Selection of welding process

There are many different ways to join metals together. These have been built up over a long time. Each process is different in terms of how well it can apply heat for fusion, how well it protects the weld pool, and how well it makes the weld joint work. But the choice of how to make a weld joint depends on the size and shape of the part to be made, the metal system to be welded, the availability of consumables and machines, the level of precision needed, and the cost. No matter what method is used to make a weld joint, it must be able to do its job for as long as it is supposed to.

Here is a list of welding processes and where they can be used:

  • Welding with resistance: Car
  • Thermite welding is used to join rails together.
  • Aerospace and nuclear reactors both use tungsten inert gas welding.
  • Heavy construction and shipbuilding use submerged arc welding.
  • Gas metal arc welding is a way to join metals that are sensitive to gases in the air, like stainless steel, aluminum, and magnesium.

Keep reading : Welding Equipment

Applications of welding

General applications

Welding is often used to make pressure vessels, bridges, building structures, aircraft and spacecraft, railway coaches, and other things. It is also used in shipbuilding, the automobile industry, the electrical, electronic, and defense industries, the laying of pipelines and railway tracks, and nuclear installations.

Specific components needing welding for fabrication include

  • Transport tankers for transporting oil, water, milk, etc.
  • Welding of chains, LPG cylinders, tubes, and pipes, among other things.
  • Steel furniture, gates, doors, door frames, and bodies are made.
  • Making white goods like refrigerators, washers, and dryers,
  • Microwave ovens and a lot of other things used in everyday life

The requirement for welding in a specific area of the industry is given in the following section.

Oil and Gas

Welding is used to connect pipes, to lay crude oil and gas pipelines, and to build tankers for storing and transporting oil and gas. Welding is also used to make offshore structures, dockyards, and for loading and unloading cranes.

Nuclear Industry

For safe and reliable operations, you need to weld spheres for the nuclear reactor, bends in pipelines, and connections between pipes that carry heavy water.

Defense industry

Welding is used in the defense industry to make tank bodies and attach turrets to the main body of tanks, among other things.

Electronic industry

  • Welding is used in the electronic industry sometimes, like when joining the leads of special transistors, but brazing and soldering are much more common.
  • Soldering is how electronic parts are attached to printed circuit boards (PCBs).
  • Robotic soldering is often used to attach parts to the printed circuit boards of computers, TVs, communication equipment, and other control equipment, among other things.

Electrical Industry

Welding is used to make parts of both hydro and steam power systems, like penstocks, water control gates, condensers, electrical transmission towers, and equipment for the distribution system. Welding is also used to connect the blades of a turbine and the cooling fins.

Surface transport

  • Railway: Welding is used a lot in the railway industry to make coaches and waggons, fix wheels, lay new tracks with mobile flash-butt welding machines, and fix cracked or damaged tracks with thermite welding.
  • Automobiles: Welding is used to make car parts like the chassis, body, and its structure, as well as fuel tanks and door hinges.

Aerospace Industry

  • Aircraft and Spacecraft: Like ships, early aircraft were made by riveting, but since jet engines came along, welding has been used a lot more for the structure of aircraft and to join the skin sheet to the body.
  • Space vehicles that have to deal with both friction heat and low temperatures need to be made of special materials for the outside skin and other parts. Welding these materials is a great way to make them safe and reliable.

Read on : Buy Welding Items in Dubai at Wholesale Price from SAFATCO

Welding Processes and their Applications

Applications of air-acetylene welding

  • Lead welding
  • Low-melting-temperature metals and alloys

Applications of oxy-hydrogen welding

  • Welding of aluminum
  • Welding of lead and magnesium

Applications of gas welding

  • A lot of thin steel sheets are joined together with oxyacetylene welding.
  • It is also used for brazing, braze-welding, silver soldering, heating metal (so that it can be bent and shaped), and oxyfuel cutting.

Application of Carbon Arc Welding:

  • Carbon-arc welding is used to join metals that are neither iron nor steel.
  • This method can be used to join together sheets of steel, copper alloys, brass, and aluminum.

