Sheet metal welding is one of the most essential and practical fabrication processes used in various industries for creating a wide range of products. Welding systems are fundamental to metalwork, and learning them will be helpful for projects that involve architecture. This article provides complete information about sheet metal welding methods, including MIG and TIG techniques and comparing different welds. Architectural and construction materials such as aluminum sidings, modern ACM panels, and other rain-screen wall systems benefit from this fabricating process. If any individual considers getting into metalwork, welding sheet metal is the first and the most crucial industrial procedure they need to learn.
Methods and Techniques for Sheet Metal Welding
There are many techniques and methods obtainable that manufacturers apply for welding sheet metal. However, only two of these methods are very common, which are MIG welding and TIG welding. Both methods are easy to use and understand once welders utilize the proper procedure and precautions to the process. MIG and TIG methods are perfect for complex projects in which more straightforward techniques such as spot welding cannot undertake after learning the technique.
MIG Sheet Metal Welding Method
MIG sheet metal welding, also known as gas metal arc weld, is matched better with beginners as it is a prevalent fabrication method among new industrial workers. Before starting the process, the metal panel must be cleaned thoroughly for getting the smoothest surfaces and best results, especially for fabricating aluminum composite panels.
During the MIG welding process, the operator feeds a welding pool with a solid electrode through a welding gun to fuse the base substances. For protecting the collection from potential contamination, it is essential to use a shielding gas. This method is relatively straightforward if the relevant safety procedures and industrial advice for equipment preparation are correctly followed.
MIG is often chosen by hobby or DIY welders due to the belief in this method’s easy process. Additionally, the MIG technique is not labor-intensive compared to other sheet metal welding systems.
TIG welding is another method of sheet metal welding that is used frequently in the industry. This system is also known as gas tungsten arc welding and is practical for metal sheets with lower thickness, such as aluminum plates systems. The tungsten is used to create a small and defined weld, while the smallest electrode reduces the chances of contamination. For higher quality results, the arc length must be shorter.
TIG welding method utilizes heat developed by the electric arc between an electrode and a heat torch to fuse the sheet metals. It is essential to note that the gap between the heat-torch and the electrode must be considered small to ensure the heat allows the base substance for better fusion. For preventing both electrode and metal from oxidizing, the molten metal and the electric arc must be guarded by an inert gas. Due to the versatility of the TIG system, this method is practical for both beginner and intermediate welders.
Butt-welding is not considered a separate method, but it can accommodate both MIG and TIG methods. Whether TIG or MIG does it, this method can be essential for creating more sturdy, reliable metal products that can be utilized to develop any panel works, including ACM panels for architectural and construction projects. Due to the natural ability to connect two sections, butt-welding is an efficient way of fabricating sheet metals. It is easy to determine the weld’s properties, such as corrosion resistance level and the overall strength or durability of the product, by utilizing the butt-weld system.
When using butt-welding for sheet metals, it is crucial to be aware of many of its intricacies for ensuring the creation of the best pieces of metal products. Factors such as the thickness of the metal, width of the weld, gas type used for providing heat, and the wire’s type are crucial.
Sheet Metal Welding Problems
Even though it is impossible to stop the weld shrinkage of the metal thoroughly, steps can be taken to avoid metal warping in parts of products that require thin panels. Distortion is expected during the fabrication process as straight thin panels deform themselves and make jointing very difficult. It is essential not to weld more than enough for avoiding such problems, and the intermittent process can be helpful. Additionally, manufacturers balance welds at a natural axis and make fewer connections for minimizing shrinkage and warp properties of thin panels. Other mentionable problems are excessive heat-affected zones and melt-though.
It is incredibly challenging to avoid or fix all potential issues while ensuring the strength of the weld for the demanding application. However, there is a trade-off between the possible quality of welding and the quality of the equipment manufacturers manage to ensure that issues such as warping are avoided.