Manual welding is the most common form of welding. It is used to bond two different metal parts using a clean process. The main part of the welding process is done by using an electrical current that can be either AC or DC. This electrical current generates an electrical arc
between the metal that you are welding and the electrode that is used by the operator who is performing the welding process.
The polarity of the current affects the heat transfer to the pieces. Depending on the application, we can use one type of heat transfer or another. Usually, the most common way of doing it is by connecting the negative pole to the electrode – it is called direct polarity. When you connect the electrode to the positive pole, this process is called inverse polarity, and it is used to weld thin materials.
Being an electrical process, current and tension are important parameters that you need to consider. These parameters are handled using a transformer, and you can set the needed value according to the pieces technical parameters.
The equipment for arc welding is typically a current source and an electrode. You use a gripper for mass. Another gripper for the electrode will be used to make the process and cables to connect both grippers to the current source.
Welding is notoriously dangerous without the appropriate equipment. It can generate skin burns and permanent damage to the retina if you are watching the directly without proper security equipment. There is a need for eye protection and gloves that must be considered as part of the welding equipment.
Types of welding
Welding is a process that requires a lot of knowledge and skills. Up to the point that good welders are in high demand and can be an excellent trade to learn and forge a career path. Good welders are demanded in different sectors and industries such as metal manufacturing, agriculture, and the auto industry just to name a few. Welding has limitless possibilities depending on the used welding type.
There are three different types of manual welding. Let’s overview them.
Metal Active Gas (MAG)
MAG welding is one of the most popular welding processes that along with MIG uses a protector gas. This process uses an electrical arc, and gas is used to protect the fusion from undesired contact with the oxygen present in the environment.
MAG uses active gases like carbon dioxide and oxygen that work as protectors, and they are added to the gas working as a carrier, argon.
Metal Inert Gas (MIG)
MIG is also an arc welding process that is similar to MAG. A solid wire electrode goes through a welding gun to combine the two materials. In the same fashion as MAG, a shielding gas is sent through to protect the weld pool from contamination. The main difference between MAG and MIG is in the gas that is used in the welding process.
MIG uses an inert gas or a mixture of inert gases as the shield gas. For example, Helium and Argon are some of the most common gases used in the MIG welding process.
The type of shielding gas is important because it affects the stability of the arc, the penetration, and the degree of spatter.
Both MIG and MAG welding are used widely in different industries. For example, in the auto industry, it is used to repair exhaust systems. What is more, it is used in building and construction industries to build fences and many other objects that are needed. Both of the mentioned welding types are considered such as two of the most common welding techniques.
Tungsten Gas Arc Welding (TIG)
Like MAG and MIG, it uses an electrical arc. The main difference here is the fact that when you work using TIG Welding, the electrode will be made of tungsten. Tungsten is considered one of the toughest metals. TIG will also be using gas, like argon or helium. Both MIG and TIG are processes that work under similar principles. An electrical current generates heat that melts the base materials creating a bond between the two.
However, when comparing TIG to MIG, TIG is much slower which increases production times and costs. Also, welders need to be trained at the proper level and the relevant knowledge to perform welding coordination activities is required.
Yet despite all, TIG offers great control and accuracy while producing strong and aesthetically pleasing results. Therefore, TIG welding is used where high precision is needed. For example, the aerospatial industry benefits a lot from this type of welding to create clean and resistant bonding. It is also used to create wagon frames for high control and a good finish.
Welding is a process that requires specific skills, and producing high-quality welding requires a lot of practice, training, and quality equipment. Therefore, selecting the most appropriate welding method will enhance the resilience of the weld and produce a finish that is the most suitable for the particular part or good, and that is free from defects.
At Hennordic there are more than 42 welding stations available, including all conventional welding processes (MIG, MAG, TIG). The welding process is certified by Adaptive cruise control systems – ISO 3834-3 standard. All welders are constantly tested and trained, besides that, the welding quality is validated using the macroscopic examination. Here could be found more information about our welding equipment which is part of Hennordic production line.