7 May

Getting Started with Arc Welding: A Welding Guide for Beginner

Arc Welding is used in everything from construction and transportation to agriculture and professional services, so it’s an incredible skill to welding possess as you can work in almost any industry.
Demand for skilled welders is at an all-time high, so whether you’re looking to improve your DIY skills or start a career, it’s a great time to get into welding!
In this beginner’s guide to welding, we’ll look at:
  • What welding is
  • How to get started
  • The different types of welding
  • The welding process
  • Careers in welding

What is welding?

Welding is a versatile process that uses high heat to melt and fuse materials, usually metals, together. Unlike lower heat metal-joining processes such as soldering and brazing, welding melts the base metals, creating a stronger structure. A variety of sources can be used to create the high temperatures required for welding, including electricity, gas, lasers, electron beams, friction, and even ultrasound. This means welding can be performed almost anywhere – even underwater and outer space!

How to get started with welding 

Welding can seem intimidating: it’s a process that creates extremely hot temperatures and usually involves electricity and gas. There’s a lot to think about! Don’t be put off though – some types of welding are relatively easy to pick up with a little time and patience. There are also plenty of introductory opportunities available, including:
  • A college course or degree – welding courses are widely available from schools, colleges and even welding stores.
  • Scholarships – scholarships can be an option for those undertaking a bachelor’s or associate degree in welding.
  • On the job training – getting a job that involves welding is a great way to develop your skills and gain real-world experience.
  • Metal art classes – try checking out a local metal art class to get some exposure to welding.
  • Teaching yourself – if you have the time and budget, investing in your own welding kit can be a fantastic way to get into welding.

The different types of welding

There are several different types of welding. Some welding processes – such as MIG, TIG, flux core and stick – can easily be performed in the home with a relatively inexpensive store-bought welding machine. Others are performed by a machine, such as a laser and electron beam welding. There are a number of different welding methods and processes, but as this is a beginner’s guide to welding we’re going to stick to the four most common: MIG, TIG, Stick and flux-cored.

MIG welding

Advantages
  • Ideal for those new to welding
  • Low cost
  • Fast process
  • Little cleanup required
  • Can be used on a wide variety of metals and base metal thicknesses
  • Ideal for most household requirements
Disadvantages
  • Not as visually appealing as other welding processes
MIG welding, also known as GMAW (Gas Metal Arc Welding), is one of the easier skills for beginners to learn and is a common entry point for DIY enthusiasts. It’s relatively easy to perform, doesn’t require too much equipment and it’s suitable for a range of plate metals of different thicknesses, making it versatile enough for most household needs.

MIG welding works by creating an electric circuit between the metal to be welded and an automatically-fed, consumable electrode wire. The wire is then removed a short distance from the metal, which creates an arc of electricity and partially melts the metal and electrode wire, resulting in a bead of molten metal that creates the weld. A filler material, usually similar to the metal being welded, is also fed alongside the electrode to further strengthen the weld. An externally fed gas source protects the metals from contaminants like oxygen and nitrogen during the process.

TIG welding

Advantages
  • Produces superior welds
  • Suitable for almost all types of metals
  • Filler material optional
  • Minimal cleanup required
  • Provides greater control over the weld
Disadvantages
  • Difficult to automate
  • Slow process in comparison to other types of welding
TIG welding, also known as Gas Tungsten Arc Welding (GTAW), is a precise form of welding that is a bit more advanced as it can be difficult to produce quality, attractive welds. Unlike most welding processes, filler material is optional, though it can be used. TIG is similar to MIG welding in that it works by creating an electrical circuit between the metal and a non-consumable tungsten electrode. A shielding gas is used to protect the weld – helium and argon are common choices. TIG welding is a manual process that provides the welder with greater control, thanks to the ability to alloy the electrode.

Stick welding

Advantages
  • Suitable for most types of metals
  • No gas supply required
  • Can be used with direct current
  • Equipment is portable
  • Best suited for windy or draughty environments
Disadvantages
  • Can be more costly than other types of welding
  • Manual process that cannot easily be automated
  • Not suitable for reactive metals
Mention welding to someone and they’ll probably picture stick welding. Also known as shielded metal arc welding (SMAW), this is welding the old-fashioned way: simple, easy to learn and versatile. Stick welding uses an electrical current and a fixed-length electrode that is coated with mineral compounds and metal powders. When the electrode is applied to the metal, the coating produces gases that act as a shield for the weld.
The composition of the electrode coating affects the outcome of the weld; many different types of electrodes and coatings are available, making stick welding an incredibly versatile process. This, and the lack of external gas source, means that it can be performed almost anywhere. Power can be supplied via alternating or direct current, or by a generator – making it ideal for remote areas.

