Welding is the process of combining materials by melting them through sufficiently high heat and consequently letting them cool off so that they strongly collaborate.
Nevertheless, the term itself isn’t as much uncomplicated as we believe.
There are lots of complex and diversified types of welding that exist so regarding properly carry out the combining process according to the main objective.
Assuming this fact, we are going to share with you about 14 different types of welding and what they are used for.
So let’s start:
1. Protected Metal Arc Welding (SMAW)
Protected Metal Arc Welding is the basic process of manually joining materials through decaying a wire of electrode that’s been covered with flux and is set between the metal and electrode in the form of an arc.
The process is sustained by an electrical present and as quickly as the melting process is carried out, the disintegrated electrode produces some vapor which is usually called the shielding gas, and thus produces a slag layer throughout the bonded location. This layer secures the metal from all sorts of climatic contamination.
Let’s check out some of the benefits and flaws of this specific welding process:.
Advantages: The primary advantage of this welding process is its simpleness and inexpensiveness. Besides, it is one of the most popular and widely used welding procedures because of its versatility and simpleness.
Drawbacks: 2 of the typical flaws associated with this process are porosity and weld spatter. 2 other typical downsides which are the threat of burn and skin damage can occur from any other welding process if enough precautions are not carried out effectively.
2. Plasma Arc Welding
Plasma Arc Welding is carried out by forming an electrical arc right in between the workpiece and the electrode. The electrode is usually located inside the torch and the plasma goes through a copper nozzle which consequently forms the arc.
If you go through the types of welding we have discussed here, you’ll see this process is rather similar to that of Gas Tungsten Arc Welding whereas the only difference pushes the capability of the first one to separate the shielding gas from the plasma arc.
Let’s find out about its benefits and downsides:.
Advantages: The torch which is designed to perform Plasma Arc Welding makes it possible for a welder to be efficient sufficient to get the controlling of the arc and therefore to observe the total welding process. Besides, the plasma jet and increased heat concentration guarantee faster travel speed.
Drawbacks: The types of equipment used in Plasma Arc Welding are fairly expensive than that of other procedures which result in greater startup expense. Besides, some specialized training is required for the welders to properly carry out this task.
3. Flux Cored Arc Welding (FCAW)
Flux Cored Arc Welding is carried out through a continuously fed electrode wire which has flux in it and continually runs on a consistent welding power supply system. The arc location is protected by the continuous supply of shielding gas that secures the weld pool from all sorts of climatic contamination. Besides, the shielding gas is generally provided from an external link & the flux likewise works as a protective supplement for contamination (Hop Over To HERE).
Flux-cored arc welding is preferred in the welding industry because of its mobility and speed. Flux-cored welding is rather similar to that of MIG welding although both of them have several technical distinctions.
Advantages: Some attractive benefits of using this welding process are low startup expense and a higher deposition rate. Besides, most steel applications don’t require any shielding gas to be applied while performing this process. On top of that, the possibilities of porosity are super less in comparison to other welding techniques and the electrodes are very inexpensive as they are flux-cored.
Drawbacks: Among the typical problems of this strategy is the level of sensitivity of the electrode as it’s been made from moderate steel or alloy. This attribute is likewise called voltage tolerance which can be bypassed by supplying shielding gas to the weld pool and by preserving a consistent electrode feeding speed.
4. Immersed Arc Welding
As the name suggests, Immersed Arc Welding likewise utilizes a continuously fed electrode wire to molten the arc before which the weld pool is immersed under a flux layer including silica, lime, manganese oxide, and other supplements. This flux secures the welding location from all sources of climatic contamination along with avoids weld spattering and decreases high ultraviolet radiation.
Nevertheless, no shielding gas is required to carry out this process. In addition, there is no possible methods for heat loss as the whole arc is covered with a layer of flux and the slag layer can be removed consequently.
Advantages: Some benefits of this process include a high deposition rate and the capability to prevent weld spattering to the weld metal. Besides, it has a faster take a trip speed and can safeguard the air from high radiation.
