While the metal stamping process can produce a completed or finished part, there are times that welding services are required to join metals to create subassemblies or final assemblies. Welding offers a cohesive bond that gives strength, durability, and longevity to the metal components. Welding is said to be both a skill and an art form because of the challenges of achieving sufficient weld strength for the application while avoiding burn-through, warping, or excessive heat-affected zones.

At Die-Matic Corporation, we offer MIG, TIG, resistance, and Spot welding. Below we explain each type of welding.

MIG Welding

MIG Welding, or Gas Metal Arc Welding (GMAW), joins metal using a continuous consumable solid wire electrode fed through a welding gun at a predetermined speed. The electrically charged contact tip in the gun transfers current to the wire creating an arc between the wire and base metal. The arc produced enough heat to melt the wire and base metal, generating a weld pool, or weld puddle, which fuses the two pieces together. A shielding gas safeguards the weld pool from environmental contaminants, which could introduce defects.

MIG welders can cater to both thin and thick metals without the threat of burn-through or subpar weld quality because the power output range can be regulated. MIG welding can be used on various metals, such as carbon steel, stainless steel, and aluminum. However, one limitation is the creation of spatter during the welding process, making it most suitable for projects where weld aesthetics are not a paramount concern.

TIG Welding

TIG Welding is another arc welding process. It is also known as gas tungsten arc welding (GTAW). Unlike MIG welding, TIG uses a non-consumable tungsten electrode to create the weld. An electric arc is created between the tungsten electrode and the workpiece. This arc heats the metal, creates a weld pool, and allows the welder to join pieces of metal together. Filler material is added when there’s a need to build up the weld bead, bridge a gap between pieces, or when working with thicker metals that need added material for strength. Like MIG welding, a shielding gas protects the weld pool from contamination.

TIG welding typically requires more skill and finesse than other methods like MIG, primarily because it requires both hands and often involves a foot pedal to control the amperage (heat). However, it results in a more precise and cosmetically appealing weld with minimal post-weld cleanup.

Resistance Welding and Spot Welding

Resistance welding is a broad term for welding processes that use pressure and electrical current to create a weld between two metals. The welding heat is generated by the resistance of the material to the flow of electrical current. A low-voltage, high-amperage electric current is passed through the metal, which creates heat and melts the metal at the joint. The pressure of the welding electrodes holds the metal in place while it melts and cools, forming a strong weld.

Spot welding is the most common type of resistance welding. It is used to weld thin sheets of metal together by producing individual “spots” or points of weld rather than continuous seams. Two sheets of metal are placed between the upper and lower electrodes of the welding machine. Electrical current is passed through the electrodes, and the resistance to this current in the metals creates heat, melting the materials and forming a weld.

Partnering with Die-Matic for Welding

At Die-Matic, we are known for our precision metal stampings, but we offer much more. As a single-stop manufacturer, our range of services includes prototypes, value-added services (e.g., heat-treating, coating), assembly, and welding. If welding is needed for your project, our weld technicians or manufacturing engineers will choose the best method suited to your needs. Our skilled weld specialists have honed the art and science of proficient welding, focusing on quality and attention to detail with each job. Contact us to learn how we can add value to your precision metal stamping project.