Welding is the procedure of integrating products by melting them through adequately high heat and consequently letting them cool off so that they highly join together.
However, the term itself isn’t as much straightforward as we believe.
There are numerous complex and varied types of welding that exist so regarding properly carry out the integrating procedure according to the primary goal.
Presuming this reality, we are going to share with you about 14 various types of welding and what they are used for.
So let’s begin:
1. Shielded Metal Arc Welding (SMAW)
Shielded Metal Arc Welding is the simple procedure of manually joining products through decomposing 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 procedure is fueled by an electrical current and as quickly as the melting procedure is performed, the disintegrated electrode produces some vapor which is usually referred to as the shielding gas, and hence produces a slag layer throughout the welded area. This layer secures the metal from all sorts of climatic contamination.
Let’s explore a few of the advantages and flaws of this specific welding procedure:.
Advantages: The primary advantage of this welding procedure is its simplicity and inexpensiveness. Besides, it is one of the most popular and commonly used welding procedures because of its flexibility and simplicity.
Disadvantages: 2 of the common flaws related to this procedure are porosity and weld spatter. 2 other typical drawbacks which are the risk of burn and skin damage can take place from any other welding procedure if enough precautions are not performed appropriately.
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 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 actually gone over here, you’ll see this procedure is quite comparable to that of Gas Tungsten Arc Welding whereas the only difference pushes the ability of the very first one to separate the shielding gas from the plasma arc.
Let’s discover its advantages and drawbacks:.
Advantages: 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 for that reason to observe the overall welding procedure. Besides, the plasma jet and increased heat concentration ensure faster travel speed.
Disadvantages: The types of devices used in Plasma Arc Welding are reasonably expensive than that of other procedures which result in greater startup expense. Besides, some specialized training is needed for the welders to properly carry out 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 runs on a consistent welding power supply system. The arc area is protected by the continuous supply of shielding gas that secures the weld swimming pool from all sorts of climatic contamination. Besides, the shielding gas is generally supplied from an external link & the flux also works as a protective supplement for contamination (gmaw vs fcaw for beginners choose the best process for your small operation).
Flux-cored arc welding is incredibly popular in the welding industry because of its portability and speed. Flux-cored welding is quite comparable to that of MIG welding although both of them have numerous technical differences.
Advantages: Some appealing advantages of using this welding procedure are low startup expense and a greater deposition rate. Besides, many steel applications don’t need any shielding gas to be applied while performing this procedure. On top of that, the opportunities of porosity are very less in contrast to other welding strategies and the electrodes are extremely low-cost as they are flux-cored.
Disadvantages: Among the common issues of this method is the sensitivity of the electrode as it’s been made from moderate steel or alloy. This quality is also referred to as voltage tolerance which can be bypassed by supplying shielding gas to the weld swimming pool and by maintaining a consistent electrode feeding speed.
4. Submerged Arc Welding
As the name recommends, Submerged Arc Welding also uses a continually fed electrode wire to molten the arc before which the weld swimming pool is submerged under a flux layer including silica, lime, manganese oxide, and other supplements. This flux secures the welding area from all sources of climatic contamination along with avoids weld spattering and reduces high ultraviolet radiation.
However, no shielding gas is needed to carry out this procedure. In addition, there is no possible ways for heat loss as the whole arc is covered with a layer of flux and the slag layer can be gotten rid of consequently.
Advantages: Some advantages of this procedure consist of a high deposition rate and the ability to prevent weld spattering to the weld metal. Besides, it has a faster travel speed and can secure the air from high radiation.
Disadvantages: The essential constraint of this procedure is just a handful number of products can be welded 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 essential role are the electrode and flux.
Basically, the flux does the primary work. It melts the filler metal and the workpiece by changing electrical energy into heat energy 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 up the flux and produces a slag layer.
As a result, 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.
Advantages: The primary advantage of this welding procedure is the low cooling rate that avoids it from cold cracking. Besides, the procedure is quite faster and there are extremely low opportunities of porosity because of the advanced system.
Disadvantages: A key downside of this welding procedure is the constraint in performing the task on vertical positions just. Besides, the excessively heat might sometimes need a heat control system.
6. Gas Metal Arc Welding (GMAW/MIG)
Based on a MIG welding guide, Gas Metal Arc Welding, also referred to as Metal Inert Arc Welding is an easy 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 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 needed to successfully carry out the task. GMAW welding can be performed by using one of these four approaches: short-circuiting, pulse spray, globular, or regular spray.
Advantages: Some advantages of the GMAW procedure consists of greater travel speed, low hydrogen welding which can prevent undesirable hydrogen cracking. Besides, the ability to quickly switch from semi-automatic to fully automated for increased output.
Disadvantages: The weapon size is reasonably larger which can be a challenge for reaching smaller locations. Besides, the startup expense is a bit high because of the intricate devices required 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 used to carry out the welding task & the formation of an arc.
