Welding is the procedure of integrating materials by melting them through adequately high heat and subsequently letting them cool off so that they highly join together.
Nevertheless, the term itself isn’t as much uncomplicated as we believe.
There are many complex and varied kinds of welding that exist so regarding properly perform the integrating procedure according to the primary goal.
Presuming this reality, we are going to share with you about 14 various kinds of welding and what they are utilized for.
So let’s begin:
1. Protected Metal Arc Welding (SMAW)
Protected Metal Arc Welding is the easy procedure of by hand joining materials through decomposing a wire of electrode that’s been covered with flux and is set in between the metal and electrode in the form of an arc.
The procedure is sustained by an electrical current and as quickly as the melting procedure is performed, the disintegrated electrode produces some vapor which is usually called the protecting gas, and thus produces a slag layer throughout the bonded location. This layer secures the metal from all sorts of climatic contamination.
Let’s explore some of the benefits and flaws of this specific welding procedure:.
Advantages: The main advantage of this welding procedure is its simplicity and inexpensiveness. Besides, it is one of the most popular and extensively utilized welding procedures because of its versatility and simplicity.
Disadvantages: Two of the typical flaws connected with this procedure are porosity and weld spatter. Two other usual downsides which are the threat of burn and skin damage can take place from any other welding procedure if enough safety measures are not performed properly.
2. Plasma Arc Welding
Plasma Arc Welding is performed by forming an electrical arc right in between the workpiece and the electrode. The electrode is usually positioned inside the torch and the plasma goes through a copper nozzle which as a result forms the arc.
If you read through the kinds of welding we have actually discussed here, you’ll see this procedure is quite similar to that of Gas Tungsten Arc Welding whereas the only distinction pushes the ability of the very first one to separate the protecting gas from the plasma arc.
Let’s learn 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 enough to get the controlling of the arc and therefore to observe the total welding procedure. Besides, the plasma jet and increased heat concentration make sure faster travel speed.
Disadvantages: The kinds of equipment utilized in Plasma Arc Welding are fairly costly than that of other procedures which lead to higher start-up cost. Besides, some specialized training is required for the welders to properly perform this task.
3. Flux Cored Arc Welding (FCAW)
Flux Cored Arc Welding is performed through a continually fed electrode wire which has flux in it and continually operates on a consistent welding power supply system. The arc location is safeguarded by the constant supply of protecting gas that secures the weld swimming pool from all sorts of climatic contamination. Besides, the protecting gas is normally supplied from an external link & the flux also works as a protective supplement for contamination (support).
Flux-cored arc welding is incredibly popular in the welding market because of its portability and speed. Flux-cored welding is quite similar to that of MIG welding although both of them have several technical distinctions.
Advantages: Some appealing benefits of using this welding procedure are low start-up cost and a higher deposition rate. Besides, many steel applications do not need any protecting gas to be used while performing this procedure. On top of that, the possibilities of porosity are incredibly less in comparison to other welding techniques and the electrodes are really low-cost as they are flux-cored.
Disadvantages: Among the typical problems of this strategy is the sensitivity of the electrode as it’s been made from moderate steel or alloy. This characteristic is also called voltage tolerance which can be bypassed by providing protecting gas to the weld swimming pool and by preserving a consistent electrode feeding speed.
4. Submerged Arc Welding
As the name suggests, Submerged Arc Welding also uses a continually fed electrode wire to molten the arc before which the weld swimming pool is immersed under a flux layer consisting of silica, lime, manganese oxide, and other supplements. This flux secures the welding location from all sources of climatic contamination as well as prevents weld spattering and decreases high ultraviolet radiation.
Nevertheless, no protecting gas is required to perform this procedure. In addition, there is no possible ways for heat loss as the entire arc is covered with a layer of flux and the slag layer can be removed subsequently.
Advantages: Some benefits of this procedure consist of a high deposition rate and the ability to prevent weld spattering to the weld metal. Besides, it has a much faster travel speed and can protect the air from high radiation.
