Updated 8/21/2023
Welding serves as the foundation for many metal fabrication processes. Today, skilled professionals can weld metal by hand or with automation to form parts and products. At Fairlawn Tool, Inc., we perform manual and robotic welding as part of our services. This guide will provide an overview of the history of welding, how it works, different methods, materials used, and its use in an industrial context.
As you might imagine, welding has been around for quite some time. We can assume it existed in some form as far back as the Iron Age and the Bronze Age. There is evidence that the Egyptians learned to weld iron together, and we have found small gold boxes with pressure-welded lap joints from over 2,000 years ago.
However, the type of welding prevalent then and during the Middle Ages was a very rudimentary type of welding that typically involved hammering two pieces of metal together under heat until they joined. Conventional welding as we know it did not appear until the 19th century.
Welding history is a rich study of human ingenuity and spirit. After its invention, welding continued to evolve, bringing it to its modern-day form. Ancient welding looks a lot different than it does now. But each step in the welding timeline is an impressive leap in mechanical engineering. Here are some of the pivotal moments in welding history.
The welding process involves a variety of approaches and joint types. Techniques for welding can fall into one of two broad categories:
Welders use fusion welding in a wide range of applications for many industries. Pressure welding techniques tend to involve specialized methods that suit more niche applications. Types of joints formed in welding include:
Since welding involves multiple techniques and connections, it’s used in numerous applications.
This is a type of welding that uses a wire attached to an electrode current to join two pieces of metal together. A shielded gas along the electrode heats up the two metals you are fusing. You would use this type of welding in industrial situations when fusing stainless steel or aluminum. Gas metal arc welding requires a direct current power source with constant voltage.
This is similar to the above except you are using a tungsten electrode which heats the base metal to create a molten puddle. Because of this, you can create an autogenous weld where you simply join the two pieces together with the molten base metal as your joining material. This is a more complex welding process that an expert welder would use when you need a seamless join with a superior finish. Click here to learn more about the differences between MIG and TIG welding!
Sometimes just called arc welding, or occasionally “stick,” this is a very basic type of welding where the welder uses a stick with an electric current that creates an arc between the stick and the two metals you are joining. This is an effective method of welding steel or iron in construction, manufacturing, repair, and other industrial applications.
Flux-cored arc welding was created as an alternative to shielded metal arc welding or metal inert gas welding. However, instead of shielded gas to heat the metal, flux-cored arc welding uses a tubular wire filled with flux. Flux-cored arc welding is quite easy to learn and implement. It’s also cost-effective, but it does not always produce as high-quality or attractive a weld as other methods. For that reason, it’s usually used in construction projects where speed and flexibility are a priority over aesthetics.
Stitch welding is also known as intermittent welding. The reason for this name is that a stitch weld is not continuous along a joint. You’ll find gaps in stitch welding, which make it look like stitching. A stitch weld is not as durable as a seam weld because of these gaps. A stitch weld is most often used when the durability of a seam weld is not needed, or when you need to prevent heat distortion.
What we call seam welding is also known as continuous welding. Seam welds, like stitch welds, can be used to form fillet and butt joint welds – the only difference being that there are no gaps or spaces. Seam welds are far more durable than stitch welding because of the integrity of continuous seaming.
Most suitable welding techniques: SMAW, DC-TIG, MIG, FCAW, resistance
Iron-based metals such as steel and stainless steel tend to work with the highest number of techniques compared to others. Low-carbon mild steel acts as one of the most weldable metals available. Its composition includes low amounts of elements that can decrease the risk of a failed weld. Stainless steel has a more complex chemical composition, but it can also work with multiple techniques that account for oxidation.
Most suitable welding techniques: SMAW, AC-TIG, MIG
Grades of aluminum that fall in the 1XXX and 6XXX series can undergo select welding techniques. A 1XXX series aluminum does not require much extra effort during the welding process, making it simple to handle. Meanwhile, a welder can work with 6XXX aluminum if they use proper welding operations and filler material.
Most suitable welding technique: DC-TIG
When a welder protects titanium from oxidation, they can use it to achieve sturdy and long-lasting results. Titanium requires full coverage from a shielding gas to provide a high level of weld integrity.
Most suitable welding technique: SMAW
Cast iron poses more difficulty during the welding process than metals such as steel or aluminum. Its high carbon content requires careful preheating and heating methods that provide gradual temperature changes.
Most suitable welding technique: DC-TIG
Copper and brass have high corrosion resistance which makes them useful for a variety of welding applications. During the welding process, the welder needs to account for any alloys in the material that cause cracks or oxidation.
Most suitable welding technique: AC-TIG
A magnesium alloy has similar properties to aluminum. The magnesium in the alloy has a much lower melting point than oxides, making it critical to remove oxides before welding.
Welding has become a more streamlined process with each passing century. Welders of the past could have only dreamed about our modern-day advances. When your business needs medium or large-scale welding services, Fairlawn Tool is the company to call.
We provide high-quality automated welding and cutting, along with tube bending, CNC turret punching, and a wide array of other state-of-the-art metal fabrication services to meet your metalworking needs. To learn more about welding and other metal fabrication processes, or to find out how Fairlawn Tool can help your business, contact us today.
