Welding is one of the most important methods of connecting a body of material. In some instances, welding is the only method of joining material and in others, it is the preferred method. Welding can be divided into two different processes. Fusion welding, which uses high temperatures to melt the material and then shape it, and solid-state welding, which uses pressure and force to join the material together.
Fusion welding is the traditional technique that typically requires a third party to regulate the high temperature of the welding arc and the voracity of the metals. It is used in a variety of industries, most notably automotive and aerospace. The process works by melting the materials into liquid and then bringing them back together in a solid form. The third party plays an important role in monitoring the temperatures and gas pressures to achieve the most precise weld.
Brazing is the process of joining two metals through a filler material of high melting point. It is different to fusion welding in that it bonds two pieces of metal together, rather than making a separate entity, by using a low temperature binder that is stronger than the metals being joined. Brazing also typically requires a torch and welding rod and other welding accessories. The joint is usually cleaner and neater because it does not involve melting of the metals being joined together.
Welding alloys can be used to provide a stronger bond between materials. These alloys have either a higher melting point or lower melting point than the metals being joined together to create a stronger joint. Some alloys are used to increase the strength of the joint by increasing the flow of the weld pool or by reducing the shrinkage of the weld pool. When welders use different types of welding alloys, they are essentially forming a new alloy instead of joining two separate materials.
Finally, there is the use of chemical welding agents to create a strong bond between two materials. These chemical agents are also sometimes referred to as weld fluxes. The flux is essentially a chemical that is mixed with the welding rod and applied to the joint prior to heating. It makes the connection free of any trapped air or other contaminants which would weaken the bond. Chemical weld fluxes are most commonly used in the joining of aluminum, stainless steel, and nickel alloys.
No matter what welding process is chosen, one thing remains true: the joining of two pieces of metal is not a task to be taken lightly. It is important to consider the requirements of the welding process and select the appropriate materials, welding accessories, and welding techniques for the job. Taking the time to make sure each step is done properly will ensure that the welds are strong and reliable for a long time to come.
