Welding Processes - Advantages and Disadvantages of Commonly Used Industrial Welding Processes

Topics Covered

Background

Shielded Metal Arc Welding (SMAW)

Advantages

Disadvantages

Submerged Arc Welding (SAW)

Advantages

Disadvantages

Flux Cored Arc Welding (FCAW)

Advantages

Disadvantages

Gas Tungsten Arc Welding (GTAW)

Advantages

Disadvantages

Background

For efficient and economical fabrication, the choice of welding processes should primarily be based on productivity and cost factors, together with material and weld position considerations.

Shielded Metal Arc Welding (SMAW)

Advantages

         Versatility - readily applied to a variety of applications and a wide choice of electrodes

         Relative simplicity and portability of equipment

         Low cost

         Adaptable to confined spaces and remote locations

         Suitable for out-of-position welding

Disadvantages

         Not as productive as continuous wire processes

         Likely to be more costly to deposit a given quantity of metal

         Frequent stop/starts to change electrode

         Relatively high metal wastage (electrode stubs)

         Current limits are lower than for continuous or automatic processes (reduces deposition rate)

Submerged Arc Welding (SAW)

Advantages

         Lends itself to the production of consistently high quality welds with minimum operator skills.

         Minimum of welding fume and of arc visibility (radiation).

         Well suited to welding thick sections.

         Suitable for welding carbon, low alloy and alloy steels.

         Relatively high metal deposition rates

Disadvantages

         Flat or horizontal position welding only

         Care required to preserve correct electrode alignment, as electrode

         Tip and weld pool are underneath solid flux cover

Flux Cored Arc Welding (FCAW)

Advantages

         Versatility - suitable for a variety of positions and applications

         Capable of relatively high deposition rates

         Enables “one process” operation for individual projects – simplifies training, supervision and logistics

Disadvantages

         Incorrect selection of consumables and parameters may lead to lower weld toughness

         Potential for lack-of-fusion type defects if welding parameters are incorrect or misalignment occurs

         Fume extraction may be required

Gas Tungsten Arc Welding (GTAW)

Advantages

         Applicable to a very wide range of materials.

         Especially good for welding thin sections and delicate workpieces

         Capable of producing welds of high quality and appearance

Disadvantages

         Generally restricted to flat or horizontal welding

 

Source: The Institute of Materials Engineering Australasia.

 

For more information on this source please visit The Institute of Materials Engineering Australasia.

 

Date Added: May 10, 2004 | Updated: Jun 11, 2013
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