Introduction
Welding is a fabrication or sculptural process that joins materials, usually metals or thermoplastics, by using high heat to melt the parts together and allowing them to cool, causing fusion. Welding is distinct from lower temperature metal-joining techniques such as brazing and soldering, which do not melt the base metal. In addition to melting the base metal, a filler material is typically added to the joint to form a pool of molten material (the weld pool) that cools to form a joint that is usually stronger than the base material.
Flat welding is a kind of welding which requires more attention than other welding types. Heliarc and TIG welding are both flat welding techniques as well as homemade solutions. This article will mainly focus on the position of flat welding, but before that a general introduction to flat welding must be given.
Position of Flat Welding
Flat welding is the process of joining two workpieces together in a flat or horizontal position. This type of welding is typically used when the workpieces are too large and bulky to turn over or lay on its side or when uniform weld penetration is required on both sides of the workpiece. The weld must be positioned to where it does not interfere with the function of the component or cause uneven weld penetration.
When flat welding, the edges of the two pieces must be placed together and secured to ensure uniform alignment and a proper fit. The joint of the two pieces should be as tight as possible when welding so as to prevent any gaps between them. The workpieces should be clamped securely together to prevent any shifting while welding. In addition, any contaminants, such as rust and paint, must be removed from the joint before welding.
In order to achieve an even weld penetration and a strong bond, the correct welding technique must be used. This includes using the correct type and size of welding electrode, the correct amperage, and the correct technique. Additionally, it is important to use the correct type of filler material and to maintain the correct speed and travel angle when welding.
The welding electrode must be chosen based on the type of material being welded. Generally, when flat welding, a low amperage should be used, and a slow travel speed should be maintained to ensure uniform penetration. Additionally, the workpieces should be rotated back and forth while welding to maintain uniform heat distribution.
Finally, proper post-weld treatments should be done to ensure the strength and integrity of the weld. For example, depending on the type of material being welded, some welds may require a post-weld heat treatment. Additionally, any porosity, slag, and excess weld material should be removed as these can weaken the joint and cause corrosion.
Conclusion
Flat welding requires slowly depositing the weld metal and slowly rotating the workpieces back and forth to ensure uniform heat distribution. The welding technique, type of filler material, and the size and type of welding rod must all be taken into consideration for the best results. Additionally, the weld joint should be cleaned of all contaminants, and proper post-weld treatments should be done to ensure the strength and integrity of the weld. All of these factors can greatly affect the quality of the weld and the strength of the joint.
