WELDING PROCESSES
in industries like electronics, aerospace, automotive, repair, and even art. Advantages of TIG welding include
precision and a superior cosmetic appearance compared to other welds. It is often chosen for visible welds because it creates an aesthetically pleasing appearance. These welds are also durable and of high quality. However, TIG welding is complex and requires a great deal of expertise. Welders using this welding process use both hands, one to hold the torch and the other hand to hold the filler metal. Most of the time, only experienced
and educated welders can manage this type of welding in a production environment. And, although it produces strong welds, you have to be sure to work with clean metals as impurities can produce weaker welds. One of the earliest and most common
welding techniques is Shielded Metal Arc Welding (SMAW) is also called ‘stick’ welding. This type of welding uses a protected and consumable electrode (stick). This stick melts in the arc and becomes the filler metal to join the two metal parts. As the
stick melts, it also emits a gas that protects the area to be welded. Construction projects, underwater
pipelines, and industrial fabrication businesses use this type of welding. You can use this type of welding to join steel, cast, ductile iron, nickel, or copper. However, it’s rarely used on aluminium. Because it does not require external
shielding gas stick welding is very portable, making it possible to weld anywhere. SMAW doesn’t need the metal to be free of impurities. So, you can even use this type of welding process on rusty materials. You can also easily change the welding rods to adapt to different metals. However, it is advanced and needs
skilled welders. It also produces a lot of waste from the materials used - mostly coming from the slag. The slag is the leftover material formed at the top of the welded metal. It’s also slower because you need to chip away the slag every time the rod is finished. The final variant of our four is Flux-
Cored Arc Welding (FCAW) which is similar to Gas Metal Arc Welding but can be performed without shielding gas. The difference lies in the electrode
material. FCAW uses a flux-cored electrode as a filler material for the weld. Flux is a mix of silicate and carbonate
material. Since its density is lighter than the welded material, it floats to the surface. The flux protects the metal being welded from contaminants from the atmosphere. FCAW is usually the welding technique used in bridge construction, shipbuilding, and heavy equipment repair. It has a heavy deposition rate.
Depending on the electrode used, a welder can deposit up to 9 kg of metal. It also has a more stable arc compared to other types of welding processes. Unlike GMAW, Flux Cored Arc Welding can be used outdoors without gas shielding. Moreover, the metal doesn’t have to undergo precleaning. You can also weld in any position with this type of welding process. However, FCAW produces more fumes
than other welding methods, and it can even be carcinogenic. So, if you want to do FCAW indoors, ensure that the area is well-ventilated and supported with extraction systems. The electrode is also more expensive, and the metals it can weld are limited to carbon and stainless steel, cast iron, and hard surfacing alloys.
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