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What Should You Know About Sheet Metal Welding?

December 21, 2022


The process of welding is a prevalent one that is used widely to combine two different metals for a purpose. Most objects in your surroundings are made of welded metals, and these metal structures are then given a purpose and shape for which they are meant to be.



Sheet metal welding is also a part of the welding process and is one of the most complex methods. Specific methods and some tips must be followed when carrying out sheet metal welding. Here we have provided a detailed guideline on the sheet metal welding process that could greatly help you. So, let's read below.

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What is Sheet Metal Welding?

Sheet metal welding is a process where two different sheets are joined together. This process is carried out by bringing two sheets together and melting them. Once the metal sheets have reached their melting point, they are fused using a torch together.


The application of sheet metal welding is commonly observed in various industries like automobiles, aerospace, medicine, and other equipment. Numerous metal based structures are created by joining different sheets together.



Methods for Welding Sheet Metal

Sheet metal welding is a process that is carried out through different techniques that are different in different ways. Kaiao can do the following sheet metal welding there in the following ways:



1.MIG Welding

MIG stands for Metal Inert Gas, a form of welding process where two pieces of metal sheets are joined together. The process consists of using an electric arc. This electric arc melts the material and helps in joining.The process of MIG welding is suitable for thin material sheets. It is commonly used for tubing and sheet metal because these are thinner materials. The fillers used in the process are added as a mixture of carbon dioxide and argon.MIG welding consists of using an electrode with a wire which helps in melting the metal, and eventually, they join together. The gas in the gun of MIG welding protects the puddle of the weld from contamination due to the surrounding atmosphere.This process is one of the most cost-effective welding techniques, commonly chosen for various purposes. Also, the outcome of this kind of welding is very long-lasting as it creates the finest welds.



2.TIG Welding

TIG welding involves using material tungsten during the process. The main reason behind using this material is that it can offer a high melting point and provides a low vapor pressure.This kind of welding also involves using a shielding gas; primarily, helium or argon is used for this purpose. It is suitable for welding metals like copper, titanium, aluminum, chromium, magnesium, etc., and non-ferrous metals. The products manufactured mainly by this process comprise feeders, motorcycle frames, and doors.TIG welding is complex, and the welder must be an expert. However, the results are optimal and give a very clean and strength-oriented output.




3.Stick Welding

Stick welding is also a form of arc welding, and the covering over the stick comprises a flux that acts as an electrode. The current released from the stick creates an arc and joins the metal sheets.Stick welding is mainly used for joining solid metals, for instance, steel and iron. There is no shielding gas in the stick welding process because of the flux, which creates a slag and protects the area of the weld from all kinds of contamination.Stick welding is commonly observed to be popular in the construction industry and also the industry that looks after steel fabrication.



4.Plasma Arc Welding

Comparing plasma arc welding and TIG welding, both are not much different. Plasma arc welding also uses a tungsten electrode. The only difference here is that this type carries out a short arc welding process, creating a hot plasma due to pressure. This plasma causes the sheet metal to melt, creating a weld.


Plasma arc welding creates perfect-quality welds and is quite common in the marine industry and aerospace. However, the speed of this technique is also high, requiring very low power.



5.Electron Beam Laser Welding

Electron beam laser welding also comprises the arc process, but the stream of electrons is released from the arc that causes the metal sheets to melt and then combine.The best thing about this kind of welding is that it is a high-precision technique focusing on the tiniest details. It is suitable for working on metals like steel, titanium, aluminum, and many more.



6.Gas Welding

Gas welding is a process that doesn't need electricity and offers an ideal way of joining the metal sheets. This process is quite suitable for small components and joining them properly. These may include bolts, screws, and nuts. The best part of this kind of welding is that it is a low-cost method.



This process uses heat for welding purposes and burns fuel to produce this heat that ends up melting the materials. There are many applications of this welding, and it is used primarily on tubes, pipes, and ventilation systems.





Surface Selection of Sheet Metal Welding

When you look to weld plates, you may encounter different surfaces, and each surface will follow a different welding method.Kaiao can help you finish a high-quality welded surface, so let's learn how Kaiao will finish the welding job on different surfaces.



Flat Surface

Working on a flat surface for welding requires you to use flat welding techniques. In such a case, the torch of the welding machine is kept pointed as a way of making an angle with the surface. The torch is then moved back and forth, so the seams are melted and appropriately attached.The welding process suitable for flat surfaces amounts to TIG or MIG welding. This is the easiest and ideal form of welding.



Horizontal Surface

When the surface is horizontal, there are two ways a welder may weld the sheet metal. These two techniques commerce of the following:


One way is called the filet weld. In this process, the welding is done on the end of the horizontal surface on the upper side and is kept against the vertical surface. This way, a joint of an "L" shape will be created.There is another way, called the groove weld, and in this case, the surface is kept in a vertical direction, and then on the same plan, the two sheets are welded together. Stick welding proves to be the right choice in such kinds of welding.



Vertical Surface


The vertical welding princess requires a lot of control for the molten metal as it flows in the lower end when the welder welds the surface in a vertical direction. The welding gun in such a case is kept at an angle of 45 degrees.


The better the angle of the torch, the better the outcome of the weld, and stick welding is quite a suitable welding method for this kind of welding surface.



Overhead Surface

Overhead welding is a very complex kind of welding where you need to handle the molten metal while welding. Sufficient filler material must be used to shrink the weld pool size.


The most suitable method of overhead welding surfaces is using stick welding, which offers a very neat and robust weld.



Tips to follow for Sheet Metal Welding

After going through the details above, you must have had a lot of ideas regarding welding sheet metal. Let's look at some tips that might help you weld sheet metal.


● It is essential to choose a technique for welding that is suitable for the purpose. Every material has a different kind of requirement, and hence it must be taken into consideration. It is imperative to choose the ideal method for the chosen material to have optimal results.

● Moving the torch back and forth while welding is known as the sip welding method, and it is an ideal way to weld with perfection. Hence you may opt for this.

● Always have a test run on the metal before you start welding the sheets; this will help you gain a little confidence in handling the material and understanding if a particular material and welding process it one another.

● The compatibility between the filler metal and the welding process must be present; hence make sure to keep an eye on the metal sheet. It must be thick enough, as this may cause trouble in welding, and the sheets might not hold each other firmly.

● The welding machine's rod must be thinner than the metal sheet. The small electrode size allows it to have a tight arc.

● Heat management is also a factor that must be taken into consideration. One must always ensure that the heat is manageable so that it might melt the material thoroughly. Also, on the other hand, the heat must be just enough that it doesn't let the material attach properly.




At Kaiao, you will have your hands on the finest services for rapid prototyping. We have an experienced and well-equipped team of professionals ready to deliver the best quality final products. So, get in touch with us today, and we are ready to assist you with all the services you need.