As the name recommends, the electrode is generally made of tungsten. The weld area is properly protected by a protecting gas that comprises Helium and Argon.
Filler metals can be used in the welding procedure if it’s thick, otherwise, there’s no requirement for utilizing any filler metal for thinner products and welding joints.
Advantages: Some advantages of this procedure consist of absolutely no weld-spattering and focused arc formation which enables a welder to reach narrower weld locations to provide intense heat. Apart from that, as no fluxes have actually been used in this procedure, there is no production of slag.
Disadvantages: 2 of the essential constraints 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 an easy welding procedure that uses a laser beam to provide focused heat to the desired welding area which consequently melts the welding metal and forms a joint between the two edges.
There are generally four types of devices required to carry out this task. They are the laser, a constant source of power, WEB CAM & CAD integration for the design, and accurate operation by the computer. Protecting gas might be used while performing this welding task.
Besides, this procedure is primarily used in extremely automated industries such as electronic devices manufacturing and vehicle.
Advantages: Some lucrative advantages of this procedure consist of narrow heat-affected zones, strong and accurate welding, the ability to bond a broad variety of metals, lower scrap generation, and the reality that the light can be positioned while making a distance from the welding metal.
Disadvantages: The essential downside of this welding procedure is the greater purchase expense of all devices, consisting of the filler product. Besides, upkeep expenses are also high and a specialized labor force is required to carry out the whole task.
9. Electron-Beam Welding
Electron-Beam Welding is performed by supplying high-velocity electron beams to the welding area which consequently melts the metals and highly joints the edges.
Besides, no filler products are used to carry out 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 precisely focused and applied to the welding products by using electromagnetic fields.
Advantages: Advantages of this procedure consist of smaller heat-affected zones, strong and accurate welding, and the ability to join dissimilar products which can be an important advantage for any welder. Besides, this procedure does not need any filler product which results in low cost.
Disadvantages: Some drawbacks of this procedure are the complexity of the devices and the initial startup expense. Besides, precaution should be taken against harmful 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 up the surface 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 area. Later, the arc is formed precisely onto the edges which will lead to a strong fusing of the parts.
Advantages: Some advantages of using Laser Hybrid Welding consist of greater welding speed and the ability to join hard welding products because of its strong energy generation.
Disadvantages: The only downside might consist of the initial setup expense which is comparatively less than regular laser beam welding.
11. Resistance Welding
Resistance welding is performed by supplying a constant flow of electrical current to the weld metal that offers heat to that area and consequently melts the metals to be collaborated.
Besides, a constant force or pressure is all at once supplied to that area which helps to solidify and highly joints the edges together.
There are four types of resistance welding approaches that are regularly used. They are seam welding, spot welding, resistance butt welding, and flash welding.
Advantages: Some advantages of using Resistance Welding are greater welding rates, expense effectiveness, and the ability to automate the procedure in an effortless way. Besides, it produces extremely low fumes and distortions.
Disadvantages: 2 of the common flaws related to this procedure are greater startup expense and discontinuous welding that generally 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 electrical arc which melts the filler rod to form a strong joint.
The application of shielding gas is optional for protecting the metal from climatic contamination.
However, this kind of welding has actually been in usage because the invention of the welding technique itself for which it can be considered as the oldest welding technique on the list.
Advantages: Some advantages of Carbon Arc Welding are lower devices expense, low workpiece distortion, and the ability to quickly automate the procedure on-demand, without hiring any unique labor force.
Disadvantages: In some cases, the weld metal gets contaminated with the carbon inside the electrode.
13. Gas Welding (GW)
Gas Welding is usually performed by supplying continuous flame from the welding torch.
The torch all at once provides oxygen from another cylinder in addition to the fuel gas in a needed proportion.
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 secure the weld swimming pool from contamination.
There are generally three types of gas welding approaches that are regularly used. They are oxyhydrogen welding, pressure gas welding and, oxyacetylene welding.
Advantages: This procedure is quite helpful for its flexibility and portability. In addition, it does not need any electrical energy to carry out the task and the expenses of devices are reasonably lower in contrast to other welding procedures.
Disadvantages: Unique labor force is needed to carry out this welding procedure.
14. Thermit Welding (TW)
Thermit Welding is an easy welding procedure that uses an exothermic chemical reaction to produce heat.
Basically, this Thermit is comprised of a combination of aluminum powder and a metal oxide that produces heat after reaction and, for that reason, melts the metal which creates a strong joint after solidification.
This procedure is often used over steel parts.
Advantages: 2 essential advantages of using this procedure are the ability to bond larger and thicker parts of metal. Alongside, no electrical energy is needed to carry out the task.
Disadvantages: The variety of welding parts is limited to Steel, Nickel, and chromium. Besides, the welding speed is reasonably slower than other welding procedures.
Conclusion
Thanks for reading the whole short article. We believe you’ve got a detailed concept about all the various types of welding and what they are used for.