Archive for May, 2011
Tuesday, May 31st, 2011
There has been a lot of research in the field of welding. The use of welding to join metals has been so widespread that continuous efforts have been taken to improve on the standard and quality on welding. There has been a great amount of research that has gone into the whole process of welding which has resulted in welding becoming a staple and simple means to join two metals together. Today, the equipment that is available for welding help to create stronger joints and also the work can be done with more precision than it originally could have been done. CNC welding has become very popular in the industrial world today. There are many crash courses and workshops that are made for people who would like to take up their career as welders. The best subject to focus on would be CNC welding as this is the current scenario in the world of welding today.
Tags: TIG welding, welding, welding process
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Monday, May 30th, 2011
During the times of world war one; the welding process saw a steep surge in their demand. This is because welder the various welding processes were used and required in the machinery that was a part of the war. Ships were made out of the welding process as well as guns and other such equipment were manufactured with the help of welding. Around this time, welding was powered with the help of DC current alone as AC current was not discovered as of yet. However, later on, with the advantages of the AC current over DC, several machines were manufactured to cater to the AC current need of the welding process. This was also because AC current was much easier to handle than he DC current as it could be stepped up or stepped down to suit the need of the project. Thus most machines today also come with a AC current power. This helps to reduce the power consumption of the unit.
Tags: AC & DC Arc welders, welding, welding process
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Friday, May 27th, 2011
This is a form of welding where the metals are joined without actually melting them. These are also known as solid state welding process. In this process, the metals to be welded are brought together under high pressure and strong vibrations are passed through the metals. Ultrasonic acoustic vibrations are applied to the metal locally which creates the weld between the two welds. This method is very effective in joining metals that are not similar. Also with the use of this method, there is no necessity of bolts, nails or adhesives necessary to hold the metal pieces together. A sonotrode is made use of in this form of welding. The sonotrode will apply the high frequency ultrasonic vibration that will cause the metal pieces to join together under high pressure. Due to the absorption of the vibrations, the thermoplast will melt locally causing a joining of the two metals. High pressure dispersion of the surface oxides can also be attributed to the joining of the metals.
Tags: TIG Welders, welder, welding process
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Thursday, May 26th, 2011
Spot welding is a very common form of resistance welding. In this welding process, sheet metals that are up to 3mm thick can be joined. The reason why this welding process is very effective is because of the concentrated area of welding that is taken in when the welding process happens. This method makes efficient use of energy and does not waste energy by making long welds. Welding is done in spots, as per the name, which forms hard thick joints which are very effective in holding the two metals together. This method of welding makes it easy to work with limited workspace and also increases the production rate. There are no filler elements required in this form of welding and the whole process can be easily automated. It should be remembered that the weld strength of this process is comparatively lesser than the other welding methods and hence this method is only suitable in certain applications.
Tags: resistance spot welding, spot welding, welding, welding process
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Wednesday, May 25th, 2011
This is a welding technique that does not melt the metal to make the weld. This type of welding is normally done to make electrical connections out of aluminum or copper. This is almost similar to resistance welding but instead of heat that is used to melt the metals, the energy is provided in form of vibrations. The metals pieces in high pressure join with each other under the influence of the vibrations. When plastic materials are joined like this, it should be kept in mind that both the materials should have the same melting points. Also, when joining plastics, the vibrations are introduced vertically under high pressure. Examples of solid state welding can be ultrasonic welding and explosion welding. With the metals not welding under heat, there is no wastage of metals and also the weld is much cleaner without any marks or deformation in the line of weld as the other forms of welding.
Tags: resistance spot welding, types of welders, welding
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Tuesday, May 24th, 2011
Resistance welding is a welding process that is used to join two or more metals. In this process, heat is generated with the help of the property of resistance between the two metals. When the two metals are in contact, a high current of 1000 A to 10,000 A is passed and heat is generated by the resistance property of the two metals. This heat will cause the metals to melt and small pools of molten metal will be formed. When these pools are cooled down, they form a hard metal bond between the metals which would create a perfect weld. This welding process is very efficient and it causes the least amount of pollution. However, the cost of equipment for resistance welding is quite high. There are many processes that are included under resistance welding. Spot welding is a very famous form of resistant welding that makes use of this welding process to make clear concentrated welds.
Tags: resistance spot welding, welding, welding process
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Monday, May 23rd, 2011
The primary process of welding is the creation of an electric arc between the electrode and the metal. This arc should be stable and maintained between the electrode and the metal. The arc is created when electricity is passed through the electrode. A consumable or a non consumable electrode can be used in the process of welding. The welding process melts down the metals and the two melted metals join in their molten form to form a slag. When this cools down, the metals are joined together where they were melted at and become one whole structure. This creates a strong bond between the two metals that does not yield to pressure or wear and tear. In case of a consumable electrode, the electrode might melt and form a part of the weld. This will make the join even stronger between the two metals. There are many different types of welding used for different purposes.
Tags: TIG welding, welding, welding process
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Friday, May 20th, 2011
Welding can be done using a DC power supply as well as an AC power supply. Each of these supplies has their own advantages and disadvantages. They are chosen based on the type of power supply that is available of the project that is undertaken. A stabilizer or a voltage regulator is used to keep the power supply that is needed for the welding operation constant. A stabilizer will step up the voltage if it is too low or brings the voltage down if it is too high. When using direct current, the electrode will only provide the arc and no the filler material. For shallow welds, a positively charged electrode is used and for deeper welds, a negatively charged electrode is used. The type of current t be used therefore is dependent on the welding project that is being undertaken. We should keep the availability of the power source as well as the metals involved in the process into consideration before proceeding with welding.
Tags: AC & DC Arc welders, welder, welding
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Thursday, May 19th, 2011
The magnetic pulse welding makes use of magnetic pulse to join to metal pieces together. This welding process makes use of the magnetic forces to drive two work pieces together under high pressure thereby creating a weld. This is mostly used to join two dissimilar metals together. However it should be kept in mind that these two metals are electrically conductive in nature and are not eddy current resistant. The metal to be weld is magnetically accelerated with the help of a conductive coil through with a powerful AC current is passed. This produces a secondary eddy current in the electrically conductive material and with the generation of Lorentz force, this material moves at a high impact trajectory. The base material on which the metal is to weld is kept in the trajectory path and this creates a high impact collision which leads to the formation of the weld. The weld that is formed in this method is a solid state weld.
Tags: AC & DC Arc welders, welder, welding
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Wednesday, May 18th, 2011
This is a common question in the minds of many that are recently learning about welding. The answer to this, as a surprise to many is, yes! Welding can be performed underwater and underwater welding has been used for a long time to make quick repairs to parts of the ship that are underwater like the hull or the propeller. The process that is used underwater in wet conditions is known as shielded metal arc welding. This process makes use of a waterproof electrode. With the help of such techniques, repairs to a ship or a submarine can be done on the go without the necessity to dock the ship at a port all the time for repairs. Also welding underwater is possible by using friction welding techniques and also by using flux coated arc welding. With such possibilities, experiments are going on to carry out welding in greater depths on thicker materials.
Tags: Arc Welder, welder, welding
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