Sheet Metal Welding
Welding is a manufacturing process and technology that joins metals by heating, high temperature, or high pressure. According to different classification standards, welding has different classification forms. For example, according to the process principle, welding can be roughly divided into three categories: fusion welding, pressure welding and brazing. The most commonly used basic welding technologies in the sheet metal industry are manual arc welding, argon arc welding, CO₂ gas shielded welding, laser welding, and spot welding. 1. Manual arc welding: commonly known as electric welding, is the most basic welding process. It uses the manually operated welding rod and the workpiece to be welded as two electrodes and uses the arc heat between the welding rod and the weldment to melt the metal for welding. The advantages of electric welding are simple equipment, low cost, and strong adaptability without auxiliary gas. The disadvantages are high labor intensity, low efficiency, and some welding rods are prone to hydrogen embrittlement, which requires high technical skills for welders. It is widely used in manufacturing and maintenance industries such as shipbuilding, boilers and pressure vessels, machinery manufacturing, building structures, and chemical equipment. 2. Argon arc welding: Based on the principle of ordinary arc welding, it uses argon gas to protect metal welding materials. Through high current, the welding materials are melted into liquid on the welded substrate to form a molten pool, so that the welded metal and welding materials can achieve metallurgical bonding. Since argon gas is continuously supplied during high-temperature molten welding, the welding materials cannot contact with oxygen in the air, thereby preventing the oxidation of the welding materials. Therefore, stainless steel and iron hardware metals can be welded. Advantages: Argon gas protection can obtain dense, spatter-free, and high-quality welding joints; the arc burns stably, the heat is concentrated, the arc column temperature is high, the efficiency is high, the heat-affected zone is narrow, and the strain of the welding part of the workpiece is small; open arc welding is easy to operate and observe; all-position welding is possible, not limited by the welding part of the workpiece; the electrode loss is small, easy to maintain, easy to realize mechanization and automation; all metals can be welded, especially some refractory and easily oxidized metals, such as magnesium, titanium, molybdenum, zirconium, aluminum, and their alloys. Disadvantages: Affected by the environment (wind), the welding speed is slow, the workers have high technical requirements and low melting points and volatile metals cannot be welded. 3. 03CO₂ gas shielded welding: commonly known as two-shield welding, it is a welding method that uses carbon dioxide as gas protection. The welding wire is melted by the arc and fed into the welding area. The electric drive roller feeds the welding wire from the spool into the welding torch according to the welding requirements. It belongs to the type of consumable gas-shielded welding. The advantages are good arc visibility, which is conducive to observation, small welding deformation compared to electric welding, low cost, and high production efficiency. The disadvantages are that the welding machine equipment is complex and prone to failure, requiring high technical ability to maintain the equipment, poor wind resistance, and large welding spatter. 4. Laser welding: It is a method of welding that uses the heat generated by bombarding the weldment with a focused laser beam as energy. The surface of the workpiece is heated by laser radiation, and the surface heat diffuses to the inside through heat conduction, so that the workpiece melts to form a specific molten pool. The advantages are fast welding speed, small metallographic change range of the heat-affected zone, minimum deformation caused by heat conduction, a wide range of weldable materials, and various heterogeneous materials that can also be joined to each other. The disadvantages are that the position of the weldment needs to be very precise, the weldable thickness is limited, the energy conversion rate is low, and the equipment is relatively expensive. 5. Spot welding: Also known as butt welding, it is a method of assembling welded parts into overlapping joints and pressing them between two electrodes, using resistance heat to melt the parent metal and form welds. It is mainly suitable for welding thin-plate components and stamping parts that do not require airtightness. The advantages are a short heating time for the connection area, fast welding speed, only consumption of electricity, no need for filling materials or flux, simple operation, high productivity, low labor intensity, and good working conditions. The disadvantages are that it cannot work in a small space, the production scene is limited, it is not suitable for welding thicker materials, an