In an industrial context, welding refers to a
fabrication process that joins materials such as metals and
thermoplastics, by causing coalescence. This is typically done by
melting the work pieces and adding a filler material such as a welding
rod, to form a pool of molten material that cools to become a strong
joint. Various processes and energy sources are used for welding such
as a gas flame, electric arc, laser, electric beam, friction, and ultra
sound. All these methods involve the use of various unique equipments,
specific to each process.
A basic welding process requires
certain common equipments. These include the power supply, electrodes,
welding rods and arcs, and shielding gas. The process of automated
welding employs the use of robots.
A welding power supply is
equipment that supplies an electrical current to perform the welding
operation and often uses a high current, usually over 80 amps. The
current can be as high as 12000 amps, which is required for spot
welding. Power supply equipment includes a transformer, generator, and
alternator and inverter. Generator and alternator stylized machines
convert mechanical energy into electrical energy. The latest technology
in this category use internal combustion engines, where as the
conventional machines often use an electric motor to drive the
alternator or the generator. However, the inverter-based machines are
entirely controlled by software and implement features such as pulsing
the welding current, variable ratio and automatic spot welding.
However, a transformer based welding structure is often expensive but
can assist in a variety of applications.
Electrodes or filler
materials are one of the most vital components in welding as they
facilitate the intended joint. However, depending on the process, the
electrode is either consumable, in case of gas metal artwork, or
non-consumable as in case of tungsten arc welding. Filler materials are
also available in different materials such as magnesium and tungsten.
The
shielding gas is used mainly in gas metal arc work to protect the weld
area from atmospheric gases. Robots have become crucial equipment in
modern welding process as it facilitates automated welding, thus
increasing the efficiency and enhancing various welding processes.