11/5/2020 What is Fusion Welding?

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WHAT IS FUSION WELDING?

  

Fusion welding is a process that uses heat to join or fuse two or more materials by heating

them to melting point. The process may or may not require the use a ller material.

External application of pressure is not required for fusion welding processes, except for

resistance welding, where substantial contact pressure is required during welding for

sound joining.

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Fusion Welding Processes

Fusion welding processes can be grouped according to the source of the heat, for example,

electric arc, gas, electrical resistance and high energy.

These processes include:

Arc Welding Processes - withtothe

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Shielded Metal Arc Welding (SMAW), also known as manual metal arc welding (MMA or

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MMAW), ux shielded arc welding > welding. Suitable for welding ferrous and non-
or stick

ferrous materials in all positions.

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Metal Inert Gas Welding (MIG) and Metal Active Gas Welding (MAG), also known as Gas Metal

Arc Welding (GMAW). MIG and MAG welding are the most common arc welding processes, in

which an electric arc forms between a consumable wire electrode and the workpiece leading

them to melt and join. Both use a shielding gas to protect the weld from airborne

contaminants, or oxidation in the case of MIG welding.

Tungsten Inert Gas Welding (TIG), also known as Gas Tungsten Arc Welding (GTAW). This arc

process uses a non-consumable tungsten electrode to create the arc between the electrode

and the base plate. An inert shielding gas is used to protect from oxidation or other

atmospheric contamination. This process can be used autogenously on thin parts, but will

require the addition of a wire, rod, or consumable to be added for thicker parts.

Plasma Arc Welding (PAW). This process uses an electric arc created between an electrode and

the torch nozzle. The electric arc ionises the gas (usually argon) in the chamber creating what is

called a 'plasma.' It is then forced through a ne bore copper nozzle that constricts the arc and

directs it to the workpiece, allowing the plasma arc to be separated from the shielding gas

(which is usually made from a mixture of argon and hydrogen).

Submerged Arc Welding (SAW). This frequently-used arc welding process uses a continuously-

fed consumable electrode and a blanket of fusible ux which becomes conductive when

molten and provides a current path between the workpiece and the electrode. The ux also

prevents spatter and sparks while suppressing ultraviolet radiation and fumes.

Flux Cored Arc Welding (FCAW). Developed as an alternative to SMAW, this process uses a

continuously fed consumable electrode with a ux and a constant voltage or constant current

power supply. Sometimes using a shielding gas this process can also just use the ux to
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Gas Welding Processes - the most common process being:

Oxy-Fuel Welding, also known as Oxyacetylene Welding but commonly called gas welding, this

process uses a hand-held torch or blow pipe and a mixture of oxygen and acetylene which

combusts to create a ame.

Resistance Welding Processes

Resistance Spot Welding. This fast welding process delivers heat between two electrodes

according to the material properties and thickness of the workpieces. The welding current is

concentrated to a small spot as the workpieces are simultaneously clamped together.

Resistance Seam Welding. This variant of spot welding produces a series of overlapping

nuggets of a continuous joint by replacing conventional spot welding electrodes with wheels

which rotate as the workpieces are fed between them.

High Energy Welding Processes - with the main ones being:

Electron Beam Welding (EBW). This fusion process is performed under vacuum conditions,

using a beam of high velocity electrons to melt the workpieces as the electrons generate heat

upon penetration into the material. Welds are often deep and narrow.

Laser Beam Welding (LBW). Often used in high volume applications, LBW uses a laser beam to

provide a concentrated heat source with high levels of accuracy which can be used to join

metal and polymers.

Fusion Welding Services

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Where is Fusion Welding used?

Fusion welding processes are commonly used across a range of industries including

aerospace, automotive and construction amongst others. Used to join metals for a variety of

applications, fusion welding is also used to create artwork by a growing community of artists.

What are the Advantages of using Fusion Welding?

Edge preparation and joint design are not imperative as these will only a ect achievable
penetration

 Large spaces can be lled due to the ease of applying ller material

The primary shape of components does not matter as there is no need to apply external
pressure

Fusion welding allows for the easy joining of more than two components

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What are the Disadvantages

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11/5/2020 What is Fusion Welding? - TWI

Di cult to join dissimilar metals when they have di erent melting points and thermal
expansion coe cients

Intense heating can severely a ect the mechanical properties of parent materials

Melting and solidi cation can generate distortion and residual stress

The heat a ected zone (HAZ) creates a weak area in the welded materials

Related Frequently Asked Questions (FAQs)

For more information about fusion welding, please email:

contactus@twi.co.uk

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Granta Park, Great Abington, Cambridge, CB21 6AL, UK

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