Factors to Determine the Right Welding Process
Selecting the right welding process requires consideration of many important factors, such as:
- Joint analysis Determining the size, position, and thickness of the base metal must be done to understand if the needs of the joint are fast-fill, fast-freeze, fast-follow, or penetration.
- Type of materials Different types of materials call for the use of particular welding processes. While MIG and TIG welding works for copper, other welding types may not suit the material.
- Structure of parts Checking base-metal conditions and arc visibility helps to decide the appropriate welding technique. Knowing the fixturing of equipment can also lend a hand in choosing the appropriate method.
- Application If a welding process does not fit the weld specifications necessary to provide the desired weld properties, it should not be used. Additionally, availability and cost of equipment should be taken into consideration.
- Volume of parts to be welded Because so many welding types rely on high-cost equipment, the volume of parts to be welded should be examined alongside the amount of productivity or work and expertise necessary.
Welding requires a checklist of basic equipment, namely:
- Welding machines Each welding method has its own specialized machinery.
- Consumables Used for welding the base materials, consumables such as electrodes, fillers, and flux play an essential role in the welding process. The specific type selected for a job depends on the base materials.
- Safety equipment Since welding involves working in close proximity to high electrical currents, noise levels, and temperatures, welder safety should remain a paramount concern. Personal protective equipment such as welding helmets, shields, goggles, gloves, earplugs, and fire-resistant overalls often prove essential in ensuring welder safety.
Materials We Can Weld
Steel, especially alloys of mild steel, is a popular choice for manufacturing weldable parts with high strength and low costs. We commonly weld the following steels:
- AISI 1018 steel A low carbon steel, this material is considered the best choice for manufacturing carburized parts because of its malleability and weldability, while still maintaining strength and toughness.
- 1215 steel This mild steel suits parts requiring machining and case hardening.
- C1026 steel Its chemical composition resembles 1215 steel, except that this material has more carbon and lower machinability than 1215 steel.
- 316 stainless steel As a marine-grade, corrosion-resistant steel, this material sees wide use by the food processing industry since it performs well at high temperatures.
We recommend the above metals because they don’t contain lead. While the cost-effectiveness of some other steels may be appealing, welding these alloys can produce toxic fumes welders may inhale during welding processes. Plating materials like zinc or chrome may produce the same noxious results. Sulphur, which improves machining in some stainless steel, does not have strong weldability.
Welding at Stafford Manufacturing
Stafford Manufacturing Corp. manufactures a variety of mechanical parts such as coupling adapters, rigid couplings, and shaft collars used in clamping, motion control, mounting, and power transmission applications. With good welds, these parts can work reliably for their lifetime and help to ensure the safety of the people who depend on them. We prioritize quality in all of our parts and services, and we can provide standard parts with excellent weldability or create custom parts with the right weldability required for specific applications.
Please contact us with your questions about the weldability of our products and how they are suitable for your applications.