Top Facts for Novices to Note About Sheet Metal Welding
Sheet metal design requires several fabrication processes to produce final products for clients. Notably, welding is a cost-effective and straightforward method of joining sheet metal. Novices should know that a good sheet metal welding system should help reduce costs, enhance efficiency and simplify the production process. Here are a few facts for novices to note about sheet metal welding.
Types of Base Materials for Welding
Different types of welding, such as TIG and MIG, are known to weld almost all types of base materials, both ferrous and nonferrous. Common types of ferrous metals that can be welded include tungsten carbide, steel and iron. Nonferrous metals include aluminium and copper. TIG welding is recommended when you want to weld dissimilar base materials such as steel to copper alloys. However, when dealing with different materials, ensure that you consider various factors that can affect the final welds, such as welding technique, corrosion, metal conductivity and expansion rates, among others.
Weld Strength
Ideally, any weld should be strong enough to hold two pieces of sheet metal together. However, for thin sheet metal, special considerations and methods are needed to increase weld strength while improving safety. Welders are advised to consult metal-forming vendors to ascertain the best welding technique. Also, the strength of the base metal determines the weld strength.
Impurities
During sheet metal welding, contaminants from gases such as carbon, oxygen and nitrogen can lead to defects. Some of the common defects include slag inclusions, porosity, oxides and blowholes. During welding, care should be taken, especially when manipulating a torch flame and rod to reduce defects caused by the formation of iron oxides. Such oxides can cause a finished sheet metal product to become brittle or porous.
So how can impurities be minimised during welding? Several factors should come into play to minimise sheet metal defects, such as regulating the melting rate of a welding rod or sheet metal. Further, it is essential to consider the welding speed, puddle size and flame adjustment to reduce impurities during the welding process.
Weld Distortions
Sheet metal welding is prone to distortion because of the high temperature associated with a welding process. A simple rule of thumb is that the more you weld sheet metal, the more distortions arise. Distortions can only be reduced but not avoided unless you want to incur prohibitive costs. Novice fabricators can achieve minimal distortions by improving on their welding techniques. For example, avoid welding configurations that cause more distortions in sheet metal, such as welding all four corners of an enclosure or cover. Besides, reduce deformities by use of heat sinks or through clamping of sheet metal.
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