Applications of SMAW

  • Shielded metal arc welding is one of the most popular welding methods in the world because it can be used for many different things and is easy to set up and use.
  • SMAW is often used to join carbon steel, low- and high-alloy steel, stainless steel, cast iron, and ductile iron.
  • It is less common for non-ferrous materials, but it can be used for nickel, copper, and their alloys.
  • It is sometimes used to make aluminum.

Applications of TIG welding

  • Alloys of aluminum, magnesium, and copper are easy to weld. It is possible to weld Inconel, carbon steel, and stainless steel.
  • Welding is a very effective way to make things like can seals, instrument diaphragms, and transistor cases.
  • Bellows for expansion and other small, fragile parts can be put together.
  • This welding method is used in the atomic energy, aircraft, chemical, and instrument industries.
  • This method can be used to weld the chamber of a rocket motor.

Applications of MIG welding

  • Since temperatures aren’t too high, a thin sheet section can be used (less than 6 mm). For example, making cars, ships, aeroplanes, heavy electrical engineering, tanks, pressure vessels, and pipes;
  • It is also used in the industries of making and building.
  • Most of the time, MIG welding is used to fix cars. This can be done on a wide range of vehicles, no matter how big, small, light, or heavy they are.

Applications of plasma arc welding

  • It is used in the space industry.
  • It is used to melt metals that are hard to melt.
  • It is used to join two pieces of titanium together.
  • It’s used to join nickel alloys together.
  • It is used for things like tube mills.

Applications of electroslag welding

  • It is mostly used to join very thick plates and sections of low-carbon steel.
  • It is used to join together thick pieces of steel alloys and nickel alloys.
  • This method is used to make large sections of structural steel for things like heavy machinery, bridges, ships, and even vessels for nuclear reactors.
  • Welding is done on forgings and castings.
  • You can weld together heavy plates.
  • If certain precautions are taken, it can also be used on structural steel.

Applications of resistance welding

  • Resistance welding is used in mass production for welding sheet metal, wire, and tubes.
  • It is used to weld steel, stainless steel, monel metal, and silicon bronze, which are all easy to weld metals, into bars, boxes, cans, rods, pipes, and frames.
  • It is used in welding aircraft and automobile parts.
  • It is used to make tools that cut.
  • It is used to make the gas tanks in cars, tractors, and other vehicles.
  • It is used to make wire fabrics, grids, grills, containers, mesh welds, and more.

Applications of spot resistance welding

  • It is used to join things like titanium, low-alloy steel, high-alloy steel, killed carbon steel, and so on.
  • It is used to put together steel structures made of sheet metal.
  • It’s used to make pots, pans, and mufflers.
  • Other uses include appliances and metal furniture, or pretty much anything that needs to join two pieces of sheet metal.

Applications of seam welding

  • It is used to make tin cans, tanks that don’t leak, mufflers for cars, gas tanks, drums, radiators, kitchen tools, transformers, refrigerators, evaporators and condensers, car bodies, and other things. It can also be used to join thin sheets together.
  • It is possible to do a circumference weld on shapes that are square, rectangular, or even round.

Applications of Projection Welding

  • Press tools are made with it.
  • This method is better for cross-welding multiple wires or rods together, which is often done to make wire fencing, shopping carts, and stove grills.

Applications of flash butt welding

  • Butt welding is used to make the body, axles, wheel frames, and other parts of an automobile. This method cannot be used to weld non-ferrous alloys, such as lead, tin, zinc, antimony, bismuth, and their alloys.
  • It is also used to weld motor frames, transformer tanks, barrels, floats, and other types of sheet steel containers.

Applications of stud welding

  • In the automotive industry, this method is used to put together heat shields, parts for power steering and the dashboard, instrument panels, insulation, exhaust systems, lighting systems, brake lines, trim, and electrical wire routing.
  • It is used to put together fenders, orackets, cabs, spreaders, shrouding, thresher teeth, wiring, and parts for managing hoses in the farm equipment industry. It is also used in tractors, mowers, and seeders, which are lawn and garden tools.
  • It is used in commercial dishwashers, bottle washers, cooking equipment, and griddle plate assemblies.

