Types of Welding

Welding

Welding is a process that bonds two pieces of metal together. A welder uses filler metal and the parent material to form a joint. The welder uses a shielding gas to prevent contamination of the weld. The heat used during welding can change the properties of metal and straighten warped pieces. The welder may also use a specialized torch to weld large pieces of metal. Here are some common types of welding.

Spot welding

The process of spot welding uses an electric current to join two metal sheets together. The intensity and duration of the current determine the amount of heat that is delivered to the spot. This amount of energy is chosen to match the properties of the sheet material and its thickness. Applying too little or too much energy will not melt the metal, while applying too much will eject the molten metal and form a hole. By adjusting the amount of energy, the weld is a reliable and durable process.

When performing spot welding, the welder must apply a high-current that melts the raw materials. Once the electric currents are turned off, the electrode pressure continues to work on the joint, and the molten sheet metals solidify. To keep the process efficient, spot welding machines have a cooling water system. Depending on the project, spot welding machines vary in power supply, magnitude, and resistance among electrodes. In general, spot welders are most efficient when they can join middle-to-middle metals.

TIG welding

TIG welding, or tungsten inert gas welding, uses shielding gas and a filler metal to join two pieces of metal. Though more complex and time consuming than other methods, TIG welding offers the most control and results in higher-quality welds. Furthermore, TIG welding is considered the cleanest type of welding, requiring minimal clean-up after the weld process. The quality of TIG welds is often referred to as stacking, and an experienced TIG welder can produce an aesthetic weld.

TIG welding is widely used in the automotive industry, where it is ideal for joining dissimilar metals. It is also an excellent choice for repairing tools, dies, and bicycle tubing, and reduces corrosion. TIG welding also minimizes mess, making it ideal for small-wall tubing. As such, it is best suited for small-wall tubing and other small-wall materials. And since TIG welding produces high-quality welds, this process is perfect for a variety of applications.

MIG welding

The basic set-up for MIG welding involves selecting the right voltage. This determines the intensity of the electrical arc and the amount of metal melted. A high voltage will melt the metal but not burn it through. Using the correct voltage can lead to more efficient welding. Listed below are some of the key steps to successfully set up your MIG welding machine. Once you've mastered these steps, you can begin welding! Just remember to follow these steps to ensure maximum productivity and safety.

When welding with MIG, wires are usually continuous. A continuous wire allows higher current density, a necessity because excessive current can cause electrodes to crack. Different expansion coefficients can also lead to coating failure. Wires are typically 0.8 to 1.2 mm in diameter, though thinner wires are sometimes used. A continuous wire is also easier to clean than single-wire welding. However, if you're looking for high productivity, you'll want to choose a machine that has a continuous wire.

Pulsed-spray welding

Despite the many advantages of pulse spray welding, many people have mistaken it for the end all be all of their welding problems. Although it can reduce spatter and distortion, and increase deposition rates, pulse spray is not a magic potion. While it is an effective process in some applications, assuming that it will work in all applications is asking for trouble. However, there are a number of applications where pulse spray can improve overall welding quality.

The main advantage of pulsed-spray transfer over other welding techniques is a reduction in the heat input, as compared to TIG. The process has similar advantages, such as high deposition rates and low spatter, making it an excellent choice for welding in horizontal situations. However, there are some drawbacks to the process. It may not be suitable for vertical or overhead applications because the wire may get stuck in the weld pool, resulting in drips and poor fusion.

FCAW welding

One of the benefits of FCAW is that it does not require shielding gas, unlike MIG welding. This method of welding is also easier to use and does not require much manual dexterity on the part of the operator. Just like MIG welding, operators must configure their welding gun for the specific job and aim the nozzle to create the weld. Both techniques have their advantages and disadvantages, so it's important to choose the right one for your needs.

The FCAW wire contains a mix of raw materials, including flux, arc stabilizers, alloying elements, and micro-alloyed elements. These elements improve the quality of the metal weld by nucleation and contribute to the fine grain structure of the weld deposit. The flux coating also contains deoxidizers and gas-forming agents. For more information, visit the FCAW website. FCAW welding can be a great option for joining thick metals such as carbon steel.

Stick welding

When welding sticks, arc voltage and amperage requirements differ greatly, but the basic principle remains the same. The length of the arc should be adjusted to allow for differences in electrode diameter. Likewise, the current generated by the electrode must be adjusted for varying degrees of heat. This can be compared to lighting a match, which can heat tin foil or a frying pan. To choose a proper stick welding power supply, you need to select one that supports both AC and DC currents, or one that is designed to support both.

The ideal size of a weld bead is 2.5 times the diameter of the electrode, but if it is too narrow, the weld will lack penetration. To avoid this, slowing down the pull of the electrode will improve the final product. If you are pulling the electrode too slowly, the resulting weld will be lumpy and not completely penetrate the metal. Low amperage can also limit penetration, making filler metal sit on top of the joint.