The construction industry is responsible for the creation of all kinds of structures with varying sizes, levels of complexity, and uses. From simple, small structures such as family homes to large, complex ones like bridges, dams, and manufacturing plants. Structural integrity and durability are the most important considerations in this industry. This is why the construction industry employs a very large quantity of metals. In the United States alone, more than 40 million tons of steel are used annually in the construction industry. The majority of this quantity is used to create structural frameworks. This is where welding plays an indispensable role in construction.
yigao contains other products and information you need, so please check it out.
Welding technologies are widely used in the construction industry, mainly for the fabrication of structurally sound metal frameworks by fusing various metals components. It is also used to create and maintain non-structural components. Some of the welding used for construction is pre-fabricated in a shop environment while other parts of the welding process are done on-site.
Construction comprises numerous industries, including transportation, oil, and gas, telecommunication, power, manufacturing, many others. The construction industry is very broad & diverse and is divided into three major sectors which differ by the type of structures they create. These sectors are Building, Infrastructure, and Industrial.
The application of welding is crucial to all three sectors.
As the name suggests, the building construction sector involves the creation of structures in which people can dwell and carry out their activities. This sector is further divided into residential and non-residential. Building construction mainly employs welding in the creation of structural frameworks from metal components. Welding is used for connecting steel I-beams, trusses, columns, and footers, to support the walls, roof, and floors of a building. These components are cut to shape and size, lifted into position, and welded together.
Structural welding is not employed as extensively in small buildings, as it is in high-rise buildings that require thousands of metal joints. Welding in building construction is also used for the fabrication of non-structural building components such as firewalls, stairs, handrails, and floor joists. Furthermore, welders work with other professionals in setting up various systems in a building. These include:
This sector is responsible for the creation of infrastructures such as bridges, dams, railways, stadia, water supply systems, highways, and wastewater management systems. The application of welding in infrastructure construction is mainly structural. This is because most of the structures created in this sector are megastructures that completely depend on structural reliable metal frameworks created via welding. Certain infrastructure such as bridges can be made almost entirely of metal. Others such as dams and water systems require a lot of pipe welding.
Industrial construction covers all structures that are utilized industrially. Structures created by this sector hardly stand alone but are usually part of a large system of numerous components and structures that work together for specific purposes. Such systems include manufacturing plants, refineries, mills, power generation stations, and many more. Industrial construction is considered the most diverse sector within the field as it cuts across numerous industries. The applications of welding in this sector are as diverse as the sector itself. TIG welders are used for the fabrication and maintenance of structural frameworks, pipelines, industrial equipment, and support structures for large components.
The construction industry has a wide range of welding needs. Most existing welding technologies have one use or the other in the industry. Some of these and their uses are as follows:
The importance of structural integrity and durability in construction can hardly be overemphasized as structural failure can lead to a devastating loss of life and resources. Structures created weigh thousands of tons and are expected to last for hundreds of years. With the high strength and durability of weld joints, stakeholders in construction can rest assured that there’s nothing to worry about from the point of the framework.
Productivity is crucial to saving costs, resources, and time on any construction project. Productivity in a project is dependent on the efficiency of the processes involved. In terms of advancing construction efficiency, welding is at the forefront. While welding itself is a highly efficient process when using the right equipment, several other technologies have been incorporated into the process to make it even more efficient. Some of the technologies used in welding that are particularly beneficial to the construction industry are as follows:
This technology saves builders thousands of dollars and increases speed and productivity by eliminating the need for a welder to move to and from a power source to make necessary adjustments during welding. This is particularly helpful in high altitude welding where the actual welding may be 100s of meters above the ground where the power source is located. Some of the solutions that make up ArcReach include Cable Length Compensation (CLC™) which automatically adjusts the delivered voltage based on the cable length to ensure that the set voltage is always supplied; and Adjust While Welding (AWW™), which allows the operator to remotely adjust weld settings right from where they are working.
Types of automation equipment that increase efficiency and accuracy include automatic wire feeders, welding manipulators, turning rolls, and welding positioners which are used to hold and rotate the pipe or other weldment.
Some welding projects require more than one welding technology at a spot. It is stressful enough to switch equipment not to imagine doing this at heights where you would need to ascend and descend repeatedly. Multi-process welders eliminate this problem by combining various welding technologies into a single compact unit. In addition to all these, another factor that boosts productivity is the portability of welding equipment. This is appreciated when work has to be carried out over rugged terrain, at height, or in relatively small spaces.
The construction industry has a wide range of fabrication requirements. One of the numerous reasons why welding is indispensable in construction is its flexibility. For any size, work environment, or material, there is a suitable welding technique. For example, 5 cm diameter pipes can be welded as good as 50 m long beams and columns. Also, the various metal grades used in construction are all compatible with one welding technology or another.
Metal inert gas (MIG) welding joins together two pieces of metal, using an electrical supply to fuse the base metal with a consumable electrode filler.
Also known as gas metal arc welding (GMAW) or simply wire welding, the MIG process differs from TIG in that it uses a consumable wire that acts as both the electrode and the filler material. Whereas TIG welding simply relies on a tungsten tip to heat and join the metal surfaces directly.
