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Shielded Metal Arc Welding (SMAW or Stick Welding):
This is one of the most traditional and versatile welding processes, using a consumable electrode covered in flux to create the weld. It's widely used for construction, repair work, and outdoor projects because of its portability and ability to work in various environments. Metals commonly welded include carbon steel, low alloy steels, and cast iron.
2. Gas Metal Arc Welding (GMAW or MIG Welding):
GMAW employs a continuous wire feed and inert or active gases to shield the weld pool, making it fast and easy for beginners and professionals alike. It’s predominantly used in automotive, manufacturing, and fabrication industries. Suitable for stainless steel, aluminum, steel, and other non-ferrous metals, GMAW is ideal for quickly producing clean, strong welds on thin to medium-thick materials.
3. Gas Tungsten Arc Welding (GTAW or TIG Welding):
TIG welding offers the highest level of control, producing clean, precise welds with excellent appearance. It’s often employed in aerospace, jewelry making, and high-end fabrication. Metals such as stainless steel, aluminum, magnesium, copper alloys, and nickel are commonly welded using TIG due to its precision and control.
4. Flux-Cored Arc Welding (FCAW):
This process is similar to MIG but uses a flux core wire instead of a solid wire, allowing for better welding in windy outdoor conditions. FCAW is favored in heavy fabrication, shipbuilding, and structural work, particularly on thicker steel sections. It can handle carbon steels, low alloy steels, and some stainless steels.
5. Submerged Arc Welding (SAW):
SAW involves a continuously fed electrode beneath a blanket of granular flux, providing deep penetration and high welding speeds. It’s typically used in heavy industries like shipbuilding, pressure vessel fabrication, and large structural components. Suitable for thick carbon steel and alloy steel plates.
6. Plasma Arc Welding (PAW):
Similar to TIG but with a concentrated plasma arc, PAW enables precise cuts and welds, especially useful for thin materials and intricate applications. It’s used in aerospace, electronics, and fine art fabrication, suitable for stainless steel, aluminum, and other non-ferrous metals.
7. Laser Beam Welding (LBW):
This advanced process uses a focused laser beam to perform highly precise welding, often automated. Industries like automotive, electronics, and medical device manufacturing rely on laser welding for its speed and accuracy, working well with stainless steel, aluminum, titanium, and other metals.
8. Electron Beam Welding (EBW):
Utilizing a high-velocity electron beam in a vacuum, EBW creates deep, high-quality welds with minimal distortion. Common in aerospace, defense, and scientific industries, it’s ideal for welding titanium, stainless steel, and nickel alloys.
