Welding parameters comparison of different welding methods for steel pipes
1 Introduction
Steel pipes are widely used in a variety of engineering applications and are usually welded together. Due to different welding methods, the welding parameters for steel pipes are also different. This paper will compare the different welding parameters of various welding methods for steel pipes, so that we can understand the differences between different welding methods and choose the most suitable welding method in practical applications.
2 Types of Welding Methods for Steel Pipes
At present, the commonly used welding methods for steel pipes in engineering applications include shielded metal arc welding (SMAW), gas metal arc welding (GMAW), flux-core arc welding (FCAW), and tungsten inert gas welding (TIG).
Shielded metal arc welding (SMAW): It is one of the most widely used welding methods in engineering, and is also referred to as manual arc welding. This method requires the welder to automate the arc welding process by manual operation and regulation of the arc length between the welding electrode and the welding material surface.
Gas metal arc welding (GMAW): It is one of the most commonly used arc welding methods, and it is also called metal inert gas welding (MIG) and metal active gas welding (MAG). The welding material is heated and melted by the arc generated between the welding material and the welding wire, and then a certain shape welding seam is formed.
Flux-cored arc welding (FCAW): FCAW is a welding process that uses a tubular wire electrode filled with metal powder to melt the metal materials. The flux contained in the electrode core is used as the welding shielding gas, which can protect the welding area from oxidation and impurities.
Tungsten inert gas welding (TIG): Also known as heliarc welding. The welding heat source is an electric arc generated between the workpiece to be welded and the tungsten electrode. The arc is completely enclosed in the inert gas protection layer to prevent oxidation and impurities in the weld.
3 Comparison of Welding Parameters
3.1 Welding Speed
The welding speed of SMAW is the slowest. It moves slowly, with a welding speed of 0.5 ~ 3 m/h. Gas metal arc welding (GMAW) has a relatively fast welding speed, usually 5-15 m/h. Flux-cored arc welding (FCAW) welding speed is the fastest, usually 15-25 m/h. TIG welding speed is second, usually 5-10 m/h.
3.2 Welding Quality
The welding quality of SMAW is the lowest. Due to manual operation, there is deviation in welding process parameters, which affects the stability of welding quality. GMAW stability of welding quality is relatively higher, and the welding quality is high. FCAW and TIG welding methods have a strong ability to resist welding defects such as porosity and crack, and the welding quality is also high.
3.3 Welding Ease
SMAW is relatively more labor-intensive and requires certain manual welding skills. Due to the use of welding gun to complete the welding process while controlling the gas flow, GMAW has a certain labor intensity. The welding process of FCAW and TIG is completely automatic, and the labor intensity is the least.
3.4 Welding Cost
The welding cost of SMAW is relatively high. The main factors influencing cost are welding equipment and electrodes. Due to the wide range of arc welding parameters, the operating environment also has a certain impact on the welding cost. The weld cost of GMAW is relatively low, as it does not require any additional special welding parts other than gas cylinder. The cost of FCAW is in the middle, being slightly higher than that of GMAW and lower than that of SMAW. The cost of TIG welding is the highest, mainly because of the high cost of inert gas.
4 Conclusion
Different welding methods for steel pipes have different welding parameters. After a comprehensive comparison of these welding parameters, we can easily select the most suitable welding method according to the actual demand when welding steel pipes. SMAW is suitable for manual operations with small scale and low cost. At the same time, it can save the welding cost of GMAW by using flux cored wire instead of solid wire, and FCAW can be selected when it requires higher welding quality and speed. When more perfect welding quality is required, welding with TIG welding should be chosen.
