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Facts about Types of Welders and Welding Process

People with excellent skills at welding do two things well: practice and work. Working with metals is as inspiring as it is empowering.

Note that joining pieces of metals together requires skills, and such skills are best acquired with the assistance and guidance of professionals.

Indeed, to be an accomplished welder, it takes time. You need to familiarize yourself with the entire working process and master each level. Paying attention to details is a primary pre-requisite.

What precisely to welders do?

Primarily, welders join metal parts together. Every single piece of metal you've seen out there carved into a particular shape is the handiwork of welders. With the fly of sparks and heats, turning up welders transform materials into forms that can be put into various uses.

Welders can use various types of welding machines to not only create a visually appealing object but also create objects with precision. That means they have exceptional abilities to read blueprints, calculate dimensions, and understand the specifications of a given project.

Besides, the welders’ training puts them in a prime position to monitor the process of welding to prevent overheating, inspect structures as well as maintain the various tools and equipment used for welding.

The process of welding is one of the pillars of technological advancement. Each metal joined to the other is a great contributor to the skyscrapers you see around the world.Electronic gadgets too, have some welding done to them. 

So far, three things are certain:

  • First, welding is a very skilled trade.
  • Second, there are different types of welders.
  • Lastly, welding has a more comprehensive application.

Now...

How do you become a welder?

Like any other profession, welders are well-trained individual. Moreover, these individuals gain experience through practice and under the supervisor of professionals.

With a high school diploma and professional certification, one can be a good welder. To gain professional accreditation, you'll need to go through private programs, community college, or vocational schools.In America, welders can obtain certification through the American society of welders.

In some technical instances, you can enroll in a welding technology program where you’ll learn a wide range of skills spanning from using industry-standard tools to metal liquefying. Other relevant courses to learn include mechanical drawing, blueprint reading, metallurgy classes, physics, and chemistry.

Welders work in places such as pipelines, refineries, power plants, bridges, etc. Also, you'll find them in manufacturing environments such as electronics ship and car manufacturing and construction sites.

DIFFERENT TYPES OF WELDERS AND HOW TO WELD?

A well-trained welder has a crisp understanding of different types of welding machines. That means he/she can use the tools effectively to obtain an object to specifications.

Without a doubt, there are numerous types of welders and uses of each welder vary depending on the make. Let’s look at some of the popular welders.

1

SPOT WELDERS

The mode of action of this welder is like that of a staple gun. They have a massive application for the manufacture and repair of vehicles. The tool is excellent at assembling of sheet steel vehicle bodies, making it fit for parts up to 3mm thick.


The general outlook of a spot-welded surface involves making spot welds at regular intervals on overlapping metal sheets.


 A spot welding is a type of resistance welding: joins two sheets of metal together without using any filler. It merely applies pressure and heat to specific points to be welded. This gives a weld of diameter between 3- and 12.5-mm range.


The process of spot welding uses copper alloy electrodes to apply the pressure as well as transmit the electrical current through the workpieces. The material between the electrodes will yield, hence, is squeezed together. It then melts, destroying the interface between them. When the current is switched off, it solidifies forming a joint.


Spot welding is one of the quickest as well as an efficient method of joining sheets of metals. Besides, this method does not need any specific skills to apply.


The only limitation with this method is that it creates localized joints that might not be strong enough. Note that the strength of a joint is dependent on temperature, electrode cleanliness, force, and type of metal.

2

MIG WELDERS

Though a simple tool, the use of a MIG welder requires some skills. A MIG welder feeds a spool of welding wire continually, which melts to fuse two pieces of metal. 


The machines are very versatile in nature and can fuse different kinds of metals, including carbon steel, aluminum, stainless steel, copper magnesium, etc. It can combine the metals when butted up either at an angle or flat to form a strong joint. Also, the thicknesses of metals they join vary greatly. This makes these tools very popular.


To use the MIG welder, you’ll have to clamp an electrode to the metal you intend to join first. Then the MIG welder will feed a wire continuously through the gun and finally onto the metal. The wire will serve as a second electrode. This wire forms an arc between the wire and the metal to create a pool that fuses the pieces.


Also, from the gun, a shielding gas is released to protect the weld from contamination.

Much as the process of using a MIG welder is simple; you can make it easier by obeying some simple tricks. Such tricks include:

  • Using a lightweight machine – it is easier to control the speed of the gun with lightweight tools. Remember that the MIG machine controls the rate at which the wire is fed, but the operator controls the speed of the gun. Lighter devices make this process easier.
  • Using a push/pull torch – this is important to add a pulling force that creates tension in the wire to reduce the chances of buckling. This is specifically important when using a thinner wire to weld. Sin such cases there are higher chances that it might buckle as it is pushed out by the wire feeder on to the machine.
  • Soft start: this is a setting that comes with specific welders. It feeds the wire slow as the beginning of welding to allow a smoother start.
3

TIG WELDERS

This type of welder is similar to the MIG welders in the sense that both of them use a shielding gas usually argon. However, a TIG welder uses a non-consumable electrode created from tungsten, which works by melting metals together without using filler.


