Welding is an essential process in the industrial sector; it’s what keeps products that we rely on functioning every day. From the car you drive, to the bridge you cross – welding creates structures that hold together metal for strength and durability. But how does welding work? In this definitive guide on manufacturing welding, we’ll carefully breakdown the steps it takes to build welding, so you can understand it with ease, even if you’re new to the field.
Engineers take prudent precautions during the pre-welding stages by designing the product from scratch while considering the materials, strength required, and what the final product will have to do. They indicate the places where the welds are supposed to be and they often choose the type of welding to follow.
Welding is not a “one size fits all” type of endeavor. One application of one procedure does not fit all. In manufacturing there are some common examples such as:
MIG (Metal Inert Gas) Welding
MIG (Metal Inert Gas) welding is a multi-use welding process. A spool of wire is fed into the welding gun. The wire is automatically charged with electrical current. This wire heats the workpiece. Simultaneously, the wire is being melted by heat from the electric arc. The wire melts until a pool of molten metal is formed. This is how fusion occurs.
TIG (Tungsten Inert Gas) Welding is a precision welding process. A non-consumable tungsten electrode is used to produce the weld. Also, they use a shielding gas to protect the weld area from atmospheric contamination. This gas prevents oxidation of the molten weld pool and tungsten electrode. TIG welding produces clean, precise welds, especially on stainless steel and aluminum.
Shielded Metal Arc Welding: It is very portable and uses a flux coated electrode making it a good option for welding outdoors or in the field.
Keeping things clean is very important. When welding, it’s necessary to clean and prepare the metal surfaces thoroughly. Particular things that generally need to be done are:
Cleaning involves taking away any soil, oil, or oxidation to support a true and trustworthy weld.
Beveling is the process of producing angled edges on thicker metals to improve weld penetration.
Having the right tools can make a world of difference when it comes to welding. Some of the necessary welding equipment includes:
The power source is what gives the welding the electricity it will use to make the weld work.
The welding torch/gun is responsible for providing the current, as well as, in some cases, the filler metal, to the joint.
Gas Flow (if applicable): This gas surrounds the welding area, keeping the welding area from the air, avoiding oxidation.
It’s time for the best part! An expertly managed welding torch elegantly swoops and swings along the weld, fuming vigorously as a calming pool of molten metal forms. A moment later the puddle solidifies again, and two once-distinct pieces become one solid object of the desired strength.
Quality control is very important in manufacturing. Once a weld has solidified, you look at it closely to find any cracks or holes. The checks can involve:
Visual Examination: Searching for surface flaws.
The ability to use x-ray or ultrasound to see inside solid objects looking for flaws without destroying them is important in many modern manufacturing techniques.
If necessary, the weld can be ground down, polished, and painted to match the material around it.
Welding is more than just sticking metal parts together; it’s building the backbone of countless objects which make up the modern world. From giant machines in factories to micro components in electronic devices, welding is a foundational skill that drives innovation and advancement for today’s world powered by manufacturing.
Next time you come across a welded assembly, take a moment to think about the art and accuracy required to produce it. It demonstrates the power and importance of welding to modern manufacturing
Find more information about welding wire and welding techniques at UDO website – https://www.udo.co.th/