Joining Metals

Chapter 7.2,7.3
Name Name Thickness Comments Production
SMAW Shielded Metal Arc Welding
(stick)
0.06-0.75 in Flexible, portable, requires
skilled operator (ASME
certification for pressure
vessels))
Low Capital Cost
High Labor Cost
Good for Repair and low
quantity
SAW Sumberged Arc Welding Usually thick
>0.18 in
More automated version of arc
welding
4-10 times as fast as Stick
welding.
Higher Capital, lower labor
cost
High quantity
FCAW Flux Cored Arc Welding Similar to SAW
0.060-16.0 in
Automated, higher power Medium to high quantity.
Higher capital cost.
GMAW
(MIG)
Gas Metal Arc Welding
(Metal Inert Gas)
0.06-0.5 in Non ferrous and sheet metal lower quantity
GTAW
(TIG)
Gas Tungsten Arc Welding
(Tungsten Inert Gas)
0.005-0.120 in Non ferrous and sheet metal More about technical than
economic
OFW OxyFuel Gas Welding (oxy-
acetylene)
Good for sheet metal Low capital cost, slow, good
for repair
EBW Electron Beam Welding foil to 6 in (Al)
(3.5 in for steel)
narrow heat affected zone
thick butt joints with no bevel
Vacuum slows process,
increases cost, limits size
LBW Laser Beam Welding foil to 1 inch
(multiple passes)
narrow heat affected zone
smaller parts
Expensive equipment.
CW Cold Welding Roll bonding of US quarters.
Two 1.2 mm cupro nickel layers
on 5.1 mm Cu core. Final total
thickness is 1.36 mm
FRW Friction Welding n.a. Shafts Can do dissimilar metals medium to high production
RW
RSW
Resistance Welding
Resistance Spot Welding
0.001-0.315 Auto bodies, office furniture Medium to high production
SMAW Stick
GMAW MIG
www.weldingengineer.com/ 1tig.htm
www.weldingengineer.com/ 1tig.htm
GTAW - TIG
Electron Beam Welding
www.acceleroninc.com/ techdata/ebweld.htm
Electron Beam Welding
www.twi.co.uk/j32k/ getFile/laser_thick.html

Laser Weld Advantages

Deep narrow welds
Low heat input
Minimal distortion
High joint completion rates
Joint design flexibility
Minimal use of consumable
Ease of automation

Friction Welding
Resistance Spot Welding
Spot Weld and Ultrasonic Inspection
: www.me.metu.edu.tr/ me114/loc_key_spr_riv.htm
www.m-bco.com/article_ welding_basics.php
www.aussieweld.com.au/.../ page10/page10.htm
www.aussieweld.com.au/.../ page10/page10.htm
: www.me.metu.edu.tr/ me114/loc_key_spr_riv.htm
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