A gas nozzle shields the electrode for it to use the shielding gas more effectively.  The shielding gas displaces oxygen to give quality welds.

4

STUD WELDERS

These types of welders are good at fixing stud on a piece of metal. In essence, it forces a stud onto metal and an arc forms between the metal and the stud. Upon cooling, the molten material forms a bond.


This tool is better used when repairing a dent: add a stud onto an indentation and pull it out so that it pops the dent. After that, cut the stud.

5

LASER WELDERS

Laser welders use laser beams to join metals. These welders are great at joining work pieces as well as creating deep weld seams. Still, in some instances, this type of welding can be used for soldering.


This type of welds is used for high precision welding and in areas where welded seam is required, e.g., gearbox components, high-speed trains, pacemakers, etc. The welds are highly proportional with minimal distortions.

Related article: Tig welder under 1000

TYPES OF WELDING TECHNIQUES


Considering the numerous applications of welding, it is only logical to have different types of welders. The most common types of welding include;


MIG is one of the easiest types of welding to learn. It can be easily used by DIY welders, home-hobbyist, motorsport enthusiasts, ranchersand artists to repair, make fabrications or general maintenance processes on materials that have a thickness of anywhere between 24-gauge and half an inch.


1. METAL INERT GAS (MIG) WELDING


This method of welding is also called gas metal arc welding (GMAW). Sometimes, people refer to it as wire welding.


This type of welding utilizes two welding methods. One method uses a bare wire to join pieces of metal together hence called the bare wire MIG welding. The other process (flux core) does not require the supply of gas or flow meter.


MIG welding is a process of welding in which a continuous wire electrode is fed through a welding gun into the welding pool, to join the two base materials. Moreover, a shielding gas is sent through the welding gun and protects the weld pool from contamination.


The shielding gas heats the two metals to be joined. To successfully use this method;a welder needs a constant supply of high voltage as well as a direct current power source to cause the metals to melt and join.


It has four primary methods of transferring metal: 


  • Globular transfer – ideal for heavier metals. It produces high heat, spatters and an inferior weld surface
  • Short-circuiting – Ideal for thin sheets of metals. It has less spatter hence better quality welding
  • Spray – this is the hottest type
  • Pulsed-spray

This process can be automatic or semi-automatic.


Due to its ease of use, the method is one of the most industrially used welding techniques.

If you use the solid MIG wire for welding, it will notcombat rust, oil, dirt, and other contaminants. So, you will need to clean it down to the bare metal. To do so, you’ll need to use a grinder or a metal brush.


Ensure that you have a clean metal; otherwise, you will have electrical impedance a feature that gravely affects wire feeding performance. And if you want a stronger weld on thicker metals, bevel the joints to ensure that the weld thoroughly penetrates to the base metal. Such a feature is essential for but joints.


2. FLUX CORED ARC WELDING

Flux-cored wire fed welding comes with excellent portability and simplicity. This method avoids the use of gas but instead use a cored wire that has solid flux. During welding, the flux vaporizes to produce a plum of shielding gas.


3. TIG WELDING

This is an intense type of welding. Unlike all the other methods, this is a versatile method that requires time and experience to master the process. TIG welders are the most skilled types of welders you’ll find around. To accomplish this practice, you’ll need a versatile TIG welder machine.


Tungsten inert gas welding (TIG), also called Gas tungsten arc welding (GTAW) is a type of arc welding that uses a non-consumable tungsten electrode to produce a weld. This method works well for thick or non-ferrous kinds of metals.


5. GAS WELDING

This method not commonly used nowadays. This method requires the use of oxygen and acetylene. They are used in lighter jobs like welding the car exhaust.


For any welder, it takes a lot of practice to be able to create a consistent and sturdy weld. Besides the ability to use the welding equipment properly is a plus for a welder.

CONCLUSION

The Types of welders and uses vary a lot. However, you will find all the types of welders in a repair shop.


Certainly, using a welding machine requires a versatile person, considering the different types of welds that need to be made. A well-trained welder, will and can deliver the best joining in metals surfaces.


Remember, these individuals have been trained to follow instructions by reading the blueprints and specifications as well as understand how different metals behave under different temperatures.It is with only such knowledge that an envisioned product can be created.


Welding has a wider application: from the manufacturing industry to the construction industry, almost every object needs a weld.

Yes, you read that right.


Buildings have metals to reinforce them, cars are made of sheets of metals where spot welding is extensively used, airplanes and trains use different types welds to give them a more beautiful look, to mention but a few.


No one can underestimate the contribution of welding in technology.

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