Disadvantages: The key restriction of this procedure is only a handful variety of materials can be bonded through utilizing this welding procedure. And these are stainless-steel, nickel alloy, and steel.
5. Electroslag Welding
Electroslag Welding is a bit intricate and various procedure from that of other welding procedures. The main parts that play the key role are the electrode and flux.
Essentially, the flux does the main work. It melts the filler metal and the workpiece by changing electrical energy into heat energy and subsequently, this heat develops the joint.
Initially, the arc is produced in between the electrode and the base metal after which the flux is added. Now, this development produces a high temperature that naturally warms the flux and produces a slag layer.
Subsequently, the slag reaches a temperature of 3500F which suffices to melt the metals and made a strong joint in between the electrode wire and the workpiece.
Advantages: The main advantage of this welding procedure is the low cooling rate that prevents it from cold splitting. Besides, the procedure is quite faster and there are really low possibilities of porosity because of the sophisticated system.
Disadvantages: An essential drawback of this welding procedure is the restriction in performing the task on vertical positions only. Besides, the excessively heat might in some cases need a heat control system.
6. Gas Metal Arc Welding (GMAW/MIG)
According to WeldingHeadquarters.com, Gas Metal Arc Welding, also called Metal Inert Arc Welding is a simple welding procedure that produces an arc in between the electrode and the weld metal whereas, the electrode is fed by a nozzle within which there’s another different nozzle for the protecting gas to pass. This protecting gas secures the weld metal from all sorts of climatic contamination.
Apart from that, a consistent welding power supply is required to effectively perform the task. GMAW welding can be performed by using among these four techniques: short-circuiting, pulse spray, globular, or regular spray.
Advantages: Some benefits of the GMAW procedure includes higher travel speed, low hydrogen welding which can prevent undesirable hydrogen splitting. Besides, the ability to easily switch from semi-automatic to totally automatic for increased output.
Disadvantages: The gun size is fairly larger which can be an obstacle for reaching smaller locations. Besides, the start-up cost is a bit high because of the intricate equipment needed to properly perform this procedure.
7. Gas Tungsten Arc Gas Welding (GTAW/TIG)
Gas Tungsten Arc Welding, aka Tungsten Inert Gas Welding, is an unique welding procedure where the electrode is usually non-consumable and is utilized to perform the welding duty & the development of an arc.
As the name suggests, the electrode is generally made of tungsten. The weld location is properly safeguarded by a protecting gas that consists of Helium and Argon.
Filler metals can be utilized in the welding procedure if it’s thick, otherwise, there’s no requirement for utilizing any filler metal for thinner materials and welding joints.
Advantages: Some benefits of this procedure consist of absolutely no weld-spattering and focused arc development which allows a welder to reach narrower weld locations to supply intense heat. Apart from that, as no fluxes have actually been utilized in this procedure, there is no production of slag.
Disadvantages: Two of the key limitations of this procedure are the lower travel speed and lower deposition rate of the filler metal.
8. Laser Beam Welding (LBW)
Laser Beam Welding is a simple welding procedure that uses a laser beam to provide focused heat to the preferred welding location which as a result melts the welding metal and forms a joint in between the two edges.
There are generally four kinds of equipment needed to perform this task. They are the laser, a continuous source of power, WEBCAM & CAD integration for the design, and exact operation by the computer. Protecting gas might be utilized while performing this welding task.
Besides, this procedure is mainly utilized in extremely automated industries such as electronic equipment manufacturing and vehicle.
Advantages: Some rewarding benefits of this procedure consist of narrow heat-affected zones, strong and exact welding, the ability to weld a broad variety of metals, lower scrap generation, and the reality that the light can be put while making a range from the welding metal.
Disadvantages: The key drawback of this welding procedure is the higher purchase cost of all equipment, including the filler material. Besides, upkeep costs are also high and a specialized workforce is needed to perform the entire task.
9. Electron-Beam Welding
Electron-Beam Welding is performed by providing high-velocity electron beams to the welding location which as a result melts the metals and highly joints the edges.
Besides, no filler materials are utilized to perform the procedure. To prevent electron beam dissipation, the procedure is performed under vacuum conditions.
