What is Arc Welding? Discover the Process, Types, and Tips

Arc welding is a metal joining process that uses electricity to create heat. It joins materials together by melting and fusing them.

If you thought about getting into welding, you might want to ask yourself, what is arc welding? Understanding this process is crucial since it’s widely used in construction, manufacturing, and repairs. I’ve seen firsthand how a solid weld can hold two materials together, making structures safer and helping projects succeed.

In this guide, you’ll discover what arc welding is, how it works, types of arc welding, steps for performing it, factors affecting the weld, common issues, aftercare tips, typical uses, and other methods to achieve results similar to arc welding. Get ready to learn the ins and outs of what is electric arc welding and much more.

What is Arc Welding?

Arc welding is a process that joins metals using an electric arc. This method generates intense heat, melting the metal edges together. It’s widely used in construction and automotive industries for strong, durable seams.

How Does Arc Welding Work?

Arc welding is a process where an electric arc generates heat to melt the materials being joined. This technique typically uses a power supply that provides a continuous current, usually measured in amperes (A). The electrical arc reaches temperatures of about 3,600°F (2,000°C), hot enough to melt steel. In fact, arc welding can produce joint strengths up to 90% of the base metal’s strength.

This method includes several variations, like Gas Tungsten Arc Welding (GTAW) and Submerged Arc Welding (SAW). Each type has its specifics and applications but shares the same fundamental principle of creating an arc to weld.

I once tackled a project using electric arc welding to fix heavy machinery parts. The heat from that electric arc was immense; it was amazing to see how easily it melted metal together. It’s fascinating how such a simple concept can create such strong and durable joints.

Types Of Arc Welding

What are the types of arc welding?

• MIG Welding

  MIG (Metal Inert Gas) welding uses a continuous wire feed as an electrode. An electric arc forms between the wire and the metal, melting both to create a joint. To perform MIG welding, you need a MIG machine, shielding gas (Usually Argon or Carbon Dioxide), and filler wire. Connect the wire to the electrode holder and start welding!

• TIG Welding

  TIG (Tungsten Inert Gas) welding employs a non-consumable tungsten electrode. This method creates an arc between the tungsten and the workpiece, allowing precise control of the weld. To do TIG welding, set up your machine, choose the right tungsten electrode, and manually add a filler rod to the molten pool as needed.

• Stick Welding

  Stick welding uses a consumable electrode coated in flux to create the arc. The arc melts the electrode and the base metal together, forming a strong bond. To start stick welding, select the correct electrode, adjust the amperage on your machine, and strike the arc against the metal while moving smoothly.

• Submerged Arc Welding

  Submerged arc welding involves drawing a wire electrode through a bed of granular flux, which protects the weld pool from contaminants. To perform this method, set up a welding machine that can feed the wire into the flux bed and monitor the weld for consistency.

• Flux-cored Arc Welding

  Flux-cored arc welding (FCAW) uses a tubular wire filled with flux to generate a shielding gas during welding. This protects the arc and reinforces the joint. To engage in FCAW, you need a flux-cored wire, a welding machine, and a proper setup for feeding the wire into the weld area.

That covers the different types of arc welding. Let’s now take a look at electrode specifications for arc welding.

Arc Welding Electrode Specifications

Understanding electrodes is crucial in arc welding. This section dives into the different types of electrodes used in the process, along with their specifications and applications.

Electrode Type	Classification	Common Applications	Amperage Range (A)	Diameter Range (inches)
E6010	Cellulosic	Root pass, welds with a significant amount of workpiece movement	40-110	1/16 to 5/32
E6011	Universal	All-purpose; works on dirty surfaces	40-130	3/32 to 1/8
E7018	Low Hydrogen	Structural steel, strong and ductile welds	70-180	1/8 to 1/4
E7024	High Deposition Rate	Flat horizontal or overhead positions	175-300	1/8 to 5/32
E309	Stainless Steel	Welding dissimilar metals	50-150	3/32 to 1/8

Knowing these specifications helps you choose the right electrode for your project, impacting the weld’s quality and strength. So, which electrode will you pick for your next job?

