ArmaWeld  /  Welding Methods

Welding
Methods.

MAG, TIG, MMA and SAW processes — selecting the right process according to material, thickness and application requirements.

Boru kaynağı uygulaması Welding Processes · MIG · TIG · MMA
01 / Process Selection Guide

PROC.SEL — INTERACTIVE

The right welding process for material and application.

In the selector below, enter material, thickness and environment — and ArmaWeld's engineering knowledge base recommends the best welding process for you.

Parameters

RECOMMENDED PROCESS

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ISO Code
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Efficiency
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Filler Metal
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ALTERNATIVE: — —
MIG / MAG
Gas Metal Arc Welding · ISO 4063 Process 131/135/136

A semi-automatic, high-deposition process using a continuously fed wire under shielding gas. The backbone of our workshop; first choice for crane bodies, structural steel and earthmoving frames.

Current
DC+ · 120 – 320 A
Voltage
18 – 32 V
Gas
Ar (131) · Ar+CO₂ (135/136)
Wire Diameter
0.8 – 1.6 mm
Efficiency
≈ %95
Deposition Rate
1.5 – 5 kg/h
Advantages
  • High deposition rate, suited to series production
  • Easy automation (robot welding)
  • Usable in all positions
  • Clean, slag-free weld
Limitations
  • Outdoor gas dispersion issues
  • Cannot be applied at wind ≥ 3 m/s
  • Higher equipment cost
KOD PROSES GAS / APPLICATION
131 MIG — Metal Inert GasSolid wire · inert gas Saf Ar / Ar+He
Stainless steel, aluminium, copper alloys
135 MAG — Metal Active GasSolid wire · active gas Ar+CO₂ (M21) / saf CO₂
Carbon steel, low-alloy steel, series production
136 FCAW-G — Flux-Cored Wire + Active GasFlux-cored wire · active gas CO₂ / Ar+CO₂
Structural steel, thick sections, high deposition, site welding
■ MIG / MAG / FCAW ISO 4063 · 131 / 135 / 136
MIG/MAG
Gas Metal Arc Welding
Deposition Rate
1.5–4.5 kg/sa
Efficiency
%95
Automation
High
Wind Resist.
Low
CARBON STEELLOW ALLOYSERIES PRODUCTIONROBOT
DC+ · 120–320 A ● PRIORITY
MIG/MAG kaynak uygulaması
● MIG/MAG · Structural Welding
■ TIG ISO 4063 · 141
TIG
Gas Tungsten Arc Welding
Weld Cleanliness
Highest
Efficiency
%100
Precision
Very High
Speed
Slow
STAINLESSALUMINIUMTITANIUMTHIN-WALLFOOD
AC/DC · 20–220 A ● PRECISION JOB
TIG kaynak uygulaması
● TIG · Precision Arc Welding
TIG
Gas Tungsten Arc Welding · ISO 4063 Process 141

Non-consumable tungsten electrode and pure argon, with hand-fed filler — the cleanest and most precise arc process. First choice for stainless tanks, pressure vessels, aluminium parts, sanitary applications and visible welds.

Current
AC / DC · 20 – 220 A
Voltage
10 – 18 V
Gas
%100 Argon
Electrode
WT20 / WC20
Efficiency
≈ %100
Deposition Rate
0.3 – 0.8 kg/h
Advantages
  • The cleanest weld — slag-free, spatter-free
  • Precise current control (for thin walls)
  • Compatible with stainless, aluminium, titanium
  • Ideal for visible / aesthetic welds
Limitations
  • Slow — not suited to series production
  • Operator skill critical
  • Material surface must be very clean
E-ARC
Shielded Metal Arc Welding (SMAW) · ISO 4063 Process 111

Classic process with consumable coated electrodes; needs no gas, resists wind. Preferred for site work, outdoors and repair welds. With basic electrodes also suitable for critical joints requiring high toughness.

Current
AC / DC · 60 – 300 A
Voltage
20 – 34 V
Gas
None (from coating)
Electrode
Basic · Rutile · Cellulosic
Efficiency
≈ %65
Deposition Rate
0.5 – 2.5 kg/h
Advantages
  • Resistant to wind / outdoors
  • Simple, portable equipment
  • High toughness with basic electrode
  • Usable in any position
Limitations
  • Electrode change interruptions
  • Slag cleaning required
  • Low efficiency — high waste
  • Electrode dryness control is critical
■ E-ARC / SMAW ISO 4063 · 111
E-ARC
Shielded Metal Arc Welding
Wind Resist.
Highest
Portability
Site Ready
Toughness (Basic)
Very Good
Efficiency
%65
SITEREPAIRHEAVY SECTIONOUTDOOR
AC/DC · 60–300 A ● SITE / REPAIR
05 / Advanced Processes

SAW, robotics and WPS scope

SAW

SAW — Submerged Arc Welding (ISO 121)

