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Although a high initial investment is necessary, laser welding is being more widely employed by companies requiring large quantities of multi-point welds. This method employs robots, welding at speeds of up to 150 inches (3.8 m) per minute. Other processes–plasma arc, ultrasonic, and electron beam welding–are also available, but these methods are usually restricted to welding of particular materials with special design requirements. Gas metal arc welding, commonly called MIG (metal inert gas), creates an arc between a continuous wire filler metal (consumable electrode) and the sheet metal workpieces. Shielding gas protects both the molten metal and the arc from the atmosphere (Figure 1). This process is suitable for most metals and alloys. Gas tungsten arc welding, commonly called TIG (tungsten inert gas), produces an arc between a non consumable tungsten electrode and the sheet metal workpieces. Weld Joint Design. Several types of joints can be appropriate for welded sheet metal design, among them: butt, corner, edge, lap and T- joints. See Figure 3 for joints typically used for stampings and sheet metal fabrications. For joints made on thin sheet certain dimensional recommendations or limitations apply to single-pass fillet and groove welds. See Figures 5A-5E for details. Specifying Welds To avoid extra cost and excessive part distortion, the knowledgeable designer avoids over-specifying welds. In structural or dynamically loaded parts where strength and performance are important, the welding method is usually specified. In statically loaded parts like cabinets, the method is not as critical, because service loads are relatively small. With a tack weld, for instance, length of weld, size, spacing, location and frequency (number of welds) are typically specified, but not the method.
Tags : gas metal arc, electron beam welding, sheet metal fabrications, gas tungsten arc, tungsten electrode, gas metal arc welding, metals and alloys, tungsten inert gas, plasma arc, types of joints, metal inert gas, continuous wire, welding design, frequency number, corner edge
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