Traditional Welding Processes

Traditional welding methods have stood the test of time and remain employed in several sectors of the economy up to this minute. A breakdown of some the key methods follows:

Tungsten Inert Gas (TIG) Welding

The workpiece is heated by a non-consumable tungsten electrode, and if need be, a filler material may also be melted to build the weld. The method is highly accurate, cleaner, and has been generally complimented.

Metal Inert Gas (MIG) Welding

In MIG welding, a consumable wire acts as both the electrode and filler material. This process offers versatility, efficiency, and is suitable for thicker materials.

Spot Welding

Spot welding is a resistance welding process in which workpieces are clamped between two electrodes, across which an electric current is passed, creating a weld at the joint. It is ideal for thin materials and high-volume production.

Laser Conduction Mode Welding

Conduction mode laser welding represents the quantum leap forward in technology for joining metals. The method uses a focused laser beam to melt the workpiece in localized areas, with or without filler material, exactly. Laser welding can be substituted for traditional methods in accordance with the geometry of the parts, the type of joint, and structural requirement.

For example, Titanova offers both autogenous (no filler) and non-autogenous laser welding, in hot-wire or cold-wire fashion. This flexibility in delivery enables laser welding to provide high precision with adaptability for various applications.

Advantages of Traditional Welding

Despite the developments accompanying laser welding, traditional methods remain very valuable. Here is why they are irreplaceable:

Familiarity Everywhere

Traditional techniques are also more understood across the manufacturing industry and hence easy to incorporate into legacy operations.

Tolerant to Imperfections

The processes allow for less-than-perfect alignments of workpieces, reducing the need for perfect fits.

Automation-Friendly

The traditional methods have proven easier to automate using existing equipment.

Lower Initial Costs

The initial investment in traditional welding equipment is usually lower compared to laser systems.

Manual Operation

Unlike laser welding, traditional techniques can be done manually; this provides greater flexibility in small-scale projects.

Advantages of Laser Welding

Laser welding has a lot of advantages, especially in the operations where precision is highly called for and volumes of operation are huge:

Minimal Heat Input

The HAZ in laser welding is much smaller, leading to less thermal stress and less damage to the workpiece.

Reduced Distortion

Lower heat input means fewer macro deflections and distortions, thus preserving the integrity of the material.

Faster Production

The speed of laser welding can offset the generally higher initial cost by way of increased capacity and quicker turnaround times.

Ideal for Thinning Materials

Due to the adjustable spot size of a laser, it is ideal for welding thin or fragile parts. Minimizing heat-induced stresses, distortion, and defects while producing precision welds.