We have always seen the sparkling light coming out of the workshops. Our inquisitive mind would question that light and our parents would tell us that it was a welding process. But we merely got to know how it actually worked.

Well, it is more a complex process and it is a cornerstone in the manufacturing of the machinery. Whether it’s your car, bike, ships, planes, locomotives, spacecraft, or home appliances, they all need welding to join their various parts.

welding

There are different types of welding processes mentioned below

  • MIG – Gas Metal Arc
  • Stick – Shielded Metal Arc
  • TIG – Gas Tungsten Arc
  • Energy Beam
  • Flux-Cored Arc
  • Gas Tungsten
  • Atomic Hydrogen

Weld Joint

Weld joint plays a crucial role in joining different metals at different positions. A particular weld joint can’t withstand metals joined at different positions, lest joint should break easily. Therefore, the weld joint is determined by the magnitude of load that will act on it.

Weld joints undergo shear stress, torsional stress, and in some cases both shear and torsional stress. Weld joints types are namely butt, lap, corner, T, plug, and edge.

welding

Welding joints can be classified under two broad categories

Pressure welding

In this process, external pressure brings out the weld joint either at a temperature below the melting point or above the melting point. The two pieces to be joined needs to be free from not metallic films, oxides, and other dirt. This makes the strongest weld joint.

The atoms are moved together to a distance that is equal to or less than the equilibrium inter-atomic separation distance. This process is usually used for metals having high ductility. The processes that come under pressure welding are:

  • Cold pressure welding is used for joining sheets, wires, and electric components.
  • Explosive welding is used when joints of dissimilar metals are to be welded.
  • Ultrasonic welding, when thin sheets are to be joined.
  • Percussion welding is utilized for joining dissimilar metals.
  • Friction welding is used when similar or dissimilar metals are to be joined.

Fusion Welding

In this process, the metals are joined at their edges by heating them above their melting point temperature. The weld joint is made when the fused metal solidifies. As no pressure is required in this process, the filler may be used to fill the joint. Also, inert gases can be used to improve the quality of the weld. 

Under this process, metals that have some extent of mutual solubility in the solid-state. For metals that are highly soluble in the solid-state doesn’t make a strong weld joint and metals with no solubility doesn’t create a joint at all. Therefore, it becomes important to use only intermediate soluble metals for this process.

Every manufacturing processes has a potential risk. These processes may present several hazards to the people who are doing it or to the people in their vicinity. Therefore, it is imperative to have high safety measures.

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