Welding Techniques

Welding is a core metal fabrication process that is widely used in the

manufacturing and construction industries.

Welders are able to transform different types of metals into unique shapes and
products that they envision.

The type of metal that is being welded will often determine the welding technique
that will be used to provide the best possible result.

Like any other specialized skill, the art of welding is something that has to be
mastered.

Most welding in metal fabrication involves common metals like steel, iron,
aluminum, copper and other metals that can be joined using different welding
techniques.

There isn’t a single welding process that is suitable for all applications.

It’s important to consider these factors when deciding on the type of welding
technique to use for metal fabrication:

The type of metal

The thickness of the metal
The size of the welding project
What you want the welds to look like
Your overall budget
Whether you’re welding indoors or outdoors

To understand the different types of welding, we’re going to look at the four
common welding techniques used in metal fabrication:

Different Types of Welding

Stick or Arc Welding (SMAW)

Stick welding, otherwise known as Shielded Metal Arc Welding is one of the easiest
and widely used welding techniques in metal fabrication. This welding technique
uses a consumable electrode stick that produces electric current. When in contact
with steel, iron or any heavy metal that’s being welded, it creates an electric arc
that generates temperatures as high as 6500 fahrenheit.

This type of welding can be performed on metals that have not been pre-cleaned and
is quite effective when working on rusty metals, making it less time-consuming for
welders. However, when using this welding technique, it’s important to use the
proper amount of amperage for the thickness of the metal being welded. Working with
thin metals can make the process more complicated and may require the presence of
an experienced and highly skilled welder.

Stick, or arc welding is mostly suitable for heavy metals like iron and steel
ranging from size 4 mm and above. As one of the most common welding techniques,
stick welding is mostly used for repairing heavy metal equipment, pipeline welding,
steel structure erection as well as metal work in the manufacturing and
construction industries. Learning the right arc welding procedure is important to
ensure a proper weld.

MIG Welding (GMAW)

MIG Welding

Unlike the stick welding technique, Gas Metal Arc Welding (GMAW) uses a gun that’s
continuously fed with a consumable electrode. This method uses an external gas to
shield the welded metal from various environmental factors like oxygen, therefore,
making the welding process quick and continuous. This method produces less welding
fumes and is easy to learn, requires less heat input and has a high electrode
efficiency.

Find the right equipment for Metal Inert Gas (MIG) welding can, however, be costly.
This welding method is not effective on thick metals but works well on metals like
magnesium, stainless steel, aluminum, silicon bronze, nickel and copper. It’s
widely used in construction, automotive repairs, metal fabrication, plumbing,
robotics and maritime repairs. To create high-quality welds, the metal has to be
cleaned before any welding in metal fabrication takes place.

This can easily be done by grinding the metal to remove any paint, rust or solvent
that may have accumulated on the metal. If you don’t have a metal grinder, you can
also use a detergent, solvent and water to remove any grease that is present on the
metal. Once the metal is clean and the welding begins, it’s important to ensure
that the welding torch doesn’t touch the metal being welded. A zigzag pattern
should be used in this common welding technique to ensure that both sides of the
metal joint are being welded.

TIG Welding (GTAW)

TIG welding, also referred to as Gas Tungsten Arc Welding uses tungsten rods to
create a well defined and neat weld that is visually appealing. View PostTo produce
a high-quality weld, the metal needs to be cleaned thoroughly. It’s also important
to choose the smallest electrode possible when performing the weld so you can
minimize the chances of contamination. Different arc lengths must be used for
different metals when it comes to using the TIG welding technique.

For high-quality work, welders should use the shortest arc length possible. Unlike
other types of welding techniques, this method can be time-consuming and
challenging and requires a high level of focus and skill to perfect the technique
and perform the highest standard of work. An external shielding gas is also
required. While TIG welding may be one of the most difficult of all the common
welding techniques used in metal fabrication, it produces a top-quality weld and
can be used to weld virtually any type of metal.

Because of the high level of skills required to master TIG welding, many welding
and metal fabrication companies are in constant search for professional and highly
experienced TIG welders. TIG welding is most suitable for vehicle welding,
aerospace welding, bike manufacturing, motorcycle manufacturing, tubing and piping
and high-precision welds.

Flux Cored Arc Welding

This welding method is almost similar to the MIG welding technique as far as the
overall welding process and the equipment used is concerned. This welding technique
in metal fabrication requires an electrode containing a flux and a constant amount
of voltage. It also requires a shielding gas that is used to protect the welding
surface from any atmospheric contamination. This is a quick welding process that
can be used on many different types of metals.

The Flux Cored Arc Welding process is more costly than other welding techniques.
The method has quickly developed as a reliable alternative to shield welding.
Thanks to its high welding speed and portability, this semi-automatic arc weld is
widely used in construction projects that involve metal fabrication work, heavy
equipment repairs and steel erection. This common welding technique is effective in
welding thick metals.