Drawbacks: The crucial constraint of this process is just a handful variety of materials can be bonded through utilizing this welding process. And these are stainless steel, nickel alloy, and steel.
5. Electroslag Welding
Electroslag Welding is a bit complicated and different process from that of other welding procedures. The main parts that play the crucial role are the electrode and flux.
Basically, the flux does the primary work. It melts the filler metal and the workpiece by transforming electrical energy into heat and consequently, this heat develops the joint.
At first, the arc is produced between the electrode and the base metal after which the flux is added. Now, this formation produces a heat that naturally heats the flux and produces a slag layer.
Consequently, the slag reaches a temperature of 3500F which suffices to melt the metals and made a strong joint between the electrode wire and the workpiece.
Advantages: The primary advantage of this welding process is the low cooling rate that avoids it from cold breaking. Besides, the process is rather faster and there are very low possibilities of porosity because of the advanced system.
Drawbacks: A key downside of this welding process is the constraint in performing the task on vertical positions just. Besides, the excessively high temperature might sometimes require a heat control system.
6. Gas Metal Arc Welding (GMAW/MIG)
According to [dcl=8743], Gas Metal Arc Welding, likewise called Metal Inert Arc Welding is an easy welding process that produces an arc between the electrode and the weld metal whereas, the electrode is fed by a nozzle within which there’s another separate nozzle for the shielding gas to pass. This shielding gas secures the weld metal from all sorts of climatic contamination.
Apart from that, a consistent welding power supply is required to successfully perform the task. GMAW welding can be carried out by using one of these four methods: short-circuiting, pulse spray, globular, or regular spray.
Advantages: Some benefits of the GMAW process includes greater travel speed, low hydrogen welding which can avoid unwanted hydrogen breaking. Besides, the capability to easily change from semi-automatic to completely automated for increased output.
Drawbacks: The weapon size is fairly larger which can be an obstacle for reaching smaller sized areas. Besides, the startup expense is a bit high because of the complicated equipment needed to properly perform this process.
7. Gas Tungsten Arc Gas Welding (GTAW/TIG)
Gas Tungsten Arc Welding, aka Tungsten Inert Gas Welding, is a distinct welding process where the electrode is usually non-consumable and is used to perform the welding task & the formation of an arc.
As the name suggests, the electrode is generally made from tungsten. The weld location is properly protected by a protecting gas that comprises Helium and Argon.
Filler metals can be used in the welding process if it’s thick, otherwise, there’s no need for utilizing any filler metal for thinner materials and welding joints.
Advantages: Some benefits of this process include zero weld-spattering and focused arc formation which permits a welder to reach narrower weld areas to provide intense heat. Apart from that, as no fluxes have been used in this process, there is no production of slag.
Drawbacks: 2 of the crucial limitations of this process are the lower travel speed and lower deposition rate of the filler metal.
8. Laser Beam Welding (LBW)
Laser Beam Welding is an easy welding process that utilizes a laser beam to provide focused heat to the preferred welding location which consequently melts the welding metal and forms a joint between the two edges.
There are generally four types of equipment needed to carry out this task. They are the laser, a constant source of power, CAMERA & CAD combination for the style, and accurate operation by the computer system. Shielding gas might be used while performing this welding task.
Besides, this process is mainly used in extremely automated industries such as electronic equipment production and automotive.
Advantages: Some lucrative benefits of this process include narrow heat-affected zones, strong and accurate welding, the capability to bond a broad range of metals, lower scrap generation, and the fact that the light can be positioned while making a range from the welding metal.
Drawbacks: The crucial downside of this welding process is the greater purchase expense of all equipment, consisting of the filler material. Besides, upkeep expenses are likewise high and a specialized workforce is needed to carry out the whole task.
9. Electron-Beam Welding
Electron-Beam Welding is carried out by supplying high-velocity electron beams to the welding location which consequently melts the metals and strongly joints the edges.
