VARIOUS COMMONLY USED WELDING PROCESSES

Stick Welding
Shielded Metal Arc Welding (SMAW) is frequently referred to as stick or covered electrode welding. Stick welding is among the most widely used welding processes.

The flux covering the electrode melts during welding. This forms the gas and slag to shield the arc and molten weld pool. The slag must be chipped off the weld bead after welding. The flux also provides a method of adding scavengers, deoxidizers, and alloying elements to the weld metal.

Stick Welding Benefits

Equipment used is simple, inexpensive, and portable Electrode provides and regulates its own flux Lower sensitivity to wind and drafts than gas shielded welding processes All position capability

Common Stick Welding Concerns

We can help optimize your welding process variables. Evaluate your current welding parameters and techniques. Help eliminate common welding problems and discontinuities such as those listed below: Weld Discontinuities Undercut Incomplete fusion Porosity Slag Inclusions Cracks Stick Welding Problems

Arc Blow Arc Stability Excessive spatter Incorrect weld profile Rough surface Porosity

Submerged Arc Welding

Submerged arc welding (SAW) is a high quality, very high deposition rate welding process. Submerged arc welding is a high deposition rate welding process commonly used to join plate.

Submerged Arc Welding Benefits

Extremely high deposition rates possible High quality welds Easily automated Low operator skill required

Common Submerged Arc Welding Concerns

We can help optimize your welding process variables. Evaluate your current welding parameters and techniques. Help eliminate common welding problems and discontinuities such as those listed below:

Weld Discontinuities Cracks Porosity Slag Undercut Submerged Arc Welding Problems Solidification Cracking Hydrogen Cracking Incomplete fusion Irregular wire feed Porosity

GTAW Welding
Gas Tungsten Arc Welding (GTAW) is frequently referred to as TIG welding. TIG welding is a commonly used high quality welding process. TIG welding has become a popular choice of welding processes when high quality, precision welding is required.

In TIG welding an arc is formed between a nonconsumable tungsten electrode and the metal being welded. Gas is fed through the torch to shield the electrode and molten weld pool. If filler wire is used, it is added to the weld pool separately.

TIG Welding Benefits

Superior quality welds Welds can be made with or without filler metal Precise control of welding variables (heat) Free of spatter Low distortion

Shielding Gases
Argon Argon + Hydrogen Argon/Helium Helium is generally added to increase heat input (increase welding speed or weld penetration). Hydrogen will result in cleaner looking welds and also increase heat input, however, Hydrogen may promote porosity or hydrogen cracking.

GTAW Welding Limitations

Requires greater welder dexterity than MIG or stick welding Lower deposition rates More costly for welding thick sections

Common GTAW Welding Concerns

We can help optimize your welding process variables. Evaluate your current welding parameters and techniques. Help eliminate common welding problems and discontinuities such as those listed below:
Weld Discontinuities Undercutting Tungsten inclusions Porosity Weld metal cracks Heat affected zone cracks TIG Welding Problems Erratic arc Excessive electrode consumption Oxidized weld deposit Arc wandering Porosity Difficult arc starting

MIG Welding
Gas Metal Arc Welding (GMAW) is frequently referred to as MIG welding. MIG welding is a commonly used high deposition rate welding process. Wire is continuously fed from a spool. MIG welding is therefore referred to as a semiautomatic welding process

MIG Welding Benefits

All position capability Higher deposition rates than SMAW Less operator skill required Long welds can be made without starts and stops Minimal post weld cleaning is required

MIG Welding Shielding Gas

The shielding gas, forms the arc plasma, stabilizes the arc on the metal being welded, shields the arc and molten weld pool, and allows smooth transfer of metal from the weld wire to the molten weld pool. There are three primary metal transfer modes: Spray transfer Globular transfer Short circuiting transfer The primary shielding gasses used are: Argon Argon - 1 to 5% Oxygen Argon - 3 to 25% CO2 Argon/Helium

CO2 is also used in its pure form in some MIG welding processes. However, in some applications the presence of CO2 in the shielding gas may adversely affect the mechanical properties of the weld.

Common MIG Welding Concerns

We can help optimize your MIG welding process variables. Evaluate your current welding parameters and techniques. Help eliminate common welding problems and discontinuities such as those listed below: Weld Discontinuities Undercutting Excessive melt-through Incomplete fusion Incomplete joint penetration Porosity Weld metal cracks Heat affected zone cracks

MIG Welding Problems Heavily oxidized weld deposit Irregular wire feed Burnback Porosity Unstable arc Difficult arc starting

Flux Cored Welding

Flux Cored Arc Welding (FCAW) is frequently referred to as flux cored welding. Flux cored welding is a commonly used high deposition rate welding process that adds the benefits of flux to the welding simplicity of MIG welding. As in MIG welding wire is continuously fed from a spool. Flux cored welding is therefore referred to as a

semiautomatic welding process.

Self shielding flux cored arc welding wires are available or gas shielded welding wires may be used. Flux cored welding is generally more forgiving than MIG welding. Less precleaning may be necessary than MIG welding. However, the condition of the base metal can affect weld quality. Excessive contamination must be eliminated. Flux cored welding produces a flux that must be removed. Flux cored welding has good weld appearance (smooth, uniform welds having good contour).

Flux Cored Welding Benefits

All position capability Good quality weld metal deposit Higher deposition rates than SMAW Low operator skill required Metallurgical benefits that can be gained from a flux

Common Flux Cored Welding Concerns

We can help optimize your flux cored welding process variables. Evaluate your current welding parameters and techniques. Help eliminate common welding problems and discontinuities such as those listed below: Weld Discontinuities Undercutting Excessive melt-through Incomplete fusion Incomplete joint penetration Porosity Cracks Slag inclusions Flux Cored Welding Problems Melted contact tip Irregular wire feed Burnback Porosity