Welder Product Guide

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Arc welding is one of several fusion processes for
joining metals. By applying intense heat, metal at
the joint between two parts is melted and caused to
intermix - directly, or more commonly, with an
intermediate molten filler metal. Upon cooling and
solidification, a metallurgical bond is created.
Since the joining is an intermixture of metals, the
final weldment potentially has the same strength
properties as the metal of the parts. This is in
sharp contrast to non-fusion processes of joining
(i.e. soldering, brazing etc.) in which the mechanical
and physical properties of the base materials cannot
be duplicated at the joint.

In arc welding, the intense heat needed to melt metal
is produced by an electric arc. The arc is formed between
the actual work and an electrode (stick or wire) that is
manually or mechanically guided along the joint. The
electrode can either be a rod with the purpose of simply
carrying the current between the tip and the work. Or, it may be a specially prepared rod or wire that not only conducts the current but also melts and supplies filler metal to the joint.
Most welding in the manufacture of steel products uses the second type of electrode.

Primary Types and How They Work:

MIG:
Gas metal arc welding (GMAW), sometimes referred to by its subtypes metal inert gas (MIG) welding or metal active gas (MAG) welding, is a semi-automatic or automatic arc welding process in which a continuous and consumable wire electrode and a shielding gas are fed through a welding gun. A constant voltage, direct current power source is most commonly
used with GMAW, but constant current systems, as well as alternating current, can be used. There are four primary methods of metal transfer in GMAW, called globular, short-circuiting,
spray, and pulsed-spray, each of which has distinct properties and corresponding advantages and limitations.

TIG:
Gas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG) welding, is an arc welding process that uses a nonconsumable tungsten electrode to produce the weld. The
weld area is protected from atmospheric contamination by a shielding gas (usually an inert
gas such as argon), and a filler metal is normally used, though some welds, known as autogenous welds, do not require it. A constant- current welding power supply produces energy which is conducted across the arc through a column of highly ionized gas and metal vapors known as a plasma.

STICK WELDING:
Shielded metal arc welding (SMAW), also known as manual metal arc (MMA) welding or informally as stick welding, is a manual arc welding process that uses a consumable electrode coated in flux to lay the weld. An electric current, in the form of either alternating current or direct current from a welding power supply, is used to form an electric arc between the electrode and the metals to be joined. As the weld is laid, the flux coating of the electrode disintegrates, giving off vapors that serve as a shielding gas and providing a layer of slag,
both of which protect the weld area from atmospheric contamination.

PLASMA CUTTING:
Plasma cutting is a process that is used to cut steel and other metals (or sometimes other materials) using a plasma torch. In this process, an inert gas (in some units, compressed air)
is blown at high speed out of a nozzle; at the same time an electrical arc is formed through that gas from the nozzle to the surface being cut, turning some of that gas to plasma. The plasma is sufficiently hot to melt the metal being cut and moves sufficiently fast to blow molten metal away from the cut. Plasma can also be used for plasma arc welding and other applications.

INDUCTION WELDING:
Induction welding is a form of welding that uses electromagnetic induction to heat the workpiece. The welding apparatus contains an induction coil that is energised with a radio-frequency electric current. This generates a high-frequency electromagnetic field that acts on either an electrically conductive or a ferromagnetic workpiece. In an electrically conductive workpiece, such as steel, the main heating effect is resistive heating, which is due to magnetically induced currents called eddy currents. In a ferromagnetic workpiece, such as plastic doped with ceramic particles, the heating is caused mainly by hysteresis as the
magnetic component of the electromagnetic field repeatedly distorts the crystalline structure
of the ferromagnetic material. In practice, most materials undergo a combination of these two effects.

ULTRASONIC WELDING:
In ultrasonic welding, high frequency (15 kHz to 40 kHz ) low amplitude vibration is used to create heat by way of friction between the materials to be joined. The interface of the two parts is specially designed to concentrate the energy for the maximum weld strength.

VIBRATION OR FRICTION WELDING:
In vibration or friction welding, the two parts to be assembled are rubbed together at a lower frequency (typically 100-300 Hz) and higher amplitude (typically 1-2 mm) than ultrasonic welding. The friction caused by the vibration motion combined with the clamping pressure between the two parts creates the heat which begins to melt the contact areas between the two parts. At this point, the plasticized materials begin to form layers that intertwine with one another, which therefore results in a strong weld. At the completion of the vibration
motion, the parts remain held together until the weld joint cools and the melted plastic re-solidifies. The friction movement can be linear or orbital, and the joint design of the two parts has to allow this movement.

Repair Procedures:

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