A Brief Overview of the Welding Techniques for Pipe Fabrication

27 September 2022

Pipe welding is utilised in a wide variety of markets, including but not limited to the construction industry, the oil and gas industry, the water industry, the fabrication market, and the power generating market. The process of manufacture in question is extremely specialised and vital. Fabricators must have a solid understanding of various welding procedures to produce goods in the most efficient and risk-free manner. The technique most appropriate for a given situation can be determined by several factors, including the application, the material, the temperature, the availability of filler material, and more.

The following will provide an overview of different ways of welding pipes, along with a comparison of how each approach differs from the others.

The Need to Weld Pipes

Welding is an efficient way of connecting pipes. It offers a wide variety of advantages to producers. Welding removes the requirement for fittings to be used between pipe sections, reducing the amount of work required and the overall fabrication cost. Because connectors create an additional barrier to fluid movement through a pipe, welded pipes have better flow than pipes with fittings. This part that has been simplified is also less likely to develop leaks or fractures. Because there is no need for disassembly or reassembly, repairs on welded pipes are often quite simple and may be completed in a short amount of time.

Gas Metal Arc Welding (GMAW)

Gas Methods, known as Metal Inert Gas (MIG) Welding and Metal Active Gas (MAG) Welding, are both examples of Metal Arc Welding (GMAW), which stands for Gas Metal Arc Welding. These heat the two portions of the metal pipe that will be welded together while applying a shielding gas along the electrode.

Since this procedure is carried out using semi- or fully-automatic equipment, it is superior to SMAW in terms of speed, adaptability, and overall productivity. In addition, it generates very little smoke and has a high deposition rate. There is also little danger of entrapping slag.

To generate high-quality welds, however, this method needs the welder to exert greater control over the welding process. A steady voltage and a direct power supply are necessities for its tools. Since the wind might scatter the welding gas, it cannot be done outside without any enclosures.

Shielded Metal Arc Welding (SMAW)

An electric arc is used in this process, which results in the electrode melting due to the heat produced by the arc. The molten substance is applied by hand to the portions of the metal pipe to be joined together before the process is complete. SMAW welding does not require using flux or shielding gas, which is the primary benefit of employing this technique. Additionally, SMAW welding is straightforward, portable, and requires a minimum amount of equipment. However, compared to other methods, the SMAW approach has a lower travel piece, which results in poorer overall productivity. In addition, welders are responsible for ensuring that their welding equipment is outfitted with the appropriate electrode for welded material.

Welders must consider arc stability, penetration depth, metal deposition rate, and positioning capabilities to produce a high-quality weld. The chemical makeup of the flux coating that is on the electrode has a significant impact on these aspects of the process.

Submerged Arc Welding

This method is semi-automatic and produces a welding arc that is not visible to the naked eye. During this process, an electric arc is created by connecting an electrode that is constantly being fed to the metal pipe. The arc is covered by a coating of powdered flux created during this process. When this flux melts, it creates a conduction path between the electrode and the metal, which safeguards the weld zone.

This method works exceptionally well for applications that need longitudinal and circumferential butt welds and for companies that have skilled welders on staff. This method is most frequently utilised in the production of line pipes and materials for pressure vessels.

Contact Sharp Welding Service today to know more about the pipe welding techniques we use in our service!