Robert Yates Posted June 15, 2012 Share Posted June 15, 2012 Welcome to Welding 101-02 Types of Welding Process, their respective description and uses in the welding industry. In this lesson we will cover the types of welding process used in the welding industry by many welders today. In addition we will cover starting with Arc Welding (the Main types of welding rods utilized in the field and a few shops in the welding industry) this includes What the numbers ,colors and uses of commonly used welding rods Classed by the AWS (American Welding Society) classification A5.1. I will give you my nontechnical version of a few rods and how they are used my expert opinion comes from being trained in high school, the military , field operation’s (as a welder, and supervisor), while burning 1000’s of rods while balancing on a 2 – 4 inch beam 40 stories high, lying under many types of transportation vehicle’s, and vessels, swinging from all types of boatswain’s chairs and finally being crammed into so many tight claustrophobic tiny places while welding Qualifies me to expand on these rods. Oh yes ! I have fell off of way to many the buildings and structures I have built , that would be another day and another story. With that short story out of the way let’s get started shall we . Here is The AWS Master Welder's Chart http://imgur.com/UJ6oGTable 1. Welding processes and letter designation. Group Welding Process Letter Designation Arc welding Carbon Arc CAW oman,times,serif]Flux Cored Arc FCAW Gas Metal Arc GMAW Gas Tungsten Arc GTAW ]Plasma Arc PAW Shielded Metal Arc SMAW Stud Arc SW Submerged Arc SAW Brazing Diffusion Brazing DFB Dip Brazing DB Furnace Brazing FB Induction Brazing IB Infrared Brazing IRB Resistance Brazing RB Torch Brazing TB Oxyfuel Gas Welding Oxyacetylene Welding OAW Oxyhydrogen Welding OHW Pressure Gas Welding PGW Resistance Welding Flash Welding FW High Frequency Resistance HFRW Percussion Welding PEW Projection Welding RPW Resistance-Seam Welding RSEW Resistance-Spot Welding RSW Upset Welding UW Solid State Welding Cold Welding CW Diffusion Welding DFW Explosion Welding EXW Forge Welding FOW Friction Welding FRW Hot Pressure Welding HPW Roll Welding ROW Ultrasonic Welding USW Soldering Dip Soldering DS Furnace Soldering FS Induction Soldering IS Infrared Soldering IRS Iron Soldering INS Resistance Soldering RS Torch Soldering TS Wave Soldering WS Other Welding Processes Electron Beam EBW Electroslag ESW Induction IW Laser Beam LBW Thermit TW Arc Welding The arc welding group includes eight specific processes, each separate and different from the others but in many respects similar. The carbon arc welding (CAW) process is the oldest of all the arc welding processes and is considered to be the beginning of arc welding. The Welding Society defines carbon arc welding as "an arc welding process which produces coalescence of metals by heating them with an arc between a carbon electrode and the work-piece. No shielding is used. Pressure and filler metal may or may not be used." It has limited applications today, but a variation or twin carbon arc welding is more popular. Another variation uses compressed air for cutting. The development of the metal arc welding process soon followed the carbon arc. This developed into the currently popular shielded metal arc welding (SMAW) process defined as "an arc welding process which produces coalescence of metals by heating them with an arc between a covered metal electrode and the work-piece. Shielding is obtained from decomposition of the electrode covering. Pressure is not used and filler metal is obtained from the electrode." Automatic welding utilizing bare electrode wires was used in the 1920s, but it was the submerged arc welding (SAW) process that made automatic welding popular. Submerged arc welding is defined as "an arc welding process which produces coalescence of metals by heating them with an arc or arcs between a bare metal electrode or electrodes and the work piece. Pressure is not used and filler metal is obtained from the electrode and sometimes from a supplementary welding rod." It is normally limited to the flat or horizontal position. The need to weld nonferrous metals, particularly magnesium and aluminum, challenged the industry. A solution was found called gas tungsten arc welding (GTAW) and was defined as "an arc welding process which produces coalescence of metals by heating them with an arc between a tungsten (non-consumable) electrode and the work piece. Shielding is obtained from a gas or gas mixture." Plasma arc welding (PAW) is defined as "an arc welding process which produces a coalescence of metals by heating them with a constricted arc between an electrode and the work piece (transferred arc) or the electrode and the constricting nozzle (non-transferred arc). Shielding is obtained from the hot ionized gas issuing from the orifice which may be supplemented by an auxiliary source of shielding gas." Shielding gas may be an inert gas or a mixture of gases. Plasma welding has been used for joining some of the thinner materials. Another welding process also related to gas tungsten arc welding is known as gas metal arc