~
Special Purpose Welding Electrodes
Welding is a process that bonds two overlapping pieces of metal together by heat or pressure in a combination of melting and reshaping the metals and adding a filler material. Special purpose welding electrodes are designed for specific applications that require specific weld properties or specific weldment environments. Special purpose welding electrodes must not be used for regular welding applications, as they are not designed to meet the requirements of a standard welding application.
Special purpose welding electrodes are typically designated using codes such as: GMAW (Gas Metal Arc Welding), GTAW (Gas Tungsten Arc Welding), SMAW (Shielded Metal Arc Welding), SAW (Submerged Arc Welding), FCAW (Flux-Cored Arc Welding), and FCW (Flux Core Wire). These are abbreviated versions of the welding processes used by the electrodes. It is important to understand the purpose of each process and the welding electrodes associated with it before making a selection for a specific welding job.
GMAW (Gas Metal Arc Welding) - GMAW is a welding process that uses an electric arc between a consumable electrode and the work piece to form a weld. Electrodes for GMAW are typically alloy steel, stainless steel, aluminum, and sometimes titanium. GMAW is typically used for applications such as sheet metal fabrication, automotive body work, pressure vessels, and pipelines.
GTAW (Gas Tungsten Arc Welding) - GTAW is a welding process that utilizes a tungsten electrode to form an electric arc. Electrodes used with GTAW are typically a tungsten alloy or zirconiated tungsten. It is often used on exotic metals such as titanium and nickel alloys. GTAW is typically used in applications where precision is key, such as aerospace welding, automotive restoration, food processing, and medical instrumentation.
SMAW (Shielded Metal Arc Welding) - SMAW is a welding process that uses a consumable electrode in conjunction with a shielding gas to protect the weld from contaminants. These electrodes are generally low alloy and mild steel, but can also be stainless steel, aluminum, and other metals such as chromium and nickel. SMAW is used for industrial applications such as oil and gas, automotive frames, and boilers.
SAW (Submerged Arc Welding) - SAW is a welding process that uses an electric arc created between a bare, consumable electrode and the work piece. The weld is formed underwater, and the electrode typically consists of a flux and wire combination that contains elements such as sodium, ferrochrome, manganese, silicon, and chromium. SAW is used mainly in heavy industries such as ship building and bridge construction.
FCAW (Flux-Cored Arc Welding) - FCAW is a welding process that uses a consumable, self-shielding hollow wire electrode and a shielding gas. FCAW electrodes used vary in composition and can include alloys such as nickel, stainless steel, aluminum, and more. FCAW is typically used in heavy industries such as the construction of machinery, tanks and pressure vessels, and structural steel.
FCW (Flux Core Wire) - FCW is a welding process that works similar to Gas Metal Arc Welding (GMAW) but uses a flux core wire instead of a solid wire. FCW electrodes are typically alloy and mild steel. FCW is used mainly in manufacturing and fabrication, such as automotive repair and welding structural steel.
Using special purpose welding electrodes correctly is key to producing quality welds and avoiding costly rework. It is important to understand the purpose of each welding process and the welding electrodes associated with them before making a selection for a specific welding job. Using the proper electrode for the job is critical for producing the desired results.
