Welding is the procedure of combining products by melting them through adequately high heat and subsequently letting them cool off so that they strongly join together.
Nevertheless, the term itself isn’t as much simple as we believe.
There are lots of complex and varied kinds of welding that exist so as to appropriately perform the combining procedure according to the primary objective.
Assuming this fact, we are going to show you about 14 various kinds of welding and what they are utilized for.
So let’s start:
1. Shielded Metal Arc Welding (SMAW)
Shielded Metal Arc Welding is the easy procedure of manually joining products through decaying a wire of electrode that’s been covered with flux and is laid down between the metal and electrode in the form of an arc.
The procedure is sustained by an electric existing and as quickly as the melting procedure is performed, the disintegrated electrode produces some vapor which is typically known as the protecting gas, and therefore produces a slag layer across the bonded location. This layer protects the metal from all sorts of climatic contamination.
Let’s check out some of the advantages and flaws of this specific welding procedure:.
Benefits: The primary advantage of this welding procedure is its simpleness and inexpensiveness. Besides, it is one of the most popular and extensively utilized welding processes because of its adaptability and simpleness.
Downsides: 2 of the common flaws associated with this procedure are porosity and weld spatter. 2 other normal drawbacks which are the danger of burn and skin damage can take place from any other welding procedure if enough preventative measures are not performed properly.
2. Plasma Arc Welding
Plasma Arc Welding is performed by forming an electric arc right in between the workpiece and the electrode. The electrode is typically located inside the torch and the plasma goes through a copper nozzle which consequently forms the arc.
If you go through the kinds of welding we have discussed here, you’ll see this procedure is rather comparable to that of Gas Tungsten Arc Welding whereas the only difference pushes the ability of the very first one to separate the protecting gas from the plasma arc.
Let’s learn about its advantages and drawbacks:.
Benefits: The torch which is developed to carry out Plasma Arc Welding enables a welder to be efficient sufficient to get the controlling of the arc and therefore to observe the overall welding procedure. Besides, the plasma jet and increased heat concentration ensure faster travel speed.
Downsides: The kinds of equipment utilized in Plasma Arc Welding are fairly costly than that of other processes which result in greater startup cost. Besides, some specialized training is needed for the welders to appropriately perform this task.
3. Flux Cored Arc Welding (FCAW)
Flux Cored Arc Welding is performed through a constantly fed electrode wire which has flux in it and continually operates on a consistent welding power supply system. The arc location is protected by the continuous supply of protecting gas that protects the weld swimming pool from all sorts of climatic contamination. Besides, the protecting gas is normally supplied from an external link & the flux likewise works as a protective supplement for contamination (Look THESE Up).
Flux-cored arc welding is preferred in the welding industry because of its portability and speed. Flux-cored welding is rather comparable to that of MIG welding although both of them have numerous technical differences.
Benefits: Some appealing advantages of using this welding procedure are low startup cost and a higher deposition rate. Besides, a lot of steel applications don’t need any protecting gas to be applied while performing this procedure. On top of that, the chances of porosity are super less in comparison to other welding techniques and the electrodes are extremely low-cost as they are flux-cored.
Downsides: One of the common issues of this strategy is the sensitivity of the electrode as it’s been made from moderate steel or alloy. This characteristic is likewise known as voltage tolerance which can be bypassed by providing protecting gas to the weld swimming pool and by maintaining a consistent electrode feeding speed.
4. Immersed Arc Welding
As the name suggests, Immersed Arc Welding likewise utilizes a constantly fed electrode wire to molten the arc before which the weld swimming pool is submerged under a flux layer consisting of silica, lime, manganese oxide, and other supplements. This flux protects the welding location from all sources of climatic contamination as well as avoids weld spattering and decreases high ultraviolet radiation.
Nevertheless, no protecting gas is needed 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.
Benefits: Some benefits of this procedure include a high deposition rate and the ability to prevent weld spattering to the weld metal. Besides, it has a faster take a trip speed and can protect the air from high radiation.
Downsides: The essential limitation of this procedure is just a handful variety of products can be bonded through using this welding procedure. And these are stainless-steel, nickel alloy, and steel.
5. Electroslag Welding
Electroslag Welding is a bit complex and various procedure from that of other welding processes. The main parts that play the essential role are the electrode and flux.
Generally, the flux does the primary work. It melts the filler metal and the workpiece by transforming electrical energy into heat energy and subsequently, this heat establishes the joint.
At first, the arc is produced between the electrode and the base metal after which the flux is included. Now, this formation produces a heat that naturally warms the flux and produces a slag layer.
Consequently, the slag reaches a temperature level of 3500F which suffices to melt the metals and made a strong joint between the electrode wire and the workpiece.
Benefits: The primary advantage of this welding procedure is the low cooling rate that avoids it from cold breaking. Besides, the procedure is rather faster and there are extremely low chances of porosity because of the sophisticated system.
Downsides: A crucial drawback of this welding procedure is the limitation in performing the task on vertical positions just. Besides, the exceedingly heat may in some cases need a heat control system.
6. Gas Metal Arc Welding (GMAW/MIG)
Based on a MIG guide I found, Gas Metal Arc Welding, likewise known as Metal Inert Arc Welding is a basic welding procedure 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 protecting gas to pass. This protecting gas protects the weld metal from all sorts of climatic contamination.
Apart from that, a consistent welding power supply is needed to effectively carry out the task. GMAW welding can be performed by using one of these four techniques: short-circuiting, pulse spray, globular, or typical spray.