welding (GMAW). It was developed in the late 1940s for welding aluminum and has become extremely popular. It is defined as "an arc welding process which produces coalescence of metals by heating them with an arc between a continuous filler metal (consumable) electrode and the work piece. Shielding is obtained entirely from an externally supplied gas or gas mixture." The electrode wire for GMAW is continuously fed into the arc and deposited as weld metal. This process has many variations depending on the type of shielding gas, the type of metal transfer, and the type of metal welded. A variation of gas metal arc welding has become a distinct welding process and is known as flux-cored arc welding (FCAW). It is defined as "an arc welding process which produces coalescence of metals by heating them with an arc between a continuous filler metal (consumable) electrode and the work piece. Shielding is provided by a flux contained within the tubular electrode." Additional shielding may or may not be obtained from an externally supplied gas or gas mixture. The final process within the arc welding group of processes is known as stud arc welding (SW). This process is defined as "an arc welding process which produces coalescence of metals by heating them with an arc between a metal stud or similar part and the work piece". When the surfaces to be joined are properly heated they are brought together under pressure. Partial shielding may be obtained by the use of ceramic ferrule surrounding the stud. Brazing ( B) Brazing is "a group of welding processes which produces coalescence of materials by heating them to a suitable temperature and by using a filler metal, having a liquidus above 450oC and below the solidus of the base materials. The filler metal is distributed between the closely fitted surfaces of the joint by capillary attraction." A braze is a very special form of weld, the base metal is theoretically not melted. There are seven popular different processes within the brazing group. The source of heat differs among the processes. Braze welding relates to welding processes using brass or bronze filler metal, where the filler metal is not distributed by capillary action. Oxy Fuel Gas Welding (OFW) Oxy fuel gas welding is "a group of welding processes which produces coalescence by heating materials with an oxy fuel gas flame or flames with or without the application of pressure and with or without the use of filler metal." There are four distinct processes within this group and in the case of two of them, oxyacetylene welding and oxyhydrogen welding, the classification is based on the fuel gas used. The heat of the flame is created by the chemical reaction or the burning of the gases. In the third process, air acetylene welding, air is used instead of oxygen, and in the fourth category, pressure gas welding, pressure is applied in addition to the heat from the burning of the gases. This welding process normally utilizes acetylene as the fuel gas. The oxygen thermal cutting processes have much in common with this welding processes. Resistance Welding (RW) Resistance welding is "a group of welding processes which produces coalescence of metals with the heat obtained from resistance of the work to electric current in a circuit of which the work is a part, and by the application of pressure". In general, the difference among the resistance welding processes has to do with the design of the weld and the type of machine necessary to produce the weld. In almost all cases the processes are applied automatically since the welding machines incorporate both electrical and mechanical functions. Other Welding Processes This group of processes includes those, which are not best defined under the other groupings. It consists of the following processes: electron beam welding, laser beam welding, thermit welding, and other miscellaneous welding processes in addition to electroslag welding which was mentioned previously. Soldering (S) Soldering is "a group of joining processes which produces coalescence of materials by heating them to a suitable temperature and by using a filler metal having a liquidus not exceeding 450 oC (840 oF) and below the solidus of the base materials. The filler metal is distributed between the closely fitted surfaces of the joint by capillary attraction." There are a number of different soldering processes and methods. Solid State Welding (SSW) Solid state welding is "a group of welding processes which produces coalescence at temperatures essentially below the melting point of the base materials being joined without the addition of a brazing filler metal. Pressure may or may not be used." The oldest of all welding processes forge welding belongs to this group. Others include cold welding, diffusion welding, explosion welding, friction welding, hot pressure welding, and ultrasonic welding. These processes are all different and utilize different forms of energy for making welds. Arc welding NameNAWSCharacteristicsApplications Atomic hydrogen welding (149) AHW Two metal electrodes in hydrogen atmosphere Historical Bare metal arc welding (113) BMAW Consumable electrode, no flux or shielding gas