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Joining rails in situ by liquid metal Induction welding: 74: IW Laser beam welding: 521 522: LBW Deep penetration, fast, high equipment cost Automotive industry Laser-hybrid welding: Combines LBW with GMAW in the same welding head, able to bridge gaps up to 2mm (between plates), previously not possible with LBW alone.
A thermite weld in progress. Exothermic welding, also known as exothermic bonding, thermite welding (TW), [1] and thermit welding, [1] is a welding process that employs molten metal to permanently join the conductors. The process employs an exothermic reaction of a thermite composition to heat the metal, and requires no external source of heat ...
The welder must also keep the filler metal in the hot outer flame zone when not adding it to the puddle to protect filler metal from oxidation. Do not let the welding flame burn off the filler metal. The metal will not wet into the base metal and will look like a series of cold dots on the base metal. There is very little strength in a cold weld.
Melted contact tip – when the contact tip actually contacts the base metal, fusing the two and melting the hole on the end. Irregular wire feed – typically a mechanical problem. Porosity – the gases (specifically those from the flux-core) don’t escape the welded area before the metal hardens, leaving holes in the welded metal.
Spray transfer GMAW. Gas metal arc welding (GMAW), sometimes referred to by its subtypes metal inert gas (MIG) and metal active gas (MAG) is a welding process in which an electric arc forms between a consumable MIG wire electrode and the workpiece metal(s), which heats the workpiece metal(s), causing them to fuse (melt and join).
Cold cracking—also known as delayed cracking, hydrogen-assisted cracking (HAC), or hydrogen-induced cracking (HIC)—is a type of defect that often develops after solidification of the weld when the temperature starts to drop from about 190 °C (375 °F); the phenomenon often arises at room temperature, and it can take up to 24 hours to appear even after complete cooling. [8]
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Cross-section of cold welding – before and after the weld. Cold welding or contact welding is a solid-state welding process in which joining takes place without fusion or heating at the interface of the two parts to be welded. Unlike in fusion welding, no liquid or molten phase is present in the joint.