Flux-Cored Arc Welding (FCAW)

Advantages
  • Ideal for thicker, heavier metals
  • Suitable for contaminated base metals
  • Fast process
  • Visually pleasing weld
Disadvantages
  • More cleanup required
  • toxic fumes and more spatter
Flux-cored arc welding, also known as FCAW, is another easy-to-learn welding skill that doesn’t require too much expensive equipment, so it’s a good option for those just starting out. FCAW is often used in construction thanks to its suitability for thicker, heavier metals.
Similar to MIG welding, flux-cored welding uses a continuously fed electrode.
 
In fact, many MIG welding machines can also be used for FCAW welding. The difference is that, with FCAW, the electrode has a flux core that contains the filler material. When it melts, gases are released to create the shield, so an external gas supply is not necessary – though it can be used, and be advantageous, for certain applications. This makes it relatively portable and a good choice for external applications – though the results are usually not as aesthetically pleasing as other types of weld.

The welding process

Even though the methods vary, the welding process generally follows these steps. 

1. Choose your welding method

The first thing you need to decide is the welding method required for the job. You’ll need to consider: the material being welded, the surrounding environment, how good the weld needs to look, and your budget.

2. Get your equipment

The right welding equipment is essential to the success of the job – and more importantly, your safety. You will need:
  • The welder itself
  • Welding helmet
  • Safety goggles (optional)
  • Leather gloves
  • A leather jacket or welding apron
  • Heat resistant clothing and work boots

3. Prepare the weld

Clean the metals to be welded of any oil, grease and contaminants. A wire brush and acetone is particularly effective. Cut your metal to size if you need to. Grind the edges of the metals where you plan to weld, to help add structural integrity and create space for the filler.

4. Prepare yourself

Make sure you’re equipped with all the appropriate safety equipment, including a fire extinguisher – you’re dealing with heat and electricity, remember!

5. Layer the weld

The first step of welding is called tack welding. This is where you weld along the edges of the metals, just enough to join them. The process is then repeated to create a second layer and the final weld. Your aim is to repeat a smooth, fluid motion to achieve the best results. When you’ve reached the end of the weld, let it cool down to finish the job.
Tip: Focus on the edge of the melt puddle, not the arc, to create a neater weld.

6. Grind the weld

This is an optional step to improve the appearance of the weld. If looks don’t matter, feel free to skip this step! Lightly grinding your weld with a right-angle grinder can help to create a smooth finish – just be careful not to push too hard as you may end up having to start over!

Welding Career Opportunities

Welding is a highly skilled trade that offers versatility, challenges, and decent pay on a daily basis. One way or another, welding spans almost every industry: construction, engineering, agriculture, industry, manufacturing, aerospace, maritime, military, education, business, and even sales.
There is a huge shortage of skilled welding technicians in the USA, UK, and many other countries, so with enough skill and experience under your belt, the world is your oyster.
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7 May

Arc Welding: A Comprehensive Guide to the 5 Welding Processes

Arc welding is the welding process of melting two metals together. It uses electricity to create intense heat which melts the two metals together in a molten pool, effectively making them one material. This is called welding fusion and is the reason welded structures are so strong.

How does arc welding work?

Arc welding uses electricity to create a circuit between two metals: the base metal and the electrode, which is attached to the welding gun. When the circuit is broken by removing the electrode from the base metal, it creates an arc of electricity which is extremely hot – temperatures of 11,000 Fahrenheit can be achieved!

This molten pool of metal is what creates the weld – but it can be affected by gases and other contaminants in the air. A Welding Shield of inert gas is used to protect the weld while it’s in progress. Depending on the type of arc welding process you’re using, this gas will either be supplied externally (via the welding machine) or through an electrode (via a flux coating).

There are a few ways arc welding can be achieved, and the most common processes are:

  • Metal inert gas welding (MIG)
  • Tungsten inert gas welding (TIG)
  • Flux-cored arc welding (FCAW)
  • Welding Shield metal arc welding (SMAW)
  • Plasma arc welding

The Basics of Arc Welding

There are a few things in arc welding that don’t change, regardless of the process you’re using:

  • The materials being welded need to have a similar melting point, otherwise one will melt before the other, resulting in a failed weld.
  • Power can usually be supplied via alternating (AC) or direct (DC) currents. The type of power supply can affect the settings for the weld so always check before you start.
  • The more power, the higher the temperature of the arc. Manufacturers usually provide the standard settings for the equipment, but voltages should be changed to suit the job at hand.
  • The choice of electrode can massively affect the outcome of the weld.
  • Always clean the base metal with a metal brush or grinder before you start, even if you’re using a welding process that is compatible with contaminated base metals.
  • Safety is essential! You’re dealing with seriously powerful electricity and extremely high temperatures. Protect yourself. Wear safety gear and keep a suitable fire extinguisher nearby.

Below is a basic diagram of how arc welding works.

Arc Welding: A Comprehensive Guide to the 5 Welding Processes

Arc Welding: A Comprehensive Guide to the 5 Welding Processes

Arc Welding Terminology

If you’re new to welding, there are a few technical terms you need to know.

