Methods Of Welding
Most of us agree that professional welding really involves skill, experience and expertise. In essence, to become a welding expert, you need to have substantial knowledge and experience. Similarly, you need many years of exposure and skill to master the art of welding. However, its essential for anyone to learn the basics and build on that to learn more complex skills.
First, one has to take adequate safety precautions when carrying out welding. Otherwise, you are at high risk of harming yourself due to unforeseen circumstances. For example, damaging to the eyes is a high possibility due to intense light rays generated from the welding. Similarly, you might be at a risk of electrocuting yourself as high voltage electricity is used in certain cases of welding. Hence, before starting any welding job, its essential to wear a helmet with a shield or googles protecting your eyes, hair, head & face. Similarly, wearing protective thick gloves, long sleeved, clothing, thick boots and gas mask is necessary in welding
Arc Welding:
Arc welding is the most common welding method used by many. In arc welding, a high voltage electricity is used instead of a gas torch. The welding process of arc welding involves a spark or an arc that melts the metal peaces to form a weld. This process is accurate and creates a cleaner and a stronger weld. There are many categories of arc welding. For example, there are seven different methods to be chosen from. For example:
Shielded metal arc welding: This is the most suitable method for large welds or metal welding that do not have normal angles and positions. This type of welding method, high voltage electricity is sent through an electrode creating an arc which metals can be melted to form a weld.
MIG welding (Metal Inert Gas welding): This is useful in welding projects that require speed. In this method, a welder or a welding machine is used that passes current through a metal tip, while a separate wire is fed continuously to the tip which forms the weld.
Tungsten inert gas welding(TIG): This is almost similar to MIG welding. However, it is mainly used to weld thin materials that require high quality welds and where speed is not an issue.
Besides above, there are other techniques of arc welding namely Flux-Cored arc welding (FCAW), submerged arc welding (SAW), plasma welding, etc.
Aluminum Welding:
Aluminum is the most difficult metal to weld. First, aluminum oxide has to be cleaned from the aluminum metal surface. Also note that heat treatable aluminum alloys derive its strength through the process of aging. Aluminum alloys tend to decrease its tensile strength owing to over-aging. Aluminum alloys can be categorized into nine groups, such as:
1. Unalloyed (pure) >99% Al
2. Copper is the major alloying element in the Aluminum alloy.
3. Manganese is the major alloying element in the Aluminum alloy
4. Silicon is the major alloying element in the Aluminum alloy
5. Magnesium is the major alloying element in the Aluminum alloy
6. Magnesium & Silicon are major alloying elements.
7. Zinc is the major alloying element in Aluminum alloy
8. Other elements (including Tin, some Lithium compositions)
9. Reserved for future use
The undermentioned factors associated with aluminum alloys greatly affect the aluminum welding process:
Aluminum Oxide coating.
Thermal Conductivity.
Thermal Expansion Coefficient.
Melting characteristics.
Other welding techniques:
Along with above welding methods, there are several other welding techniques used in industrial applications as well as for large scale and specific requirements.
In going through the above welding methods, you only have to remember few basic methods. To become an expert on particular welding method or methods, one has to have the basic knowledge as well as experience in welding. If anyone intends to become an expert on welding, he has to have patience, commitment, dedication and be prepared to learn from his mistakes.
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