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Tip Ignition Process (CD)

Easy handling and high quality for thin sheet metal,

that is what makes tip ignition processes so convincing

Process advantages

- Inexpensive weld studs
- A standard 230 V AC socket is sufficient
- Easy handling
- Cost-effective equipment
- Easy to automate
- No marks on the reverse side or, depending on the application, only marks visible in reflected light
- Pre-painted reverse sides possible

Typical areas of application:

Control cabinet construction, vehicle construction, facade technology, cathodic corrosion protection, insulation on metal

Process types:

The tip ignition process is further divided into the contact method and the gap method. Both methods are explained in more detail below, along with their application strengths and technical details.

Tip Ignition Overview

The basic rule also applies to stud welding: The joint must not fail in the weld zone!

During the extremely short welding time, the entire surface of the weld stud and the workpiece must be melted.

As a result, there are process limits beyond which compromises in strength must be accepted. The following table shows dimensions with which process-reliable joints according to DVS can be achieved. Other dimensions can in some cases be welded well and safely, but should be verified by tests on the actual welding application. A welding procedure test according to DIN EN ISO 14555 can usually only be passed with considerable effort.

Parameter	Gap welding	Contact welding
Process number according to ISO 4063	786	786
Stud diameter d (mm)	0.8 to 8 (aluminium up to 6)	0.8 to 8 (aluminium up to 6)
Peak current approx. (A)	10,000	10,000
Welding time approx. (ms)	0.5-2	1-4
Spring force approx. (N)	40-60	60-100 (depending on piston dimensions and bearing)
Impact velocity approx. (m/s)	0.5-1 (aluminium 1-1.5)	0.5-0.7
Ignition	Usually correct = (premature ignition possible) high process reliability	Always correct high process reliability
Barely visible marks on the reverse side	yes	yes
Material	Steel, stainless steel, brass, aluminium (and others)	Steel, stainless steel, brass, aluminium (and others)
Min. workpiece thickness (mm)	0.5	0.5
Insulation applications	yes	yes
Application strengths	Automated welding Thin sheet with high demands on the reverse side Aluminium	Manual welding of steel (alloyed/unalloyed) Electrogalvanised surfaces Slightly curved surfaces
Application outside the process limits
Geometric limit	< Ø10, Ø12 in steel, stainless steel and brass < Ø8 in aluminium (These joints are possible, but fracture in the weld zone cannot always be ruled out)
Limit of weldability of the workpiece material	Unsuitable coatings, some exceeding 25 µm (e.g. galvanising) Thick coatings combined with large diameters Oxides on aluminium surfaces Alloying elements such as lead, sulphur
Values may vary depending on equipment and application

The values in the table above are based on Table 1 of DVS 0903:2018.