What is Fusion Welding? | Top Q&A
Fusion welding is a process that uses heat to join or melt two or more materials by heating them to a melting point. This process may or may not require the use of fillers. No external pressure is required for fusion welding processes, with the exception of resistance welding, where significant contact pressure is required during the welding process for negative joining.
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Combined welding process
Contents
Fusion welding processes can be grouped by heat source, for example, electric, gas, resistive, and high-energy arc. These processes include:
Arc Welding Process – with the most common processes being:
Shielded Metal Arc Welding (SMAW), also known as manual metal arc welding (MMA or MMAW), flux shielded arc welding or rod welding. Suitable for welding ferrous and non-ferrous materials in any position. Read more: Shop for replacement windows: Learn window partsMetal Inert Gas (MIG) Welding and Metal Active Gas (MAG) Welding, also known as gas metal arc welding (GMAW). MIG and MAG welding are the most common arc welding processes, in which an electric arc is formed between the consumable wire electrode and the workpiece that leads them to molten and bond together. Both use a shielding gas to protect the weld from airborne contaminants or oxidation in the case of MIG welding.Tungsten Inert Gas (TIG) Welding, also known as Gas Tungsten Arc Welding (GTAW). This arc process uses a non-consumable tungsten electrode to create an arc between the electrode and the substrate. Shielding inert gas is used for protection from oxidation or other atmospheric contamination. This process can be used natively on thin parts, but will require extra wire, rods or consumables to be added for thicker parts. Plasma arc welding (PAW). This process uses an electric arc created between an electrode and the nozzle of the torch. The electric arc ionizes the gas (usually argon) in the chamber creating what is known as a ‘plasma’. It is then pressed through a copper nozzle with a small hole that shrinks the arc and directs it to the workpiece, allowing the plasma arc to be separated from the shielding gas (usually made from a mixture of argon and hydrogen). .Submerged arc welding (SAW). This frequently used arc welding process uses a continuously charged consumable electrode and a molten flux layer that becomes conductive when melted and provides a current path between the workpiece and the electrode. Flux also blocks sparks and electrical sparks while blocking UV radiation and smoke.Flow arc welding (FCAW). Developed as an alternative to SMAW, this process uses a continuously charged consumable electrode with constant flux and voltage or a constant power supply. Sometimes a shielding gas is used, this process can also only use flux to protect from the atmosphere. Read more: what is a hike up the campground | Ask and Learn More
Gas welding process – the most common ones are:
Oxygen fuel weldingAlso known as Oxyacetylene Welding but more commonly known as gas welding, this process uses a hand-held torch or bellows and a combustible mixture of oxygen and acetylene to create a flame.
Resistance welding process
Resistance spot welding. This rapid welding process transfers heat between the two electrodes according to the material properties and the thickness of the workpiece. The welding current is concentrated to a small point when the workpieces are clamped together.Welding resistance. This variation of spot welding creates a series of overlapping grains of a continuous joint by replacing conventional spot welding electrodes with wheels that rotate as workpieces are inserted between them.
High energy welding process – with the main processes being:
Electron beam welding (EBW). This fusion process is carried out under vacuum conditions, using a high-velocity electron beam to melt the workpiece as the electrons generate heat as they penetrate the material. Welds are usually deep and narrow.Laser Welding (LBW). Typically used in high volume applications, LBW uses a laser beam to provide a highly precise source of concentrated heat that can be used to join metals and polymers. Read more: what is audi plus parking system | Top Q&A
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