Welding and Repair Process of Common Metals
Welding is the most commonly used process for joining two pieces of material together, and can be used to create a strong, permanent bond between two pieces of metal. Most often, welding is used to connect two pieces of metal for manufacturing purposes, but can also be used for parts repair, or even for art. Welds are made by connecting two pieces of metal with the application of heat, pressure, and/or with a filler material. There are many different types of welding processes and techniques that can be used on various metals, including steel, aluminum, copper, magnesium, and other alloys.
Steel Welding
Steel is one of the most commonly welded metals, due to its strength and durability. As steel is prone to oxidation when exposed to the atmosphere, many welding processes use inert gases such as argon, helium, or carbon dioxide to protect the weld material from oxidation. The two primary processes used for steel welding are gas metal arc welding (GMAW) and flux-cored arc welding (FCAW). GMAW relies on an electric arc to form the weld while the top of the weld is covered with a layer of molten flux material. FCAW takes a flux-cored wire electrode and uses an electric arc to create the bond.
Aluminum Welding
Aluminum is one of the most commonly used metals in manufacturing due to its light weight and strong strength-to-weight ratio. However, due to its extremely low melting point, welding aluminum can be challenging. Special care must be taken to ensure that the heat used to create the weld is not too high, as it may cause contamination or deformation in the metal. In addition, aluminum is prone to oxidation, so welding processes must include the use of inert gases to protect the molten metal from oxidation. The two primary welding processes used for aluminum welding are gas tungsten arc welding (GTAW) and gas metal arc welding (GMAW).
Copper Welding
Copper is widely used in electrical applications, plumbing applications, and heat devices as due to its excellent electrical and thermal conductivity. Copper is a relatively soft metal, making it more difficult to weld than steel or aluminum. Because copper is more resistant to heating than other metals, welds must be created quickly at very high temperatures. In addition, copper is prone to tarnishing and oxidation, so welding must be done quickly and under a layer of inert gas to protect the weld material. The two primary processes used for copper welding are gas metal arc welding (GMAW) and tungsten inert gas welding (TIG).
Magnesium Welding
Magnesium is one of the lightest metals and is commonly used in the aerospace industry and in the manufacturing of engines and other parts. Magnesium is especially useful for its ability to be strong yet lightweight. Magnesium is, however, difficult to weld due to its low melting point and the flammability of the material. The two main processes used for welding magnesium are gas tungsten arc welding (GTAW) and plasma arc welding (PAW). In both processes, an inert gas is used to protect the weld material from oxidation and flammability.
Repair Processes
In some cases, it may be necessary to repair a damaged or corroded part or piece instead of replacing it. Repairs of metal parts are often done using welding processes, though repairs may also be done using brazing or soldering. In brazing, a softer metal (such as copper or brass) is melted and then used to fill in gaps and create a bond. In soldering, a liquid solder (often containing lead or tin) is melted and used to join two pieces of material. In welding, heat and/or pressure is used to connect two pieces of material and create a strong, permanent bond.
Conclusion
Welding is an important process for the manufacturing and repair of many different types of metal products. Steel, aluminum, copper, and magnesium are all common materials used in manufacturing, and each has its own particular welding process with which it should be joined. Each material must be joined in the correct way using the correct welding process and material in order to ensure a strong and permanent weld. In some cases, brazing or soldering may be used instead of welding, depending on the application.
