What Type of Materials Can Be Stud Welded?

Stud welding is a time-saving and less-expensive method for many welding projects. In addition, the strength created during the process can make it a preferred method for many types of work. Typically, this type of weld will outlive the rest of the product, solidifying its placement at the top of the welding options. By ensuring a durable and long-lasting finished product, you are doing yourself a favor.

Different types of materials can be stud welded, including steel, aluminum, brass, and copper. The variety of materials that can effectively be welded, as well as the multiple uses, make it a very versatile technique. Educating yourself about the different materials can go a long way toward ensuring you are choosing the right material and the best stud welding tools for your stud welding project.

Steel

Low, medium, high-carbon, and stainless steel can always be stud welded. Low carbon stud welding does not require pre or postheating. Medium and high carbon, above 0.25, will require preheating to prevent cracking. Postheating is also recommended for higher carbon levels. Steel is a great stud and base material. As a side note, stud welding steel alloy is limited and generally not recommended. Try to avoid this unless your options are severely limited.

Aluminum

Another preferred stud welding material is aluminum, both as a base material and a stud. Aluminum and aluminum alloys are both good options, with aluminum alloy being a good option for a stud. Although aluminum alloy material is the better option for a stud, pure aluminum will work well.

Brass

Brass is a good stud welding material, if it is lead-free. Using brass as a base can be an effective alternative to other materials. Strong options for studs include brass, mild steel, and stainless steel. The capacitator discharge process is the best option when stud welding brass.

Copper

Copper is another material with distinct advantages and disadvantages. If you are looking for a project without marking, the copper base should be used with brass weld studs. Stainless steel and mild steel are good options as well, but they may result in marking. If you are concerned with marking, copper seems to be the logical choice. High-speed capacitator discharges are the best option for stud welding copper.

Stud Welding Selection Chart

Below you will find a chart that will help determine stud welding material selections. Prepared by AWS Committee on Arc Welding and Cutting, Production Fastening Systems, LLC, published the chart.

Stud Metal Options

Carbon Steel
Stainless Steel
Alloy Steel
Aluminum
Brass

A
A
B
B
C

A
A
C
A
A

A
A
C
A
D

Base Metal Options

Carbon Steel
Stainless Steel
Alloy Steel
Aluminum
Brass

A
A
B
B
C

A
A
A
A
A

A
A
C
A
D

Source: Production Fastening Systems, LLC

Legend:
A- Applicable without special procedures or equipment
B- Applicable with special techniques or for the specific applications that justify preliminary trials or testing
C- Limited application
D- Not recommended

Arc Stud Welding vs. Capacitor Discharge

Arc stud welding is a reliable fastening method that will weld almost any size stud to a metal piece in a very short time. This method creates welds on base metals that can be as thin as .048 inch. The process requires a power supply, stud welding gun, and metal fasteners.

A capacitor discharge (CD) can be completed even faster than an arc stud weld. The quick method of welding will reduce marking and burning on the materials. The CD method is typically used when the result will need to be free of markings and have a smooth appearance. The fasteners used in capacitor discharge are relatively unchanged following the process, so this can be an effective tool if you are looking to cause minimal changes to your fasteners and studs.

Product result, tools available, and type of weld will all determine which materials should be used for stud welding. It is imperative to do your due diligence when you are preparing a stud welding project. The materials you use, the methods you employ, and your overall experience in welding will all play a factor in the success of your welding project. If you are unsure of results or combinations, a quick online search will lead to thorough explanations and video tutorials. If you need help purchasing stud welding equipment, do not hesitate to give us a call at the Stud Welding Store!