{"id":3388,"date":"2022-06-09T11:55:55","date_gmt":"2022-06-09T11:55:55","guid":{"rendered":"https:\/\/www2.adorfon.com\/?p=3388"},"modified":"2022-09-12T09:35:55","modified_gmt":"2022-09-12T09:35:55","slug":"a-complete-guide-to-types-of-welding","status":"publish","type":"post","link":"https:\/\/adorwelding.com\/adorfon\/a-complete-guide-to-types-of-welding\/","title":{"rendered":"A Complete Guide to Welding"},"content":{"rendered":"<p><strong>Table of Contents<\/strong><\/p>\n<ul>\n<li><strong>Welding Metals \u2013 An Introduction<\/strong><\/li>\n<li><strong>Welding &#8211; A Definition<\/strong><\/li>\n<li><strong>Types of Welding by Metal<\/strong><\/li>\n<li><strong>Types of Welding by Method<\/strong>\n<ul>\n<li><strong>Fusion Welding (Electrical Energy)<\/strong><\/li>\n<li><strong>Solid-State and other Non-electric Fusion Welding<\/strong><\/li>\n<\/ul>\n<\/li>\n<li><strong>Welding Processes<\/strong>\n<ul>\n<li><strong>Fusion welding<\/strong><\/li>\n<li><strong>Solid State welding<\/strong>\n<ul>\n<li>DEFORMATION WELDING<\/li>\n<li>DIFFUSION WELDING<\/li>\n<li>Non-Fusion Process<\/li>\n<\/ul>\n<\/li>\n<\/ul>\n<\/li>\n<li><strong>Introduction to Arc Welding<\/strong><\/li>\n<li><strong>Conclusion<\/strong><\/li>\n<\/ul>\n<p><strong>Welding Metals \u2013 An Introduction<\/strong><\/p>\n<p>To join ferrous with non-ferrous metals, various methods can be adopted.<\/p>\n<ul>\n<li>Mechanical methods: Fasteners, rivets, etc.<\/li>\n<li>Adhesive bonding method: Brazing and Soldering (a.k.a. welding)<\/li>\n<li>Base metal does not fuse: Molten filler gets drawn into close-fit joints through capillary action (surface tension forces).<\/li>\n<li>Brazing filler melts at &gt;450\u2070C, soldering at &lt;450\u2070C<\/li>\n<\/ul>\n<p>Welding is the most commonly used process of all.<\/p>\n<p><strong>Welding &#8211; A Definition\u00a0<\/strong><\/p>\n<p>Welding can be described as a process of joining two or more pieces \/edges of metal by producing a localized union through heat (fusion) with or without pressure to create a homogenous joint.<\/p>\n<p><strong>Types of Welding by Metal:<\/strong><\/p>\n<p><strong>Autogenous:<\/strong> In this process, similar materials are joined without filler wire or electrode<br \/>\n<strong>Heterogeneous:<\/strong> Process of joining dissimilar materials, using a filler wire or <a href=\"https:\/\/www2.adorfon.com\/products-and-services\/welding-electrodes-wires\/electrodes-for-mmaw\/stainless-steel\/\">welding electrode<\/a><\/p>\n<p><strong>Types of Welding by Method:<\/strong><\/p>\n<p>1.<strong> Fusion Welding (Electrical Energy):<\/strong><\/p>\n<ul>\n<li><a href=\"https:\/\/www2.adorfon.com\/products-and-services\/welding-electrodes-wires\/electrodes-for-mmaw\/\">Manual Metal Arc welding<\/a> \/ Flux Cored Arc welding \/ Shielded Metal Arc Welding<\/li>\n<li>TIG \u2013Tungsten Inert Gas welding<\/li>\n<li>Metal Inert Gas welding or Metal Active Gas welding<\/li>\n<li>SAW \u2013 Submerged Arc Welding<\/li>\n<\/ul>\n<p>2. <strong>Solid-State and other Non-electric Fusion Welding: <\/strong>Examples of non-fusion, non-electric process welding are:-<\/p>\n<ul>\n<li>Thermit welding<\/li>\n<li>Ultrasonic welding<\/li>\n<li>Diffusion welding<\/li>\n<li>Deformation welding.<\/li>\n<\/ul>\n<p><strong>Welding Processes<\/strong><\/p>\n<ul>\n<li><strong>Fusion welding:<\/strong> Welding in the liquid state with no pressure, Union is by molten metal bridging<\/li>\n<li><strong>Solid State welding:<\/strong> Carried out below the melting point of the metal without filler additions, Pressure is often used,<br \/>\nUnion is often by plastic flow.