Various types of Welding techniques application are to join metal and thermoplastic parts. A highly skilled workforce is required to perform welding operations. But nowadays, robots are replacing welding operators for repeated welding tasks.
We can automate the welding operation and improve weld quality using welding robots. This article covers various types of welding techniques, their advantages, and their limitations. Click this link to know the benefits of implementing automation in manufacturing.
Different Types of Welding Processes and their uses
For years, different types of Welding techniques are evolving. Nowadays, even underwater welding is also possible. The following types of welding techniques are available in the manufacturing industry. Each of these welding techniques has its advantages, limitations, and applications.
- Arc Welding
- Gas Welding
- Resistance Welding
- Solid-State Welding
- Energy Beam Welding (EBW)
- Laser Welding
Arc Welding
Arc welding melts and fuses the metal parts by generating an arc between the electrode (consumable or non-consumable) and the base metal to be joined. An electric arc between base material and electrode generates using AC or DC voltage.
Types of Arc welding Techniques
The following types of arc welding techniques are used in the manufacturing industry.
- Tungsten Inert Gas welding (TIG)
- Metal inert Gas Welding (MIG)
- Metal Active Gas welding (MAG)
- Carbon Arc Welding
- Metal Arc Welding
- Plasma Arc Welding
Advantages of Arc Welding
The arc welding process has the following advantages compared to other welding processes.
- High strength weld.
- High weld speed.
- Low welding equipment and process cost.
- Automation with robotic arms is possible.
- High corrosion resistance.
Limitations of Arc Welding
Despite having so many advantages, the arc welding process has the following limitations.
- Low efficiency.
- A highly skilled workforce is required.
- Difficult to weld thin materials.
Gas Welding
Gas welding utilizes flames to melt and fuse the base material. It is one of the oldest forms of welding, easy to use, and low in cost.
Type of Gas welding
Following gas welding techniques are available in the market.
- Oxy-Acetylene Gas Welding
- Oxy-Hydrogen Gas Welding
- Air-Acetylene Gas Welding
Advantages of Gas Welding
The gas welding process has the following advantages compared to other welding techniques.
- Low equipment cost.
- Portable equipment.
- Low Welding Cost.
- Highly skilled welders are not required.
Limitations of Gas Welding
Gas welding has the following limitations:
- Low weld quality.
- Generally used for repair work.
- Not suitable for thick sections.
Resistance Welding
Resistance Welding joins metal parts by applying pressure and passing a current through the welding section using welding electrodes (copper-based alloy materials).
Spot or resistance welding offers a cost-effective solution because welding occurs without filler material. It has applications for a wide range of automotive, aerospace, and industrial parts.
Types of Resistance welding
Several types of resistance welding techniques are available according to the types and shapes of welding electrodes.
- Spot Welding
- Seam Welding
- Projection Welding
- Flash Welding
- Upset welding
Advantages of Resistance Welding
Resistance welding has the following advantages.
- Low Processing cost because filler material is not required.
- The process is easy to implement.
- Welding Dissimilar materials are possible.
Limitation of Resistance Welding
Resistance welding has the following limitations.
- Comparatively low welding strength.
- Aesthetics are not good near the weld area.
Solid State Welding (SSD)
In solid-state welding, base materials are fused and joined by applying pressure and vibration motion. For example, ultrasonic welding utilizes pressure and high-frequency vibrations to join two plastic parts.
Types of Solid State Welding Techniques
Following types of solid-state welding techniques are used to join metal and plastic parts.
- Ultrasonic Welding
- Friction Welding
- Forge Welding
- Cold Welding
- Explosive Welding
- Diffusion welding
Advantages of Solid State Welding
Solid-state welding has the following advantages:
- Welding dissimilar materials and thermoplastic is possible.
- Weld joints are free from microstructure defects.
- Welded joints have mechanical properties similar to the base material.
- Low operational cost because filler material is not required.
Limitations of Solid State Welding
Solid-state welding has the following limitations.
- Difficult to set up.
- Implementing automation is a challenging task.
- Surface preparation is required.
Electron-beam welding is a type of fusion welding where a beam of high-velocity electrons heats the welding section. As a result, base material melts and flows together to create a joint due to the kinetic energy of electrons.
Advantages of Electron Beam Welding
Electron Beam welding has the following advantages:
- Weld strength up to 95% is achievable.
- A vacuum environment eliminates impurities.
- Precise control and repeatability.
Disadvantages of Electron Beam Welding
Electron Beam Welding has the following limitations:
- EBW requires vacuum conditions to prevent dissipation of the electron beam.
- Implementing automation is a challenging task.
- Welding Materials with high vapor pressure like Zinc, Magnesium, and Non-metal is not possible.
Laser Beam Welding
Laser Beam Welding is a type of fusion welding that utilizes a high power density (1 MW/cm²) laser beam to melt and join metal or thermoplastic parts. The laser-spot size can vary from 0.2 mm to 13 mm.
The laser beam welding process has application in the automotive industry for large production volumes.
Advantages of Laser Beam Welding
The laser beam welding process has the following advantages compared to other welding processes.
- High-quality welds.
- Welding a wide variety of thermoplastics and metal parts is possible.
- Narrow and deep welds are possible.
- Used for high volume applications because of the high welding rate.
- Automation is easy to implement.
- Consumable electrodes are not required.
- A small laser spot size up to 0.2 mm is feasible.
Limitations of Laser Beam Welding
The laser beam welding process has the following limitations.
- High initial equipment and maintenance cost.
- Sometimes cracking is a concern due to the high cooling rate.
We will keep updating this article on different types of welding techniques. Add your comments or questions on various types of welding their advantages, and limitations in the comment box. Click this link If you are interested in the difference between soldering welding and brazing.
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