PART 149 What Is Fusion Welding

Fusion welding is a process that uses heat to join or fuse two or more materials
by heating them to melting point. The process may or may not require the use a
filler material. External application of pressure is not required for fusion welding
processes, except for resistance welding, where substantial contact pressure is
required during welding for sound joining.
Fusion Welding Processes

Fusion welding processes can be grouped according to the source of the heat, for
example, electric arc, gas, electrical resistance and high energy.
These processes include:
Arc Welding Processes - with the most common processes being:
Shielded Metal Arc Welding (SMAW), also known as manual metal arc welding (MMA
or MMAW), flux shielded arc welding or stick welding. Suitable for welding ferrous and
non-ferrous materials in all positions.
Metal Inert Gas Welding (MIG) and Metal Active Gas Welding (MAG), also known
as Gas Metal Arc Welding (GMAW). MIG and MAG welding are the most common arc
welding processes, in which an electric arc forms between a consumable wire electrode
and the workpiece leading them to melt and join. Both use a shielding gas to protect the
weld from airborne contaminants, or oxidation in the case of MIG welding.
Tungsten Inert Gas Welding (TIG), also known as Gas Tungsten Arc Welding
(GTAW). This arc process uses a non-consumable tungsten electrode to create the arc
between the electrode and the base plate. An inert shielding gas is used to protect from
oxidation or other atmospheric contamination. This process can be used autogenously
on thin parts, but will require the addition of a wire, rod, or consumable to be added for
thicker parts.
Plasma Arc Welding (PAW). This process uses an electric arc created between an
electrode and the torch nozzle. The electric arc ionises the gas (usually argon) in the
chamber creating what is called a 'plasma.' It is then forced through a fine bore copper
nozzle that constricts the arc and directs it to the workpiece, allowing the plasma arc to
be separated from the shielding gas (which is usually made from a mixture of argon and
hydrogen).
Submerged Arc Welding (SAW). This frequently-used arc welding process uses a
continuously-fed consumable electrode and a blanket of fusible flux which becomes
conductive when molten and provides a current path between the workpiece and the
electrode. The flux also prevents spatter and sparks while suppressing ultraviolet
radiation and fumes.
Flux Cored Arc Welding (FCAW). Developed as an alternative to SMAW, this process
uses a continuously fed consumable electrode with a flux and a constant voltage
or constant current power supply. Sometimes using a shielding gas this process can
also just use the flux to provide protection from the atmosphere.
Gas Welding Processes - the most common process being:
Oxy-Fuel Welding, also known as Oxyacetylene Welding but commonly called gas
welding, this process uses a hand-held torch or blow pipe and a mixture of oxygen
and acetylene which combusts to create a flame.
Resistance Welding Processes
Resistance Spot Welding. This fast welding process delivers heat between two
electrodes according to the material properties and thickness of the workpieces. The
welding current is concentrated to a small spot as the workpieces are simultaneously
clamped together.
Resistance Seam Welding. This variant of spot welding produces a series of

overlapping nuggets of a continuous joint by replacing conventional spot welding
electrodes with wheels which rotate as the workpieces are fed between them.
High Energy Welding Processes - with the main ones being:
Electron Beam Welding (EBW). This fusion process is performed under vacuum
conditions, using a beam of high velocity electrons to melt the workpieces as the
electrons generate heat upon penetration into the material. Welds are often deep and
narrow.
Laser Beam Welding (LBW). Often used in high volume applications, LBW uses a
laser beam to provide a concentrated heat source with high levels of accuracy which
can be used to join metal and polymers.

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PART 149 What Is Fusion Welding

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Fusion welding is a process that uses heat to join or fuse two or more materials

Fusion Welding Processes

These processes include:

Arc Welding Processes - with the most common processes being:

Gas Welding Processes - the most common process being:

Resistance Welding Processes

Resistance Seam Welding. This variant of spot welding produces a series of

High Energy Welding Processes - with the main ones being:

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