In this blog, we answer some frequently asked questions, such as ‘what is MIG welding’, while exploring pros and cons of the process.
MIG welding uses a constant voltage power supply to create an electric arc that fuses the base metal with a filler wire that is continuously fed through the welding torch. At the same time, an inert shielding gas is also fed through the gun, to protect the weld pool from atmospheric contamination. (Inert gases do not react with the filler material or the weld pool.)
MIG welding is generally used for heavy duty fabrication projects such as metal gates. Compared to TIG welding, it is much faster resulting in shorter lead times and lower production costs. Additionally, MIG is easier to learn and produces welds that require little to no cleaning and finishing. However, TIG will always be the first choice where precise, strong and very clean welds are primary concerns.
The welding process creates powerful joints for structural efficiency and integrity, and there are many different techniques. With MIG, the process starts with a pre-weld clean up: MIG electrodes are not resistant to rust, dirt, oil, etc, so it’s vital to start with a contaminant-free area.
Here are 3 top tips for how to MIG weld:
Getting the right position and angle of the gun is vital for successful MIG welding to avoid the filler sagging or rolling over the side of the weld joint. MIG can weld from flat, horizontal, vertical and overhead positions. According to the type of weld and metal involved, you also need to take work and travel angles into consideration:
Travel angle: defined as the angle relative to the gun in a perpendicular position. Normal welding conditions in all positions require a travel angle of 5 to 15 degrees. (Travel angles beyond 20 to 25 degrees can lead to more spatter, less penetration and general arc instability.)
Work angle: this is the gun position relative to the angle of the welding joint, and it varies with each welding position and joint configuration.
If you want to learn more, please visit our website builders warehouse welding machine.
The rate at which you move the gun along the join influences both the shape and quality of a weld bead to a significant degree. Many experienced MIG welders determine the correct travel speed by judging the weld puddle size in relation to the joint thickness.
Metal transfer describes how the filler metal (electrode) is processed through the welding arc and into the weld puddle:
Let’s take a look at MIG equipment and materials and their role in the process:
With MIG welding, the electrode carrying the current, also acts as a filler. There are 2 basic types of wire electrodes available according to the projects and metals involved:
As the metals fuse in the welding pool, shielding gas is supplied through the welding torch keeping the weld pool free from contamination without affecting the metal’s properties. Shielding gas selection in MIG welding depends on the material being welded and the application. The most commonly used are argon and helium sometimes mixed with other (semi-inert) gases, such as carbon dioxide, to reduce cost.
Cheaper than argon and helium, carbon dioxide allows for deeper penetration but also creates more spatter in the weld pool. In specific situations, non-inert gases are used in very small quantities to further increase metal penetration. However, the resulting oxygen creates rust and oxidation on the weld can affect its quality.
A welding torch, or gun, is a specialised tool for fusing and melting metals. MIG torches are versatile in their application to a variety of metal types and thicknesses. MIG torches are divided into two groups:
There are 4 different nozzle types used in a welding torch: recessed, flush, protruding and adjustable. The choice is determined by the type of wire electrode being used.
Modern MIG welding equipment auto-corrects the current when the arc length and wire feed speed change, creating a stable weld puddle. These are your choices for both TIG and MIG welding:
First, let’s look at the advantages of MIG welding:
Disadvantages of MIG Welding can be described as:
These are FAQs relating to MIG welding:
MIG welding is a cost-efficient and diverse welding process, making it one of the most attractive welding methods, especially in industrial environments. It is used extensively in fabrication with thicker materials.
A good MIG welding machine is an investment. Set-up can be expensive but shorter lead times and lower production costs are can also be key outcomes.
MIG welding uses electrode wire that bonds with the metal to form the weld. Spatter is the excess molten droplets wire that bonds generated around the welding arc. Once these molten droplets land and cool, they create spatter around the worksurface and sometimes on the product you are actually welding. Good practice can reduce spatter however.
Active shielding gases used in TIG welding are carbon dioxide or mixtures of argon, helium, carbon dioxide and oxygen, depending upon the project.
Successful MIG welding calls for skill and experience, like any welding process. That said, it is one of the easiest welding techniques to learn.
The power source in a MIG welder is mostly set to DC as it offers constant voltage. This is the most widely used setting since it offers a stable arc, ensuring better bead quality, weld penetration, and less spatter. AC is hardly ever used in MIG welding.
All welds are stronger than the base metal because they are fused with filler material. However, if the metal is not clean, the weld will be weak or brittle. You can make a MIG weld even stronger by controlling the speed of the weld, the level of voltage and the depth of penetration.
Yes. You will need to use a shielding gas that comprises argon on its own or mixed with carbon. For example, a 75:25 ratio of argon to carbon dioxide gives excellent results.
Yes. Cleanliness of materials and workspaces is particularly important in welding stainless steel. Stainless steel is corrosion resistant, but it’s also susceptible to contamination so avoiding even the tiniest particulate is vital.
MIG is a fast and versatile welding process, especially suited to fabrication projects where speed and cost are key considerations. Let Alroys metal welding experts help you decide if and how MIG welding is the best option for your fabrication projects.
The company is the world’s best dc welding machine supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.