The Four Different Types of Welding for Hydraulic Systems
The methods involved in the creation of hydraulic equipment are complex, coming together to complete an intricate set of machinery that can do incredible things. One of the methods that contribute to the creation of hydraulic systems is welding. While welding can be a daunting ability to learn, it can be broken down into four main types. Read on to explore the world of the main welding methods that contribute to the formation of our hydraulic systems.
MIG Welding
Metal Inert Gas Welding
MIG welding is one of the easier welding methods to master, making it more common for beginners to utilize. H.E. Kennedy invented MIG welding in 1948, and, despite more sophisticated equipment having developed, the basic method is still the same.
A metal wire and high-voltage circuit is fed through the nozzle of the gun in order to send electricity between the two, creating electrical arcing. The electricity heats to a temperature of 3000 degrees Celsius or higher, enabling it to melt and adhere metal together.
While you don’t technically need a protective gas to MIG weld, it is recommended in order to keep contaminants like hydrogen and nitrogen from the surrounding atmosphere out of your welded projects. A shielding gas will prevent those contaminants from weakening the structure of your metal. Without it, your project is subject to structural damage, like porosity and destabilization. Gases that are most commonly used in MIG welding are helium and argon, to prevent a reaction with any present oxygen or nitrogen.
MIG welding can be used on a variety of projects, anywhere from major construction to home improvement projects. While it is beginner-friendly, it is a very effective method that experts also use effectively.
Advantages
- Versatility
- Simplicity
- Speed
- High quality
- Clean method
Disadvantages
- Cost
- Shielding gas
- Limitations in Positions
- Cannot be used on thicker metals
- Should not be performed outside
TIG Welding
Tungsten Inert Gas Welding
TIG Welding was invented by Russell Meredith in 1941 in order to weld aluminum and magnesium alloys, which wasn’t yet possible with other welding methods.
The TIG method uses a non-consumable tungsten electrode, whereas MIG welding uses a consumable electrode along with its continuously fed wire. While it is a more difficult method of welding to master, TIG welding can also produce stronger holds. TIG welding also offers a high degree of control and precision for a project, so it is optimal for a clean weld with minimal splatter.
Another difference between TIG welding and MIG welding is that, while MIG welding does not technically require a protective gas, you must use a gas when using the TIG welding method.
Because of the specialties of TIG welding, it is more costly and difficult to master than MIG welding.
Industries that utilize TIG welding include the automotive industry, the fabrication industry (the manufacturing of raw materials, and even the aerospace industry. Since the materials used in these industries require high quality, TIG welding is the optimal method for many of their projects.
Advantages
- Precision
- Aesthetically appealing
- Produces strong welds
- Can be used for a wider variety of metals
- Minimal splatter
Disadvantages
- Cost
- Difficult to master
- Time
- Must have a protective gas
- Thicker materials are harder to use
Stick Welding
Shielded Metal Arc Welding
The invention of Stick welding precedes MIG and TIG welding by nearly four decades. Oscar Kjellberg invented the method sometime before 1910, creating the first coated welding electrode. By dipping a bare wire into a mix of carbonates and silicates, the materials coat the wire and create a barrier and binder.
Metallurgy has advanced greatly since the early 1900s, providing better materials to stick weld. Much like MIG welding, however, the basic process has remained much the same. A core wire is coated in a barrier and conducts electricity into an arc that is then used to melt the metal.
While Stick welding is more difficult to master than others, the materials and machinery are more simplistic. So a welder will need to develop more skill and ability to graduate to using Stick welding, but will not need to spend a great deal more money in acquiring the tools to do so.
Advantages
- Simple equipment
- Portable
- Versatile
- Less expensive
- Contaminant tolerant
Disadvantages
- Must be highly skilled
- Consumable rod that must be changed out
- Current variations
- Should not be used on thin materials
- Slow speed
Friction Welding
Solid-State Welding Process
As the name suggests, Friction welding utilizes the heat of friction to weld metals together. Two pieces of metal are made to rub together at high frequencies, producing the heat needed. The history of Friction welding is more contentious than the others we have talked about, with the invention of it being able to be traced back to several sources around the same time period.
In which one element is rotated at a high speed and pressed to the stationary piece to adhere.
In which one element is moved along a linear line at a high speed in order to adhere to a stationary piece.
In which two stationary elements are placed together and a high speed rotating tool moves along the seam.
Friction welding is helpful with circular materials, as well as smaller devices. Because it can weld different types of metal to one another, it can be helpful with larger projects that stem many elements. It is particularly common to find in the electrical industry, as wiring can be combined of several types of wires.
Advantages
- Minimal defects
- Speed
- Efficient
- No external heat
- Can be used on dissimilar metals
Disadvantages
- Expensive equipment
- Slow
- Difficult
- Limited shapes of materials
- Cannot be used on non-forgeable materials
When crafting hydraulics equipment, All Phase has mastered welding styles to create the best machinery possible. Shop our products with confidence that you will find the best hydraulic equipment for your needs.