Do you need to make metal grilles, fences, stairs or other types of welded parts for industrial production? It probably won’t be possible without the use of welding technology. The extensive technological background of various productions brings a range of welding methods, including MIG, MAG and TIG welding.
Want to know more about welding?
- What is Welding?
- Benefits of Welding
- Welding Options at Pro Tool Solutions
- Industries Using Welding
- Welding Preparation
- Arc Welding Methods
- Welding Methods by Direction and Position
- Post-Welding Inspection
- Welding Finishing
- Welding Safety
- Welding Cost
What is welding?
Welding is the process of joining two or more materials, usually metallic, to form a strong and permanent joint – a weld. This joint is created by the action of heat, pressure or a combination of both factors, while the structure of the material around the joint changes.
The goal of welding is to achieve a strong, permanent joint that can withstand mechanical and thermal stress. To do this, it is necessary to ensure suitable conditions so that inter-atomic bonds can form. The resulting product is called a weldment and can have various shapes and sizes – from small components to large structures.
Not only metals, but also other materials can be welded. For successful welding, it is important that the materials have suitable weldability – for example, in steel, the key factor is the carbon content (ideally up to 0.22%). Depending on the type of material and the required properties of the joint, various welding methods are used, whether manual, semi-automatic or fully automated.
Advantages of welding
Welding offers a number of advantages, including high strength, durability and tightness of the weld. This process enables efficient joining of materials, which leads to shorter production times and increased productivity. Compared to cast structures, welding can save up to 50% of material, which reduces production costs and the weight of the final product.
Another advantage is the possibility of refurbishing worn or damaged components, which makes welding a key process in the repair industry. Thanks to its flexibility, even complex design designs can be quickly implemented, which is especially advantageous in single-piece and small-series production.
Welding options
- Building structures: balconies, railings, metal stairs, designer stairs
- Fencing and entrance systems: gates, automatic sliding gates, swing gates, fences, grilles
- Interior and exterior elements: shelves, tables, railings, decorative metal elements
- Special weldments: supporting frames, console structures, industrial racks, containers, platforms
Industries using welding
Welding is a key technology in many industrial sectors. The main areas where it is applied include:
- Mechanical engineering – production of frames, chassis, heavy structures
- Automotive industry – bodies, chassis parts, exhaust systems
- Electrical engineering – switchboards, structural elements for electrical installations
- Energy and nuclear industry – welded pressure vessels, piping systems
- Armour industry – armor, military equipment, protective structures
- Healthcare – surgical instruments, stainless steel structures for laboratories
- Telecommunications – supporting structures for transmitters and antenna systems
- Art and design – metal sculptures, decorative elements, luxury furniture
Preparation for welding
Construction and technical preparation
Before welding, it is crucial to carefully assess the design and technical documentation of the welded element. It is important to:
- Evaluate the weldability of the base material
- Select the optimal welding technology
- Select the appropriate filler material
- Consider the possibilities of mass production and the overall economic aspect
At Pro Tool Solutions, we will be happy to prepare a complete design according to your requirements.
Mechanical preparation before welding
To achieve a high-quality weld, it is necessary to thoroughly remove impurities, i.e. to remove paint, oxides and rust from the weld surfaces. This is achieved by mechanical machining, for example by milling.
Heat treatment of welded joints
Heat treatment of welded joints Careful material preparation and correct technological procedures ensure that the weld achieves the best possible mechanical properties. The most common methods include:
- Normalizing annealing Ensures a uniform distribution of mechanical properties and is performed mainly for unalloyed steels and weldments of greater thickness.
- Tempering Improves the ductility and toughness of the weld, thereby increasing the weldment’s resistance to stress and giving it the required plastic properties.
- Soft annealing Softens the structure and helps to achieve the lowest possible hardness and good weldability in structural alloy steels.
- Preheating This involves heating the material to 100–400 °C (exceptionally up to 700 °C), which minimizes the temperature gradient during welding and reduces the risk of weld cracking.
Arc welding methods
Arc welding is a process in which two workpieces are melted at the joint using an electric arc and filler materials (in some methods, without them). There are several welding methods – the choice of the most suitable one depends on the properties of the base material, the type of joint, the welding position, the desired weld quality and production efficiency. Below are the welding methods that we implement at Pro Tool Solution. You can find laser welding here.
Manual arc welding with a covered electrode
ROS or SOE (method 111 according to ISO 4063)
This is the oldest, but still very widespread method of arc welding, valued for its versatility, use in all welding positions and easy availability of welding sources and filler material. Compared to semi-automatic and automatic methods, it has a lower melting performance, but it brings high weld quality and good mechanical properties.
During the process of covered electrode arc welding, the base material (weld pool) is melted together with a metal electrode covered with flux. The flux performs a metallurgical, gas-generating and ionizing function. During combustion, the electrode melts and the metal is deposited in the weld pool, creating a solid weld joint.
