Welding is an essential process used in industries from automotive to aerospace since it is one of the most reliable and strong ways of joining two sections of metal. In fact, more than 40 million tonnes of welded products are produced every year around the world, many of which are critical components used in life-saving medical devices or reliable transport vehicles.
Welding is used to fabricate or repair many materials including steel, aluminum, magnesium, and several other alloys. It is also used to manufacture products such as tools, pipes, and aircraft frames that can withstand extreme conditions. So, what type of process is welding?
Read further to find out the answer.
What type of process is Welding?Welding is a process of joining two or more elements such as metal parts, thermoplastics, or even concrete together by using heat, pressure, and/or sometimes a chemical bond. This technique has been used for centuries, but today, it is one of the most popular techniques used in many industries.
Welding is a versatile method that can be used to join different types of metals and materials to create strong and durable joints.
Types of Welding ProcessesWelding processes can be divided into two main types: fusion welding and solid-state welding.
Fusion welding is the process of welding two materials together by melting them together and fusing them together, creating a molecular bond. This type of welding is used when high-strength and reliable joints are needed. Solid-state welding processes use pressure and heat to fuse materials together without actually melting them.
These processes are often used for lighter gauge metals and getting a more precise weld than the fusion processes.
Types of Fusion WeldingFusion welding has numerous subtypes, and depending on the application and material type, different processes are used.
Here are some of the most common types of fusion welding processes:
- Gas Metal Arc Welding (GMAW) – Often referred to as “MIG welding”, this process uses an electric arc to melt and join together metal parts. This process is fast, and it is often used for manufacturing and repairs.
- Shielded Metal Arc Welding (SMAW) – Also known as “stick welding” or “arc welding”, this process uses an electric arc to initiate the weld between two metal parts. This type of welding is relatively economical and very popular in many industries.
- Gas Tungsten Arc Welding (GTAW) – Also known as “Tig welding”, this process uses a non-consumable tungsten electrode arc to initiate the weld.
This process is often used for thinner metals and low-alloy steel and requires more skill than the more automated processes.
- Flux-Cored Arc Welding (FCAW) – This process is similar to MIG welding but uses a hollow, flux-filled electrode instead of a solid wire. This process is faster than most others and is often used for thicker metals.
Solid-State Welding ProcessesSolid-state welding processes are used to join materials by applying pressure and heat, but without fusing the materials. These processes do not require an electrical arc for the weld, which makes them easier to use. There are several popular solid-state welding processes, including:
- Oxy-Fuel Welding – Also known as “Oxy-Acetylene”, This process uses a flame to melt a portion of the joining material, creating a temporary liquid bond between the materials that solidifies when cooled.
- Friction Welding – This process uses a combination of heat and pressure to create a bond between two materials. This process is usually used for joining large parts.
- Explosion Welding – This process uses a small explosive charge to create a weld between two materials. This process is usually used for larger parts, and it requires precise control.
- Ultrasonic Welding – This process uses high-frequency sound waves to join two materials. This process is often used for joining plastics.