<\/li>\n<\/ul>\n<p><strong>Solid State welding:<\/strong><\/p>\n<p><strong>DEFORMATION WELDING: <\/strong>Two Surfaces in contact are brought into very close contact by applying high pressure, which deforms them. E.g., \u2013 Forge welding, Roll welding, Extrusion welding. (Not at very high temperatures)<\/p>\n<p>&nbsp;<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter wp-image-3458\" title=\"deformation welding\" src=\"https:\/\/www2.adorfon.com\/wp-content\/uploads\/2022\/06\/ador-blog1-150x150.png\" alt=\"deformation welding\" width=\"160\" height=\"192\" \/><\/p>\n<p><strong>DIFFUSION WELDING: <\/strong>Joining takes place by atomic diffusion of 2 surfaces in contact. Surfaces are usually heated to high temperatures (below the melting point) &amp; pressure may be employed. E.g., Brazing, Braze welding &amp; Soldering. Soldering is an oxy-fuel process of joining metals. The process temperature does not exceed 450\u2070. Brazing is also an Oxy-Fuel joining process. The process temperature is between 450\u2070 Degrees \u2013 750\u2070 degrees. Braze welding is similar to Brazing; the process temperature is above 750\u2070 Degrees but below the melting point of the base metal.<\/p>\n<p><strong>Non-Fusion Process: <\/strong>Thermit welding is the most common process used in joining of railway tracks. In this process iron powders and Al binders are kept in Vat or a conical container above the joining rails. When they are fired due to chemical reaction and exothermic reaction, the iron powder melts and forms a joint between rails.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter wp-image-3459\" title=\"non fusion process\" src=\"https:\/\/www2.adorfon.com\/wp-content\/uploads\/2022\/06\/ador-blog2.png\" alt=\"non fusion process\" width=\"160\" height=\"113\" \/><\/p>\n<p><strong>Introduction to Arc Welding: <\/strong>Basic welding processes used in Industry are<\/p>\n<ul>\n<li>MMAW &#8211; Manual Metal Arc Welding or Shielded Metal Arc welding<\/li>\n<li>GMAW \u2013 Gas Metal Arc Welding\/ Flux Cored Arc Welding (MIG, MAG)<\/li>\n<li>GTAW &#8211; Gas Tungsten Arc Welding (TIG)<\/li>\n<li>SAW &#8211; Submerged Arc Welding<\/li>\n<\/ul>\n<p><strong>MMAW or SMAW- Shielded Metal Arc process: <\/strong>In the Shielded Metal Arc process or Manual metal Arc welding process the arc is established between Parent Metal and a <a href=\"https:\/\/www2.adorfon.com\/products-and-services\/wear-resistant-products\/flux-cored-wires\/\">flux coated welding<\/a> electrode using electrical energy to melt and deposit weld metal. This is the most commonly used process in the world.<\/p>\n<p><strong>Basic Requirements for the SMAW process: <\/strong><\/p>\n<p><strong>Heat source:<\/strong> Welding Equipment Current Range 30-400 A \u2013depending on size of the electrode in general, even though there are welding machines used up to 600 Amps AC or DC welding machines can be used in SMAW Operation.<\/p>\n<p><strong>Welding Consumable<\/strong>: Flux coated welding electrode (1.6- 8 mm diameter)<br \/>\nA trained welder is required to operate the process, So SMAW or MMAW is the most commonly used process in the world.<\/p>\n<p><strong>SMAW Process advantages:<\/strong><\/p>\n<ul>\n<li>This is the simplest of all welding process.<\/li>\n<li>Equipment Portable<\/li>\n<li>Economical Cost of Equipment<\/li>\n<li>Variety of application &amp; wide availability of electrodes<\/li>\n<li>Range of metals &amp; their alloys can be welded<\/li>\n<li>Welding in all Positions<\/li>\n<li>Welding in Indoor &amp; Outdoors<\/li>\n<li>Extended welding cable to long distances in comparison to another process<\/li>\n<\/ul>\n<p><strong>Limitations of SMAW process:<\/strong><\/p>\n<ul>\n<li>Low productivity as in a 10-minute cycle welding happens only for 6 minutes<\/li>\n<li>Process also involves a frequent changes of welding electrode<\/li>\n<li>Moisture from flux coatings can create weld-related problems<\/li>\n<li>Safety problems like arc strike, Stray current &amp; electric shock risks<\/li>\n<li>Absolutely Manual process \u2013 hence called Manual metal arc welding<\/li>\n<\/ul>\n<p><strong>GMAW &amp; FCAW processes:\u00a0<\/strong><\/p>\n<ul>\n<li>A continuous solid wire, small diameter<\/li>\n<\/ul>\n<p style=\"text-align: left;\">\u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0GMAW uses solid wire, no flux<\/p>\n<p>\u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0FCAW use flux-filled wire<\/p>\n<ul>\n<li>Wire feed through the gun to the arc by wire feeder.