Electrode – the material that transfers the arc to the base metal, and controls the weld

Arc – the arc of electricity between the base metal and electrode, which creates the heat required to weld

Gas shield – the shield of inert gas surrounding the weld, usually carbon dioxide, argon, helium or a combination of the three

Weld pool – the pool of molten metal that is formed from the base metal and electrode, and filler material if it is being used

Base metal – the metal that is being worked on

MIG welding

  • Highly versatile
  • Easy to learn
  • Semi-automatic process
  • Not suitable for outdoors
  • Can be used on metals of various thicknesses

MIG welding is arguably the most common type of welding, and the easiest type to learn. MIG stands for metal inert gas, though it is sometimes referred to as gas metal arc welding (GMAW). MIG welding is a semi-automatic process that is best suited to indoor applications where there is shelter from the wind.

The MIG welding process

A MIG welding gun uses a continuously fed solid wire electrode to create the arc of electricity to meld two metals together. An electric current is fed to the electrode which, in MIG welding, also acts as the filler material to improve the weld. The electrode controls the arc, which produces the heat to melt the electrode, filler and base metal. Shielding gas is supplied externally via the welding machine to protect the process.

MIG welding is suitable for a range of metals of varying thicknesses including steel, aluminium, nickel and various alloys. The shielding gas can also be changed, depending on the metals being used. Generally, MIG shielding gas is a concoction of CO2, oxygen and carbon. The voltage can also be preset via the MIG welding machine to suit the application.

What is MIG welding used for?

MIG welding is a highly versatile process that can be used for a variety of applications. It is most commonly used projects such as automotive repairs, structural steelwork and the manufacture of various objects such as furniture, computer components and machinery for agriculture or mining.

TIG welding

  • Uses a pointed electrode for precision
  • Produces high quality, attractive welds
  • Slow process
  • Minimal cleanup required
  • Filler material optional
  • Best performed indoors
  • More difficult to learn
  • Good for welding round things

TIG welding, also known as tungsten gas arc welding (GTAW). It uses a non-consumable, pointed tungsten electrode, which allows for superior precision. TIG welding produces high-quality welds when it’s done properly – but it is quite difficult to master the skill. TIG welding isn’t the easiest to learn but the results are worth it!

The TIG welding process

A TIG welding gun features a pointed tungsten electrode, a connector and a shielding gas. An arc is created when the electrode is applied to the base metal and then removed. It is a small, intense arc, which makes it ideal for high quality, precision welding.

TIG welding is one of the few processes that does not require a filler metal, but you can use one if needed. The absence of filler makes TIG welding clean, with little to no cleanup required upon completion of the weld. If you do use a filler, you’ll need to feed it manually by hand.

Various tungsten electrodes are available to suit different types of welds. Pure tungsten electrodes are the most common and are applicable for metals such as aluminium. The shielding gas should also be changed depending on the metals being used – argon is the most common. As with MIG welding, the external gas supply of TIG welding means it’s best performed indoors away from wind and draughts.

Where is TIG welding used?

With high precision and minimal mess, TIG welding is ideal for thin sheet metals and projects that will be on show. It is commonly used in metal art sculptures.

Stick welding

  • Fixed length electrode
  • Can be used on dirty, painted and rusty surfaces
  • Difficult to master
  • Some cleanup required

Stick welding is the most widely used form of arc welding. It is also known as shield metal arc welding (SMAW) and is suitable for both indoor and outdoor environments. Stick welding can be used on most common metals and alloys including steel, aluminium and iron. It can also be used on dirty and rusted surfaces, which makes it incredibly popular in the repair and maintenance industries.

Stick welding isn’t easy to learn though. It’s a highly skilled process – the ability to strike an arc can be difficult and the learning process is usually long, but well worth it!

The stick welding process

The ‘stick’ of stick welding is a fixed-length electrode, which is coated in a flux of powdered metals. When heated with electricity, the flux creates the shielding gas, while the melting electrode produces the filler material to create the weld with the base metal. As such, there’s no need for an external gas supply, which is why stick welding is usually the process of choice for remote and difficult environments.

Stick welding can be a bit messy and produce spatter, so there’s usually some cleaning up to do afterwards. The end result varies on the skill of the welder, but it must be said that stick welding doesn’t usually produce the most attractive of welds.

The characteristics of the weld can be changed by choosing a different flux coating and altering the angle of the weld.

Where is stick welding used?

Stick welding equipment is easily transportable, so it can be carried out almost anywhere. As there is no need for an external gas supply, stick welding is ideally suited to outdoor and hard to reach places. You can even stick weld in the wind and rain.

Flux Cored Arc Welding (FCAW)

  • High productivity
  • No external gas supply required
  • Easy to transport
  • Not recommended for thin metals
  • Can be used on dirty base metals
  • Some cleanup required

The flux-cored welding process is like a combination of MIG and stick welding. It’s fast like MIG and does not require a shielding gas, like stick welding.

