What Is Welding?
“What is welding?” It's a question that comes up often for those stepping into the world of metal fabrication. At its core, welding is the process of joining materials using heat, pressure, or sometimes both.
As the materials cool, they fuse together, forming a strong and lasting bond.
In this article, we'll break down the basics of welding, explore different welding methods and look at the common joint types such as T-joints, corner joints, edge joints, cruciform joints, and lap joints.
Let's start by getting a clear understanding of what welding actually involves.
What this article covers:
What Is Welding?
Welding is a fabrication process used to join metals or thermoplastics by creating a coalescence between them. This involves melting the materials and introducing a filler that forms a molten pool. As this pool cools, it hardens into a strong joint.
Depending on the method, the process may rely solely on heat, pressure, or a combination of both.
What sets welding apart from other joining techniques, like brazing or soldering, is that it melts the base materials themselves, creating a much stronger bond. The final result is known as a weldment.
Welding is a crucial part of many industries, including construction, automotive, aerospace, and manufacturing. This is thanks to its ability to create durable, high-strength joints. Its versatility makes it the go-to method for assembling metal components and structures.
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Welding Types
Stick Welding (Shielded Metal Arc Welding - SMAW)
On the list of types of welding is stick welding, also known as shielded metal arc welding (SMAW). It is one of the most widely used and versatile techniques.
It works by using a consumable electrode that's coated in flux. An electric arc forms between this electrode and the metal pieces being joined, generating the heat to melt both.
The beauty of stick welding lies in its simplicity. It's well-suited for outdoor use and rough environments, making it a popular choice for construction, repair, and maintenance work. It's particularly effective when working with iron and steel in heavy-duty applications.
Gas Metal Arc Welding (GMAW Or MIG)
Gas metal arc welding (GMAW), more commonly known as MIG (metal inert gas) welding, uses a continuously fed solid wire electrode that runs through a welding gun into the weld pool. At the same time, a shielding gas flows through the gun to protect the weld from atmospheric contamination.
Our findings show that mig welders are appreciated for their speed and relative ease of use. They produce clean welds and are useful for working with thinner to medium-thickness metals. That's why they are so common in the automotive industry, fabrication shops, and even at-home DIY projects.
For MIG applications, consider the Lincoln POWER MIG 360MP Multi-Process Welder. It is a versatile machine capable of MIG, Pulsed MIG, Flux-Cored, Stick, and TIG welding. It features advanced technologies like ArcFX and a 7-inch color display for intuitive control.
Flux-Cored Arc Welding (FCAW)
Flux-cored arc welding (FCAW) is closely related to MIG welding but with a twist. Instead of a solid wire, it uses a tubular wire filled with flux. Depending on the type of wire, you may or may not need an external shielding gas.
Thanks to its efficiency and high welding speed, FCAW is favored in construction and heavy equipment repair. It excels at welding thicker materials and performs well in outdoor or windy conditions.
Its portability and speed make it an ideal solution across applications.
Tungsten Inert Gas Welding (TIG or GTAW)
Tungsten inert gas welding (TIG), also called gas tungsten arc welding (GTAW), uses a non-consumable tungsten electrode to carry the arc. A separate filler material can be added if needed, and an inert gas, usually argon, is used to shield the weld area from contaminants.
TIG welding is all about precision. It's the method of choice when working with thin materials or non-ferrous metals like aluminum, copper, and magnesium. It's often used in aerospace, automotive, and artistic metalwork where fine, high-quality welds are crucial.
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Submerged Arc Welding (SAW)
Submerged arc welding (SAW) creates a weld by forming an arc between a continuously fed electrode and the workpiece. The arc and molten weld are covered by a granular flux, which shields the weld from spatter and atmospheric exposure.
SAW stands out for its deep weld penetration and fast deposition rates. It's typically used for thick steel plates and large structures, making it a staple in industries like shipbuilding, pressure vessel manufacturing, and large-scale structural fabrication.
How Does Welding Work?
Our research indicates that welding works by applying heat, pressure, or both to the materials being joined. In many cases, the base materials are heated to their melting point, allowing them to flow together and form a single, solid joint as they cool.
Common Joint Configurations
T Joint
A T joint is created when two pieces of material intersect at a 90-degree angle, forming the shape of the letter “T.” This is one of the most commonly used joints in structural applications. It's typically welded using fillet welds on both sides of the vertical piece, ensuring strength and stability.
Corner Joint
Corner joints are formed when two metal pieces meet at the corner, usually at a right angle. These are common in box-like structures such as frames, enclosures, or tanks. Corner joints are welded with fillet welds, striking a balance between strength and a clean exterior finish.
Depending on the application, corner joints can be reinforced with either inside or outside welds, allowing for design flexibility based on load requirements.
Edge Joint
An edge joint is formed when two parallel or nearly parallel pieces are joined at their edges. This configuration is mostly used with thinner materials that don't experience heavy stress.
Edge joints are common in sheet metal work, such as in the construction of tanks, casings, or ducts. Depending on the strength requirements, filler metal might be added, and the weld may be placed on one or both sides.
Cruciform Joint
Based on our observations, a cruciform joint results when two T joints intersect at right angles, creating a cross-like structure. These joints are often found in heavy structural applications where maximum strength is needed.
That said, due to their geometry, cruciform joints are prone to stress concentration in the middle. Proper welding technique is crucial to prevent failure. You'll find these joints in bridges, industrial frames, and other high-load structures.
Lap Joint
Lap joints are formed when two pieces of material overlap and are welded at the edges. This configuration is effective when joining materials of different thicknesses or handling shear loads.
They're commonly used in automotive manufacturing, aerospace components, and HVAC systems. Lap joints can be executed with different types of welds, including fillet, plug, or spot welds, depending on what the job calls for.
Working on lap joints in car panels? The Hobart Handler 140 MIG Welder is ideal for 24-gauge to 1/4-inch mild steel and is perfect for home garages and auto body repair shops. Don't forget your welding helmet!
Conclusion
Welding is a cornerstone of modern manufacturing and construction. It allows for the permanent joining of materials. With a wide range of techniques available, there's a solution for just about every application.
Equally important are the different joint types, each with its own strengths and ideal use cases. Whether you're working on a high-strength cruciform joint in an industrial frame or a clean lap joint in an automotive panel, understanding the right methods and configurations is key to ensuring craftsmanship in any project.
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