What is Fusion Welding? A Beginners Guide

Last Updated on Apr 17, 2022

If you are producing steel pipes metal structures, you might want to know more about Fusion Welding. This process gets commonly used in welding construction materials – however, it’s not so common for other materials. This article is about the fusion welding process, types, and use.

Welding joins two pieces of metal together by melting them at very high temperatures. The melted pieces are then fused, creating a permanent bond.

Welding provides many advantages for manufacturing and construction. With welding, you can create unique shapes, fasten objects with incredible strength, and repair broken parts permanently.

Fusion welding plastic sometimes referred to as hot air welding, is a common joining method. It works by melting the parts together with a heat gun or extruder and forming them into a joint when they are cooled.

What is Fusion Welding?

Fusion welding is a process in which two pieces of metal are joined together using heat and pressure. It is known as fusion because the two pieces of metal are melted together at high temperatures.

The melting point of the metals must reach 1,000 degrees Fahrenheit for the fusion to take place. There are several different methods of fusion welding. The method used depends on the type of material to be welded.

When To Use Fusion Welding?

Fusion welding can be used in a wide range of industries and applications. It is commonly used in construction projects, automotive manufacturing, shipbuilding, home appliances, and aerospace work.

Fusion welding is often used when the welds are subjected to high levels of stress or heat since it is such a strong weld with great tensile strength. It can also get used in low-temperature applications and corrosive substances.

Welding with this technique is easy to perform, making it so popular among many different industries and projects.

Types of fusion welding:

Arc welding

These are types of fusion welding that uses electric-arc to produce enough heat to liquefy metal and join two workpieces before it cools and solidifies. An arc welder uses a particular power-supply that produces direct current (DC), which flows from the negative terminal through the welder to the positive terminal through the circuit. A non-consumable or consumable electrode completes the circuit during the electrical transfer process.

Shielded metal arc welding (SMAW)

This is the simplest form of arc welding and uses an electrode that has flux built around it, which melts and provides gas protection during the weld. Stick electrodes can be used in all positions for general fabrication, pipeline work and iron or steel castings.

MIG (inert metal gas) and MAG (active metal gas) welding

This type of arc welding uses a continuous feed of wire electrodes and a shielding gas that protects the weld pool from contamination as it solidifies into a strong joint. MIG/MAG is often used in manufacturing industries and maintenance and repair work on vehicles and machinery.

Tungsten inert gas welding

This is basically arc welding technology that produces welds with tungsten conductor, which is non-consumable. A shielding gas protects the weld region from contamination from the atmosphere (usually argon), and normally filler metal is used. However, some welds, recognized as autogenous welds, basically do not entail it.

Gas welding

This is among the most common forms of welding. A torch is accustomed to heat the metal, and then a filler rod is used for welding the two pieces together. This form of welding is perfect for smaller projects that don’t require a fine finish.

Oxy-fuel welding

Oxy-fuel welding uses a filler rod to join two pieces together. The difference is that instead of an open flame, oxygen and fuel gasses are used to heat the metal. This type of welding works well on thicker metals that cannot join with gas welding. This type of welding can get done manually or with a machine. Depending on the project’s size and scale, it can be semi-automatic or automatic if a machine is used.

Resistance Welding

Resistance welding merges pieces of metal by using pressure and an electric current. The heat created by the current fuses the two pieces. Resistance welding is commonly used in the automotive industry, but it can also get used for other metalworking needs.

Resistance Spot Welding

In resistance spot welding, two metal sheets are placed together. The electrodes supply the electric current, which heats the metal and melts it together to create a welded seam. This type of welding is most often utilized in the automotive industry, where thin sheets are welded to make cars and other products.

Resistance seam welding

A wheel-shaped electrode rolls along a seam in this process, creating a weld. This method has three variations: lap seam welding, butt seam welding, and lap-butt seam welding.

The advantages of fusion welding

  1. Fusion welding can be used on various materials, including steel, aluminum and titanium.
  2. If the weld is done properly, the welded joint will often be as strong as or even stronger than the surrounding metal.
  3. Fusion welding can construct almost any shape, from a simple straight line to a complex curve. This allows for greater freedom in designing shapes and profiles.
  4. Many different fusion welding techniques can get used for different applications.
  5. Fusion welding is readily mechanized for automated production to minimize labor costs.

The disadvantages of fusion welding:

  1. Inadequate control of process parameters.
  2. It isn’t easy to weld large section thicknesses or thin plates.
  3. The depth of penetration is not uniform.
  4. Fusion welding requires more expertise than other joining techniques.
  5. High rates of heat input are involved, which may lead to distortion and shrinkage of joints

Fusion welding is a great method for creating excellent and strong welds, even for the less experienced welder. When used properly and on the right material, fusion welding’s benefits can allow you to create stronger welds without specialized equipment.

Questions from readers

Where is fusion welding used?

Fusion welding is used to construct high-rise buildings, pipelines and bridges. It is also used in the automobile industry to create cars, trucks and buses. Many small items fit together, such as bicycles and lawnmowers, are constructed with fusion welding. When two metals need to be joined permanently, fusion welding can be used.

How exactly does fusion welding work?

Fusion welding is a method of welding that involves the melting of the base metal at the joint and the joining together of the molten metals to form a weld. The process requires a certain amount of heat and pressure but not necessarily an external filler material. Fusion welding can be done using various techniques, but electric arc welding is the most common.