The flux-cored arc welding process

As the name says, with FCAW the electrode has a flux core consisting of various compounds and powdered metals. The electricity is transferred through the electrode to the base metal, forming the arc. When heated with the arc, the flux produces the gas shield around the molten electrode, filler metal and base metal in the weld pool. The weld will be covered with residual slag which also provides protection, and it can be easily removed when needed.

Flux-cored welding is usually performed with a drag technique, where the weld gun is pointing back into the weld pool and being pulled away from the completed weld.

Where is flux-cored welding used?

Flux core arc welding is commonly used for heavy-duty industrial fabrication and manufacturing processes. It’s generally not recommended for beginners and those with little experience as the technique can be difficult to master.

As there’s no need for a shield gas, flux-cored arc welding can be used outdoors.

Plasma arc welding

  • Can be used on incredibly thin and thick base metals
  • Uses a non-consumable pointed tungsten electrode
  • High productivity
  • Precise and accurate
  • Produces high quality, attractive welds
  • Difficult to master

Plasma arc welding (PAW) is similar to TIG welding in that it uses a pointed tungsten electrode, and requires no filler material. Unlike with TIG welding, the electrode is positioned inside the torch. This allows the plasma to be kept separate from the shield gas, which envelops the arc and weld.

A plasma arc is incredibly powerful, bursting from the electrode at almost the speed of sound! Plasma welding arcs can reach temperatures over 55,000 Fahrenheit – over 5 times the heat of a typical welding arc!

A PAW welding torch uses pressurised gas to create plasma, which creates incredibly precise and strong welds that look great too. Plasma arc welding also offers a high productivity rate.

The Plasma arc welding process

Inside a PAW nozzle, gas is pressurized to create plasma. This plasma is then ionized so it can then conduct electricity, which produces the arc from the non-consumable tungsten electrode, which is pointed to increase precision. The arc that is produced is small and incredibly powerful. The power of the arc can be adjusted by changing the voltage on the machine. The shielding gas – usually argon or hydrogen – surrounds the weld.

Where is Plasma arc welding used?

Plasma arc welding can be used in a range of applications, though it is most commonly used for electronic applications. The aerospace, marine and healthcare industries also use PAW for its high precision.

Getting Started Welding

Just getting started with welding? PowerWelds has you covered. Check out our guide to getting started with welding, which covers the welding process in more detail and the equipment you’ll need for a successful and safe weld. You can also learn more about the career opportunities that welding offers – you can work anywhere from under the sea to the International Space Station.

If it’s the equipment you’re after, we offer a fantastic range of welding machines at entry-level prices, so if you fancy trying your hand at welding it won’t cost you a fortune. You can also stock up on welding equipment like guns, torches, helmets and accessories.

At PowerWelds, we build our equipment based on our customers’ feedback. And if you want to stand out, check out our awesome range of eye-catching welding helmets.

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30 April

Arc Welding – The 5 Processes You Need to Know

If you’re interested in learning about arc welding, you’ve come to the right place. Arc welding is a process that involves melting two metals together using electricity to create intense heat. The heat melts the metals together in a molten pool, creating a strong bond between the two materials.

This process is called welding fusion, and it’s what makes welded structures so strong. When two metals are welded together, they effectively become one material, with the bond between them being as strong as the metals themselves.

In the following sections, we’ll explore the different types of arc welding, the equipment and safety gear you’ll need, and some tips for getting started with this fascinating process.

How Does Arc Welding Work?

The Basics of Arc Welding

Arc welding is a process that uses electricity to join two metals together. The two metals are the base metal and the electrode, which is attached to the welding gun. When the circuit is broken by removing the electrode from the base metal, it creates an arc of electricity which is extremely hot – temperatures of 11,000 Fahrenheit can be achieved! This molten pool of metal is what creates the weld.

There are a few things in arc welding that don’t change, regardless of the process you’re using. The materials being welded need to have a similar melting point, otherwise one will melt before the other, resulting in a failed weld. Power can usually be supplied via alternating (AC) or direct (DC) currents. The type of power supply can affect the settings for the weld so always check before you start. The more power, the higher the temperature of the arc. Manufacturers usually provide the standard settings for the equipment, but voltages should be changed to suit the job at hand. The choice of electrode can massively affect the outcome of the weld. Always clean the base metal with a metal brush or grinder before you start, even if you’re using a welding process that is compatible with contaminated base metals. Safety is essential! You’re dealing with seriously powerful electricity and extremely high temperatures. Protect yourself. Wear safety gear and keep a suitable fire extinguisher nearby.

Arc Welding Terminology

If you’re new to welding, there are a few technical terms you need to know. The following are some of the key terms used in arc welding:

  • Electrode – the material that transfers the arc to the base metal, and controls the weld
  • Arc – the arc of electricity between the base metal and electrode, which creates the heat required to weld
  • Gas shield – the shield of inert gas surrounding the weld, usually carbon dioxide, argon, helium or a combination of the three
  • Weld pool – the pool of molten metal that is formed from the base metal and electrode, and filler material if it is being used
  • Base metal – the metal that is being worked on

In arc welding, the choice of electrode can have a significant impact on the outcome of the weld. The electrode is the material that transfers the arc to the base metal and controls the weld. There are various types of electrodes available, each with its own unique characteristics. Some electrodes are designed for welding specific metals, while others are more versatile. The type of electrode you choose will depend on the type of metal you are welding and the specific requirements of the job.

