New Jersey, USA
Welding is responsible for much of the physical structure of our word today, from homes to bridges and towers.
The process involves joining two pieces of metal under extreme heat and pressure. A welded part includes two metal structures forced to form a robust bond at the joints. Experts believe that in one way or another, welding contributes to 12% of our national GDP.
What is the magic that happens in the joining and bonding of two metal pieces (and sometimes wood and plastic) under high heat? Well, the welding process, in simple definition, is an operation that leads to sturdy and robustly linked joints using heat, pressure, or both. A welding machine produces heat of up to 20,000 °C, making possible the joining of different metal parts in a bond that holds forever or something close to that.
The fabrication process can be traced back to the 1800s, but experts convey that the methods of joining metal go back over millennia to the Bronze Age. All the electric welding processes and techniques have one thing in common; they use high current or an electric arc together with a filler material to melt and join metal pieces together.
Arc welding processes use an electric arc (from the alternating current) together with a filler material to melt and form unbreakable links between the metal surfaces. The process involves temperature changes by thousands of degrees in close contact with the workpieces. Most arc welding processes use alternating current.
Shielded arc welding techniques achieve more than just joining two pieces together vis-a-vis soldering and brazing. Instead, they combine high temperatures and inert metal gases that result in melting and stronger connections. A shielding gas and wire electrode flows through the welding gun at the same time, helping to melt and bind parts without atmospheric contamination
Torch welding is less commonly used industrially. However, it is the easiest and most accessible welding process for small repairs and maintenance jobs. The process involves using an oxyacetylene torch to melt the welding rod with the working material.
There are many types of welding techniques and unique advantages and drawbacks. The amount of power and skill required for the job varies significantly with each process. The strength of the resultant bonding and the amount of time it takes to achieve that is also what sets each of these methods apart.
Metal Inert Gas welding is the most frequently used type of welding thanks to its speed and ease of use. The MIG welding technique learning curve is shorter for new beginners compared to other welding techniques. The process involves placing a welding arch between the base metal and the consumable electrode in a heating process that results in permanent joining.
However, unlike standard arc welding techniques, MIG is a shielded arc welding process that uses argon or carbon dioxide to protect the molten base metal and welding arc from atmospheric contamination. The arc, in this case, is voltage breakdown that produces heat of between 3,000 and 20,000 °C to melt the end of the electrode and the base metal.
The welding gear uses an inverter, generator, or transformer to supply the power needed to maintain the arc between the electrode and base material. The electrode is a continuous wire feed that sometimes generates fumes and plasma in the heating process. The MIG welding process is most applicable for ferrous metal types like carbon and steel and others like cast iron, aluminum, and nickel.
The arc welding process uses an electric arc together with an electrode to heat and join metal parts. Unlike MIG, the process doesn't use any gases to shield the wire or arc. This the most aged welding technique, and experts concur that it can be the hardest to master for student welders.
Arc welding machines produce either AC or DC power that generates heat of up to 6500°F. The arc is guided along the length of the join. The electrode picks up the current and melts in the process to form the filler metal for the binding.
There are many types of arc welding techniques including the MIG process that leverages shielding gases as earlier seen. The other forms of arc welding include flux core arc welding, submerged arc welding, and gas tungsten arc welding.
Flux core welding is in many ways, similar to metal inert gas welding. The process uses a core wire that is a tiny metal tube filled with flux materials (that help to prevent impurities) in powder foam. The welding machine may or may not use a shielding gas in the process, because the flux materials effectively help you shield the bonding process from atmospheric oxygen and impurities. Flux core arc welding is suitable for industrial operations because of speed.
In the submerged arc welding process, the arc is created and maintained beneath a layer of flux. The process leads to a high arc quality free of all forms of contaminants. Any slag that forms on the workpiece falls off by itself in a short time.
The welding process uses a continuous electrode feed that further leads to high rate weld deposition. You might choose this type of welding over others because the melting that happens under the arc is fume-less. This is an automated process suitable for industrial applications.
