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Pioneer : Total Manufacturing Solutions

Welding

Welding has long been a core element of our production cycle. Modern spot welding machines complement a run of six welding bays, each with the latest equipment and staff that have proven themselves capable enough to meet our high standards. As well as mild steel, we regularly weld non-ferrous material such as stainless steel, aluminium, and we can even braze brass.

Below, is an outline of the main welding systems we use:

MIG WELDING

MIG welding is an automatic or semi automatic process in which a wire connected to a source of direct current acts as an electrode joining two pieces of metal, as it is continuously passed through a welding gun. A flow of an inert gas is also passed through the gun at the same time as the wire electrode. This inert gas acts as a shield, keeping air borne contaminants away from the weld zone.

The primary advantage of MIG welding is that it allows metal to be welded much quicker than other welding techniques. This makes it ideal for welding softer metals such as aluminum. When MIG welding was first developed, the cost of the inert gas (i.e., argon) made the process too expensive for welding steel. However, over the years, the MIG welding process has evolved and semi inert gases such as carbon dioxide can now be used to provide the shielding function which makes MIG welding cost effective for welding steel.

Besides providing the capability to weld non-ferrous metals, MIG welding has other advantages:

  • It produces long continuous welds much faster than other welding methods.
  • Since the shielding gas protects the welding arc, MIG welding produces a clean weld with very little spatter.
  • The versatility of MIG welding means it can be used with a wide variety of metals and alloys.

The primary disadvantages of MIG welding are:

  • The welding equipment is quite complex (MIG welding requires a source of direct current, a constant source and flow of gas as well as the continuously moving wire electrode) plus, electrodes are available in a wide range of sizes and made from a number of metal types to match the welding application.
  • The actual welding technique used for MIG welding is different from other practices, so there is a learning curve associated with MIG welding even for experienced welders. For example, MIG welders need to push the welding puddle away from them and along the seam.
  • The necessity for the inert gas shield means that MIG welding cannot be used in an open area where the wind would blow away the gas shield.

TIG WELDING.

During the process of TIG welding, an arc is formed between a pointed tungsten electrode and the area to be welded. As a result of the gas shield, a clean weld is formed. This prevents oxidization from occurring.

The type of gas shielding typically used for TIG welding is argon, helium, or a combination of both. When combined, these two gases can ensure a higher welding speed and welding penetration. Argon is the preference of most welders when it comes to TIG welding. It is often used simply because it is heavier than air and provides better coverage when welding.

With TIG welding, one can perform a variety of weld types on several different metals. Steel and aluminum, however, are the two most widely used metals. The filler rod is another important aspect of TIG welding. Usually made from the same material as the base metal, it is used for reinforcing joints and welding heavy metals.

There are several different types of joints designed for use with TIG welding. These include the butt joint, lap joint, corner joint and t-joint. The butt joint can be welded without the assistance of a filler rod. With this type of joint, two pieces of metal are joined together along the seams.

With a lap joint, the top edge is welded to the bottom piece in an area between the two overlapping metals. A corner joint involves welding one piece of metal at a right angle to the edge of a second piece of metal in order to form a corner. To create a t-joint, a filler rod is necessary. The t-joint is created by placing one piece of metal perpendicular to another piece of metal to form a T shape. This type of TIG welding is done along either side of the perpendicular seam.

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