Besides, no filler materials are used to carry out the process. To prevent electron beam dissipation, the process is carried out under vacuum conditions.
Electrons are usually produced by electron guns after which their speed is extremely accelerated through electrical fields.
Subsequently, they are specifically focused and applied to the welding materials by using magnetic fields.
Advantages: Advantages of this process include smaller sized heat-affected zones, strong and accurate welding, and the capability to join dissimilar materials which can be a vital advantage for any welder. Besides, this process does not require any filler material which results in low cost.
Drawbacks: Some downsides of this process are the complexity of the equipment and the preliminary startup expense. Besides, precaution need to be taken versus hazardous radiation.
10. Laser-Hybrid Welding
The laser hybrid welding process is the combination of Arc welding and Laser Beam Welding. This process is carried out by at first heating up the surface area of the workpiece with the help of a laser.
By doing this, the metal reaches its vaporization point and makes a narrow and deep penetration to that location. Later, the arc is formed specifically onto the edges which will result in a strong fusing of the parts.
Advantages: Some benefits of using Laser Hybrid Welding include greater welding speed and the capability to join hard welding materials because of its strong energy generation.
Drawbacks: The only downside might include the preliminary setup expense which is comparatively less than regular laser beam welding.
11. Resistance Welding
Resistance welding is carried out by supplying a constant circulation of electric present to the weld metal that provides heat to that location and consequently melts the metals to be collaborated.
Besides, a constant force or pressure is at the same time provided to that location which assists to solidify and strongly joints the edges together.
There are four types of resistance welding methods that are regularly used. They are seam welding, area welding, resistance butt welding, and flash welding.
Advantages: Some benefits of using Resistance Welding are greater welding rates, expense efficiency, and the capability to automate the process in an effortless way. Besides, it produces very low fumes and distortions.
Drawbacks: 2 of the typical flaws associated with this process are greater startup expense and alternate welding that generally result in lower strength.
12. Carbon Arc Welding
Now, Carbon Arc Welding is carried out by a non-consumable carbon electrode whereas the heat is produced from the electric arc which melts the filler rod to form a strong joint.
The application of shielding gas is optional for safeguarding the metal from climatic contamination.
Nevertheless, this type of welding has been in use considering that the invention of the welding method itself for which it can be thought about as the oldest welding method on the list.
Advantages: Some benefits of Carbon Arc Welding are lower equipment expense, low workpiece distortion, and the capability to easily automate the process on-demand, without employing any unique workforce.
Drawbacks: Sometimes, the weld metal gets contaminated with the carbon inside the electrode.
13. Gas Welding (GW)
Gas Welding is usually carried out by supplying continuous flame from the welding torch.
The torch at the same time provides oxygen from another cylinder in addition to the fuel gas in a needed percentage.
This flame causes the melting of the parts and forms a strong joint after solidification. The use of filler rod is conditional and fluxes might be used to safeguard the weld pool from contamination.
There are primarily 3 types of gas welding methods that are regularly used. They are oxyhydrogen welding, pressure gas welding and, oxyacetylene welding.
Advantages: This process is rather advantageous for its versatility and mobility. In addition, it does not require any electrical energy to carry out the task and the expenses of equipment are fairly lower in comparison to other welding procedures.
Drawbacks: Special workforce is required to carry out this welding process.
14. Thermit Welding (TW)
Thermit Welding is an easy welding process that utilizes an exothermic chain reaction to produce heat.
Basically, this Thermit is comprised of a mix of aluminum powder and a metal oxide that produces heat after response and, therefore, melts the metal which develops a strong joint after solidification.
This process is often used over steel parts.
Advantages: 2 crucial benefits of using this process are the capability to bond larger and thicker parts of metal. Alongside, no electrical energy is required to carry out the task.
Drawbacks: The range of welding parts is restricted to Steel, Nickel, and chromium. Besides, the welding speed is fairly slower than other welding procedures.
Thanks for reading the whole short article. Our company believes youhave actually got a detailed concept about all the different types of welding and what they are used for.