TIG (GTAW)
Tungsten inert gas or TIG, also known as gas tungsten arc welding uses a nonconsumable tungsten electrode with an inert or semi-inert gas but requires a separate material as a filler. TIG is a slow process that requires an experienced operator but the benefit is high quality welds that are very useful for welding thinner materials. TIG can be used on many different metals but is used mostly for welding stainless steel.
MIG (GMAW)
Metal inert gas or MIG welding, also known as gas metal arc welding, uses a continuous feed wire as an electrode and a mixture of inert or semi-inert gas to protect the weld area from enivronmental contamination. Welding speed is fast due to the the wire being contiuously fed. MIG can be used on both ferrous and non-ferrous metals.
Flux Core (FCAW)
Flux core arc welding is similar to MIG welding though the wire is a steel electrode filled with a powder. Using this cored wire allows for a faster feed with better penetration of the metal.
Stick (SMAW)
The most common and relatively inexpensive form of welding, stick welding also known as shielded metal arc welding (SMAW) or manual metal arc welding (MMA). Stick welding uses an electric current to create an arc between a consumable electrode made of a flux covered steel rod. Its the flux that protects the weld area from oxidation during the welding process by producing carbon dioxide. Additionaly the steel rod acts as the filler material. Generally limited to ferrous metals, with special electrodes it is possible to weld cast iron, copper, nickel and aluminum.
Spot
Resistance welding process involves passing current through two overlapping sheet metals. The spot of contact where the current is passed through creates a small pool of molten metal effectively welding the two together at that spot. Weld strength is much lower than other forms of welding.
Metal Forming
Precision Machining
Machining involves milling which is the precise removal of material from a work piece using a cutter that spins like a drill. The work piece is on a movable table that can move incrementally in multiple dimesions. Macining is generally a costly process due to the amount of time that complex parts can require. Speed is dependant on the material. The softer the material the faster the speed, while the harder the material requires a slower speed and smaller amounts removed. Tolerances are usually measured in the thousandths of an inch.
Roll Forming
Roll forming involves a set of stands and rolls used to create bends in a sheet of metal. The bends are created incrementally until the desired shape is formed. Excellent for creating long lengths in large quantities.
Bending
Bending is a process that creates a v shape or channel shape along the length of metal. This is accomplished using a press brake or other machine press that work with a punch and die that are placed along the straight axis of the machine. The punches and dies are replacable.
Shearing
Designed to make straight cuts in metal a shear can be mechanically operated or foot operated. The process of shearing sheet metal is accomplished with a movable blade that comes down across a fixed blade attached to the shear table to cut the material.
Drilling
Drilling is any cutting process that involves a drill bit used to create or enlarge a hole in any material. Cuts are created by applying pressure and the rotational force of the drill bit.
Punching
Punches made from tool steel of various sizes and shapes are used to create holes in metal. The punches are placed in a hydraulic press that rams the punch through the metal into a corosponding die under the metal sheet.
