Stud Welding Vs. Resistance Welding

7 April 2016
 Categories: Construction & Contractors, Blog


When trying to join two pieces of metal together, two welding strategies you can use are stud welding and resistance welding. Both are effective ways of welding together two pieces, but there are different circumstances under which each option might be better.

The Use Of Fasteners

Stud welding relies on fasteners to hold two pieces of metal together. This allows for materials to be fastened together in one step. The welding process leads to the stud base and the area that is being melted merging. Then, the melted metal hardens and the two parts of the weld are secured into place.

The Method Of Heating The Metal

Resistance welding, in contrast, joins pieces of metal together by heat that is generated through an electric current. The electric current first melts the materials that will be joined. Stud welding, on the other hand, uses the heat generated from the arc.

The Use Of Pressure

The strong pressure is used to hold the materials together. This leads to a joint without the need for filler materials. There is no need for pressure with stud welding, on the other hand. Therefore, resistance welding requires access to both of the pieces. Therefore, under some circumstances, stud welding is the only viable option.


Stud welding can be performed more quickly than resistance welding. Under circumstances where there is a limited amount of time, stud welding might be required.

Overall Costs

Resistance welding can be more expensive than stud welding. There are less maintenance costs regarding stud welding. Also, given that stud welding doesn't take as long, there is less money spent on labor. Also, stud welding has lower initial equipment costs than resistance welding.

The Strength Of The Weld

Stud welding can be stronger than resistance welding, which has lower tensile and fatigue strength. Materials that have a high tensile strength are less likely to break when placed under pressure. Fatigue strength refers to how well the material will be able to handle dynamic loading. If the weld is subjected to fluctuating stresses and it does not have adequate fatigue strength, the weld is more likely to fail.

The Utility Of The Welding Method In Mass Production

Though there are some differences to both approaches, they are both great ways to mass produce welds overall. The results created by both resistance welding and stud welding are very consistent. Both processes are easy to automate.