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WHAT ARE THE WELDING PROCESSES?
In any manufacturing sector that requires metal processing, there is a welding generator with specific characteristics and qualities to allow the operator to permanently bond 2 metal joints into a single part. There are a variety of welding processes that allow you to accomplish this. The 3 most common welding techniques are:
MMA, coated electrode welding process
MIG/MAG, continuous wire welding process with gas protection
Flux, continuous wire welding process NO GAS
TIG, welding process with tungsten and inert gas
Let's now take a closer look at these welding techniques, exploring their qualities and limitations.
MMA COATED ELECTRODE WELDING PROCESS.
The coated electrode welding process is the most common and widely used among DIY enthusiasts, but it is also widely used by professional operators on construction sites, for important work outdoor. One of the most appreciated qualities of this welding technique compared to other welding processes is the ability to obtain excellent penetration results. It also guarantees an excellent physical and mechanical quality of the weld bead without the support of a gaseous protection.
Inverter generators for coated electrode welding are usually small and light, meaning that they can be easily transported even in places that are difficult to reach. Although small, professional models are designed to work at high amperages with significant work cycles. There is a wide variety of coated electrodes available, differing in material, coating, and thickness, allowing you to work on a wide range of thicknesses and materials.
As mentioned above, the coated electrode welding process is highly appreciated for its ability to perform gas-free welding and to perform outdoor machining that is difficult to achieve with a gaseous protection welding process. The absence of gas makes this welding technique economically affordable for everyone, since with little expense it is possible to obtain everything necessary to make the first welds.
The coated electrode in contact with the base material connected to the ground melts by short-circuit. The outer coating burns simultaneously with the metal core, creating a controlled (oxygen-free) atmosphere that surrounds and protects the weld pool. To avoid oxidation of the incandescent metal, the residue of the coating enriches the weld pool with alloying elements and the waste elements, being lighter than the molten metal, are deposited by floating on the most superficial part of the weld bead, creating a barrier (slag) that allows a more gradual cooling.
The MMA welding process generates a very intense heat compared to other welding techniques, so its use is recommended on parts thicker than one and a half millimeters to avoid piercing the material.
MIG/MAG, FLUX CONTINUOUS WIRE WELDING PROCESS
The continuous wire welding process is the most widely used welding technique in the manufacturing sector, as it guarantees a higher output than all other welding processes. The operator can proceed with the process without interruption until the wire coil, which can have a maximum size of 30 cm in diameter and 16 kg in weight, is finished. This welding technique, using the protective gas, generates a minimum amount of material spatter if the welding machine parameters are set correctly, and it is possible to weld 1 mm thick plates.
The continuous wire welding process also involves a series of short circuits caused by the contact of the wire (filler material) with the base metal connected to the ground. The wire roller unit has the task of regularly pushing the wire (based on the set parameters) to the end of the welding torch from which it is dispensed at the same time as the gaseous protection.
These MIG/MAG and FLUX welding techniques are all defined as continuous wire, but they differ from each other based on the quality of gas used during the welding process.
MIG (metal inert gas): the MIG welding technique uses an inert gas as gaseous protection, mainly 100% argon or a mixture of argon/helium (industrial level). This gas guarantees good arc stability and generates sporadic welding spots and is used to weld aluminum with a continuous wire process.
MAG (metal active gas): unlike MIG welding, the MAG welding process uses an active gas protection. The most common gas is a mixture of Argon and Co2 in various percentages depending on the base material and the filler used. The purpose of Co2 is to obtain greater fusion penetration on the base metal.
FLUX, NO GAS continuous wire welding process: this welding technique is very similar to the coated electrode welding process, with the difference that instead of gas protection, the weld pool is self-protected by the material inside the wire. The productivity is certainly greater than that of the coated electrode, but it also develops more intense heat than a welding process with gaseous protection and cannot be used to weld thin plates (< 1.5 mm).
TIG WELDING PROCESSES
TIG (Tungsten inert gas): this welding technique uses an infusible electrode made of tungsten or tungsten enriched with other elements (depending on the base material) and has the purpose of igniting and maintaining the welding arc that controls the fusion and the weld pool protected by the inert gas argon. If all parameters are respected, this welding process does not generate metal sparks, and the welding arc is stable and easy to control, giving the operator the possibility to manually add filler material inside the weld pool. These welding processes allow machining on plates that are a tenth of a millimeter thick.
