Welding is one of the most widely used processes in parts manufacturing. This technique is used to join two parts into one, i.e. to assemble them. The procedure requires melting metals or plastics with heat so that they act as a “glue” for the parts to be joined. This molten mass is then placed on the parts and left to cool. One of the most widely used tools for this process is the electric welder.
What is electric welding?
Welding is a metalworking method in which heat is generated by a thermoelectric process to join different parts. Electric current passes through the parts to be joined, which heat up until they merge. When heat is no longer applied, the parts begin to cool, solidify and fuse together. A specific machine can be used for welding: the electric welder.
This machine is very easy to use, produces no flame and can be used both indoors and outdoors. The results are of high quality and the joints are very durable. Welding is fast, which means shorter production times and lower costs.
Types of electric welding
There are different types of electric welding on the market: resistance, stick (electrode), soldering and submerged arc. In all of them the end result is of high quality and very neat. They are classified as arc, temperature and resistance processes. The choice depends on the type of work to be done and the material being worked.
Arc welding processes include:
- Stick welding, the most common and well known. It takes its name from the electrode rods through which the electric current flows to create the arc that melts the electrode. To weld, one of the parts to be joined is connected to the earth clamp, while the electrode is connected to the positive pole. This is the most economical machine on the market for this process.
- Submerged arc welding. Instead of electrodes, this process uses wire and gas to join the parts. It requires a material called flux, which protects the weld from oxidation.
Electric welding is also classified by temperature, as follows:
- Soldering: as the name suggests, it uses tin to join two metal parts. Melting occurs at relatively low temperatures and, when the tin cools, it joins the parts. A soldering iron consists of a copper tip and an electric heating element that generates the temperature.
- Resistance welding: this is used when the metal surfaces of two or more parts are heated by the electric current passing through them. The high temperature allows the parts to join because the intensity of the electric current is such that the metal melts and the parts fuse together.
Benefits of electric welding
The electric welder is one of the most widely used machines in parts manufacturing. It is not part of the primary process that shapes a material, as is the case with lathes and milling machines, but is used to assemble those parts by means of heat. The technique is not difficult, but it takes an expert welder to make the process effective.
Using an electric welder makes it possible to join parts with a flawless, very neat finish, since work done properly can be both precise and fast. In addition, electric welding equipment is fairly inexpensive and easy to obtain, and neither repairs and spare parts nor maintenance are costly. A wide variety of models is available, from large units to portable welders that are easy to carry. It all depends on what the equipment will be used for.
Another advantage of these machines is that welding is very fast and can be done indoors and outdoors.
How to weld correctly
To weld safely, the operator must have the right equipment to avoid accidents. The essential, mandatory accessory for welders is a welding helmet. It allows the operator to check that the work is being done correctly and also protects the eyes from damage. Special goggles are sometimes used instead, but it is always advisable to use a helmet or face shield. To weld successfully, the operator must control the pressure, the electric current and the right temperature. Of course, it is also important to control the time, so that once the metal has melted the heat is removed and the metal fuses as it cools.