Historical Carbon arc welding (181) CAW Carbon electrode, historical Copper, repair (limited) Flux cored arc welding 136 137 FCAW FCAW-S Continuous consumable electrode filled with flux Industry, construction Gas metal arc welding ¹ 131 135 GMAW Continuous consumable electrode and shielding gas Industry Gas tungsten arc welding ² 141 GTAW Nonconsumable electrode, slow, high quality welds Aerospace Plasma arc welding 15 PAW Nonconsumable electrode, constricted arc Tubing, instrumentation Shielded metal arc welding ³ 111 SMAW Consumable electrode covered in flux, can weld any metal as long as they have the right electrode Construction, outdoors Submerged arc welding 121 SAW Automatic, arc submerged in granular flux Also known as metal inert gas (MIG) welding or metal active gas (MAG) welding Also known as tungsten inert gas (TIG) welding Also known as manual metal arc (MMA) welding or stick welding Oxyfuel gas welding NameNAWSCharacteristicsApplications Air acetylene welding (321) AAW Chemical welding process, not popular Limited Oxyacetylene welding 311 OAW Combustion of acetylene with oxygen produces high-temperature flame, inexpensive equipment Maintenance, repair Oxygen/Propane welding 312 Gas welding with oxygen/propane flame Oxyhydrogen welding 313 OHW Combustion of hydrogen with oxygen produces flame Limited Pressure gas welding PGW Gas flames heat surfaces and pressure produces the weld Pipe, railroad rails (limited) Resistance welding NameNAWSCharacteristicsApplications Resistance spot welding 21 RSW Two pointed electrodes apply pressure and current to two or more thin workpieces Automobile industry, Aerospace industry Resistance seam welding 22 ERW Two wheel-shaped electrodes roll along workpieces, applying pressure and current Aerospace industry, steel drums, tubing Projection welding 23 PW Flash welding 24 FW Upset welding 25 RSEW Butt joint surfaces heated and brought together by force Solid-state welding NameNAWSCharacteristicsApplications Coextrusion welding CEW Dissimilar metals are extruded through the same die Joining of corrosion resistant alloys to cheaper alloys Cold pressure welding 48 CW Joining of soft alloys such as copper and aluminium below their melting point Electrical contacts Diffusion welding 45 DFW No weld line visible Titanium pump impellor wheels Explosion welding 441 EXW Joining of dissimilar materials, e.g. corrosion resistant alloys to structural steels Transition joints for chemical industry and shipbuilding. Bimetal pipelines Electromagnetic pulse welding Tubes or sheets are accelerated by electromagnetic forces. Oxides are expelled during impact Automotive industry, pressure vessels, dissimilar material joints Forge welding (43) FOW The oldest welding process in the world. Oxides must be removed by flux or flames. Damascus steel Friction welding 42 FRW Thin heat affected zone, oxides disrupted by friction, needs sufficient pressure Aerospace industry, railway, land transport Friction stir welding FSW A rotating consumable tool is traversed along the joint line Shipbuilding, aerospace, railway rolling stock, automotive industry Hot pressure welding HPW Metals are pressed together at elevated tempeartures below the melting point in vacuum or an inert gas atmosphere Aerospace components Hot isostatic pressure welding 47 HPW A hot inert gas applies the pressure inside a pressure vessel, i.e. an autoclave Aerospace components Roll welding ROW Bimetallic materials are joined by forcing them between two rotating wheels Dissimilar materials Ultrasonic welding 41 USW High-frequency vibratory energy is applied to foils, thin metal sheets or plastics. Solar industry. Electronics. Rear lights of cars. Other welding NameNAWSCharacteristicsApplications Electron beam welding 51 511 EBW Deep penetration, fast, high equipment cost Electroslag welding 72 ESW Welds thick workpieces quickly, vertical position, steel only, continuous consumable electrode. Heavy plate fabrication, construction Construction, shipbuilding. Flow welding Induction welding 74 IW Laser beam welding 521 522 LBW Deep penetration, fast, high equipment cost Automotive industry Laser-hybrid welding Combines LBW with GMAW in the same welding head, able to bridge gaps up to 2mm (between plates), previously not possible with LBW alone. Automotive, Shipbuilding, Steelwork industries Percussion welding 77 PEW Following an electrical discharge, pressure is applied which forges the materials together Components of switch gear devices Thermite welding 71 TW Exothermic reaction between alumnium powder and iron oxide powder Railway tracks Electrogas welding 73 Continuous consumable electrode, vertical positioning, steel only Storage tanks, shipbuilding Stud arc welding 78 Welds studs to base material with heat and pressure Quote Link to comment Share on other sites More sharing options...
Robert Yates Posted June 15, 2012 Author Share Posted June 15, 2012 Welding Chart Is BY Wikipedia , as the explanation and types of welding process was too vast to type out . Thank you for understanding . Sam Quote Link to comment Share on other sites More sharing options...
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