Quick welding process

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I need some help in developing a very quick process for welding a 1/8" dia steel rod to a 1/8" x 1/2" bar.  One end of the rod would be welded to the flat side of the bar and the rod would stand straight up from the flat side when finished.Ideally I would like to perform some sort of contact weld in which the end of the rod is brought to the surface of the bar and the weld is done at the point of contact.  Speed and simplicity are most important.  The strength of the weld is not important as there are very small loads or stresses on the piece when in use.Any suggestions would be greatly appreciated.Thanks.
Reply:Hey workless,Since my entire career has been in welding & production design, making a simple fixture would not entail anything elaborate & would probably fill your needs. If you would provide a pic, or a drawing with EXACT parameters, I would be willing to help you. Also, if you provide data with an approximate number of pieces you want to produce, I could also give you a detailed drawing & possibly a model for you to evaluate. Your indication of a "spot welding" setup would probably result in a higher initial cost & may not be an adequate strength factor. My application would be with using MIG with (2) easy/quick tacks for a better joint strength. Post a pic/drawing/prototype with precise dimensions.DennyComplete Welding/Machine/Fab. ShopMobile UnitFinally retired*Moderator*"A man's word is his honor...without honor there is nothing.""Words are like bullets.... Once they leave your muzzle, you cannot get them back."
Reply:If I had to make something like that in small quantities, less that 100, I would drill through the bar, slide the 1/8 rod through the hole and weld the back side.Ian TannerKawasaki KX450 and many other fine tools
Reply:The overall process would require welding well over 100 of these rods per hour on a continuous basis.  The higher initial cost of the "spot welding" that was suggested may be well worth the investment in the long term.What equipment would be necessary to perform this particular spot welding?  Again, the strength of the weld is not critical.
Reply:CD stud welding with a smooth stud?  Look up Midwest Fasteners.  This would give you a really fast setup.  Emhart Teknologies might be able to help as well.I play with Robots and do some welding.
Reply:Thanks for your suggestion of looking into CD stud welders.  I checked a few places on the internet and it appears be exactly what I am looking for.Thanks again.
Reply:+1 on the stud welder.  I am not too familiar with them but you may be able to use a unit like a body shop does for dent removal, that would be fairly inexpensive but it would be close on size I would think