Welding Procedures Specifications
If your requirement is to obtain welding procedures and/or qualifications in accordance with BS EN ISO 15614, BS EN ISO 9606 or ASME IX then Gammax should be your first choice.
Metalworking is something welders take great pride in and is often empowering. Welders can shape some of the strongest materials in the world into the goods they imagine while the heat and sparks fly. The ideal way to learn about any welding procedure is with the help and direction of professionals in the field- this is where Gammax can step in!
The process of welding involves melting and fusing distinct metal parts together. The most popular materials for welding are metals and thermoplastics, however, wood can also be used.
It can take time to get the hang of a new welding procedure. Before going on to the next level, you must become familiar with the full working procedure from beginning to end. This focus on detail is what separates an excellent welder from a more versatile future employee.
Before you decide to get weld works done, you might want to consider to know the four different types of welding procedures we offer.
4 Types of Welding Procedures
Although there can be custom welding procedures for us to follow, these are the 4 most commonly used welding processes:
- MAG Welding
- TIG Welding
- MMA, Stick Welding
- Flux Cored Arc Welding
Let’s run through each of them in detail!
1. MAG Welding
Gas Metal Arc Welding, also known as MAG Welding, warms the two metals to be connected by passing a shielding gas along the wire electrode. This procedure, which covers plates and large bore pipes, requires a constant voltage and direct-current power source and is one of the most prevalent industrial welding procedures.
The first step is to prepare your metal before turning on the welder. Unlike stick and flux-cored electrodes, which contain higher levels of specific additives, solid MAG wire has poor resistance to rust, dirt, oil, and other impurities.
Before striking an arc, clean down to bare metal using a metal brush or grinder. Any electrical impedance will have an effect on the performance of wire feeding.
4 Modes of MAG Welding
- Globular transfer: The larger metal droplet size and the tendency for spattering during globular transfer result in a rougher weld bead. Thick metal plates can be horizontally welded using this technique.
- Short Circuit: Short-circuiting involves tapping the base metal repeatedly and quickly, several times per second, as the name suggests. This technique can be applied in any welding position because it generates less spattering.
- Spray Transfer: A steady-contact arc weld is maintained throughout the process as a result of the steady way that spray transfer conveys the tiny droplets of molten metal. Despite the minimal spatter this technique creates, it works best with thick, flat horizontal pieces.
- Pulsed Spray: Spray Transfer and pulsed-spray are extremely similar, however, pulsed-spray uses a high-low current pulse to enable micro-cooling intervals. This method can be applied to a wide range of metal plate thicknesses and in practically all welding locations because of the way it is delivered.
2. TIG Welding
TIG Welding is also known as Gas Tungsten Arc Welding. The most common use for this method is to join sections of stainless steel or non-ferrous metals. A fixed, non-consumable tungsten electrode is used in the arc-welding process to create the weld. Hence, it is considered as the most time consuming among all welding procedures.
Since non-ferrous metals’ melting points vary widely, attention must be paid while determining the base metal’s composition. Steel and stainless steel both contain iron, but for a metal to be classified as stainless steel, it must have at least 11% chromium. In the 2,600 to 2,800 degrees Fahrenheit range, carbon steel melts.
All industrial sectors use TIG welding, although it is especially well suited for high-quality welding. The comparatively modest arc in manual welding is excellent for thin sheet material or controlled penetration.
3. MMA Stick Welding
Stick welding is an electric arc welding procedure that is also referred to as shielded metal arc welding, manual metal arc welding, or flux shielded arc welding. The welded junction is produced using a combination of electricity and consumable rod-shaped electrodes (welding rods) that have been coated in flux material.
To create an electrical arc between the electrode and the metal workpiece, an electric current is passed via the electrode. The electrode and the metal are both melted by this arc. The outcome is a mixture of molten metals made up of both electrode and metal workpiece material.
This is frequently used in the construction of steel structures as well as in industrial fabrication to weld iron, steel, and mild steel pipe using the open V-Groove. A filler metal is derived from an electrode, while a base metal is derived from a workpiece.
Stick welding is classified as a consumable electrode process because the electrode melts to become a component of the welded joint. This welding procedure can be used to join non-ferrous metals like nickel and copper, as well as carbon steel, alloyed steels, stainless steel, cast iron, and ductile iron. It is almost never used on aluminum.
4. Flux Cored Arc Welding
This was created as a substitute for shield welding. Due to its portability and fast welding rate, the semi-automatic arc weld is frequently used in building projects. This technique can be used for many different welding tasks because it includes many different variables. The type of wire chosen for the job and the type of welder being employed are frequently variables.
The various operating amperages, voltage levels, and polarities used, together with the speed of the wire feed, all increase versatility. The freshly bonded metal cools faster as a result of the potential for faster welding speeds. The welder must keep an eye out for porosity in the welded joint if he or she is employing a flux-cored wire.
It is best to perform flux-cored arc welding outdoors or under industrial ventilation hoods because of the amount of smoke and fumes produced during the process.
What service will you get from us?
Gammax offers four different types of welding procedures and related qualification services to our customers. We can advise you on pipe/plate diameters and thicknesses to achieve the widest possible qualification range. We test your welds so that you don’t have to!
We can advise you on selection of pipe/plate diameters and thicknesses in order for you to obtain the maximum qualification range.
All welding procedures and qualifications are written under our UKAS accreditation to ISO17020 using Welding Qualifier software developed by The Welding Institute.