Welding Procedures 101 and the Fundamentals of Welding

Welding is an engineering process by which two pieces of metal are joined together by heating them to high temperatures and fusing them into a joint. It is one of the most essential fabrication procedures with many applications in the automotive, construction, and manufacturing industries. 

Welding is increasingly benefiting from the development of modern technology – welding machines are more precise and reproduce higher quality welds than ever before. In addition, that technology allows fabrication processes to be both faster and safer. 

Technology advancements in TIG, Stick, and MIG welding procedures have refined welding, allowing for improved safety protocols, faster cycle times during production, and increased accuracy and quality control techniques in automated welding processes. The welding professionals at Elemet Manufacturing are experienced, qualified, and dedicated craftsmen ready to complete your next welding project.

Welding Procedures

According to AWS, welding procedures are comprehensive practices and techniques in producing a weldment. A typical joint welding procedure includes detailed methods, materials, and practices that welders should employ to achieve the customer’s specified result.

The welding procedure records the elements, factors, and variables involved in creating a weldment or specific weld. Welders require these procedures in various cases to achieve the following:

• Comply with certain codes and specifications
• Maintain the proper dimension by controlling distortion
• Consistently create a weldment the same way
• Reduce detrimental metallurgical changes
• Minimize residual stresses

Welding Procedure Specification

A welding procedure is only valuable for welding practices if its results can be tested, verified, and communicated to those who need to know. The parties involved include welding inspectors, designers, supervisors, and the welders themselves.

A welding procedure specification (WPS) is an important qualified document that communicates, in written form, the essential elements to perform a high-quality weld. It includes various requirements according to multiple codes and standards, as well as referencing relevant drawings and other documents for clarification, which describes the technical details of how you should implement a welding process. 

A qualified welder must have knowledge of the WPS and interpret all its elements in order to ensure that the work meets all necessary quality requirements. In short, this document serves as an explanation of how to reach welding objectives correctly.

Variables in Welding Procedures

Welding procedure variables are essential components in welding techniques and operations. Welding procedures must consider not only the proper techniques specific to a joint but also the equipment and capabilities that come into play; any of these essential or nonessential variables can affect the quality of the weld.

The typical essential variables for welding procedures include:

• The welding technique
• Welding position
• Method of applying process
• Type of welding gun used
• The welding process and its variation
• The base metal geometry changes
• Electrical or operational parameters involved

Other specifications that include nonessential variables are:

• The polarity of the welding current
• Specific details of the weld joint design
• The travel progression
• The use and type of weld backing
• Size of the welding wire

The procedure write-up should include the listed variables and detail what welders should use to create the desired result. The second portion of the welding procedure will consist of the schedule of welding conditions and a list of the joint requirements.

Basic Types of Traditional Welding

Different welding procedures apply to different welding techniques. Technology has revolutionized welding, allowing it to be used in almost any environment, including under water and in the vacuum of space. Technically, welding combines two objects using molten metal and heat, resulting in a strong joint called a weld.

The three basic types of welding include:

• Stick welding
• Metal inert gas (MIG welding)
• Tungsten Inert Gas (TIG welding)

Other welding variations include laser and plasma arc welding, but the three main types cover up to 90% of welding tasks globally.

Stick Welding Procedures

Stick welding, also known as Shield Metal Arc Welding (SMAW), is a technique that uses an electrode to provide the filler material and generate heat while simultaneously providing its own flux to protect the weld. This method joins two pieces of metal by melting both together at the joint. It can be used on any metals with a low melting point, such as aluminum, copper, magnesium, and mild steel. 

Stick welding has been an essential technique in many industries since it was invented due to its versatility and ability to join many different types of joints, from small beads to large fillet welds. It is the most common technique in use today due to its low equipment requirements, accessibility from suppliers, and ease of use.

MIG Welding Procedures

MIG welding is also easy to learn. The method works by feeding a filler wire on a welding torch and selecting the speed you want it to come out. It creates an arc allowing you to melt the wire directly on the joint. The resulting weld will be clean and strong. Welders prevent oxidation using gas, making it more expensive than stick welding.

Tig Welding Procedures

TIG welding is an arc welding process that involves using a non-consumable electrode and an arc with an inert shielding gas – typically argon or helium – to form the welded joint. TIG welding provides excellent versatility as virtually any type of metal, such as aluminum, stainless steel, and copper alloys can be worked on. 

The arc is created when current passes through a tungsten electrode, and filler wire is added by hand to increase the strength of the welded joint. The method allows welders to control the weld puddle and temperature to offer the best precision. Welds created by TIG welding are strong and aesthetically pleasing.

Welding Techniques That Meet Your Specifications

Today, welding is used in a broad range of industries, such as automotive, construction, manufacturing, shipping, and railroads. Highly-skilled welders create structures that power the global economy through ships, bridges, and skyscrapers. Overall, the scope of today’s welding projects is functional, efficient, and integral to driving progress in industries around the world.

Elemet Manufacturing is a first-class provider of precise welding services that can fulfill any need. With experienced and qualified craftsmen on staff, Elemet has all the necessary skills to handle any welding project, no matter the size or scope. Choose Elemet Manufacturing for your welding needs, and you can be assured that all your projects will meet or exceed your specifications.