Arc welding is a popular and mechanically and technologically advanced solution developed to combat the problem of breakage in metal equipment. The process generates permanent joints in materials with great strength, versatility, and durability, making it a suitable option for commercial purposes. With different types of welding processes available, arc welding is known and utilized for its characteristic benefits. There are different types of arc welding processes. Explore them through the article for better information and decision-making in your welding endeavors.
Introduction to ARC Welding
Welding defines the process of joining or fabricating joints. It occurs at high temperatures, melting the metal. Simultaneously, it fills with filler metal and cools to solidify, restoring the strength of the metal and equipment. The welding process is of multiple types, such as:
- Friction stir welding
- Laser beam welding
- Arc welding
- Forge welding
- Electron beam welding
- Magnetic pulse welding
Arc welding is among the most common types of welding processes witnessed today for joining metals. The article discusses various sub-types of arc welding. It utilizes high temperatures and either consumable or non-consumable electrodes, depending on the process type. Mechanical or manual guidance can be used in this fabrication process.
Types of Arc Welding
Arc welding uses two types of electrodes: consumable and non-consumable electrodes. Based on their usage, the different types of arc welding are as follows:
Consumable Electrodes
Types of arc welding processes employing consumable electrodes are:
MIG and MAG
Gas Metal Arc Welding (GMAW), popularly known as Metal Inert Gas Welding (MIG) and Metal Active Gas Welding (MAG), provides protection against base metal contamination through shielding gas. Additionally, it employs consumable metal electrodes that the process incorporates via the machine. The gas metal arc welding process is versatile, simple, economical, and easily automatable.
Shielded Metal Arc Welding (SMAW)
It is popularly called as stick welding, flux-shielded arc welding, or manual metal arc welding. The welding process is ideal for linking ferrous and nonferrous materials with a wide range of thicknesses. It uses a traditional approach where an arc fills the gap between metal surfaces by generating high temperatures. It melts the rod and workpiece, making a weld pool. The high temperature surrounding the pool is maintained through the release of gas and slag.
Submerged Arc Welding (SAW)
It is different from other processes as the welding joint here is completely submerged in the flux. The process requires continuous feeding of consumable electrodes. The conductive nature of the developed flux allows for the smooth carrying out of the welding process. Further, it also suppresses the fumes and ultraviolet radiation and prevents sparks and spatter.
Non-Consumable Electrode
The types employing the usage of non-consumable electrodes are:
Carbon Arc Welding
A non-consumable carbon arc is used in this process to merge the gap between the metals. The process generates high levels of fumes and spatters, making it unsafe. The associated disadvantages have led to the replacement of the welding process with modern techniques. However, the unique capabilities of the process have not completely eradicated its usage. Carbon arc welding also requires experience and expertise to handle the arc and perform the process along with the constant current power source.
Plasma Arc Welding (PAW)
It is the type of arc welding process that uses ionized gases to generate ‘hot plasma jets.’ It is the highly preferred method and exhibits increased efficiency for narrow and deep welds. The high speed of extremely hot jets is one of the unique and advantageous characteristics of the process.
Tungsten Inert Gas Welding (TIG)
Almost all industrial fields use Tungsten Inert Gas Welding (TIG) or Gas Tungsten Arc Welding (GTAW). This type of arc welding gained popularity overnight in the 1940s for linking aluminum and magnesium alloys. Gas tungsten arc welding primarily obtains high-quality welded joints. In this process, non-consumable tungsten electrodes generate the weld.
Process of Arc Welding
The process of arc welding occurs as follows:
Step 1: An electric arc is created through the application of voltage across the two electrodes. The procedure leads to a connection between electrodes through electricity.
Step 2: The electrical connection melts the metal due to extremely high temperatures, specifically above 3000 degrees Celsius.
Step 3: The melting converts metal into a molten metal state.
Step 4: The molten metal and filler from consumable electrodes join together to form a molten mixture.
Step 5: As the arc moves on, the temperature across the mixture decreases, letting it cool and solidify, which subsequently fills the gap.
Benefits of Arc Welding
There are numerous benefits of electrical arc welding. Let us explore some of the following:
- Arc welding machines are simple and portable, allowing easy application at any desired location.
- The arc welding equipment is affordable
- The requirement of shielding gas is not mandatory to carry out the process
- The high temperature reached during the welding process allows quick completion of the task of joining the metal parts or pieces, saving time
- Compared to other types of welding, the quantity of generated smoke, spatter, spark, and flash is less.
- Non-ideal conditions of the atmosphere do not limit the process
- The higher impact strength of the arc welding process makes the welded items capable of withstanding heavy loads
- It also offers resistance to corrosion, thus eliminating the expenditure of extra cost to apply corrosion-resistant items
- Arc welding also fits into imperfect sizes requiring welding
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