{"id":19290,"date":"2022-10-27T12:41:07","date_gmt":"2022-10-27T09:41:07","guid":{"rendered":"https:\/\/fractory.com\/?p=19290"},"modified":"2024-01-26T13:26:25","modified_gmt":"2024-01-26T11:26:25","slug":"types-of-welding-processes","status":"publish","type":"post","link":"https:\/\/fractory.com\/types-of-welding-processes\/","title":{"rendered":"Welding – 12 Types Explained"},"content":{"rendered":"

Welding is a fabrication process<\/a> that joins two or more metals using heat, pressure, or both to form a strong, permanent bond. Weldable materials generally include metals and thermoplastics, but welding other materials like wood are also possible.<\/p>\n

Modern welding was pioneered in 1800 when Sir Humphry Davy struck an electric arc using a battery and two carbon electrodes. Since then, welding has developed into highly versatile forms, paving the way for its use in a variety of applications, from small DIY projects to large-scale manufacturing assemblies.<\/p>\n

Different welding processes are a staple in most industry sectors and thus, let’s understand how these work and the principles behind them.<\/p>\n

How Does Welding Work?<\/h2>\n

Welding is a high-heat process that melts the base materials. This is also the main differentiating factor from soldering<\/a> and brazing where only the filler material is melted and no fusion between the parent materials occurs.<\/p>\n

Welding works by joining two or more workpieces together at high temperatures. The heat causes a weld pool of molten material which after undergoing cooling, solidifies as one piece, forming a weld. The weld can even be stronger than the parent metals.<\/p>\n

There are many different types of welding but all of them involve heat or pressure to melt the metals to create welded joints<\/a>. The source of heat or pressure may vary depending on the application and the material used.<\/p>\n

Metals are known as the most commonly welded materials, given their easy and straightforward welding principles. Plastic welding<\/a> is also quite widespread but welding wood is just in its nascent phase.<\/p>\n

The welding process is influenced by many factors, such as the need for specific additional tools, shielding gases, welding electrodes and filler material. Let’s have a closer look at some of the most common welding methods used today and find out what makes each of them unique.<\/p>\n

Different Welding Types<\/h2>\n

Although the fundamental concept of welding is rather simple, we categorise them by the energy source used. As we break these subcategories down even further, we can dive deeper into the operating principles behind each separate method.<\/p>\n

Arc Welding<\/h3>\n

Arc welding includes some of the most well-known welding processes and these are most likely what come to mind when visualising the welding process in general. In these processes, an electric arc generates heat between the electrode and the metal to be welded. The electrode may be consumable or non-consumable, and its power source can vary from alternating (AC) to direct current (DC).<\/p>\n

MIG\/MAG Welding<\/h4>\n

\"MIG\/MAG<\/p>\n

Gas metal arc welding (GMAW)<\/a>, also known as MIG\/MAG welding (metal inert gas\/metal active gas), uses a continuous wire electrode fed through a welding gun. As the electric arc melts the electrode wire it is then fused along with the base metals in the weld pool.<\/p>\n

Shielding gas is simultaneously supplied to the weld area to create a protective layer from atmospheric contamination.<\/p>\n

The simplicity of this welding technique allows it to be one of the preferred choices for industrial welding, manufacturing, construction and for the automotive sector. GMAW has pretty much replaced atomic hydrogen welding (AHW)<\/a>, mainly because of the availability of inexpensive inert gases.<\/p>\n

TIG Welding<\/h4>\n

\"tig<\/p>\n

Tungsten inert gas welding<\/a> uses a non-consumable tungsten electrode and an inert shielding gas. In contrast to MIG\/MAG welding<\/a>, using separate filler metal in TIG welds is optional and depends on the project.<\/p>\n

The gas tungsten arc welding (GTAW) process creates accurate and high-quality welds with great penetration making it suitable for several applications, such as aerospace and automotive industries. While TIG welding has a steeper learning curve than MIG welding, the many adjustable features and functions of a TIG welder make it a very versatile process.<\/p>\n

Shielded Metal Arc Welding<\/h4>\n

\"stick<\/p>\n

Shielded metal arc welding (SMAW)<\/a> also known as manual metal arc welding (MMAW\/MMA) or just stick welding, uses a consumable flux-coated metal electrode to join metals.<\/p>\n

As we strike the electrode with the base metal, it creates an arc that melts down the materials in the weld pool. The flux releases a shielding gas to protect the weld metal from contamination. Slag deposits are removed after the cooling process using common shop tools such as a wire brush.<\/p>\n

SMAW is a reliable welding process that offers versatility in welding different metals and various conditions. It’s also portable and lightweight, with no need for a gas tank as with some of the other welding methods mentioned previously. The welding electrode comes as a welding rod, making it perfect for tight spaces and awkward welding positions.<\/p>\n

Flux-Cored Arc Welding<\/h4>\n

\"Fluc-cored<\/p>\n

Flux-cored arc welding (FCAW)<\/a> is an automatic or semiautomatic process that uses a welding electrode that contains a flux core that acts as a shielding agent. Additional protection from contaminants is called dual-shielded FCAW, wherein a shielding gas is used along with the flux-cored electrode.<\/p>\n

FCAW is well-suited for ferrous metals<\/a> and operations requiring little pre-cleaning. It is best used for repairs, pipes, shipbuilding, outdoor and underwater welding because of its incredible protection from external conditions.<\/p>\n

Although FCAW and GMAW are two separate welding types, the only major difference lies in shielding the weld zone using electrodes and shielding gases.<\/p>\n

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