The arc is the arc of electricity between the base metal and electrode, which creates the heat required to weld. The arc is extremely hot, with temperatures of up to 11,000 degrees Fahrenheit. The heat generated by the arc causes the base metal and electrode to melt, creating a molten pool of metal that is used to form the weld.

The gas shield is the shield of inert gas surrounding the weld, usually carbon dioxide, argon, helium or a combination of the three. The gas shield is used to protect the weld from the air, which can cause contamination and weaken the weld. The gas shield is supplied either externally (via the welding machine) or through an electrode (via a flux coating), depending on the type of arc welding process being used.

The weld pool is the pool of molten metal that is formed from the base metal and electrode, and filler material if it is being used. The weld pool is used to form the weld and is shaped by the motion of the welding gun and the speed at which the weld is being laid down.

The base metal is the metal that is being worked on. The base metal needs to be clean and free from any contaminants, such as rust or oil, before welding can begin. Cleaning the base metal with a metal brush or grinder is essential, even if you’re using a welding process that is compatible with contaminated base metals.

MIG Welding

MIG welding, also known as gas metal arc welding (GMAW), is a highly versatile and easy-to-learn semi-automatic process suitable for indoor applications. This process uses a continuously fed solid wire electrode to create an arc of electricity that melts two metals together. The electrode also acts as the filler material to improve the weld. Shielding gas is supplied externally via the welding machine to protect the process.

MIG welding is best suited for indoor applications where there is shelter from the wind. It is not suitable for outdoor applications due to the need for shielding gas. However, MIG welding can be used on metals of various thicknesses, including steel, aluminum, nickel, and various alloys. The shielding gas can also be changed depending on the metals being used. Generally, MIG shielding gas is a concoction of CO2, oxygen, and carbon. The voltage can also be preset via the MIG welding machine to suit the application.

MIG welding is commonly used in projects such as automotive repairs, structural steelwork, and the manufacture of various objects such as furniture, computer components, and machinery for agriculture or mining. Its versatility and ease of use make it a popular choice for welding applications.

In summary, MIG welding is a highly versatile and easy-to-learn semi-automatic welding process that uses a continuously fed solid wire electrode. It is best suited for indoor applications and can be used on metals of various thicknesses. The shielding gas and voltage can be changed depending on the metals being used. MIG welding is commonly used in various industries due to its versatility and ease of use.

TIG Welding

TIG welding, also known as tungsten gas arc welding (GTAW), is a slow and precise process that produces high-quality and attractive welds. It is performed using a non-consumable, pointed tungsten electrode, which allows for superior precision. TIG welding is one of the few processes that does not require a filler metal, but you can use one if needed. The absence of filler makes TIG welding clean, with minimal cleanup required upon completion of the weld. If you do use a filler, you’ll need to feed it manually by hand.

The TIG welding gun features a pointed tungsten electrode, a connector, and a shielding gas. An arc is created when the electrode is applied to the base metal and then removed. It is a small, intense arc, which makes it ideal for high-quality, precision welding. TIG welding requires a shielding gas, which should be changed depending on the metals being used – argon is the most common.

Various tungsten electrodes are available to suit different types of welds. Pure tungsten electrodes are the most common and are applicable for metals such as aluminum. As with MIG welding, the external gas supply of TIG welding means it’s best performed indoors away from wind and drafts.

TIG welding is more difficult to learn than other welding processes due to its precision requirements. However, the results are worth it! TIG welding is best for welding round things and is commonly used in metal art sculptures. With high precision and minimal mess, TIG welding is ideal for thin sheet metals and projects that will be on show.

Overall, TIG welding is a slow but precise process that produces high-quality and attractive welds. It requires a pointed tungsten electrode and a shielding gas and is best performed indoors. It is more difficult to learn than other welding processes, but the results are worth it!

Stick Welding

Stick welding, also known as shield metal arc welding (SMAW), is the most common type of arc welding. It is suitable for use in both indoor and outdoor environments. This welding technique is preferred for repair and maintenance work because it can be used on most common metals and alloys, including steel, aluminum, and iron. Additionally, it can be used on dirty and rusted surfaces, making it a popular choice in the welding industry.

However, stick welding is not an easy technique to master. It is a highly skilled process and requires a long learning process. The ability to strike an arc can be difficult, but it is well worth it in the end.

The stick welding process involves using a fixed-length electrode that is coated in a flux of powdered metals. When heated with electricity, the flux creates the shielding gas, while the melting electrode produces the filler material to create the weld with the base metal. There is no need for an external gas supply, which makes stick welding the process of choice for remote and difficult environments.