Applications of solid-state welding

  • Aluminum fry pans with stainless steel liners that stick together
  • In the microelectronics industry, ultrasonic and thermo-compression bonding are used.
  • Friction welds are used in the aerospace and auto industries.
  • Automatic intake and exhaust valves

Applications of cold welding

  • It is used to join wire, foil, and bi-metals together and to seal containers that can’t handle heat, like those that hold explosives.
  • In the electronics industry, tin-plated steel crystal cans and copper packages for heat-sensitive semiconductors are sealed using cold welding.

Applications of diffusion welding

  • In the aerospace and nuclear industries, it is used to join high-strength and hard-to-melt metals that are based on titanium.
  • Most of the time, diffusion welding is used on structures made of sheet metal, like those in the nuclear and electronics industries.

Applications of explosive welding

  • This method is used to join tubes and tube plates in heat exchangers, feedwater heaters, and boiler tubes to make clad tube plates.
  • In naval brass tube plates, the tubes can be made of steel, stainless steel, copper, aluminum, brass, or bronze.
  • It is used to make clad tubes and pipes, pressure vessels, aerospace structures, heat exchangers, bi-metal sliding bearings, ship structures, and weld transitions.
  • It is used to cover thick plates with layers that don’t rust when other methods, like roll bonding, can’t be used.
  • It is used to plug tubes.
  • It is used for dangerous remote meetings in dangerous places.
  • It is used to hold cooling fins in place.
  • It is also used in industries that deal with colds.

Applications of ultrasonic welding

  • Most of the time, ultrasonic welding is used to join small pieces together in electronics, communication devices, medical tools, and watches.
  • It is used to make cars, medical equipment, and toys.
  • U is used in the medical field because it makes clean welds.

Applications of friction welding

  • Because the weld that is made is so good, this method is widely used in the aerospace and auto industries to make critical parts.
  • Friction welding is used in the aerospace industry to join turbine blades, make joints that are seamless, etc.
  • Friction welding is used to make bimetallic engine valves, axle shafts, universal joint yokes, gear hubs, and other parts for cars.
  • In the making of consumer goods, it is used to make hand tools and sports equipment.

Applications of forge welding

  • It is used to make blades that are welded in a pattern.
  • It is used to make the barrels of shotguns.
  • In some cases, the forge-welded objects are etched with acid to show the unique pattern of metal underneath.
  • This gives the object a nice look.

Applications of roll welding

  • It is used to protect stainless steel from rust by cladding it with mild steel.
  • It is used to make strips with two kinds of metal.
  • Sandwich strips that will be made into coins are made by roll welding.

Applications of hot pressure welding

  • It is used in the field of aerospace.
  • It is used to join plastics together.
  • It is used to make things like medical tools.
  • It’s used to build ships.
  • It’s used in the auto industry.

Applications of the thermite welding process

  • Thermite welding is used to fix broken crankshafts and wobblers that are big and heavy.
  • It is used in mills that roll out steel.
  • It is used to fix gears with broken teeth.
  • This process is used to make joints in pipes, rails, and shafts.
  • It is used to fix large forgings and broken castings and to weld them.

Applications of electron beam welding

  • Different metals can be welded together.
  • You can weld both hard and soft metals.
  • It is used in planes, missiles, gears, shafts, and nuclear parts.
  • It works well on a large scale.
  • Cams use this material.

Applications of laser beam welding

  • Welding can be done on metals that are between 0.5 mm and 1.5 mm thick. It involves welding foils, stents, sensor diaphragms, and surgical instruments.
  • It can join together metals that are very different from each other, like copper, nickel, chromium, stainless steel, titanium, and columbium.
  • It is a very useful tool for welding electronic parts.
  • It is used to join parts of an airplane.

Applications of friction stir welding

Most of the time, friction stir welding is used in the following industries:

  • Automobile: bimetallic engine valve, universal joint yoke, gear hub, etc.
  • Aerospace: joining turbine blades, joining without seams, etc.
  • Consumer: hand tools and sports equipment.
  • Industrial machines: Spindles, tapers, and tools are all parts of industrial machines.

Applications of underwater welding

  • Underwater welding is used in the marine industry and to put in oil pipelines offshore.
  • It is also used to fix welds on big ships that are already in the water.

You will be Interested on : Welding Products Wholesale Suppliers in Dubai – Safatco