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Welding Processes Explained.
Different metals have different characteristics that affect
their ability to be welded or cut. The welding process involves
melting the base metal parts and adding filler metal that has
the same melting temperature and characteristics of the parent
metal.
Metals are divided into two categories, ferrous and non ferrous.
Ferrous metals contain iron such as cast iron, mild steel,
forged steel, and stainless steel., where as aluminium is a non-
ferrous metal. Each metal type requires different welding
procedures and filler metals.
These are the four major welding processes that are used both in
industry and for the home hobbyist.
1) Oxyacetylene Welding or Gas Welding.
Uses a gas flame to melt base metals and fuses them together.
The gas flame is created by the combustion of oxygen and a fuel
gas such as acetylene, propane, butane or natural gas. The
hottest of any gas flame is capable of melting most metals.
Gas welding today is generally restricted to welding thin sheet
metals and brazing of mild steel, and copper pipe work. , Braze
welding is used for joining dissimilar metals and metals of
different thickness and often used to repair cracked or broken
cast iron.
2) Shielded Metal Arc Welding (SMAW)
Also referred to as stick or arc welding. The process involves
heating the base metal to fusion by an electric arc using a
welding electrode. The covering on the electrode provides both a
flux and shielding gas for the weld.. Electrodes range in
thickness from 2 mm for light work and up to 5 mm for heavy
steel.
Stick welding is used for fabrication, construction and repair
work, more suited to metal thickness 4 mm and upwards. Thinner
metals are more suited to the GMAW process.
3) Gas metal
Arc Welding.(GMAW)
Also referred to as MIG or metal inert gas welding. The most
versatile and most used of all welding processes. Uses a
continuos wire feed electrode fed through a welding gun along
with a continuos flow of shielding gas.
The advantages of a mig welder are many, the gun is easy to
manipulate and keep at a uniform distance from the weld,
continuos wire feed allows longer welds to be run, the welds
remain smooth and clean because of the shielding gas. You can
weld at very low temperatures allowing welding of 22 and 24
gauge sheet metals.
Disadvantages are outdoor welding situations where the shielding
gas can be blown away in a breeze and in tight situations where
the gun nozzle limits welding. Ideal for welding mild steel,
stainless steel and aluminium.
4) Gas Tungsten Arc Welding (GTAW)
Also referred to as TIG or tungsten inert gas welding Tig
welding is a process that generates an arc between a non
consumable electrode and the work. The electrode and the weld
are protected by a gas shield, and a filler rod may or may not
be used.
Tig welding is similar to gas welding and requires more skill.
Used for doing fine work and where a high standard of finish is
required without the need for grinding, such as bicycle frames
and food manufacturing equipment.. As Tig welding is a very
clean process its ideal for welding stainless steel and
aluminium.
This article courtesy of www.weldingorg.com. You may freely
reprint this article on your website or in your newsletter
provided this courtesy notice and the author name and URL remain
intact.
About the author:
For more information about welders, welding equipment and
excellent tutorials about how to weld visit www.weldingorg.com
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