Stick welding can produce spatter and be a bit messy, so there is usually some cleaning up to do afterward. The end result varies depending on the skill of the welder, but it must be said that stick welding does not usually produce the most attractive of welds. The characteristics of the weld can be changed by choosing a different flux coating and altering the angle of the weld.

Stick welding equipment is easily transportable, making it ideal for use almost anywhere. As there is no need for an external gas supply, stick welding is ideally suited to outdoor and hard-to-reach places. You can even stick weld in the wind and rain.

In summary, stick welding is a widely used form of arc welding that is suitable for both indoor and outdoor environments. It can be used on most common metals and alloys and is preferred for repair and maintenance work. While it is a difficult technique to master, it is well worth the effort, especially for remote and difficult environments.

Flux Cored Arc Welding (FCAW)

Flux cored arc welding (FCAW) is a welding process that combines the high productivity of MIG welding with the simplicity of stick welding. FCAW does not require an external gas supply, making it easy to transport and use outdoors. However, it is not recommended for thin metals and requires some cleanup after welding.

The FCAW process uses a continuously fed electrode with a flux core consisting of various compounds and powdered metals. When the electricity is transferred through the electrode to the base metal, an arc is formed. The flux produces a gas shield around the molten electrode, filler metal, and base metal in the weld pool. The residual slag that covers the weld also provides protection and can be easily removed when needed.

Flux-cored welding is usually performed with a drag technique, where the weld gun is pointing back into the weld pool and being pulled away from the completed weld. This technique is commonly used for heavy-duty industrial fabrication and manufacturing processes. However, it is generally not recommended for beginners and those with little experience as the technique can be difficult to master.

In summary, FCAW is a fast and efficient welding process that does not require an external gas supply. It is commonly used for heavy-duty industrial fabrication and manufacturing processes, but it is not recommended for thin metals. With some practice, it can be a valuable tool for welders looking to increase productivity and versatility in their welding projects.

Plasma Arc Welding

Plasma arc welding (PAW) is a welding process that uses a non-consumable pointed tungsten electrode to create a plasma arc. The plasma is created by pressurized gas, which is then ionized to conduct electricity. This produces a small, incredibly powerful arc that can reach temperatures over 55,000 Fahrenheit. PAW can be used on both thin and thick base metals, making it a versatile welding process.

Getting Started with Welding

If you’re just getting started with welding, Powerwelds has a guide to getting started with welding. This guide covers the welding process in more detail and the equipment you’ll need for a successful and safe weld. It also provides information on the career opportunities that welding offers.

PowerWelds offers a fantastic range of welding machines at entry-level prices, so if you want to try your hand at welding, it won’t cost you a fortune. You can also stock up on welding equipment like guns, torches, helmets, and accessories.

At PowerWelds, they build their equipment based on their customers’ feedback. If you want to stand out, check out their range of eye-catching welding helmets.

Overall, PAW is a high productivity welding process that produces precise and accurate welds with a high-quality finish. While it can be difficult to master, it is a popular choice for electronic applications, as well as in the aerospace, marine, and healthcare industries due to its high precision.

Frequently Asked Questions

What are the Primary Types of Arc Welding Processes?

There are five primary types of arc welding processes: Shielded Metal Arc Welding (SMAW), Gas Tungsten Arc Welding (GTAW), Gas Metal Arc Welding (GMAW), Flux-Cored Arc Welding (FCAW), and Submerged Arc Welding (SAW). Each process has its own unique characteristics and is used for different applications.

Can You Outline the Basic Steps Involved in the Arc Welding Procedure?

The basic steps involved in arc welding include preparing the workpiece, setting up the welding equipment, striking an arc, welding the joint, and finishing the weld. The welder must ensure that the workpiece is clean and free of any contaminants that may affect the quality of the weld.

What are the Essential Pieces of Equipment Needed for Arc Welding?

The essential pieces of equipment needed for arc welding include a welding machine, welding electrode, welding helmet, welding gloves, and safety glasses. The welding machine provides the power to create the arc, while the welding electrode is used to melt the metal and create the weld.

What are Some Common Issues Faced During Stick Welding and Their Solutions?

Some common issues faced during stick welding include porosity, undercutting, and lack of fusion. Porosity occurs when gas pockets are trapped in the weld, while undercutting is a groove that forms along the base metal. Lack of fusion occurs when the weld does not penetrate the base metal. These issues can be solved by adjusting the welding parameters, using the correct electrode, and ensuring that the workpiece is clean and free of any contaminants.

What are the Advantages and Disadvantages of Using Arc Welding Compared to Other Welding Methods?

The advantages of using arc welding include its versatility, portability, and low cost. Arc welding can be used on a variety of metals and can be performed in remote locations. However, arc welding has some disadvantages, including its low welding speed, high heat input, and the need for skilled welders.

How is Arc Welding Applied Across Different Industries?

Arc welding is used across a wide range of industries, including construction, manufacturing, automotive, and aerospace. It is used to join metal components and structures, repair damaged parts, and create new components. Arc welding is also used in the fabrication of ships, bridges, and buildings.

