Welding
Production Technique
Welding is a fabrication process that joins materials, by using high heat to melt the parts together and allowing them to cool, causing fusion. Welding is distinct from lower temperature techniques such as brazing and soldering, which do not melt the base metal. Although it is possible to weld a very broad range of materials, we restrict ourselves to steel, stainless steel and Aluminium.
Technical details:
There are several different welding techniques:
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Arc welding
These techniques usually use a filler material and are primarily used for joining metals including stainless steel, aluminium, nickel and copper alloys, cobalt and titanium. Arc welding processes are widely used across industries such as oil and gas, power, aerospace, automotive, and more.
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Friction welding
Friction welding techniques join materials using mechanical friction. This can be performed in a variety of ways on different welding materials including steel and aluminium. Friction welding doesn't require the use of filler metals, flux or shielding gas.
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Electron Beam welding
This fusion joining process uses a beam of high velocity electrons to join materials. The kinetic energy of the electrons transforms into heat upon impact with the workpieces causing the materials to melt together. Electron beam welding (EBW) is performed in a vacuum (with the use of a vacuum chamber) to prevent the beam from dissipating.
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Laser welding
Used to join thermoplastics or pieces of metal, this process uses a laser to provide a concentrated heat ideal for barrow, deep welds and high joining rates. Being easily automated, the high welding speed at which this process can be performed makes it perfect for high volume applications, such as within the automotive industry.
Materials
Steel
Steel is probably the most common metal used in welding projects. Steel has many qualities that make it ideal for this process. Steel is relatively cheap and has very good mechanical properties. As an alloy, steel comes in several different forms. Welders use carbon steel and low-carbon mild steel, depending on the project. Mild steel is especially ductile, which makes it easy to weld. The more carbon steel has, the more effort it takes to weld, though welding carbon steels still happens with the proper equipment and methods.. Because it's strong and cheap, it is often used in construction and machine building. Steel welding works with most welding types, which is another reason it's a popular material. Methods used for steel welding include stick welding, flux wire welding, gas metal arc welding, resistance spot welding, and DC-TIG welding. AC-TIG welding is not typically used with steel parts.
Stainless steel
Stainless steel is an iron-based alloy containing variable amounts of chromium, which is the element that gives stainless steel its resistance to corrosion. The degree of chromium can vary from 11% to 30% with each variation having slightly different chemical attributes that influence how it performs.
Stainless steel continues to grow in popularity because it’s a strong material that is resistant to many types of liquid, gaseous, and chemical corrosion. In fact, because many stainless-steel grades can withstand extreme hot and cold temperatures, it’s a popular material of choice for the pipe and oil industry. Restaurants, craft breweries, and medical equipment companies rely on its resistance to bacterial growth This makes it a safe choice for food prep, medical needs, and transporting corrosive chemicals. Stainless steel can be welded with shielded metal arc welding (MIG), gas tungsten arc welding (TIG), or stick welding, and each of these processes will yield a slightly different result. Depending on the application, a ferritic, austenitic or duplex steel can be used. The welding of duplex steel is more complex and we only advise to use this alloy in case that there is no other suitable alloy for the application.
Aluminium
As the most abundant metal on earth, aluminum is used in a variety of applications. Aluminum has an unusually great ability to resist corrosion, which makes it durable and less prone to damage over time. The material is used in a wide variety of industries, many of which require welding for certain materials. You can find aluminum in all sorts of vehicles, from cars to airplanes. It's also used in buildings, especially in places where its lightweight and durable features are prioritized. Aluminum welding works best with stick welding, gas metal arc welding, and AC-TIG welding. Not all aluminum can be easily welded.. Certain grades of aluminum weld more easily than others. Some require extra care, including filler materials that help the materials fuse together. Many differtent grades of Aluminium can be welded but it is important to keep in mind that the heat treatment (T4, T6) is destroyed by the welding process. Therefore, we advise to use alloys that did not undergo a prior heat treatment. Most alloys from the 5xxx- series are suitable. Our material scientists have a very good knowledge on the possible alloys and the suitable filler materials.