<\/li>\n<li>Weld pool may be protected from oxidation by shielding gas.<\/li>\n<li>High productivity 3 kg\/h or more<\/li>\n<li>Direct current (DCEP mostly).<\/li>\n<\/ul>\n<p><strong>Process Requirement:<\/strong><\/p>\n<ul>\n<li>Welding power source<\/li>\n<li>Wire feeder mechanism-\u00a0In-built\/separate<\/li>\n<li>Gun with gas supply &amp; trigger switch<br \/>\n1. Manual\/semi-automatic guns<br \/>\n2. Automatic torches available<br \/>\n3. Can be fitted to automation etc.<\/li>\n<\/ul>\n<p><strong>Advantages in GMAW:<\/strong><\/p>\n<ul>\n<li>Faster as compared to TIG &amp; SMAW.<\/li>\n<li>Can produce joints with deep penetration.<\/li>\n<li>Thick &amp; thin, jobs can be welded effectively.<\/li>\n<li>Can be used for fabrication and maintenance repair job.<\/li>\n<li>Can be mechanized easily<\/li>\n<li>Reduced distortion.<\/li>\n<\/ul>\n<p><strong>Limitation in GMAW:\u00a0<\/strong><\/p>\n<p>More Complex due to<\/p>\n<ul>\n<li>Electrode stick-out<\/li>\n<li>Torch angle<\/li>\n<li>Welding parameters<\/li>\n<li>Type and size of electrode<\/li>\n<li>Welding torch manipulation<\/li>\n<li>Not suitable for outdoor welding applications<\/li>\n<\/ul>\n<p><strong>GTAW or TIG welding: <\/strong>GTAW or Tungsten Inert gas welding uses a consumable Tungsten electrode as the heat source.<br \/>\nThis consists of the below.<br \/>\n<strong>Heat source<\/strong> \u2013 welding power source to create an arc between a tungsten tip and the parent metal<br \/>\n30-400A, AC or DC welding machine and 0-20V<br \/>\nInert gas shielding is used in the process.<br \/>\n<strong>Consumable: <\/strong>filler rod can be used between 1 to 4mm diameter<br \/>\n<strong>Process Features:<\/strong><\/p>\n<ul>\n<li>Excellent control<br \/>\n1. Stable arc at low power (80A at 11V)<br \/>\n2. Independently added filler<br \/>\n3. Ideal for intricate welds eg root runs in the pipe or thin sheet<br \/>\n4. Low productivity 0.5kg\/h manual<\/li>\n<li>High quality<br \/>\n1. Clean process, no slag<br \/>\n2. Low oxygen and nitrogen weld metal<br \/>\n3. Defect-free, excellent profile even for single-sided welds<\/li>\n<\/ul>\n<p><strong>Advantages in GTAW\/TIG Process:<\/strong><\/p>\n<ul>\n<li>No slag inclusion<\/li>\n<li>Clear visibility of arc and job<\/li>\n<li>All position weldability<\/li>\n<li>Suitable for high quality welding of thin material<\/li>\n<li>Root run of thick materials<\/li>\n<li>Ideal for Aluminum, Stainless steel &amp; Titanium<\/li>\n<\/ul>\n<p><strong>Limitations in GTAW:<\/strong><\/p>\n<ul>\n<li>Slow as compared to SMAW\/MIG\/MAG &amp; SAW welding<\/li>\n<li>Possibility of tungsten inclusion in the weld deposit which is hard &amp; brittle<\/li>\n<li>Not suitable for outdoor welding<\/li>\n<\/ul>\n<p><strong>Submerged Arc welding process (SAW Process): <\/strong>In the Saw Process, as the name signifies, welding happens submerged beneath the flux. SAW process also employs welding consumables usually a wire &amp; arc is established between the welding wire and base metal and welding happens underneath the metal powder of flux, shielding the arc from the atmosphere and its gases.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter wp-image-3460 size-full\" title=\"saw process\" src=\"https:\/\/www2.adorfon.com\/wp-content\/uploads\/2022\/06\/ador-blog3.png\" alt=\"saw process\" width=\"539\" height=\"413\" srcset=\"https:\/\/adorwelding.com\/adorfon\/wp-content\/uploads\/2022\/06\/ador-blog3.png 539w, https:\/\/adorwelding.com\/adorfon\/wp-content\/uploads\/2022\/06\/ador-blog3-300x230.png 300w\" sizes=\"auto, (max-width: 539px) 100vw, 539px\" \/><\/p>\n<p><strong>Heat source:<\/strong> Arc between a wire and base metal<br \/>\n<strong>Current Range:<\/strong> 200 Amps -1200 Amps<br \/>\nDC operation<br \/>\n<strong>Power Consumption<\/strong><\/p>\n<ul>\n<li>35-56 KVA<\/li>\n<li>Power source<\/li>\n<li>Welding head and control box<\/li>\n<li>Welding head travel<\/li>\n<li>Flux recovery system (optional)<\/li>\n<li>Positioners and Fixtures<\/li>\n<\/ul>\n<p>Hence the basic difference between the two processes is that in the SMAW process, the flux-coated electrode provides the shielding from the atmosphere &amp; in SAW process an external flux is delivered at the arcing area to act as a shield, so welding happens underneath the powder flux fed by a delivery system.