We have now covered arc welding electrode specifications. Next, we will examine the factors influencing arc welding.

Factors Affecting Arc Welding

What factors influence techniques used in arc welding?

• Material Thickness

  Thicker materials require more heat for a solid weld. For example, you’ll need about 25 to 30 amps (28 to 36 V) per millimeter (Mm) of thickness for good penetration.

• Electrode Type

  Different electrodes suit various metals and processes. Choosing the right one improves fusion; for instance, E6010 for DC (Direct Current) and E7018 for AC (Alternating Current) make a significant difference.

• Welding Speed

  Welding too fast can create weak, shallow edges, while going too slow can lead to excessive heat. The ideal speed is 6 to 12 inches per minute (15 to 30 Cm/min) for most applications.

• Gas Flow Rate

  The right flow rate keeps unwanted gases away. Typically, you’ll want 10 to 20 cubic feet per hour (Cfh) of argon to ensure a clean arc.

• Surface Cleanliness

  The surface must be clean to avoid impurities that can ruin the weld. Dirt and rust can decrease weld quality by 40% or more if not removed.

We covered the factors influencing arc welding here. Next, we will cover the steps for performing arc welding.

Steps for Performing Arc Welding

Here are the essential steps for arc welding.

1. Prepare the Workspace

   Clear clutter from your welding area. Aim for a safe, organized space with at least 25 ft² (2.3 M²) of open floor, free of flammable materials. A well-lit area helps visibility while working. A portable workbench keeps your tools and supplies within reach.

2. Set Up the Equipment

   Connect your welding machine to a power source, ensuring it’s set to the correct voltage. For arc welding, 20 to 25 volts (V) is usually ideal. Securely attach the ground clamp to your workpiece to establish a proper electric circuit. Double-check your connections; loose ones can cause inefficient welding.

3. Select the Electrode

   Choose the right electrode based on the materials being welded. For steel, I typically use an E7018 electrode; it’s dependable and creates a strong bond. Diameters usually range from 1/16 in (1.6 Mm) to 5/32 in (4 Mm), with smaller sizes for thin materials. Store electrodes in a dry place, as moisture can affect performance.

4. Prepare the Base Metals

   Thoroughly clean your metal surfaces with a grinder or wire brush. Removing rust, paint, and grease improves weld quality. For thicker metals, beveling the edges enhances penetration. An angle of 45 degrees works well for creating a V groove in the joint.

5. Conduct the Welding Process

   Start welding by maintaining a steady pace while moving the electrode across the joint. Hold the electrode at a 15 to 20-degree angle to control the arc length, ideally between 1/8 in (3.2 Mm) and 1/4 in (6.4 Mm). Monitor the molten puddle; it should be the size of a quarter for an even weld. If the puddle gets too large, you may be traveling too slowly or applying too much amperage.

6. Complete the Weld and Clean Up

   After finishing the weld, let it cool naturally, which usually takes 10 to 15 minutes, depending on thickness. Use a wire brush or grinder to remove slag from the surface, as this step is crucial for weld strength. Finally, tidy up your workspace and store your equipment—keeping things organized pays off!

That covers the steps for performing arc welding. Let’s now take a look at common issues encountered in arc welding.

Common Issues in Arc Welding

Let’s examine the specific technical problems related to arc welding.

• Porosity

  Arc welding can create pores in the weld due to trapped gas. Look for tiny bubbles or irregular surfaces. Resolve it by cleaning the metal or controlling gas flow.

• Inconsistent Arc Length

  Maintaining a steady arc length in arc welding is crucial. You can tell it’s off if the spark sounds uneven. To fix this, keep the electrode at the proper distance and avoid rapid movements.

• Cracking

  Cracks may form in arc welding if the weld cools too quickly or if the base metal contains high levels of impurities. Look for visible cracks. To fix this, preheat the metal or adjust your filler material selection.

• Undercutting

  In arc welding, undercutting appears as a groove at the weld root. Check the edges of your welds. Avoid it by adjusting your travel speed and arc intensity.

• Overheating

  Arc welding can lead to overheating of the base material, resulting in discoloration and metal distortion. The solution? Use proper heat settings and take breaks.