Arc welding with a consumable electrode in a protective atmosphere
This type of welding includes several methods that are based on the same principle, but differ in the use of different welding wires and shielding gases:
- Solid electrode in inert gas MIG (method 131 according to ISO 4063)
- Solid electrode in active gas MAG (method 135 according to ISO 4063)
MIG/MAG arc welding is one of the most commonly used welding processes, which is ideal for large-scale production thanks to the possibilities of automation and robotics. This type of welding can be performed in all positions, provides high deposition rates and offers a wide range of shielding gases and filler metals.
In MIG and MAG welding, an electric arc is created between a melting electrode and the base material (weld pool). Welding wires can be solid or tubular (filled with flux or metal powder). A shielding gas, either inert or active, protects the weld pool and the wire throughout the welding process.
Arc welding with a non-consumable electrode in an inert gas shielding atmosphere
TIG or WIG (methods group 141 according to ISO 4063)
This welding method requires high skill and experience from welders. If the entire technological process is followed correctly, very high quality welds are achieved. TIG welding is most often used in welding materials such as aluminum, magnesium, stainless steel and other metals with a high affinity for oxygen.
In TIG welding, an electric arc is created between a non-consumable tungsten electrode and the base material (weld pool) in a protective atmosphere of inert gas. During this process, the weld edges of the base material and the filler material are melted, which allows for the creation of a strong and high-quality weld.
Welding methods according to direction and position
Generally, welding can be performed in a variety of positions, however, some welding methods may have limited positioning options. Choosing the right welding position is crucial as it affects not only the quality of the weld, but also the productivity of the work and thus the costs of the welding process.
The direction and position of welding is usually determined by the design drawing. Positioners are usually used to ensure the correct mutual position of the welded parts.
Distribution of welding positions:
- Horizontal from above – (electrode vertical) – symbol PA
- Horizontal obliquely from above – (electrode below 45°) – symbol PB
- Horizontal on a vertical wall – (electrode horizontal) – symbol PC
- Obliquely overhead – (electrode below 45°, up) – symbol PD
- Overhead – (electrode vertical, up) – symbol PE
- Up on a vertical wall – (electrode horizontal) – symbol PF
- Down on a vertical wall – (electrode horizontal) – symbol PG
- Welding up to the top of the weld – symbol H-L045
- Welding from the top of the weld down – symbol J-L060
Division according to welding directions
- Forward – the electrode axis forms an obtuse angle with the welding direction (110–125°)
- Backward – the electrode axis forms an acute angle (60–70°) with the welding direction
Post-welding inspection
After the welding process is completed, it is necessary to perform dimensional and visual inspection of the welds, spatter removal, and also to perform tests to verify the mechanical properties of the welds, metallographic tests, and defectoscopic or technological tests. Depending on the requirements, heat treatment of the welds may also be performed.
Post-welding heat treatment:
- Normalizing annealing: This process is carried out at a temperature of 820–950 °C and aims to remove coarse grain structure and refine the microstructure of the weld joint. This achieves good ductility and toughness, which improves the mechanical properties of the welded material.
- Stress relieving annealing: This process is used on unalloyed steels at temperatures of 500–650°C. Its purpose is to minimize residual stresses in the material, which helps reduce the risk of dimensional changes during subsequent processing or when the weldment is used in real-world conditions.
- Tempering: This process is performed on alloy steels at a temperature of 650–750 °C and is aimed at removing internal stress and simultaneously softening the weld and the heat-affected zone. The result is better plastic and mechanical properties of the weld.
Processing of weldments
After welding is complete, further mechanical processing of the weldments may be required, usually using CNC machines. This step may include grinding, milling, turning or drilling, depending on the requirements of the product.
In order to minimize the costs of subsequent machining, it is very important to carefully check the accuracy and flatness of the weldments during the welding process. By correctly setting the welding parameters (temperature, speed, welding method, etc.), the required dimensions and properties of the weldment can be achieved. This not only reduces the time and costs of subsequent machining, but also improves the overall quality of the products.
Welding safety
Welding is a high-risk activity, so it is essential that occupational safety and health protection always come first. Only persons who are qualified and have a valid welder’s license are allowed to work, and all welding is carried out at Pro Tool Solutions under professional workshop supervision. Appropriate protective equipment is essential, such as sturdy shoes, protective clothing, leather gloves, an apron and a welding helmet.
We also place great emphasis on ensuring that the welding workplace meets not only safety regulations, but also hygiene and other legal standards. We ensure proper climatic conditions and exhaust of exhalations, which include harmful gases, vapors, smoke and dust. We also carry out regular maintenance of welding units and cleaning of nozzles to minimize complications during welding and ensure a safe and efficient working environment.
Welding price
The price of welding depends on several factors, such as the size and complexity of the weldment, the welding method used and the type of material. We offer both piece and series production, and we can flexibly respond to the needs of small and large companies. For an exact price, do not hesitate to contact us, we will be happy to prepare a tailor-made quote for you.