<\/p>\n<p><strong>SMAW Process &#8211; Advantages:<\/strong><\/p>\n<ul>\n<li>Simplest of all Arc welding process<\/li>\n<li>Equipment is portable<\/li>\n<li>Economical cost of equipment<\/li>\n<li>Variety of application &amp; wide availability of electrodes<\/li>\n<li>Range of metals &amp; their alloys can be welded<\/li>\n<li>Welding in all Positions<\/li>\n<li>Welding in Indoor &amp; Outdoors<\/li>\n<li>Extended welding cable to long distances when compared to other processes<\/li>\n<\/ul>\n<p><strong>SAW Process advantages:<\/strong><\/p>\n<ul>\n<li>High productivity up to 2 to 10 kg per hour<\/li>\n<li>Speed almost up to 2m\/ min<\/li>\n<li>Can be easily automated for even higher productivity<\/li>\n<\/ul>\n<p><strong>Limitations of the SAW process:<\/strong><\/p>\n<ul>\n<li>Bulky, expensive, and heavy equipment<\/li>\n<li>Flat and horizontal positions only<\/li>\n<li>Thicker sections (6mm and above)<\/li>\n<li>Mostly ferrous materials (also Ni alloys)<\/li>\n<\/ul>\n<p><strong>Conclusion: <\/strong>A wide variety of processes are available for joining or hard surfacing ferrous and non-ferrous materials. Each of these processes provides different mechanical properties and works in specific conditions, with a welding power source. There are several factors to consider in welding rod selection:<\/p>\n<ul>\n<li>Base metal properties<\/li>\n<li>Tensile strength required<\/li>\n<li>Welding current<\/li>\n<li>Base metal thickness, shape and joint fit-up<\/li>\n<li>Welding position<\/li>\n<li>Specification and service conditions<\/li>\n<li>No. of similar jobs \u2013 Scope for automation<\/li>\n<li>Environmental job conditions<\/li>\n<\/ul>\n<p>These methods are all commonly used by Industry. Before we select any particular method for welding, we need to analyze each of the factors listed above.<\/p>\n<p>ADFL serves the industry with the manufacture and supply of all types of consumables for MMAW, MIG \/Mag, TIG, SAW &amp; non-fusion processes like soldering, brazing, and braze welding. This is why Ador Fontech\u2019s name is synonymous with total solutions for any maintenance &amp; repair problem, ensuring the <a href=\"https:\/\/www2.adorfon.com\/products-and-services\/repair-and-reclamation-services\/\">Life Enhancement of Industrial components<\/a>, to the complete satisfaction of customers.<\/p>\n<p>Reclaim, do not Replace<\/p>\n","protected":false},"excerpt":{"rendered":"<p>Table of Contents Welding Metals \u2013 An Introduction Welding &#8211; A Definition Types of Welding by Metal Types of Welding by Method Fusion Welding (Electrical Energy) Solid-State and other Non-electric Fusion Welding Welding Processes Fusion welding Solid State welding DEFORMATION WELDING DIFFUSION WELDING Non-Fusion Process Introduction to Arc Welding Conclusion Welding Metals \u2013 An Introduction [&hellip;]<\/p>\n","protected":false},"author":1,"featured_media":3389,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[1],"tags":[34,33,32],"class_list":["post-3388","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-blog","tag-fusion-welding","tag-non-fusion-welding","tag-types-of-welding"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v24.7 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>A Complete Guide to Welding | Definition, Types &amp; Processes<\/title>\n<meta name=\"description\" content=\"Welding can be described as a process of joining two or more pieces \/edges of metal by producing a localized union through heat (fusion) with or without pressure to create a homogenous joint.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link 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