Arc Welding

What is Arc Welding?

Arc welding is an incredibly popular method of welding utilized in diverse industries, including shipbuilding, automotive, construction and aerospace. It involves using the concentrated heat produced through an electrical arc to join metals.

The arc is formed in the material that is the base up to an electrode which is the wire or welding rod, and then melts the metal. The welder is then able to fuse the molten metal , and then craft it into the weld.

The majority of Arc welding processes are consumable or non-consumable which determines the purpose of the electrode, as well as whether it melts and becomes an integral part of the welding, or only serves in the role of an arc conductor, but without melting.

While other welding processes utilize gases, the arc welding process utilizes electricity, with certain types that require directly the currents (DC) or AC. (AC). While, certain kinds of welding with arcs require gas shielding to guard the arc from contaminants.

Taylor Studwelding has put together an outline of the different kinds of arc welding that can assist you in determining which method is most appropriate for your needs.

Shielded metal Arc welding (stick welding)

Electric arcs are produced through the use of either AC or DC current, that is passed between the consumable electrode covered with flux and the workpiece. The filler material melts into a hot pool, and join the two metals. The electrode’s flux coating breaks down into a shielding gas when the process of heating.

This procedure is popular since it’s cheap and simple however, it could be slow.

Gas metal Arc welding (MIG or MAG welding)

This creates an Direct Current (DC) electricity arc that is formed between the consumable electrode wire and the material of the workpiece which causes them to melt in a process that causes them become fused. The shielding gas is then pumped through the welding torch to shield the electric arc.

MIG welding involves the use of the inert gas of metal as the shielding gas, however the MAG welding process employs the active gas of metal.

The process was originally developed to work with non-ferrous metals, such as aluminum, but it was later employed for welding different materials, such as thin sheets. It is easy and economical, as well as flexible and is easily automated.

Types of Arc Welding

The following are the various types of welding processes using arcs:

1 Welding Shielded by Metal

It’s also known as manual metal welding, also known as flux shielded welding and stick welding. It is a procedure that involves striking the arc between the rod of metal (or electrode) (flux covered) with the piece of work. the surface of electrode and workpiece is melted to form a pool of weld.

When the simultaneous melt of coating of flux on the rod creates gas and slag that helps to shield the weld joint from the environment around it. Shielded metal arc welding can be described as an incredibly versatile process that is ideal for joining non-ferrous and ferrous materials, with the thickness of the material at any position.

2 flux-cored arc Welding

The arc welding processes utilize an continuously fed flux core electrode, and the power source is of constant voltage that provides a consistent length of the arc. This method uses the use of a shielding gas, or simply a gas created by flux to protect from contamination.

3. Submerged Arc Welding

Submerged arc welding it is a method where a continuously fed electrodes and a blanket of fusible fluxes are made conductors when they are melted, providing an electrical path between the component as well as the electrode. The flux helps keep sparks and splatters out as well as reducing the emission of UV radiation and fumes.

4 Electro-slag Welding

Electro-slag welding can be applied as a vertical process to join plates that are thick (above 25 millimeters) in one go. The ESW uses an electric arc, before an additional current is created to end the spark. The flux melts once the consumable wire is fed into the melting pool, which creates an molten slag over the pool.

The heat that melts the ends of the plate and wire is created by the molten slag resistance that is created by the flow by electric charge. Two copper boots that cool in water monitor the process to prevent any molten slag that is molten from closing.

5 Arc Stud Welding

Arc stud welding technique is like flash welding. it connects a nub or fastener, typically the flange is joined by nubs that melt to connect to another metal part.