Welding process

Welding is a fabrication or sculptural process that joins materials, usually metals or thermoplastics, by causing fusion, which is distinct from lower temperature metal-joining techniques such as brazing and soldering, which do not melt the base metal. In addition to melting the base metal, a filler material is often added to the joint to form a pool of molten material (the weld pool) that cools to form a joint that can be as strong as the base material. Pressure may also be used in conjunction with heat, or by itself, to produce a weld.

Many different energy sources can be used for welding, including a gas flame, an electric arc, a laser, an electron beam, friction, and ultrasound. While often an industrial process, welding may be performed in many different environments, including in open air, under water, and in outer space. Welding is a hazardous undertaking and precautions are required to avoid burns, electric shock, vision damage, inhalation of poisonous gases and fumes, and exposure to intense ultraviolet radiation.

Until the end of the 19th century, the only welding process was forge welding, which blacksmiths had used for centuries to join iron and steel by heating and hammering. Arc welding and oxyfuel welding were among the first processes to develop late in the century, and electric resistance welding followed soon after. Welding technology advanced quickly during the early 20th century as World War I and World War II drove the demand for reliable and inexpensive joining methods. Following the wars, several modern welding techniques were developed, including manual methods like SMAW, now one of the most popular welding methods, as well as semi-automatic and automatic processes such as GMAW, SAW, FCAW and ESW. Developments continued with the invention of laser beam welding, electron beam welding, magnetic pulse welding (MPW), and friction stir welding in the latter half of the century. Today, the science continues to advance. Robot welding is commonplace in industrial settings, and researchers continue to develop new welding methods and gain greater understanding of weld quality.

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