What Is Exothermic Welding? Exothermic welding, also known as exothermic bonding, thermite welding (TW), and thermit welding, is a welding process that employs molten metal to permanently join the conductors. Exothermic welding is a process used for joining similar metals, such as copper

Today we will learn about the types of welding flames used in gas welding. In my last post, we have discussed gas welding. In this welding process gases, fuels are burned and produce high-temperature flames which are further used to create a weld joint. The flame plays lead role to create we

Soldering is a common way to bond metal together. Aluminum can be soldered, but doing so can be much more difficult than with other metals. There are tips that can be applied to make soldering aluminum easier, including using the right blend of solder and removing aluminum oxide. Aluminum is

Nickel alloys are usually selected due to their excellent versatility, corrosion resistance, and performance under high temperatures. Not surprisingly, this makes nickel alloys a popular choice for use in extreme environments, particularly in aircraft turbines, steam turbines, nuclear power pla

Cast iron welding is possible but problematic due to the high carbon content. This carbon content is often 2-4%, which is about ten times that of most steels. During the welding process, this carbon migrates into the weld metal and/or the heat-affected zone, which leads to increased brittleness

What is Flux-Cored Arc Welding (FCAW or FCA) ? Flux-cored arc welding (FCAW or FCA) is a semi-automatic or automatic arc welding process. FCAW requires a continuously fed consumable tubular electrode containing a flux and a constant-voltage or, less commonly, a constant-current welding power

Stainless steel is a popular building material long heralded for its durability and substantial resistance to corrosion. Welding with this attractive metal does pose some unique challenges that need to be considered before launching into a project with stainless steel. Let’s take a closer l

What is Metal Plating? Metal Plating is a thin layer of metal that has been added to the outside of a material. It is a surface covering process by which a metal is deposited on a conductive surface. Plating has been done for hundreds of years; it is also critical for modern technology. P

Weld Quality Testing To ensure the satisfactory performance of a welded structure, the quality of the welds must be determined by adequate testing procedures. Therefore, they are proof tested under conditions that are the same or more severe than those encountered by the welded structures in

What is Chip formation? Chip formation is part of the process of cutting materials by mechanical means, using tools such as saws, lathes, and milling cutters. An understanding of the theory and engineering of this formation is an important part of the development of such machines and their c

What are Power Hammers? Power hammers are mechanical forging hammers that use an electrical power source or steam to raise the hammer preparatory to striking and accelerate it onto the work being hammered. Also called “Open Die Power Forging Hammers.” They have been used by blacksmiths, blad

What is Fit? In precision mechanics, fit refers to the degree of ‘looseness’ with which a shaft is inserted into a bored hole. This coupling is related to the tolerance or allowance of both parts’ dimensions. The shaft and the orifice must be of a similar diameter, otherwise, there will n

Without the right instruments, you will have an impossible task clamping workpieces down, making accurate measurements, and making precision cuts in hardy materials. One of your first challenges as a metal enthusiast is to find high-quality products that get the job done and suit your budget.

What is Silver Brazing? Silver brazing is a joining process whereby a non-ferrous filler metal, the alloy is heated to melting temperature (above 800°F) and distributed between two or more close-fitting parts by capillary attraction. Silver brazing uses filler metals and alloys such as silve

Welding is a process where two materials are fused together through heating, intermixing, and then cooling the materials and/or a filler to form a strong join. From arc welding to spot welding, new and used welding robots are typically used in welding processes where the weld required is repeti

Welding Magnesium is not something many welders I know are willing to attempt, even though it is possible. Magnesium tends to catch fire if heated too much and God help you put out a magnesium fire once it gets started. Magnesium has a flashpoint of 883 ˚F and burns at a temperature of 4,00

What Is Friction Welding? Friction welding is a solid-state welding technique that welds workpieces by generating heat through mechanical friction between workpieces in relative motion to one another, with the addition of a lateral force called “upset” to plastically displace and fuse the ma

What is Friction Stir Welding? Friction stir welding (FSW) is a solid-state joining process that uses frictional heat generated by a rotating tool to join two facing workpieces without melting the workpiece material. Heat is generated by friction between the rotating tool and the workpiece m

What is Extrusion? Extrusion is a process used to create objects of a fixed cross-sectional profile by pushing material through a die of the desired cross-section. Its two main advantages over other manufacturing processes are its ability to create very complex cross-sections; and to work ma

What is Electron Beam Welding? Electron-beam welding (EBW) is a fusion welding process in which a beam of high-velocity electrons is applied to two materials to be joined. The workpieces melt and flow together as the kinetic energy of the electrons is transformed into heat upon impact. EBW i