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How to Join Metals?
Many products made today by manufacturing and construction companies require some type of joining process be used in the production of that product. There are three main categories of material joining processes, namely, mechanical fastening, adhesive bonding, and welding.
- Mechanical fastening joins two materials together by using a clamping force. Screw, bolts, nails, and rivets are examples of different types of mechanical fasteners.
- Adhesive bonding joins materials together using a non-metallic material. Adhesives are usually available in the form of gels, liquids, and pastes.
- Welding is a joining process that produces coalescence of materials by heating them to the welding temperature (with or without the application of pressure, and with or without the use of filler metal).
Welding is one of the most economical ways to join metals together. Welding differs from the other joining processes in that the joint created by welding is very strong and permanent. There are many different types of welding processes that use various sources of energy to join metals. The most common welding process is electric arc welding.
How Does Electric Arc Welding Work?
Arc welding is a fusion welding process used to join metals. An electric arc generated from a welding machine creates an intense amount of heat that melts the joint between two metal pieces. In most cases, simply melting the pieces of metal together will not create a strong enough weld. For this reason, filler metal is typically added to increase the overall strength of the weld. During welding, the puddle of liquid metal must be protected from the air to keep it from oxidizing. This can be accomplished through the use of a flux or by the use of an external shielding gas. Once cooled, the molten metal solidifies to form a metallurgical bond.
Some examples of electric arc welding include Shielded Metal Arc Welding (SMAW), Gas Tungsten Arc Welding (GTAW) and Gas Metal Arc Welding (GMAW).
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How Does SMAW Work?
SMAW or Stick welding is a technique used for melting and joining metals by heating them through an electric arc between a metal electrode (coated with flux) and the workpiece. The outer coating of the electrode, also known as flux, helps to create the arc and shields the weld from contamination by providing a protective gas and slag covering. The electrode's core primarily provides the filler metal for welding. The electrode is moved along the workpiece at the appropriate pace, and the metal is deposited in a uniform layer known as a bead.
How Does GTAW Work?
GTAW, also referred to as TIG welding, is a welding process that creates an electric arc between a non-consumable tungsten electrode and the material being welded. In order to prevent atmospheric contamination, the tungsten electrode, the molten metal, and the heat-affected zone are all shielded by an inert gas, usually Argon, that is delivered via the TIG torch. This inert gas protects the weld from the reactive properties of the air. If additional filler metal is necessary, it can be added either manually or via a wire feeder. GTAW is suitable for welding a wide range of materials and is also capable of welding dissimilar metals.
How Does GMAW Work?
GMAW, also known as MIG/MAG welding, is a welding process in which the arc is formed between a continuous, consumable electrode wire and the metal being welded. To protect the weld from atmospheric contamination, a shielding gas is used to cover the arc. There are three ways to perform GMAW: semiautomatic welding, fixed automation welding, and robotic welding. In semiautomatic welding, the welder holds the welding gun and controls the speed and movement of the welding. In fixed automation welding, the equipment moves the welding gun along the workpiece. In robotic welding, the welding is done by a robot.
Why Is Welding Important?
Welding plays a crucial role in the creation of many everyday items. Welders are responsible for constructing a wide range of metal products, from simple objects like fences to complex structures like offshore drilling rigs and even spacecrafts. They are also involved in building important infrastructure like bridges and subways. The possibilities for welding are limitless, and the variety of work is vast. There is always a demand for skilled welders, and the field offers a diverse range of opportunities for those interested in pursuing it.