Metal welding services are among the most needed metal fabrication systems in almost every industry, including outer space, ocean, construction, transportation, etc. So, the demand for learning this metal fabrication method grows day by day. If you are one of the talented people who want to learn to weld and seek a place to get the knowledge, you should read this article. This complete metal welding guide will teach you everything you need to know about the process, equipment, and applications. This guide is perfect for DIY welders and people interested in pursuing these metal fabrication services as a career.

What are Metal Welding Services?

Every metal welding guide should explain the process and how it works. Many manufacturers and professional metal fabricators in Canada use metal welding to create industrial products for different applications.

Metal welders create products by joining two pieces of metal with other molten material or melting the metal surface and then joining them. Although this metal fabrication method sounds simple, there are many techniques you can use to complete the job.

The most common method or class is metal arc welding which is the best for starters who want to learn this practical metal fabrication system.

Arc metal welding is a primary category in the metal fabrication industry, and it encompasses many methods, including:

  • Stick Welding
  • Metal Inert Gas (MIG) Welding
  • Tungsten Inert Gas (TIG) Welding

In this complete metal welding guide, you will learn the basics of all methods above.

stick metal welding guide
Stick Metal Welding System

Stick Metal Welding Guide

Stick metal welding systems are also known as shielded metal arc welding or SMAW. They are among the most traditional and commonly used techniques in the industry due to their simplicity.

Unlike MIG and TIG metal welding systems, stick welding is suitable for outdoor applications since it is not affected by the wind.

Stick Metal Welding Basics

The stick metal welding process creates an electric arc between the metal electrode and the workpiece. The electrode current melts the electrode and forms a weld pool on the workpiece.

Welding electrodes have flux coating, which guards the weld pool against contamination or corrosion after it is melted. In MIG and TIG methods, a shielding gas is used to protect.

The electrode’s flux melts and forms a slag layer over the bead, and it should be chipped off once the weld is cooled down.

Advantages of Stick Welding Method

A complete metal welding guide is not completed without the advantages and disadvantages of each method. Here are the primary benefits of the Stick Metal Welding method.

  • Stick welding is portable.
  • You can use this method on thick metal pieces.
  • A Stick metal system is not heavy, and you can easily transport it to other locations.
  • You don’t need a wire feeder or any other equipment.
  • If you want to practice a metal welding guide or do the job in outdoor areas, the stick method is the best.
  • Learning stick metal welding is more straightforward than the TIG method.
  • You can perform this metal fabrication system on every metal surface.

Stick Metal Welding System’s Disadvantages

Here is the list of the main disadvantages of the Stick metal welding system that you need to know.

  • Although it is easy to learn stick welding, this metal fabrication method requires greater skill levels for professional jobs than MIG since you need to keep the electrode at a certain distance from your workpiece.
  • The Stick metal welding method generates a lot of spatter and slag, creating some challenges for you.
  • Your work efficiency may decrease since you will need to clean the slag.
  • Stick welds are not as high-quality as TIG welds.

Metal Welding Guide for Stick Setup

Setting up your stick welder is an easy task since the system itself is simple compared to other welding methods.

Remember that the polarity setting is influenced by the electrode type you use for the project. So, make sure to double-check whether DC+/DC-/AC is involved.

We recommend beginning with a 6013-electrode using DCEN on a steel metal sheet with a considerable thickness for practicing this metal guide.

Apply Your First Weld With Stick Method

Set up your welding according to the manual, and double-check to see if all settings are accurate.

After you set up the welding system, you can position some scrap metal plates or pieces with a suitable thickness to create your first butt weld.

Since you will need experience creating high-quality welds with the Stick metal welding method, we recommend you practice this method on scrap steel pieces and then go for real projects.

The most challenging part of learning this metal fabrication method is a striking electrode to create an arc. You can master this stage with constant practice.

mig metal welding system
MIG Metal Welding Systems

MIG Metal Welding Guide

MIG metal welding is another metal fabrication method that is also known as Gas Metal Arc Welding or GMAW.

MIG is one of the most popular metal welding systems since it is the easiest method for newbies. It is perfect for home repair projects and welding auto parts. Additionally, manufacturers use this welding method to produce various building materials such as decorative metal fences.

This method is generally used for joining low-alloy steels. An arc is generated between the workpiece and the wire electrode in the MIG metal welding system, which melts the electrode and creates the weld joint.

You can feed the wire electrode with an electrode gun quickly and accurately. The electrode gun is linked to the welding machine. Additionally, the electrode gun releases-controlled amounts of shield gas to protect the weld pool from corrosion.

The Advantages of MIG Metal Welding System

Like other metal welding systems, MIG welding offers various benefits for the welders, which are:

  • Productivity: The primary benefit of the MIG metal welding system is its high productivity and low clean-up requirements. You do not need to replace electrodes in this system. So, MIG is a more productive welding method than the Stick system.
  • Low Costs: You can purchase a good MIG welding machine for less than $480. There are various MIG machines that you can choose for your job. Then, spend a small amount on wire electrodes and gas to start this welding method.
  • Simple Learning and Installing: Anyone can start learning MIG welding techniques since it is easier than other methods. So, MIG is the best choice for DIYers or home welders. You can set up your system in a few minutes and start your fabrication.
  • High Quality: The result of the MIG welding system is clean and reliable. The welder does not have to chip away slag, and the weld is very accurate since welders use both hands to control the welding gun. The MIG system allows you to change the feed rate easily by adjusting the voltage offering a flexible and versatile process.

Metal Welding Guide for MIG Techniques

There are two techniques that you can use for MIG metal welding. Here is the metal welding guide for MIG methods.

  • Forehand Technique
  • Backhand Technique

You need to push the weld using your forehand in forehand. You will have to place the welding gun at a 10-degree angle for the best results. Remember that the electrode should face the direction you want to weld.

In the backhand or pulling technique, you will move the weld gun toward your body with your backhand. You should use the same angle as the forehand technique.

TIG metal welding guide
TIG Metal Welding Systems

TIG Metal Welding Step by Step

The last method of this metal welding guide is tungsten inert gas welding which is called the TIG. In this method, the welders use a tungsten electrode to create an arc that heats the workpiece to its melting point.

You should direct the shielding gas at the weld pool to keep it safe from environmental threats. The TIG metal welding system is known as the highest quality method.

However, since you will have to hold the TIG torch with one hand and feed the filler substance with your other hand, it could be the most challenging method for you.

The tungsten electrodes used in the TIG metal welding method are non-consumable. Additionally, this is a versatile welding method since it is perfect for various metals, including stainless steel, nickel, aluminum, copper, magnesium, gold, etc. Most manufacturers use TIG welding for modern materials such as an aluminum composite panel.

Since this welding system does not rely on flux substances, there will be no danger of corrosion created from the flux. Additionally, there will be no slag which will offer you an efficient working process.

If your project requires a perfect appearance, it is better to use the TIG metal welding method to create clean welds.

Metal Welding Guide for TIG Techniques

The TIG welding system can be done in two modes:

  • Automatic
  • Semi-Automatic

In the semi-automatic method, you will configure gas flow and the current setting and then control the filler rod and the electrode.

In the automatic TIG welding system, you will configure the arc length, flow rate, filler rod position, and travel speed.

How to do the TIG Welding?

First, you need to turn on the gas flow from the cylinder. You can regulate the gas flow by the valve which is located on the torch. Hold the welding torch above the welding area and remember not to touch it.

Press the foot pedal and develop the arc between the workpiece and the tungsten electrode. With this, you will melt the filler substance and create the weld pool on the metal piece. After the weld pool is solidified, the weld joint will be created.