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31 January

Arc Welding: The 5 Welding Processes You Need to Know

Arc welding is the process of melting two metals together. It uses electricity to create intense heat which melts the two metals together in a molten pool, effectively making them one material. This is called welding fusion and is the reason welded structures are so strong.

How does arc welding work?

Arc welding uses electricity to create a circuit between two metals: the base metal and the electrode, which is attached to the welding gun. When the circuit is broken by removing the electrode from the base metal, it creates an arc of electricity which is extremely hot – temperatures of 11,000 Fahrenheit can be achieved!

This molten pool of metal is what creates the weld – but it can be affected by gases and other contaminants in the air. A Welding Shield of inert gas is used to protect the weld while it’s in progress. Depending on the type of arc welding process you’re using, this gas will either be supplied externally (via the welding machine) or through an electrode (via a flux coating).

There are a few ways arc welding can be achieved, and the most common processes are:

  • Metal inert gas welding (MIG)
  • Tungsten inert gas welding (TIG)
  • Flux-cored arc welding (FCAW)
  • Welding Shield metal arc welding (SMAW)
  • Plasma arc welding

The Basics of Arc Welding

There are a few things in arc welding that don’t change, regardless of the process you’re using:

  • The materials being welded need to have a similar melting point, otherwise one will melt before the other, resulting in a failed weld.
  • Power can usually be supplied via alternating (AC) or direct (DC) currents. The type of power supply can affect the settings for the weld so always check before you start.
  • The more power, the higher the temperature of the arc. Manufacturers usually provide the standard settings for the equipment, but voltages should be changed to suit the job at hand.
  • The choice of electrode can massively affect the outcome of the weld.
  • Always clean the base metal with a metal brush or grinder before you start, even if you’re using a welding process that is compatible with contaminated base metals.
  • Safety is essential! You’re dealing with seriously powerful electricity and extremely high temperatures. Protect yourself. Wear safety gear and keep a suitable fire extinguisher nearby.

Below is a basic diagram of how arc welding works.

Basic Arc Welding Circuit Diagram

Basic Arc Welding Circuit Diagram

Basic Arc Welding Circuit Diagram

Arc Welding Terminology

If you’re new to welding, there are a few technical terms you need to know.

Electrode – the material that transfers the arc to the base metal, and controls the weld

Arc – the arc of electricity between the base metal and electrode, which creates the heat required to weld

Gas shield – the shield of inert gas surrounding the weld, usually carbon dioxide, argon, helium or a combination of the three

Weld pool – the pool of molten metal that is formed from the base metal and electrode, and filler material if it is being used

Base metal – the metal that is being worked on

MIG welding

  • Highly versatile
  • Easy to learn
  • Semi-automatic process
  • Not suitable for outdoors
  • Can be used on metals of various thicknesses

MIG welding is arguably the most common type of welding, and the easiest type to learn. MIG stands for metal inert gas, though it is sometimes referred to as gas metal arc welding (GMAW). MIG welding is a semi-automatic process that is best suited to indoor applications where there is shelter from the wind.

The MIG welding process

A MIG welding gun uses a continuously fed solid wire electrode to create the arc of electricity to meld two metals together. An electric current is fed to the electrode which, in MIG welding, also acts as the filler material to improve the weld. The electrode controls the arc, which produces the heat to melt the electrode, filler and base metal. Shielding gas is supplied externally via the welding machine to protect the process.

MIG welding is suitable for a range of metals of varying thicknesses including steel, aluminium, nickel and various alloys. The shielding gas can also be changed, depending on the metals being used. Generally, MIG shielding gas is a concoction of CO2, oxygen and carbon. The voltage can also be preset via the MIG welding machine to suit the application.

What is MIG welding used for?

MIG welding is a highly versatile process that can be used for a variety of applications. It is most commonly used projects such as automotive repairs, structural steelwork and the manufacture of various objects such as furniture, computer components and machinery for agriculture or mining.

TIG welding

  • Uses a pointed electrode for precision
  • Produces high quality, attractive welds
  • Slow process
  • Minimal cleanup required
  • Filler material optional
  • Best performed indoors
  • More difficult to learn
  • Good for welding round things

TIG welding, also known as tungsten gas arc welding (GTAW). It uses a non-consumable, pointed tungsten electrode, which allows for superior precision. TIG welding produces high-quality welds when it’s done properly – but it is quite difficult to master the skill. TIG welding isn’t the easiest to learn but the results are worth it!

The TIG welding process

A TIG welding gun features a pointed tungsten electrode, a connector and a shielding gas. An arc is created when the electrode is applied to the base metal and then removed. It is a small, intense arc, which makes it ideal for high quality, precision welding.

TIG welding is one of the few processes that does not require a filler metal, but you can use one if needed. The absence of filler makes TIG welding clean, with little to no cleanup required upon completion of the weld. If you do use a filler, you’ll need to feed it manually by hand.

