Introduction to Welding Technology
Welding technology is a process of fabrication wherein materials (thermoplastics and metals) are joined together. The materials to be joined are called workpieces. These workpieces will then be melted at the joining point. Afterward, a filler material is added to the joining points to form the weld pool. This weld pool then solidifies forming a sturdy joint between the two workpieces.
Welding is categorized into several types depending on the method by which the workpieces are joined. These types are
- Arc
- Gas
- Resistance
- Energy beam
- Solid-state welding
Each of these types utilizes a different method of joining the materials including the use of lasers, high-temperature flame, and electricity.
How Welding Technology Has Changed Over The Years
Welding technology traces its history back to the Industrial Revolution in 1750 AD. During this period, a process known as forge welding was used. In forge welding, the ends of the materials are simply heated until they are hot enough to be hammered together.
Then, a man by the name Elihu Thomson invented resistance welding in 1886. His invention initiated the modern welding age and paved the way for other inventors to come up with other methods of joining metals. In 1920, P.O. Nobel of the General Electric Company invented automatic welding which made use of bare electrode wire and direct current.
Recent improvements in welding technology include friction, inertia, and laser welding. These recent technologies are now being taught in several Welding Schools for advanced welding programs.
Welding Automation
Propelled by unprecedented improvements in technology, the welding process has now reached the age of automation. Automation has also enabled the industry to keep up with the ever-growing demand from other industries that utilize welding products. Not only does automation allow faster production, but it also enables a more accurate process of welding materials which is important for the transportation, marine, automotive and marine industries.
Welding robots are also on the rise. Although they require a huge amount of investment, these robots are able to do the job quicker. Also, laborers are kept from possible injuries and danger associated with the welding process.
Rail Welding Technologies
One of the applications of the welding process is rail welding. Rails are vital to the construction of railways, which in turn is also vital in any country’s transportation system. Flash-butt welding machines have now replaced the usual machines used in rail welding. The process involves the use of a high amount of electricity which is then used to produce heat in the rail ends. When the optimal temperature has been reached, only then will the rails be forged together.
These machines are fully automatic and are able to produce high quality, accurate and well-documented outputs. These state-of-the-art machines can also operate on varied and even extreme conditions. Thus, the machines have already been introduced worldwide.
Recent Advancements in Welding Technology
Below are the recent advancements in the welding industry and their description.
Laser Welding
Laser welding is used for processes that require high welding speed, low thermal distortion, and small weld seams. The laser is an acronym for Light Amplification by Stimulated Emission of Radiation. Thus, laser welding is actually a non-contact process. The laser serves as a source of concentrated energy which allows the material to heat faster. There are three types of welds that can be achieved through laser welding. These are conduction, conduction-penetration, and keyhole.
Laser welding works well in high alloy metals and can be used in open-air conditions. Unlike other methods, it does not require filler metals and is extremely accurate. Its application includes the production of medical equipment, electronics, and jewelry.
Friction stir welding
Friction stir welding is a process invented in Cambridge. It works through a rotating tool that presses into the materials’ joint and traverses along the weld path. The materials are welded through frictional heat generated by the rotating shoulder of the machine. The shoulder also contains the softened material which, in the process, becomes a solid phase weld.
Just like laser welding, it does not require filler materials and is used in joining components made of aluminum and other alloys. When components are restrained properly, friction stir welding results in a high quality and solid weld.
This process has several advantages over other welding methods. It produces output with little or no distortion, does not produce fume and radiation, and is also energy-efficient.
Advanced Arc Welding
Arc Welding is a process of fusing metals together. In this process, electric current is used to create an electric arc between the materials and an electrode. With the help of heat, the filler metal placed between the joints of the two materials is melted. When it cools and solidifies, a metallurgical bond is formed. Since the joint is a mixture of different metals, the weld potentially has the same strength as that of the component metals.
This process is used in welding non-ferrous metals. It is also widely applied in the manufacture of space vehicles and bicycles. Welds produced by this process are very resistant to corrosion and cracking even after a long period of time thus, it is suitable for crucial welding operations such as sealing of spent nuclear fuel canisters.
Career Opportunities in Welding
A career in welding does not only include joining materials, it may also include studying blueprints and
sketches, calculating dimensions of materials, inspecting structures and maintaining equipment and types of machinery. Since welding is something that is involved in almost every industry, welders are one of the few careers that are always in high demand. Aside from it being financially rewarding, there are also plenty of career opportunities for welders. Some even involve traveling like shipbuilding and repair, onboard ship maintenance, military support, pipeline installation, and underwater welding.
As for the financial rewards, highly skilled welders can earn as much as $100,000 a year.
Welding Programs at a Technical Institute
One way to start a career in welding is with certification from a welding technical institute. For example, the Loenbro Technical Institute offers 12 weeks of technical training that will arm students with the skills needed to become a professional welder. After finishing the 6/12 week courses, student’s are awarded a certificate to prove that you are now indeed a professional welder.
Like other programs of this type, their Welding Program includes Structural Welding, Pipe Welding, and Manufacturing Welding. Also, their classes start every two weeks so you can enroll anytime you like and start right away. There’s no need for a long wait to start your career in welding.