Gas tungsten arc welding uses a non-melting tungsten electrode together with a filler material and an inert gas mixture. The GTAW process is most recommended for thinner workpieces. It results in superior quality welds, but even so, this is a manual process that also takes a lot of time to learn.
Even though gas tungsten arc welding can be used on all materials, it is mostly suitable for lighter metal types, including stainless steel. Due to the resultant high-quality weld, the process finds most usage in aerospace, naval and other applications where quality and precision are crucial.
Plasma arc welding or torch welding is another similar process to GTAW. With this technique, a non-consumable (non-melting) electrode and anode are placed inside the torch. An electric arc generated helps to ionize the gas inside the torch and create plasma. The hot ionized gas (plasma) gets pushed out to the base plate through a small hole in the anode.
The plasma doesn't come into contact with the shielding gas. Unlike GTAW, plasma arc welding is suitable for materials of a wide range of thicknesses. The current is stable, and welding happens much faster. This technique works well with all weldable materials except for magnesium. All the above-described welding processes use electric power sources. There are two extra types of welding that don't rely on electricity. These are gas welding and pressure welding. Gas welding has long been replaced by arc welding. However, some technicians still use it, and the process works by using oxygen and acetylene. It is thus often referred to as oxyacetylene welding. It works well for pipes and tubes and other small repair jobs.
The gas welding equipment is highly portable and comparatively inexpensive than arc welding machines. The combination of acetylene and oxygen produces a flame that burns to about 3100 degrees Celsius. The welding process, in this case, however, cools much slower and can lead to weld distortion and residual stresses.
With pressure welding, the materials are joined at high pressure below or slightly above the melting point. This is a solid-state type of welding that only relies on mechanical stress. The workpieces have to be intact, and their surfaces super clean and void of all oxides and films. A wire-brush cleaning process helps to achieve robustly welded joints when the pressure is applied.
Pressure welding is most suitable for metal types that have high elasticity. The technique finds most useful in an automotive, airplane, and other industrial applications. Types of pressure welding include friction welding for dissimilar metal parts, ultrasonic welding for thin metal sheets, induction welding for pipes, and inertial welding for tough steel alloys.
The MIG welding technique leads to a cleaner and precisely welded surfaces compared to all other welding processes and technologies. You also get limitless adjustability of power output as a welder in a process that is considerably faster.
Arc welding, especially flux core welding, is highly efficient and minimizes material wastage. The technique is recommendable, where speed and precision are in high demand.
Submerged arc welding is the best technique to use for a fumeless and thus safer welding process for the technician. It is also one of the fastest welding technologies with precision results similar to flux core welding.
If you are welding thinner and lighter metal parts, gas tungsten arc welding is the best technique to leverage. It is a manual and painstaking process, but the results are incomparable.
Plasma arc welding is one of the least expensive methods concerning the equipment used. The welding process is, however, slow and complicated.
Welding drives the manufacturing industries around the world from automotive to aerospace to construction and homebuilding. Even artists and ornamental architects primarily rely on welding for the creation of their masterpieces. With the right choice of technique and equipment, the resultant work/art piece will excel in function and durability.
We can help you reap all the benefits of wrought iron railings in your home or office buildings. We provide exceptional fabrication and installation services. We have everything you need to ramp up safety and immortalize the beauty of your home.
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We have more than 20 years experience working with all types of custom fences, gates, railings and more. Our company was opened in 2009 and since then we’ve built a reputation for providing the best steel and aluminum custom made products in the area. We are dedicated to not just meeting, but exceeding your expectations, bringing old world charm, contemporary style – or a seamless mix of both – into your home or business.
Our hard work paid off in 2016 when we received the Best of Paterson Award. The Paterson Award Program was established to recognize the best of the local businesses in the community. This achievement is given to a company that is believed to have achieved exceptional marketing success in the local community and business category – making Paterson a great place to live, work and play.
Dave's Architectural Iron LLC
34 Bergen, Paterson, New Jersey,07522