Welding Processes Overview

Shielded Metal Arc Gas Metal Arc Gas Tungsten Arc Submerged Arc Plasma Arc Oxy-Fuel Laser Beam Miscellaneous

Shielded Metal Arc Welding - SMAW (Stick welding)

AC or DC Consumable Electrode Constant Current Current Range =30 A 600 A Covering may have metal, shielding gas, arc stabilizers, and slag formers

SMAW (cont)
Advantages
Low capital expense Portable Can weld in all positions Better shielding in windy locations than gas-shielded processes Can weld dirty metal

Disadvantages
Shielding not sufficient for reactive materials Low deposition rate (217 #/hr.) Possibility of slag inclusions, defects Stub losses (1-2 of every 14= 7%-14% waste

Gas Metal Arc Welding - GMAW (Mig Welding)

Consumable Electrode Primarily DC Constant Current (CC) / Constant Voltage (CV)

GMAW (cont)
Advantages
Higher deposition rate (1-30 #/hr.) higher current density than SMAW = better penetration Less operator skill required Higher efficiency All positions Most metals weldable

Disadvantages
Higher capital cost than SMAW Shielding gas required wire can bird-nest (Al wire in particular)

Gas Tungsten Arc Welding - GTAW (Tig Welding)

Nonconsumable electrode Constant-Current AC or DC Gas shielded - AR, He, or Ar-He mix Hi-freq often used cold-feed or hot-feed wire

GTAW (cont)
Advantages
Suitable for ALL metals Suitable for very thin materials (i.e. coke cans) Allows very precise control of weld

Disadvantages
Typically very slow travel speeds Hi equipment costs 10-20% as fast as GMAW Higher skill required (OFW experience helpful)

Submerged Arc Welding

Consumable Electrode Primarily DC Constant Current (CC) / Constant Voltage (CV) Arc completely covered by granulated flux Primarily automated or semi-automated

SAW (cont)
Advantages
90%-99% Efficiency Very high deposition rate Excellent penetration Alloying can be controlled through flux composition flux may be recycled

Disadvantages
Flat and horizontal positions only Not suitable for thin material Uses roughly 1# of flux per pound of electrode

Plasma Arc Welding (PAW)

Melt-in and keyhole welding methods DCEN/DCEP/AC Pilot arc initiates main arc (30,000 plasma) cold-feed or hot-feed wire Ar used for plasma Ar, He, Ar-He, Ar-H used as shielding gas

PAW (cont)
Advantages
Can weld VERY thin material -- 0.001 Higher welding speed, improved arc stability, higher heat content -> greater penetration All metals, all positions

Disadvantages
High capital cost High maintenance cost More complex welding procedures More operator training

Process Efficiencies
Submerged GTAW can approach 99% EBW range = 80-95% LBW varies widely: 2% - 98% depending on material reflectivity

Miscellaneous Processes
Ultrasonic Welding - USW Electron Beam Welding - EBW ElectroSlag Welding - ESW Explosion Welding - EXW Friction Stir Welding - FSW Flash Welding - FW And over a 100 other processes...