11 Arc Welding Advantages and Disadvantages |Applications of Arc Welding | Types of Arc Welding

What is Arc Welding? | Arc Welding Advantages and Disadvantages | Applications of Arc Welding | Types of Arc Welding

What is Arc Welding?

Arc welding is a welding process that uses an electric arc to generate enough heat to melt metal, after which it cools and bonds. The heat source for this fusion welding is provided by an AC or DC power supply.

The power supply generates an arc between two electrodes, either consumable or non-consumable, and sends either AC or DC current to the base material.

Arc welding can be done with either direct or alternating currents, and with either consumable or non-consumable electrodes coated with flux.

Temperatures in arc welding can reach 6,500 degrees Fahrenheit. Steel erection, heavy equipment repair, pipeline welding, and numerous large building projects are some of the most typical applications for arc welding.

Arc welding is a type of fusion welding that is widely employed in a variety of industrial applications.

There are various types of arc welding, which are chosen based on the material properties, mechanism of the equipment, and gas to be utilized.

Due to the ease of automation, gas shielded arc welding, which employs a shielding gas to protect the weld from the atmosphere, such as TIG welding, MIG welding, and MAG welding, has been widely employed.

Arc welding, including gas shielded arc welding, is widely classified as either consumable (fusible) electrode type or non-consumable (non-fusible) electrode type, depending on whether or not the welding rod/wire melts during the operation.

Types of Arc Welding

1. Consumable Arc Welding

Consumable arc welding is a fusion welding process where the welding rod/wire melts during the operation.

The heated wire (consumable electrode) is then dipped into water and ground off to expose an electrode tip, which is soldered to other metals.

In consumable arc welding, the molten welded area ends up being larger than that of a welded part prior to melting due to the fact that it has been in contact with water.

Consumable arc welding is one of the most frequently used welding processes in industry and construction. It typically has a low profile and can be used to weld various metals, including stainless steel, aluminum, copper, nickel alloys, zinc alloy as well as titanium.

In industrial welding, the most common consumable arc welding process is shielded metal arc welding (SMAW) in which the electrode rod/wire has an Inconel composition.

SMAW is also known as automatic filler metal arc welding (AFMAW). The consumable electrode arc welding process, direct current (DC) arc welding, is primarily used in steel fabrication. DC arc welding also uses a shielded metal electrode.

2. Non-Consumable Arc welding

Non-consumable arc welding is a fusion welding process where the molten welded area is the same size as that of a welded part prior to melting. A non-consumable (non-fusible) electrode is used.

Non-consumable arc welding processes are either used with alternating currents (also known as AC) or direct currents (DC).

Non-consumable arc welding processes include gas tungsten arc welding, gas metal arc welding, plasma arc welding, and electron beam welding.

The process of gas tungsten arc welding is also known as GTAW. It is a carbon arc welding process that can weld a wide variety of materials including stainless steel, aluminum, copper, aluminum alloys, and titanium. GTAW can weld parts up to 700 mm in length and 300 mm in diameter.

Step by Step Free Guide to Make the Right Weld using Arc Welding Machine

The step-by-step instructions to get the perfect weld with the help of your shielded metal arc welding machine and welding equipment: –

1) Pre- welding processes

This includes selecting the right metal, cutting it into the correct shape to get a neat joint, cleaning the edges and removing any imperfections.

The weld must be done using the correct size electrode for the thickness and grade of metal being welded.

2) Wearing proper safety gear

There are a variety of safety gear (gloves etc.) to ensure that the task is done safely and to minimize possible pain and injuries.

The equipment used must be kept clean and maintained regularly.

3) Adjusting welding machine

The machine should be adjusted according to the weld exactly as it should appear on the metal being welded.

If not, then there will be distortion and that will in a way cause the metal to become weak or break apart.

4)Turning on machine

The shielding gas flow must be optimized to achieve the result desired at that particular moment in the weld. Pressure settings should be adjusted as per the metal being welded.

5) Evaluating weld quality

The first test to see how a weld is coming is whether it looks like a work of art or not.

 The metallic appearance of the weld must be flawless and clean, which will tell you that the arc has performed properly and there are no leaks through the joint.

6) Controlling the weld

The most important step is to keep a steady hand on the machine. This will allow you to get a steady and accurate weld and thus provides you with a stable and strong joint completed with minimal wastage of materials.

7) Checking for leaks

It is important to check for leaks after every weld. This will tell you whether the joint is strong enough or not.

 Also, this will determine whether the welding process should be followed up again or not, if it isn’t so.

Arc Welding Advantages and Disadvantages

Advantages of Arc Welding:

1. Good Impact Strength

The weld connection generated during the arc welding technique has a high impact strength. It can withstand heavier loads.

Many businesses choose arc welding over other procedures due to its high impact strength.

2. High Welding Performance

Arc welding has a high heat concentration, which allows us to complete the process rapidly.

So, arc welding is a necessary if you wish to weld two metal parts swiftly. As a result of the faster welding speeds, it saves you a lot of time.

3. Seamless Welding is Achieved.

Due to the high heat of the arc welding process, you will be able to melt the metal together so that there is no air gap in between. Slag and pierce marks due to high temperature are not common.

4. It is Convenient to Operate

Because arc welding heats up metal at a low cost per unit, it can be used for engineering purposes like making ductile-iron castings from ferrous scrap.

