There are many different types of welding. The most widely used welding process is electrode arc welding. There are 3 types also known as ‘systems’, of arc welding. They are:
- Stick
- MIG, and
- TIG
All 3 types of arc welding use the same 3 components. Obviously the first is electricity that creates the arc itself. Each arc welding type also uses a filler material, and the third component is flux.
What are the differences between stick, MIG, and TIG?
The 3 of these systems are used to create a bead (the weld being created), each type requires a different execution. Before we talk about the differences in welders and the methods of execution, we should go over how arc welding works in general. The best way to explain this process is to clearly definethe elements of welding and what they do.
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The Arc
Lightning, spark plugs and static shock are all forms of what we call an ‘electric arc’.
The Arc is created by an electrical current passing through metal from the welding machines earth clamp to the electrode. The electrode is what we call an ‘electrical conductor’ used to complete the circuit, and therefore allows the welding machine to create an arc.
In the MIG and stick welding processes, the electrode is also know as the ‘filler metal’. When the filler material comes into contact with the grounded piece of base metal, it completes a circuit that makes the electric arc. The arc forms at the very end of the ‘filler material’, which melts into the welding zone, creating the joint. In the TIG welding processes, the electrode is a rod of tungsten.
The arc temperature can range from 2,760C to 9982C, depending on the machine used and electricity supply. The arc’s extreme high temperature heats the metal to the point which it becomes liquified. This is known as the ‘puddle’ or ‘pool’.
The Filler Metal
The filler metal is a rod or wire of metal that is ‘fed’ into the puddle/pool that forms at the point where the arc makes contact with the metal. It adds more material to fill the weld zone, feeding the pool and creating the weld bead. The filler metal is generally the same type of metal as the type being welded, but in certain cases, it can be different metals. In the stick and MIG welding processes, it can also act as the electrode. Stick and TIG welding process requires the welding operator to manually feed the filler metal into the weld zone, which can be a more difficult welding system compared to MIG/stick.
Flux and Shielding Gas
The word flux comes from the Latin word fluxus. meaning to flow. This is exactly what flux does in welding. It assists with stabilising the arc and prevents contaminants or oxides out of the weld zone. In stick welding, flux is a chemical coating surrounding the filler rod that burns off, producing a ‘shielding gas’ which prevents oxidation of the base and filler materials. Flux is formed from a wide variation of compounds depending on the application and material to be welded. The primary job of the flux is to protect the base and filler materials from oxygen and other gases. It creates a barrier called the ‘shielding gas’ protecting the arc and metal from outside gases that cause oxidation. It creates a clean environment where the arc is to exist in. Last of all it controls the arc assisting it to come up to a higher temp to create the pool of liquid metal.
The Ground
The ground is a very important part of the power supply. All electric arc welders use a ground. Basically, you are creating a circuit, and without the ‘ground’, the circuit cannot be formed. The ground clamp has to be clamped to the metal work piece or a conductive metal table that the work piece is sitting on. The electrical current feeds through the ground and through the work piece, locating the shortest distance to the electrode as possible. The section between the earth and the welding machine’s electrode is where the arc forms. If there is no earth/ground, there will be no arc created.
The Splatter
MIG and stick welding, as well as welding with flux core, creates a “spatter,” small molten balls of metal that are jump from the weld zone at the arc point. These small molten balls can form themselves to the work piece and to the gun’s nozzle. Using nozzle spatter protection will assist the nozzle last longer and prevent double arcing and problems with welding.
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