Various tungsten electrodes are available to suit different types of welds. Pure tungsten electrodes are the most common and are applicable for metals such as aluminium. The shielding gas should also be changed depending on the metals being used – argon is the most common. As with MIG welding, the external gas supply of TIG welding means it’s best performed indoors away from wind and draughts.

Where is TIG welding used?

With high precision and minimal mess, TIG welding is ideal for thin sheet metals and projects that will be on show. It is commonly used in metal art sculptures.

Stick welding

  • Fixed length electrode
  • Can be used on dirty, painted and rusty surfaces
  • Difficult to master
  • Some cleanup required

Stick welding is the most widely used form of arc welding. It is also known as shield metal arc welding (SMAW) and is suitable for both indoor and outdoor environments. Stick welding can be used on most common metals and alloys including steel, aluminium and iron. It can also be used on dirty and rusted surfaces, which makes it incredibly popular in the repair and maintenance industries.

Stick welding isn’t easy to learn though. It’s a highly skilled process – the ability to strike an arc can be difficult and the learning process is usually long, but well worth it!

The stick welding process

The ‘stick’ of stick welding is a fixed-length electrode, which is coated in a flux of powdered metals. When heated with electricity, the flux creates the shielding gas, while the melting electrode produces the filler material to create the weld with the base metal. As such, there’s no need for an external gas supply, which is why stick welding is usually the process of choice for remote and difficult environments.

Stick welding can be a bit messy and produce spatter, so there’s usually some cleaning up to do afterwards. The end result varies on the skill of the welder, but it must be said that stick welding doesn’t usually produce the most attractive of welds.

The characteristics of the weld can be changed by choosing a different flux coating and altering the angle of the weld.

Where is stick welding used?

Stick welding equipment is easily transportable, so it can be carried out almost anywhere. As there is no need for an external gas supply, stick welding is ideally suited to outdoor and hard to reach places. You can even stick weld in the wind and rain.

Flux Cored Arc Welding (FCAW)

  • High productivity
  • No external gas supply required
  • Easy to transport
  • Not recommended for thin metals
  • Can be used on dirty base metals
  • Some cleanup required

The flux-cored welding process is like a combination of MIG and stick welding. It’s fast like MIG and does not require a shielding gas, like stick welding.

The flux-cored arc welding process

As the name says, with FCAW the electrode has a flux core consisting of various compounds and powdered metals. The electricity is transferred through the electrode to the base metal, forming the arc. When heated with the arc, the flux produces the gas shield around the molten electrode, filler metal and base metal in the weld pool. The weld will be covered with residual slag which also provides protection, and it can be easily removed when needed.

Flux-cored welding is usually performed with a drag technique, where the weld gun is pointing back into the weld pool and being pulled away from the completed weld.

Where is flux-cored welding used?

Flux core arc welding is commonly used for heavy-duty industrial fabrication and manufacturing processes. It’s generally not recommended for beginners and those with little experience as the technique can be difficult to master.

As there’s no need for a shield gas, flux-cored arc welding can be used outdoors.

Plasma arc welding

  • Can be used on incredibly thin and thick base metals
  • Uses a non-consumable pointed tungsten electrode
  • High productivity
  • Precise and accurate
  • Produces high quality, attractive welds
  • Difficult to master

Plasma arc welding (PAW) is similar to TIG welding in that it uses a pointed tungsten electrode, and requires no filler material. Unlike with TIG welding, the electrode is positioned inside the torch. This allows the plasma to be kept separate from the shield gas, which envelops the arc and weld.

A plasma arc is incredibly powerful, bursting from the electrode at almost the speed of sound! Plasma welding arcs can reach temperatures over 55,000 Fahrenheit – over 5 times the heat of a typical welding arc!

A PAW welding torch uses pressurised gas to create plasma, which creates incredibly precise and strong welds that look great too. Plasma arc welding also offers a high productivity rate.

The Plasma arc welding process

Inside a PAW nozzle, gas is pressurized to create plasma. This plasma is then ionized so it can then conduct electricity, which produces the arc from the non-consumable tungsten electrode, which is pointed to increase precision. The arc that is produced is small and incredibly powerful. The power of the arc can be adjusted by changing the voltage on the machine. The shielding gas – usually argon or hydrogen – surrounds the weld.

Where is Plasma arc welding used?

Plasma arc welding can be used in a range of applications, though it is most commonly used for electronic applications. The aerospace, marine and healthcare industries also use PAW for its high precision.

Getting Started Welding

Just getting started with welding? Perfect Power Welder has you covered. Check out our guide to getting started with welding, which covers the welding process in more detail and the equipment you’ll need for a successful and safe weld. You can also learn more about the career opportunities that welding offers – you can work anywhere from under the sea to the International Space Station.

If it’s the equipment you’re after, we offer a fantastic range of welding machines at entry-level prices, so if you fancy trying your hand at welding it won’t cost you a fortune. You can also stock up on welding equipment like guns, torches, helmets and accessories.

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