With the help of arc welding, you do not need to own a lot of tools and instruments in order to weld various types of metals for your projects.

It is a simple process and convenient to learn as well. Combine that with the fact that arc welding is compact and lightweight, you will realize that arc welding provides everything you need for welding purpose alone.

5. Minimal Welding Storage Space

Arc welding involves equipment which is lightweight and compact in size, so it does not consume a lot of storage space.

 This makes it ideal for businesses that have limited storage space; they can easily accommodate arc welding devices without problems or difficulties.

6. Complete Welding Coverage

Arc welding can be used in many types of metals for welding purposes. As a result, you do not require to have various welding solutions for specific types of metals.

The arc-welding process allows you to weld into hard and soft materials when needed.

7. Low Price

Arc welding is a low-cost method. That means you can carry it out on a limited budget. There is no additional fee involved in doing so.

 In terms of machinery, there is no need for any expensive machinery to carry out this process.

 8. Arc welding is a high-quality welding process

 the weld is clean, seam free, and free of any defects. It is suitable for welding different types of metals. The main advantage of arc welding is that it can be performed by a bench top machine. It is fast, accurate, and efficient.

9. Arc welding is a versatile process

 it can be used for a variety of applications including steel structures, pipelines, etc.

10. Cost

Arc welding equipment is reasonably inexpensive and affordable, and the procedure frequently requires less equipment in the first place due to a lack of gas.

11. Arc welding operation is a simple process and easy to operate

Arc welding does not require any special training or licensing to start a career arc welder.

Disadvantages of Arc welding

There are a few reasons why some people look to other options beyond arc welding for certain kinds of projects. These downsides can include:

1. Lower efficiency

Arc welding produces more waste than many other techniques, which might raise project costs in some situations.

2. Higher weld failures

 arc welding produces more cracking and porosity than some other techniques. For applications that require a lot of strength in the final product, other options might be favored.

3.  Not ideal for long runs

 arc welding’s efficiency and speed come at a cost: the technique can have difficulty following along with long seams, where even slight variances can increase the chance of defects in the end product.

4. High skill level

Operators of arc welding projects need a high level of skill and training, and not all professionals have this

 Arc welding Applications

The applications of Arc Welding include the following;

1.       Tank welding.

2.       Vessel manufacturing.

3.       Pipelines

4.       Pressure vessels

5.       Construction of ships, rails, bridges, lifting girders, roofs and etc.

Arc welding is a popular method for joining metal parts. It is the most common welding process and has been used across many industries.

It is suited for small production runs and some projects require large volumes of welded parts.

What are the types of Arc Welding?

The various types of arc welding include:

1.                   Plasma Arc Welding

2.                   Metal Arc Welding

3.                   Carbon Arc Welding

4.                   Gas Tungsten Arc Welding

5.                   Gas Metal Arc Welding

6.                   Submerged Arc Welding

7.                   SMAW – Shielded Metal Arc Welding

8.                   FCAW (Flux Cored Arc Welding)

9.                   ESW (Electro-Slag Welding)

10.               Arc Stud Welding

 What are the advantages of arc welding?

Arc welding is significantly more cost efficient compared to other methods. It’s also easier to learn and can be used on various materials for multiple applications.

It can also be used without interrupting your workflow, since an arc welder is portable enough that you can use it anywhere without needing any additional space to store it.

Are there disadvantages to arc welding?

One disadvantage of arc welding is that it generates a lot of fumes, which can be harmful. You are required to wear face shields and a respirator while working on an arc welder.

What are the important points that you should remember when doing arc welding?

There are multiple things you need to know regarding how to do an efficient and accurate arc weld on various metals. One point is that the metal should be properly pre-ground before you start the welding process.

What are some applications of arc welding?

Arc welding is used for the purpose of joining metals in a strong fashion. They are used to make various parts of all sorts of products from everyday objects to vehicles and aircraft.

Are the arc welding fumes harmful?

The fumes from an arc welder are harmful. If you are working with an arc welder, you have to wear a face shield and a respirator.

What do I do if my oxygen cylinder gets stuck during a weld?

If your oxygen cylinder gets stuck, it’s very important that you remove the plug-in order for the weld to be completed successfully. It will be very hard if you fail to remove the plug because of the gas buildup during the welding process.

Is Arc Welding Dangerous?

When properly installed and handled, an arc welder is very safe; unfortunately, if used incorrectly, the operator can be exposed to a variety of risks such as toxic gases, dusts, burns, fires, explosions, electric shock, radiation, noise, and heat stress. Any of these dangers has the potential to inflict injury or death.

What is the most serious danger from exposure to welding arc?

Electric shock is the most serious hazard posed by welding and can result in serious injuries and fatalities, either through a direct shock or from a fall from height after a shock.

What are the limitations of arc welding?

Limitations of arc welding:

·         Not suitable for welding thin metals.

·         Requires skilled welders.

·         Cannot be used for reactive metals like Aluminum or Titanium.

What are the 4 types of arc welding?

There are four main types of welding.

·         MIG – Gas Metal Arc Welding (GMAW),

·         TIG – Gas Tungsten Arc Welding (GTAW),

·         Stick – Shielded Metal Arc Welding (SMAW) and

·         Flux-cored – Flux-cored Arc Welding (FCAW).