Typical Uses Of Arc Welding

People use arc welding for heavy-duty applications. Its many uses include:

• Structural Steel Fabrication: Common in bridges and skyscrapers, it ensures lasting strength. It’s popular for joining thick materials effectively.
• Mining Equipment Repairs: Ideal for fixing large machinery like excavators, as the arc’s intensity handles tough outdoor conditions well.
• Nuclear Industry Components: Essential for welding pipes and reactor vessels, it maintains high integrity under radiation, making it a preferred method.
• Shipbuilding: Used to construct hulls and other structures, arc welding provides strong joints that resist harsh sea conditions.

Other Options for Achieving Similar Results As Arc Welding

When you need alternatives to traditional methods, consider Gas Tungsten Arc Welding (GTAW) or Electric Resistance Welding (ERW). These methods are preferred for their precision in delicate projects, like in aerospace or automotive applications. I’ve found tools like the Miller Dynasty 200 or Lincoln Electric’s PRO MIG 180 offer great results in these scenarios.

Another option is Submerged Arc Welding (SAW), especially for large-scale projects, such as shipbuilding. It uses a shield of flux for better protection against contaminants. From my experience, it can significantly enhance bead quality and reduce cleanup time, making it a favorite among professionals.

Frequently Asked Questions (FAQs)

Here are some questions I typically get asked about arc welding.

What Are the 4 Types Of Arc Welding?

There are four main types of arc welding: Shielded Metal Arc Welding (SMAW), Gas Metal Arc Welding (GMAW), Gas Tungsten Arc Welding (GTAW), and Submerged Arc Welding (SAW). Each type serves specific applications, with SMAW using 25-40 amperes for most tasks. SAW is efficient for thicker materials, often running at 1000 amperes.

Is Arc Welding the Same As MIG?

No, arc welding isn’t the same as MIG welding. MIG welding is a type of Gas Metal Arc Welding (GMAW) that uses a continuous feed of solid wire. Arc welding can refer to various processes, including SMAW and GTAW, each with distinct techniques and uses.

Is Arc and Stick Welding the Same?

Yes, arc welding and stick welding often refer to the same process, namely Shielded Metal Arc Welding (SMAW). This method uses a consumable electrode, typically made of stainless steel, that burns and produces an electric arc. SMAW is popular for its versatility in various materials.

What is Arc Welding Best for?

Arc welding is best for joining metals, particularly where strength is critical. It’s effective on ferrous metals like steel and can be used on materials up to 25 mm (1 in) thick. Industries widely use it for construction, automotive, and repair applications due to its strength and durability.

How Does Arc Welding Work?

Arc welding works by creating a controlled electric arc between the electrode and the workpiece. This arc generates temperatures up to 6,500°F (3,600°C), melting both the electrode and the base metal. The molten metal then fuses as it cools, forming a strong joint.

What is Submerged Arc Welding?

Submerged arc welding (SAW) is a specialized arc welding process where an arc is formed between a continuously fed electrode and the workpiece. It uses a granular flux to cover the weld pool, shielding it from contaminants and increasing penetration rates by up to 75% compared to other methods.

Conclusion

I’m glad we could cover this together. We discussed what arc welding is, how it works, different types like tungsten arc and submerged arc, and steps for performing it. We also touched on factors affecting the process, common issues, aftercare, inspection, and typical uses of arc welding.

So, what is arc welding? Simply put, it’s a method where electrical arcs create heat to melt and join metal parts together. Remember, variables like voltage and amperage can influence the weld quality, which we’ve seen in our discussion on types and factors. Whether you’re into a quick metal fix or a professional job, understanding how arc welding works makes a big difference.

References

• American Welding Society. (2020). AWS Welding Handbook: Welding Science and Technology (Vol. 1). Miami, FL: AWS.
• American Welding Society. (2020). AWS C5.6: Recommended Practices for Gas Metal Arc Welding. Miami, FL: AWS.
• American Welding Society. (2021). AWS SENSE: Guidelines for Entry-Level Welders. Miami, FL: AWS.