloy have shown to last three to four times longer than 430 stainless steel studs. This new stud technology runs colder than older studs, transfers heat better, and forms anticorrosive aluminum oxide when exposed to furnace temperatures of 1,600-1,800ºF.


Shipbuilders, especially those manufacturing naval vessels, have also found a way to eliminate cost and improve sustainable designs. A study released in 2012 showed that newer studs welding equipment with lower energy consumption during idle (between welds) could reduce shipbuilding costs on large vessels by $0.128 to $0.154 per stud. For shipyards that build destroyers and other navy warships, that could mean a reduction in cost of $589,000 to $708,000 in energy alone.

Newer technology across industries using stud welding products will only continue to prove how much more efficient and sustainable they can be. To learn more about the newest stud welding machines and the other products we offer, contact NFS at (651) 730-7770 or request a quote online.