Welding is a fabrication process of joining materials like metals or thermoplastics by a fusion technique. In the welding industry, there are many types of welding machines depending on the type of welding process. Some of the popular welding machine manufacturers are Lincoln, Miller, Hobart, etc. They produce welding machines of all sizes and shapes ranging from small home workshop welding to industrial welding machines.
- What is a Welding Machine?
- Different Types of Welding Machines
- How to Choose the Right Welding Machine?
- Types of Welding Processes
- Common Abbreviations for Welding Processes
What is a Welding Machine?
A welding machine is one of the essential tools that generates heat and melts metal parts in the joining process. Some of the welding machines are hand-held and others are computer-controlled. But there is no single welding machine in the industry that can handle all welding projects.
Different Types of Welding Machines
The following are some of the welding machines commonly employed in the welding industry.
1. MIG Welding Machine – Generally, these machines are used in home shops, small businesses, manufacturing, and metal fabrication applications. MIG machines come in single-phase, three-phase, and all-in-one. Welders use these machines in a variety of applications including the welding of stainless steel and aluminum. Some of the popular machine names are Millermatic, Deltaweld, CP, Invision, and Alumafeed.
2. TIG Welding Machine – The machine is mainly used when there is a precise, critical weld that is done on metals like mild steel, stainless steel, or aluminum. Some of the best names of TIG welding machines are Syncrowave, Dynasty, Diversion, and Maxstar from Miller Brand.
3. Spot Welding Machine – Also, the welding process is known as resistance welding. The spot welding machine joins the overlapping sheets of metals. In addition, spot welding is a subset of electric resistance welding.
4. Stick Welding Machine – Normally, stick welding is a simple but difficult welding process. This process is ideal when performed in an open space or outside. Some of the best stick welding machines are Gold Star, Thunderbolt, and CST by Miller.
5. Plastic Welding Machine – The use of machines for various welding techniques is one of the best innovations of modern times. While welding plastic materials, first films are joined and then pressure is applied against them.
How to Choose the Right Welding Machine?
Despite knowing the use of the welding technique, welders need to choose the right welding machine for the required welding results. Besides this, it depends on the type of job they want to do. So, they should take into account the following considerations.
1. Selecting Basic or Complex Machine. It depends upon the skills level of welders either beginner or trained. Novice one can go with a basic welding machine like a MIG welder. On the other hand, if you are well trained, require a job with more powers. Then you can handle even a high-tech TIG welder.
2. Weld-Quality Requirement. In case welders think to obtain high-quality welds then a good choice is a TIG welder. And if you handling rusty or dirty metals and want to get strong welds then consider going with a stick welder or flux-cored welding machine.
3. Observe the Thickness of the Metal. Generally, welders should use stick welding machines for thick metals. And thin materials or metals require MIG or TIG welding machines. The car manufacturing industry is the largest place for the welding of thin metals.
4. Consider Welding Conditions. Always check where is the welding place. Normally, stick or flux-cored welders are a good choice for rough outdoor conditions like wind, etc.
5. Choose Right Power Source. A DC output typically is a good choice for weld steel and stainless steel. And for welding aluminum and magnesium, an AC output is a good choice. In case, welders need to weld a variety of materials, then select a combination AC/DC welding machine.
6. Types of Metal and Welders. MIG welding machines are a good choice for stainless steel, steel, and aluminum alloys. While stick welders work well with stainless steel, steel, and cast iron. And TIG welders are a better choice for all metals or alloys one exception of cast iron.
7. If Portable Welding. Welders need a portable welder if the power source is subjected to movement. It is either engine-driven or works with an inverter.
8. Duty Cycle of Welding Power Source. The duty cycle is an amount of welding time without any sort of worry of burning or overheating the power source. Generally, a professional welder has a 100% duty cycle, and a hobby welder may need only a 20% duty cycle. The duty cycle of 40% to 60% is sufficient in most settings.
Different Types of Welding Processes
There are so many types of welding and processes used for joining metals, horizontally or vertically, or any other desired shape. These processes are employed in various welding areas i.e. construction, aerospace, pipelines, rail lines, tubes, steel, automobile, shipbuilding, electronics, solar, storage tanks, etc.
The following are welding types and their welding processes.
- Atomic Hydrogen Welding Process
- Bare Metal Arc Welding Process
- Carbon Arc Welding Process
- Flux Cored Arc Welding Process
- Gas Metal Arc Welding Process
- Gas Tungsten Arc Welding Process
- Magnetically Impelled Arc Butt Process
- Plasma Arc Welding Process
- Shielded Metal Arc Welding Process
- Submerged Arc Welding Process
Oxyfuel Gas Welding
- Air Acetylene Welding Process
- Oxyacetylene Welding Process
- Oxygen/Propane Welding Process
- Oxyhydrogen Welding Process
- Pressure Gas Welding Process
- Flash Welding Process
- Projection Welding Process
- Resistance Seam Welding Process
- Resistance Spot Welding Process
- Upset Welding Process
- Coextrusion Welding Process
- Cold Pressure Welding Process
- Diffusion Welding Process
- Electromagnetic Pulse Welding Process
- Explosion Welding Process
- Forge Welding Process
- Friction Stir Welding Process
- Friction Welding Process
- Hot Isostatic Pressure Welding Process
- Hot Pressure Welding Process
- Roll Welding Process
- Ultrasonic Welding Process
- Electro-gas Welding Process
- Electron Beam Welding Process
- Electro-slag Welding Process
- Flow Welding Process
- Induction Welding Process
- Laser Beam Welding Process
- Laser-hybrid Welding Process
- Percussion Welding Process
- Stud Arc Welding Process
- Thermite Welding Process
Welding processes employ different types of energy sources namely ultrasound, an electron beam, friction, an electric arc, gas flame, and a laser.
Common Abbreviations for Welding Processes
In North America and the outside as well, people use various abbreviations for welding processes. They are as follows.
|Gas Metal-Arc Welding||GMAW|
|Gas Tungsten-Arc Welding||GTAW|
|Pressure Gas Welding||PGW|
|Submerged Arc Welding||SAW|
Thus, the above-given information on types of welding machines and processes is beneficial in many ways for students, beginner welders, shop welders, and other professional welders.
Related: Other Welding Types