ParameterValueNote
Process code121 (SAW)Single/twin wire, granular flux
Flux typeAlkaline / rutile (material dependent)LF-1, BB 202 equivalent
Wire diameter2.4–4.0 mmTwin wire for high deposition
Thickness range8–50 mmLong straight welds, plate joints
Deposition rate5–15 kg/hEfficient production; low HAZ
MaterialS355, S690, P265GHStructural steel, pressure vessel

35 m submerged arc welding machine: long linear seams, machinery and crane booms, and trailer and machine chassis are welded in one set-up. Submerged arc welding service →

35 m submerged arc welding service →SAW teknik rehber →Boom and chassis welding →
Robot

Robot Welding Cell

FeatureValueApplication
Robot type6-axis, 2 m reachSeries production, repetitive welds
Repeatability±0.1 mmMachine body, chassis parts
ProcessMIG/MAG serial weldingS355, S690, HARDOX (WPS approved)
ProgrammingOffline + teach pendantParameter log per LOT
Not suitableTIG root, thin sheet, single prototypeManual welding preferred
Robotic welding →
WPS

WPQR Library Summary

Steel (EN ISO 15614-1) — 24 WPQR

  • S235+S235 · t=3–20 mm · MAG 135 · PA/PB
  • S355J2+N+S355J2+N · t=6–40 mm · TIG root + MAG · PA/PC/PF
  • S690QL+S690QL · t=8–25 mm · MAG 135 · preheat · PA/PC
  • HARDOX 450+450 · t=6–16 mm · low heat input · PA/PB
  • 316L+316L · t=2–12 mm · TIG 141 · PA/PE
  • P265GH+P265GH · t=6–30 mm · TIG root + MAG · PA/PC

Aluminium (EN ISO 15614-2) — 4 WPQR

  • 6082+6082 · t=2–8 mm · TIG 141 · PA/PB
  • 5754+5754 · t=2–6 mm · TIG 141 · PA
  • 5083+5083 · t=3–10 mm · TIG 141 · PA/PC
  • 6082+5754 · t=3–6 mm · TIG 141 · PA (dissimilar)

Approved welding positions:

PA
Flat (1G/1F)
PB
Horizontal (2F)
PC
Vertical up (3F)
PF
Vertical down (3G)
PE
Overhead (4F/4G)
WPS nedir? →WPQR nedir? →Document simulator →
Distorsiyon

Distortion Control Methodology

Preventive Methods

  • Balancing welds — symmetric sequence, opposing passes
  • Jig & fixture — clamp before welding, release after cooling
  • Tack weld sequence — equal spacing, controlled length
  • Heat input management — WPS limit, interpass temperature
  • Back-step technique — stress distribution on long welds

Measurement & Correction Limits

  • Before/after dimensional record (lazer tracker)
  • Post-weld straightening: max 3 mm/m (per project spec)
  • Out-of-straightness: L/1000 (structural) or drawing tolerance
  • Re-NDT after correction (critical welds)
  • Distortion report filed in work order dossier

Distortion management starts at WPS preparation. Weld sequence plan and jig requirements are defined by engineering review after drawing submission.

Distorsiyon rehberi →
Stud

Stud Welding (Structural Steel)

Stud welding for composite deck, insulation and equipment connections on structural steel.

Stud TypeDiameterProcessStandard
Headed studØ13–25 mmDrawn arc (783)EN ISO 14555
Shear connectorØ19–22 mmDrawn arc + ferruleEN 13918
Threaded studM10–M24Short cycle / drawn arcProject specification

Stud welding parameters are defined by WPS based on material thickness and stud diameter. Bend test and visual inspection applied per LOT.

Engineering Tools

Technical calculators and project checklist.

Heat input, preheat estimate, sector-based material recommendation and document checklist — a quick start for WPS preparation.

Heat Input Calculator

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Preheat Estimate (EN 1011-2)

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04 / Full Comparison

COMPARE — ALL

Welding processes compared by technical criteria.

Property MIG/MAG (135) TIG (141) E-ARC (111)
Full NameGas Metal Arc W.Gas Tungsten Arc W.Shielded Metal Arc W.
ElectrodeConsumable wireNon-consumable tungstenConsumable coated rod
Shielding GasAr + CO₂100% ArgonNone (from coating)
Current Range120–320 A20–220 A60–300 A
PolarityDC+AC / DC−AC / DC±
Efficiency%95%100%65
Deposition Rate (kg/h)1.5 – 5.00.3 – 0.80.5 – 2.5
Min. Thickness0.8 mm0.3 mm2.0 mm
Max. Thickness (single pass)8 mm4 mm5 mm
Site UseLimited (wind)No (wind)Ideal
AutomationHigh (robot)MediumLow
Operator SkillMediumHighMedium–High
Strong SuitSeries production, structuresThin, visibleSite, repair