Capacitor Discharge Stud Welding
Weld Studs Applied To Thin Gauge Metal
--A New Class of Its Own--

  • Instantaneous welding of studs and pins made of steel and non-ferrous metals with diameters of up to 3/8" with heavy-duty upgrade kit.
  • Stud connections onto thin sheet metals with a minimum thickness of 20 gauge.
  • This method replaces prior perforation, drilling, press-in nuts, riveting, etc.
  • Leak-proof assemblies.
  • Due to minimal thermal influence on the material, there is little reverse-side marking.
  • High performance BURCO/KOCO equipment results in high production rates.
Welding Operation:

1. A stud is welded by means of a direct discharge of a capacitor battery with high capacitance.

2. Ignition of the arc--caused by discharging of the energy-storing capacitors-- first of all concentrates on the ignition tip which vaporizes.

3. The arc melts the entire face of the flange and the surface of the parent material opposite the flange.

4. The stud is moved forward until contact is made with the parent material.

5. The arc is extinguished and the capacitors are completely discharged.

6. A uniform cross-sectional fusion of stud and parent material is achieved.

7. Weld cycle amounts to only 1 to 3 ms.

8. Hand-held guns move the stud forward mechanically by spring pressure.

Welding Conditions:  The following are conditions which must be met to assure successful welding with CD process: 
  • Clean material surface (no paint, corrosion or coatings)
  • Material surface must be flat
  • Gun must be held perpendicular to the surface (1° or less)
  • Base diameter cross section:  9.5 mm maximum
Click here  for the Burco KST-9 & KST-10 Capacitor Discharge Stud Welders.

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