In one aspect, there is disclosed a drawn arc fastener welding process that includes the steps of providing a fastener positioned in a welding tool, providing a weld control, providing a work piece, contacting the fastener against the work piece, energizing a pilot current, lifting the fastener from the work piece and drawing a pilot arc, energizing a main arc for a predetermined duration, short circuiting the fastener relative to the work piece, cyclically redrawing an arc and short circuiting the fastener relative to the work piece at least one additional cycle, dynamically sensing an arc voltage and calculating a derivative signal of the voltage over time for each drawn arc and short circuit of the cycle wherein a position and motion of the fastener relative to the work piece is controlled and the energizing of the arc is controlled, and plunging the fastener into the work piece forming a weld.