welding process


What is Welding Process

Welding is an old concept that dates back in hundreds of years. Fortunately, different techniques have been developing as time moves. As you begin the welding journey, don’t be overwhelmed by the amount of information that comes along with it.

Some welding techniques produce clean beads and require no cleanup and vice versa. Also, the type of welding materials will speak volumes. In this piece, we will simplify some of the welding information that you should not afford to overlook.

Let’s get the facts right underway.

What is welding?

Welding is simply the fabrication of metal by indulging high temperatures. In the long run, it will melt and fuse the metal parts. One can also use pressure to facilitate the process.

You can perform the process of welding by using multiple energy sources. Some of the examples are:

  • Gas
  • Laser
  • Electrical arc
  • Laser
  • Ultrasound
  • Friction
  • Electrical beam

Types of Welding

Welding is a process that is ever-growing as new approaches emerge. The most common method is:

1. Stick welding

Stick welding is the most widely used type since it happens to be economical. So, how does it work? It used the electrodes. These electrodes are usually rods of metals that will match the piece of metals.

These electrodes have flux coating and will release gases to protect the melted pool from oxidizers and contaminants. The electrical energy will pass through this metal rod. As a result, the electrical energy will melt both the rod and metal simultaneously.

The welder will use the clamp to ground the workpiece.  Such a design closes the circuit and caused electrical circulation.

You can use this stick welding to join pieces of steel plates. The system is mobile since you will only require a supply of rods and electricity. The method is standard in the repair industry for heavy equipment.

You can also apply it to exterior structural welding as it tolerates all windy conditions. You can use the methods to weld stainless steel, aluminum alloys, copper alloys, among others.

2. MIG Welding

MIG (Metal Inert Gas) is one of the fastest welding methods around. It is versatile, which one can do it manually. But that is not all. You can also achieve automatic welding by the use of robots.

MIG Welding

The process is straightforward. You begin by feeding the wire in the handheld gun. Next, you release the shielding gas around the same wire. The method is suitable for any novice without any necessary training.

For one to be consistent, you need to practice more and learn steady motion. You can use this method in the manufacturing industry. Also, the cleanup method is somewhat secure.

3. Oxyfuel welding

Oxyfuel welding is another technique that utilizes gas to produce a flame. The most common type is oxy- acetylene. You can also use filler metal to introduce more materials. The flame that comes from the welding torch will create a melted pool as you focus it on metal.

The single key advantage attached to this method is that you can use a less focused torch tip when heating the materials.

Since this method does not require electricity, it is a movable type. You can use it on farms, automotive exhaust repair, and repair of some house equipment.

4. TIG Welding

The TIG method is super clean and versatile process since it tolerates various metals. One thing for sure is that one requires the right skills to run it properly.

The welder will use the Tungsten electrode to create a melt pool. Typically, electrical energy will go via the electrode, protected by the inert gas, which usually is helium or argon. The electrical energy will melt the material.

You can also use the filer rod if you want to add extra materials to the welded area. You will be in a position to control the process more efficiently.

One will also control the flow of electricity by a foot pedal. You can use this method for aerospace and automotive application.

TIG Welding

5. Flu-cored Arc Welding (FCAW)

The technique is quite similar to MIG, although it is critical to underhand the difference. The only variance is that it will not use shielding gases. The user will only need a machine and a wire. As a result, one will not need to worry about tank refilling.

FCAW produces different results as compared to MIG. For MIG, its weld will appear better. Luckily, FCAW produces nasty fumes and smokes.

Furthermore, it uses an expensive wire. Alternatively, one can use flux core to reduce porosity.

You can use it in the construction sites as it is highly portable.

type of Welding

6. Plasma arc welding (PAW)

The method happens to be almost similar to TIG welding. The only difference is that the electrode will be within the touch’s body. Also, the shielding gas will be far from the electrode.

At this level, you will force plasma out of a small hole. The same plasma travels fast and can heat up to about 50,000 F.
One can use the touch to spray a coat on hard materials. You can also use it to cut materials. The suitable materials should be at least one inch thick.

7. Electroslag Welding (ESW)

ESW is an efficient method that will produce high-quality welds. The process has a complicated setting, but once ready, it becomes automatic. The machine will begin the process by feeding the wire in the flux.

The arc will start as it hits the bottom cap. Eventually, you will experience a pool of melted metal. You can use this method to joint, thick structural steel. The process involves high heat production.

One advantage regarding this method is that it only requires a single pass to weld the metal.

7.Electroslag Welding (ESW)

8. Laser Beam Welding (LBW)

You can use the LBW method to attain extremely narrow welds. The weld is fast and deep as the laser is high powered and focused. The only downside with this method is that its high carbon steel may crack as a result of excessive heat.

Laser Beam Welding (LBW)

One can use this method in the automotive industry. You can also automate this method with robots. As is that is not all; you can also create a semi-automatic process.

9. Spot welding

The technique is a straightforward one and you can use it to bind sheets of metal. Typically, you will use two electrodes to attach the pieces of metal. The welder will start by blasting electricity into the metal. You will partially melt it as you fuse the pieces.

You can use this method manually or trigger a robot to automate it. One can use the technique in the automotive industry.

10. Forge welding

Forge welding is one of the ancient techniques that has been in existence. You will begin by heating two similar metals until they become bright orange. You will then whack them together with the help of a hammer.

Most of the blacksmith use this skill to facilitate the process. They grind the pieces clean as they fit them up. Later, they will splash some flux on the glowing metals to avoid oxidation. Consequently, they will use a hammer to pound it.

11. Submerged Arc welding (SAW)

You can use this method to bind two pipes end by the end. You pour a flux powder over the exact area that needs welding through the tube. It also has a spoon-fed wire, which acts as both electrode and filler material.

The entire process is under the control of the machine. In other words, it is an automated process. As an operator, you set up the device. You will then adjust the settings and press the start button. You can use the method to perform various tasks in the automotive industry.

Advantages of Welding

  • The welded joints require less labor and more economical as it requires fewer materials.
  • The welded joints will typically look better than butted or riveted joints.
  • The welding process will produce less noise as compared to other procedures like riveting.
  • The welded joint is more efficient than the riveted joint.
  • You can create completely rigid joints when doing performing a welded process
  • The welding process will not need as much space as a riveting process
  • The welding process has a fast fabrication process.

In conclusion

Welding is an activity that has been in existence for many centuries. As the new methods emerge, they will simplify the entire process. Besides, the latest techniques are more efficient and economical.

Various industries require specific welding methods to produce certain equipment. Some of this equipment will require particular melting methods. In that regard, you should understand the appropriate process.

Some techniques will require robots, and these robots will automate the process. Other processes are manual. There also some of the welding methods that are fast, efficient, and needed for heavy-duty metals.

Indeed, you will need to understand the concept behind several methods so that you pick the best. It also depends on your needs and the budget.

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Related source links:

Handbook: The Complete Guide to Laser Welding

Everything You Should Know About Aluminum Sheet Metal

White Paper: The Complete Guide To Sheet Metal Fabrication

Essential Design Tips You Should Know About Welding Sheet Metal

The Basics of Bending Sheet Metal You Should Know

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