Method and device for welding an aluminum-based stud

A welding method comprising:

• (a) contacting a stud with a base;
• (b) applying voltage between the stud and the base;
• (c) lifting the stud off the base;
• (d) generating an arc;
• (e) melting the tip of the stud and a section of the base;
• (f) applying pressure to the tip of the stud and the section of the base that has been melted;
• (g) dividing a main welding current into at least three stages and incrementally increased the welding current from the beginning stage to the end stage;
• and
• (h) welding together the stud and base.

A welding system comprising:

• a stud;
• a base;
• a first device operably applying voltage between the stud and the base;
• and
• a second device operably lifting the stud slightly off the base;
• wherein a pilot arc with a small amount of current is generated, a main arc with a large amount of welding current is generated, and the tip of the stud and the section of the base are melted;
• wherein pressure is applied to the tip of the stud and the section of the base that has been melted;
• wherein the welding current is divided into stages from beginning to end and increased as the main arc is generated;
• wherein the molten tip of the stud is applied under pressure to the molten base in under five milliseconds after the main arc current has been terminated;
• and
• wherein the stud and base are operably welded together.

A welding system comprising:

• an aluminum or aluminum alloy stud;
• an aluminum or aluminum alloy base;
• a first device operably applying voltage between the stud and the base;
• and
• a second device operably lifting the stud slightly off the base;
• wherein a pilot arc with a small amount of current is generated, the main arc with a large amount of welding current is generated, and the tip of the stud and the section of the base are melted;
• wherein pressure is applied to the tip of the stud and the section of the base that has been melted;
• wherein the welding current is divided into stages from beginning to end and incrementally increased as the main arc is generated;
• and
• wherein the stud and base are operably welded together.

A weld stud comprising:

• a cylindrical shank, the shank being an aluminum based material;
• a frusto-conical section extending from the shank;
• and
• a substantially flat end located on the smallest diameter portion of the frusto-conical section opposite the shank.