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Shielded Metal Arc Gas Metal Arc Gas Tungsten Arc Submerged Arc Plasma Arc Oxy-Fuel Laser Beam Miscellaneous
SMAW (cont)
Advantages
Low capital expense Portable Can weld in all positions Better shielding in windy locations than gas-shielded processes Can weld dirty metal
Disadvantages
Shielding not sufficient for reactive materials Low deposition rate (217 #/hr.) Possibility of slag inclusions, defects Stub losses (1-2 of every 14= 7%-14% waste
GMAW (cont)
Advantages
Higher deposition rate (1-30 #/hr.) higher current density than SMAW = better penetration Less operator skill required Higher efficiency All positions Most metals weldable
Disadvantages
Higher capital cost than SMAW Shielding gas required wire can bird-nest (Al wire in particular)
GTAW (cont)
Advantages
Suitable for ALL metals Suitable for very thin materials (i.e. coke cans) Allows very precise control of weld
Disadvantages
Typically very slow travel speeds Hi equipment costs 10-20% as fast as GMAW Higher skill required (OFW experience helpful)
SAW (cont)
Advantages
90%-99% Efficiency Very high deposition rate Excellent penetration Alloying can be controlled through flux composition flux may be recycled
Disadvantages
Flat and horizontal positions only Not suitable for thin material Uses roughly 1# of flux per pound of electrode
PAW (cont)
Advantages
Can weld VERY thin material -- 0.001 Higher welding speed, improved arc stability, higher heat content -> greater penetration All metals, all positions
Disadvantages
High capital cost High maintenance cost More complex welding procedures More operator training
Process Efficiencies
Submerged GTAW can approach 99% EBW range = 80-95% LBW varies widely: 2% - 98% depending on material reflectivity
Miscellaneous Processes
Ultrasonic Welding - USW Electron Beam Welding - EBW ElectroSlag Welding - ESW Explosion Welding - EXW Friction Stir Welding - FSW Flash Welding - FW And over a 100 other processes...