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How to Fabricate a Metal by Welding Process   by Oleg Gladshteyn

Metal Fabrication is one of the traditional ways of creating heavy equipment and today many welding companies are providing a modern touch to this technique. Metal fabrication may be described as a value addition process that entails the construction of machines and structures from various raw materials.

There can be no doubt that metal fabrication welding imparts strength and stability for a working equipment or device. Metal Fabrication and welding for heavy industrial devices lends itself to different work patterns and outputs.

Fabrication is rather a wide term to denote building metal structures through the three different steps -cutting, bending, and assembling. The cutting part of fabrication is done by sawing/shearing/chiseling (either manual or powered); cutting is done via CNC cutters using laser, torch, or water jet). The bending is by means of hammering (manual or powered) or press brakes. The assembling is achieved mostly by welding – if not, through adhesives, riveting, threaded fasteners etc.

Structural steel and sheet metal are the standard materials for fabrication – not to speak of the welding wire, flux, and fasteners that will join the cut pieces. There are fabrication shops that undertake these jobs. The products produced by welders, which are often referred to as weldments are classic examples of fabrication. The field of welding continues to evolve with significant advancements in technology. There are highly skilled infrastructure fabrication welding operators who are adepts in basic welding and fabrication methods, blueprint reading etc.

Several welding processes are used in metal fabrication. The two most common welding processes we know for fabricating metals are TIG (Tungsten Inert Gas) welding and MIG (Metal Inert Gas) welding. The other name for TIG is GTAW (Gas Tungsten Arc Welding) and MIG also is oftentimes referred to as GMAW (Gas Metal Arc Welding).

The third is Arc Welding that is a type of welding that uses a welding power supply to create an electric arc between an electrode and the base material to melt the metals at the welding point. You can use either direct (DC) or alternating (AC) current and consumable or non-consumable electrodes.

The term ‘Metal’ in Gas Metal Arc Welding denotes the wire that is used to create the arc. It is shielded by inert gas and the feeding wire also acts as the filler rod. MIG is a semi-automatic welding process and it is quite straightforward. Versatility is the key advantage of MIG welding process. It is capable of joining several types of metals and it can be performed in different positions.

TIG welding starts with a tungsten electrode shielded by inert gas and filler rod is fed into the weld puddle separately. The gas shielding that is needed to protect the molten metal from contamination and amperage is supplied during the TIG welding operation. TIG welding, though slower than MIG process, produces a more precise weld and can be used at lower amperages for thinner metal and even exotic metals.

Even though TIG is a well known welding process, it has some limitations. It requires greater welder dexterity, it yields lower deposition rates and it is costlier for welding thick metal sections.

About the Author

Oleg Gladshteyn is a professional writer working with Everlastgenerators and he writing many articles about Plasma cutter, Tig welding, Welding helmets. For more information, visit our website.

Welding Basics: Techniques for Tig, Mig & Arc Welds : How to Run a Bead of Weld

Arc Tig

A complete note on Arc welding and its Process

Arc welding is a huge process wherein electric arcs concentrated heat is used for metals are joined by the parent’s fusion and all the additional metals to be added to join usually provided by a very strong consumable electrode. For an arc current used is ether alternating or a direct current, it also depends on the material and also the electrode used.

Electroslag welding is a very keen process of welding. Electroslag welding {esw} does a important work of depositing two metals into the very own weld cavity which is between the two plates which has to be joined. To enclose the space by water or copper damn or else shoes so that molten slag could be prevented from running off. An initial arc which is formed from a filler wire with a piece of work and it is done till a sufficient pool of liquid metal is formed which is also used for the molten slag s electrical resistance. This type of welding is a very huge process.

Special equipments are required for this process generally for large plates which is weld horizontal welds up to certain inches which is only done by using nuclear reactor vessels or large machinery by welding them in one pass. The ESW has variations if the shielding is provided by a very appt appropriate gas and a continuous arc where weld metal is used is provided. This are called electrogas welding .or machines of the same kind.

Fluxed core arc welding is another process of welding flux cored arc welding {fcaw} this {FCAW} uses a tabular. flux that is much less brittle than the coating on SMWA electrodes with the tabular electrodes filled while preserving bits alloying benefit most of its potential. The weld from surrounding air is shield from the emissive fluxes non emissive fluxes are employed on large scale and also shielding gases are used. The deposition rate of the FCAW over the GMAW of higher weld metals leading to its popularity to a relatively heavy section or thickness. The ease with which the specific weld metal alloy chemistries could be developed is an major advantage of FCAW and with the new robotic system especially , this process could easily automated.

Gas metal arc welding is the third of this kind. It is also called GMAW. The other name is metal internal gas or (MIG) welding. External gases such as argon, helium gas mixtures or carbon dioxide are used for the weld zone. Oxidation can completely be prevented in the weld puddle by the dioxide present in the electrode which in turn makes the multiple weld layers possible at the joint. It is a very simple and a versatile apparatus. GMAW is relatively very economically welding apparatus which is used mostly by the welders. And it is only possible because of the two welding process over SMAW the temperatures comparatively low which is suitable for thin sheets and thinner sections. It is the most easily automated process.

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