Welding technology has been widely used since its invention. It is frequently used in manufacturing, repair and construction projects. Welding is a process whereby metal parts are joined together using energy. The energy can be generated by a variety of sources such as electric current, gas, laser, electron beam, and sonic energy. The process involves placing two parts together and applying heat which causes atoms of the metal to move around, and the two parts will join together.
Welding techniques have evolved continuously over the years. This can be attributed to improvements in technology, new materials, and advancements in the equipment used to produce welds. Both manual and automated welding processes are used in modern industrial fabrication and welding is also used in medical and dental applications.
Gas tungsten arc welding (GTAW) is a commonly-used onsite welding technique which relies on the use of a non-consumable tungsten electrode and a shielding gas to create a weld. This process is advantageous in many ways; it requires minimal weld preparation, produces clean, high-strength welds, and the welding speed can be adjusted to provide a range of weld bead geometries.
The GTAW process is often used in the aerospace, automotive, and shipbuilding industries due to its capability to weld a wide variety of materials including aluminium, titanium, and magnesium. Furthermore, the process is comparatively safer than other welding techniques as it does not involve the risk of ignition from hot metals or sparks.
Friction welding is a process whereby the two components to be joined are subjected to frictional heat which causes the surface of the materials to become plasticized and flow. This process is used mainly for joining metals, but can also be used for joining metal composites or plastics.
The process is conducted by placing the two components in contact and applying a certain amount of pressure and heat. The frictional heat created causes the workpieces to become plasticized, reducing the contact surface and allowing the components to bond. The surface area required is typically lower than other welding processes, making it a quick and efficient way of joining.
Gas metal arc welding (GMAW) is a widely used semi-automatic welding process which is suitable for the fabrication of many different materials. It is often used in engineering and the automotive industry and is generally considered the most popular process of welding due to its simplicity, speed and flexibility.
In this process, an electric arc is established between the workpiece and a consumable metal electrode, where the heat from the arc melts the base material and the electrode material. The molten metal then solidifies as the arc is move along the surface of the workpiece.
Laser welding is a commonly used welding process which relies on the use of a laser beam to create extreme heat. This type of welding is often used for precision welding of thin materials which require high-integrity joint strength and a narrow weld gap.
The process is advantageous in many ways; it is a fast and cost-effective method of welding, and the welds created are strong and consistent. Furthermore, laser welding can be used to weld a variety of metals ranging from stainless steel to aluminium.
Another type of welding, electron beam welding, uses a powerful beam of electrons to create heat and melt the metal. This process is regarded as one of the most reliable welding techniques and is able to provide highly accurate, repeatable welds with minimal distortion.
The process consists of accelerating an electron beam to a very high-speed and focussing it onto the joint between two components. The electron beam is directed by an electromagnet and can be adjusted to create weld beads of various sizes and shapes.
In conclusion, welding is an essential process for joining metals and other materials. With advancements in technology, a wide variety of welding techniques have been developed and are used in industries around the world. Depending on the application, each process has its advantages and disadvantages, meaning that careful consideration should be taken in deciding the most appropriate process for a particular application.
