Sheet metal welding is a process method of connecting two workpieces by inputting high-density energy (thermal or pressure energy, etc.) into the interface between them, causing atomic (or molecular) bonding between them.
3 Methods of Sheet Metal Welding
Let’s learn about three common sheet metal welding methods:
Spot Welding
Spot welding is a resistance welding method that relies on the resistance heat generated by current passing through contact points to melt and join sheet metal pieces together. This method is mainly used for joining thin sheet materials and is characterized by fast welding speed and high efficiency. Spot welding is widely used in the processing of small and medium-sized sheet metal parts, especially when large quantities of thin sheets need to be connected efficiently.
MIG/MAG Welding
MIG (Metal Inert Gas) welding and MAG (Metal Active Gas) welding are automatic or semi-automatic welding methods. This method uses continuous welding wire and arc to melt the sheet metal and welding wire, forming a weld seam. MIG welding uses inert gas (such as argon) as a shielding gas, while MAG welding uses a mixture of active gas and inert gas. These welding methods are suitable for sheet metal materials of various thicknesses and provide high welding quality, making them suitable for mass production.
TIG Welding
TIG welding, also known as Tungsten Inert Gas welding, is a high-quality welding method. It uses a non-melting electrode (tungsten electrode) to generate an arc under the protection of argon gas, melting the sheet metal and connecting it with filler metal (welding wire). Due to the shielding effect of argon gas, TIG welding has excellent welding quality, especially suitable for workpieces with high welding quality requirements, such as stainless steel, aluminum alloy, and other materials.
5 Tips for Welding Sheet Metals
When welding sheet metal, ensuring welding quality and safety requires some key techniques:
1.Selecting Filler Metal:
In addition to considering the diameter and mechanical properties of the filler metal, its compatibility with the base metal should also be considered. The composition of the filler metal should match the base metal to avoid defects such as welding undercut, cracks, and porosity at the weld joint. In some special cases, flux-cored welding wire may be needed, as the flux inside helps improve welding quality.
2.Fixturing Sheet Metal:
Before welding, various parts of the sheet metal should be fixed to ensure no displacement or deformation during welding. This helps maintain the accuracy and stability of the welding position.
3.Using Small Wire Diameter and Electrode:
Choosing small wire diameter and electrode can indeed reduce heat input, but it also requires welders to have higher operational skills because welding with small electrodes and wire diameters is more difficult to control. When choosing the size of wire diameter and electrode, consideration should also be given to matching welding current and voltage to ensure the stability of the welding process.
4.Using High Argon-Based Shielding Gas:
Choosing the appropriate shielding gas is crucial for welding quality. In addition to a combination of argon and carbon dioxide, sometimes other gases (such as oxygen) need to be added to improve the welding process. The flow rate and pressure of the shielding gas also need to be adjusted according to the welding speed and current to ensure sufficient protection of the welding area.
5.Inspecting and Testing Welds:
After welding is completed, the welds should be carefully inspected and tested. Check for defects such as smoothness, cracks, and slag inclusions, and perform necessary strength and leak tests to ensure that the welding quality meets requirements.
Conclusion
In conclusion, welding sheet metal is a complex process involving multiple technical details and operational nuances. In practical applications, it is crucial to choose the appropriate welding method, equipment, and master the relevant techniques according to specific requirements.
However, for many manufacturers, determining the suitable welding method based on their manufacturing needs and acquiring the necessary skills can be challenging. At such times, seeking professional technical support and services becomes paramount. BoYi, as a company with extensive experience and expertise in welding and related technologies, can provide comprehensive services ranging from welding method selection to practical operational techniques. We assist clients in achieving more efficient and precise manufacturing processes. Through collaboration with us, you can obtain optimal welding solutions and ensure smooth execution of your manufacturing processes.
