Standard Welding Techniques

It's crucial to decide on your area of specialization if you're considering a welding career. There are more than 30 welding methods, from straightforward oxy-fuel methods to laser beam operations. These variants are, however, often divided into four groups.

By employing pressure, heat, or both to join two or more metals, welding is a fabrication technique that results in a robust and long-lasting bond. The most common weldable materials are metals and thermoplastics. However, other materials like wood can also be welded.

4 STANDARD WELDING TECHNIQUES

There are many other welding types, but the four most popular ones are as follows:

Some of the causes of their predominance include:

• Requisites of industry.
• Affordable for DIY craftspeople.
• The secret to TIG welding is extremely high quality.
• Simple to learn (except TIG).

1. GAS METAL ARC WELDING OR MIG WELDING

Pressurized inert gas bottles supply MIG welding shielding gas. A wire that melts also creates an arc and fills the junction.

HOW IT OPERATES?

MIG is the common name for GMAW welding. The electrode in this procedure is an electrically charged wire continuously fed into the weld from a motorized spool. It is also flooded with shielding gas.

Power is connected to the MIG gun through the welding lead. It has a slot for the electrode wire to slide into and a gas pipe for the MIG torch connection.

Carbon dioxide is frequently used as MIG shielding gas.

WHEN TO USE IT?

MIG welding is the most effective method if speed is a concern, you're a beginner, or you need to keep the heat down. Shielding gas adds complexity, but it also offers exceptional heat control and a clean weld.

PROS

• Satisfactory for production welding.
• Easy to learn because of continuous wire feed.
• Good heat management.
• Tidy welding.
• Simple to learn.

CONS

• Wind may blow away shielding gas.
• Rust and all paint must be removed.

2. GAS TUNGSTEN ARC WELDING, OR GTAW (TIG WELDING)

The TIG process is challenging to master. Compared to other procedures, it requires more expertise, finesse, time, and experience, but the results are stronger and better-looking welds.

HOW IT OPERATES?

TIG differs from other procedures in its electrode. A short, point-sharpened tungsten rod serves as the torch's electrode.

The electrode is not burned, which is the difference. Instead, the operator feeds a long rod made of filler metal into the welding puddle while controlling the torch with one hand. The welding puddle eats away at this metal rod. As with a flame torch, the electrode simply initiates and maintains the arc necessary to melt the metal.

The operator's skill with the torch, ability to regulate the heat level, and ability to feed the filler rod at the ideal rate all play a significant role in the outcome. The TIG torch connection transports pressurized inert gas to flood the arc zone, much like a MIG system but without a wire feeding mechanism. Argon is typically used as a shielding gas for TIG welding.

WHEN TO USE IT?

When strong and pristine welds are required, TIG welding is the best option. TIG-welded structures are covered after construction and are difficult to maintain. Examples include race car roll cages, high-end electronics cabinets, electric equipment, and aircraft structures.

The opposite circumstance, where the weld is always visible and necessitates a certain level of eye appeal or high-tech validation, is another example of TIG. Examples include custom bodywork, fancy lawn furniture, and exposed hot rod frames.

PROS

• Aluminum and magnesium alloys are welded with AC TIG.
• Titanium, brass, copper, steel, stainless steel, and DC TIG are all welded.
• Finest precision and highest quality.
• Capable of joining very thin materials.
• Zero slag.

CONS

• To master, you need extensive knowledge and expertise.
• Costlier TIG machines are available.

3. SHIELDED METAL ARC WELDING OR STICK WELDING

Stick welding is the oldest and most basic welding type. Stick welding has been practiced since the late 1800s. Its technology is the best, simplest, and oldest.

HOW IT OPERATES?

Stick welders use long cable leads with a sturdy clamp for the workpiece on one lead and an electrode holder on the other. They also have a power source. The electrode is made of metal and resembles a thick wire. They come in a wide variety of metals and alloys.

Welding rod diameters vary. It is chosen based on metal thickness. Flux is a substance applied thickly to welding rods and burns in an arc. This produces a gas that protects the welding puddle. Slag, a thin, brittle crust formed by flux as the metal cools, must be chipped off and brushed away with power brushes.

WHEN TO USE IT?

If welding is possible at all, it is done using a stick. Stick arc welding is preferred when the weld is difficult to access or when corrosion, oil, or other impurities are present at the weld joint. Farm equipment works on steel, cast iron, aluminum, stainless steel, and durable surfaces.

PROS

• Simple to learn.
• Affordable.
• Not sensitive to contaminants.
• Almost any metal can be welded.

CONS

• Using a thin metal can be challenging.
• Makes a lot of heat.
• It requires lots of time.

4. FLUX CORED ARC WELDING (FCAW)

Gasless MIG welding, also known as flux core welding, is a highly adaptable technology renowned for its low cost, simplicity of use, and reliable outcomes. It is also utilized in manufacturing but with modified shielding and larger equipment.

HOW IT OPERATES?

The FCAW process uses a hollow wire loaded with flux, much like the stick process, which uses an electrode covered in flux. Like MIG, FCAW passes a spool of wire into the welding lead. Stick welders change the electrode every time the wire spool runs out, so you can weld faster.

FCAW-G AND FCAW-S

Flux core welding has two types.

• FCAW-G

The "G" denotes the use of external shielding gas in addition to conventional flux core wire, and is also called dual-shielded wire welding. Compared to FCAW-S and MIG processes, this method produces smoother arcs.

• FCAW-S

The "S" stands for "self-shielded," and it is the most popular flux core approach since it is low-cost, easy to use, and highly successful.

WHEN TO USE IT?

Flux core welding is most used by amateurs, small enterprises, and fabrication shops. This is because it offers superior penetration, precise heat control, and convenience of use at a lower cost than MIG welding.

PROS

• The one that is probably the simplest to learn.
• Effective on rusty, painted, and dirty surfaces.
• Can be applied to windy circumstances.
• Thick steel is easily handled.

CONS

• Slag must be eliminated.
• A lot of splatter is produced.

There are several ways to weld, but these four techniques are the most widely used.