Electrons are usually produced by electron weapons after which their speed is extremely accelerated through electrical fields.
Consequently, they are exactly focused and applied to the welding materials by using magnetic fields.
Advantages: Advantages of this procedure consist of smaller heat-affected zones, strong and exact welding, and the ability to join dissimilar materials which can be an essential advantage for any welder. Besides, this procedure does not need any filler material which leads to low cost.
Disadvantages: Some downsides of this procedure are the complexity of the equipment and the initial start-up cost. Besides, safety measures ought to be taken against damaging radiation.
10. Laser-Hybrid Welding
The laser hybrid welding procedure is the mix of Arc welding and Laser Beam Welding. This procedure is performed by initially heating the surface area of the workpiece with the help of a laser.
This way, the metal reaches its vaporization point and makes a narrow and deep penetration to that location. Afterward, the arc is formed exactly onto the edges which will cause a strong fusing of the parts.
Advantages: Some benefits of using Laser Hybrid Welding consist of higher welding speed and the ability to join challenging welding materials because of its strong energy generation.
Disadvantages: The only drawback might consist of the initial setup cost which is relatively less than regular laser beam welding.
11. Resistance Welding
Resistance welding is performed by providing a continuous flow of electrical current to the weld metal that supplies heat to that location and as a result melts the metals to be collaborated.
Besides, a continuous force or pressure is concurrently supplied to that location which helps to strengthen and highly joints the edges together.
There are four kinds of resistance welding techniques that are often utilized. They are seam welding, area welding, resistance butt welding, and flash welding.
Advantages: Some benefits of using Resistance Welding are higher welding rates, cost effectiveness, and the ability to automate the procedure in an effortless manner. Besides, it produces really low fumes and distortions.
Disadvantages: Two of the typical flaws connected with this procedure are higher start-up cost and alternate welding that normally lead to lower strength.
12. Carbon Arc Welding
Now, Carbon Arc Welding is performed by a non-consumable carbon electrode whereas the heat is produced from the electrical arc which melts the filler rod to form a strong joint.
The application of protecting gas is optional for protecting the metal from climatic contamination.
Nevertheless, this type of welding has actually been in usage given that the invention of the welding technique itself for which it can be considered as the earliest welding technique on the list.
Advantages: Some benefits of Carbon Arc Welding are lower equipment cost, low workpiece distortion, and the ability to easily automate the procedure on-demand, without working with any special workforce.
Disadvantages: Often, the weld metal gets polluted with the carbon inside the electrode.
13. Gas Welding (GW)
Gas Welding is usually performed by providing constant flame from the welding torch.
The torch concurrently supplies oxygen from another cylinder along with the fuel gas in a needed percentage.
This flame triggers the melting of the parts and forms a strong joint after solidification. The use of filler rod is conditional and fluxes might be utilized to protect the weld swimming pool from contamination.
There are mainly 3 kinds of gas welding techniques that are often utilized. They are oxyhydrogen welding, pressure gas welding and, oxyacetylene welding.
Advantages: This procedure is quite helpful for its versatility and portability. In addition, it does not need any electrical power to perform the task and the costs of equipment are fairly lower in comparison to other welding procedures.
Disadvantages: Special workforce is required to perform this welding procedure.
14. Thermit Welding (TW)
Thermit Welding is a simple welding procedure that uses an exothermic chemical reaction to produce heat.
Essentially, this Thermit is comprised of a mix of aluminum powder and a metal oxide that produces heat after reaction and, therefore, melts the metal which creates a strong joint after solidification.
This procedure is frequently utilized over steel parts.
Advantages: Two key benefits of using this procedure are the ability to weld larger and thicker parts of metal. Alongside, no electrical power is required to perform the task.
Disadvantages: The variety of welding parts is restricted to Steel, Nickel, and chromium. Besides, the welding speed is fairly slower than other welding procedures.
Thanks for checking out the entire short article. Our company believes you’ve got a detailed concept about all the various kinds of welding and what they are utilized for.