Benefits: Some benefits of the GMAW procedure consists of greater travel speed, low hydrogen welding which can avoid unwanted hydrogen breaking. Besides, the ability to quickly switch from semi-automatic to completely automatic for increased output.
Downsides: The weapon size is fairly bigger which can be an obstacle for reaching smaller areas. Besides, the startup cost is a bit high because of the complex equipment required to appropriately perform this procedure.
7. Gas Tungsten Arc Gas Welding (GTAW/TIG)
Gas Tungsten Arc Welding, aka Tungsten Inert Gas Welding, is a distinct welding procedure where the electrode is typically non-consumable and is utilized to carry out the welding responsibility & the formation of an arc.
As the name suggests, the electrode is generally made from tungsten. The weld location is appropriately protected by a protecting gas that comprises Helium and Argon.
Filler metals can be utilized in the welding procedure if it’s thick, otherwise, there’s no requirement for using any filler metal for thinner products and welding joints.
Benefits: Some benefits of this procedure include no weld-spattering and focused arc formation which allows a welder to reach narrower weld areas to offer intense heat. Apart from that, as no fluxes have been utilized in this procedure, there is no production of slag.
Downsides: 2 of the essential restrictions 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 basic welding procedure that utilizes a laser beam to provide focused heat to the wanted welding location which consequently melts the welding metal and forms a joint between the two edges.
There are generally four kinds of equipment required to perform this task. They are the laser, a constant power source, WEB CAM & CAD integration for the design, and precise operation by the computer system. Protecting gas might be utilized while performing this welding task.
Besides, this procedure is mainly utilized in highly automated industries such as electronic equipment production and automobile.
Benefits: Some rewarding benefits of this procedure include narrow heat-affected zones, strong and precise welding, the ability to weld a broad variety of metals, lower scrap generation, and the fact that the light can be positioned while making a distance from the welding metal.
Downsides: The essential drawback of this welding procedure is the greater purchase cost of all equipment, including the filler product. Besides, upkeep costs are likewise high and a specialized workforce is required 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 consequently melts the metals and strongly joints the edges.
Besides, no filler products are utilized to perform the procedure. To prevent electron beam dissipation, the procedure is performed under vacuum conditions.
Electrons are typically produced by electron weapons after which their speed is highly accelerated through electrical fields.
Subsequently, they are exactly focused and applied to the welding products by using magnetic fields.
Benefits: Benefits of this procedure include smaller heat-affected zones, strong and precise welding, and the ability to join dissimilar products which can be a vital advantage for any welder. Besides, this procedure doesn’t need any filler product which leads to low cost.
Downsides: Some drawbacks of this procedure are the complexity of the equipment and the initial startup cost. Besides, precaution must be taken versus 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 at first heating up the surface 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. Afterward, the arc is formed exactly onto the edges which will cause a strong fusing of the parts.
Benefits: Some benefits of using Laser Hybrid Welding include greater welding speed and the ability to join hard welding products because of its strong energy generation.
Downsides: The only drawback may include the initial setup cost which is relatively less than typical laser beam welding.
11. Resistance Welding
Resistance welding is performed by providing a constant flow of electric existing to the weld metal that supplies heat to that location and consequently melts the metals to be joined together.
Besides, a constant force or pressure is all at once supplied to that location which assists to strengthen and strongly joints the edges together.
There are four kinds of resistance welding techniques that are regularly utilized. They are seam welding, area welding, resistance butt welding, and flash welding.
Benefits: Some advantages of using Resistance Welding are greater welding rates, cost efficiency, and the ability to automate the procedure in an effortless way. Besides, it produces extremely low fumes and distortions.
Downsides: 2 of the common flaws associated with this procedure are greater startup cost and discontinuous welding that normally result in 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 electric arc which melts the filler rod to form a strong joint.
The application of protecting gas is optional for safeguarding the metal from climatic contamination.
Nevertheless, this kind of welding has remained in use because the creation of the welding technique itself for which it can be thought about as the oldest welding technique on the list.
Benefits: Some benefits of Carbon Arc Welding are lower equipment cost, low workpiece distortion, and the ability to quickly automate the procedure on-demand, without employing any unique workforce.
Downsides: Sometimes, the weld metal gets polluted with the carbon inside the electrode.
13. Gas Welding (GW)
Gas Welding is typically performed by providing continuous flame from the welding torch.
The torch all at once provides oxygen from another cylinder along with the fuel gas in a needed proportion.
This flame triggers the melting of the parts and forms a strong joint after solidification. Making use of filler rod is conditional and fluxes might be utilized to protect the weld swimming pool from contamination.
There are primarily 3 kinds of gas welding techniques that are regularly utilized. They are oxyhydrogen welding, pressure gas welding and, oxyacetylene welding.
Benefits: This procedure is rather beneficial for its adaptability and portability. In addition, it doesn’t need any electrical energy to perform the task and the costs of equipment are fairly lower in comparison to other welding processes.
Downsides: Unique workforce is needed to perform this welding procedure.
14. Thermit Welding (TW)
Thermit Welding is a basic welding procedure that utilizes an exothermic chemical reaction to produce heat.
Generally, this Thermit is comprised of a combination 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 procedure is frequently utilized over steel parts.
Benefits: 2 essential benefits of using this procedure are the ability to weld bigger and thicker parts of metal. Alongside, no electrical energy is needed to perform the task.
Downsides: The variety of welding parts is restricted to Steel, Nickel, and chromium. Besides, the welding speed is fairly slower than other welding processes.
Thanks for checking out the entire article. Our company believes you’ve got an extensive concept about all the various kinds of welding and what they are utilized for.