Welding Technology 

Tucker® Stud Welding

Tucker® stud welding is a drawn arc stud welding system suitable for manual, semi-automated, and fully automated applications. Tucker® is part of STANLEY Engineered Fastening.
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Two people discussing design of a fastener.

Drawn Arc Stud Welding 

Stanley® Tucker stud welding technology is an economical and efficient drawn arc welding process. Whether manual, semi-automated, or fully automated, all process sequences are monitored according to electrical and mechanical parameters. The Tucker® system uses welding studs and clips instead of conventional holes and screws.  

Stud welding offers numerous advantages:  

  • one-sided access is possible  
  • linear motor-guided stud welding guns and welding heads  
  • fastening without holes  
  • watertight and gastight  
  • flexible system solution with low cycle times and area costs  
  • process monitoring
Close up of three Stanley Tucker standard flange weld studs
Close up of two Stanley Tucker welding pins
Close up of three Stanley Tucker unthreaded weld studs
Close up of three different Stanley Tucker aluminium welding studs
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Close up of three Stanley Tucker standard flange weld studs
  • Close up of three Stanley Tucker standard flange weld studs
  • Close up of two Stanley Tucker welding pins
  • Close up of three Stanley Tucker unthreaded weld studs
  • Close up of three different Stanley Tucker aluminium welding studs

Tucker SWS® (Stud Welding System)

Tucker® stud welding systems with linear motor technology offer a process-monitored welding sequence and precise positioning thanks to the integrated right-angle detection. Their reliability and robust, compact design make them ideal for production processes in a wide range of applications. Tucker® stud welding is therefore ideal for manual as well as semi-automatic or fully automatic production applications.  

The Stanley® Tucker system consists of the following components:  

Controller and Energy Source 

Tucker stud welding controller unit for drawn arc stud welding on white background

The controller is the heart of the SWS system. It controls the welding energy and stud movement. It also enables process monitoring, including documentation in real time. The energy source can be assigned five welding outputs, thus guaranteeing high efficiency and economy.  

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Tucker stud welding controller unit for drawn arc stud welding on white background

Feeder 

Tucker stud welding feeding unit for feeding welding studs to the stud welding system.

The feeder units ensure low impact separation of the welding studs and reliable feeding. The feeding process can therefore be fully monitored and event-controlled.  

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Tucker stud welding feeding unit for feeding welding studs to the stud welding system.

Welding Head

Close-up of a Tucker stud welding robot arm with an attached welding head

The welding head is suitable for steel applications, gas-assisted welding for aluminum and CrNi materials, and high-strength steels. Low-spatter welding is possible. Depending on the requirements, different options can be individually selected for the applications.

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Close-up of a Tucker stud welding robot arm with an attached welding head

Stud Welding Gun 

Close-up of a black Tucker stud welding gun for manual drawn arc stud welding on white background

Manual welding guns are available for semi-automatic and manual applications. All Tucker® guns use a linear motor and have an integrated right-angle sensor, which contributes to the quality of the weld.  

Tucker stud welding guns enable both steel and gas-assisted welding of materials such as aluminum or CrNi materials and high-strength steels.  

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Close-up of a black Tucker stud welding gun for manual drawn arc stud welding on white background

Additional Equipment Options 

The Tucker stud welding surface cleaning system CleanJet

We offer additional technologies and options to improve your production processes and meet complex requirements. Numerous extensions to the Tucker SWS system are available, including:  

  • The  CleanJet surface cleaning system, for example, in aluminum applications  
  • TSD stud diverters to reduce the number of welding tools  
  • The TCS cleaning station increases the service life of welding tools  
  • Hose packages and cable routing systems reduce maintenance intervals  
  • Stud testing tools  

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The Tucker stud welding surface cleaning system CleanJet