Sheet Metal Welding

1. TIG Welding (Tungsten Inert Gas Welding)   

TIG welding utilizes a non-consumable tungsten electrode and inert gas shielding (typically argon or helium) to produce exceptionally clean, high-precision welds. This process offers superior control without spatter, making it ideal for thin materials and critical applications like aerospace components, pressure piping, and artistic metalwork. While capable of joining diverse metals including aluminum, stainless steel, and titanium, the technique demands skilled operators and operates at slower speeds compared to other welding methods. The need for manual filler metal addition further contributes to its reputation as a specialized, high-quality joining process.

2. MIG Welding (Metal Inert Gas Welding)

MIG welding uses a continuously fed wire electrode with argon-CO₂ shielding gas for fast, semi-automated material joining. Delivering higher deposition rates than TIG with less operator skill, it's ideal for thick materials in high-volume applications like auto manufacturing and steel construction. While less precise and prone to spatter, its efficiency and minimal cleanup make it perfect for industrial fabrication prioritizing speed over aesthetics. This productivity-quality balance drives its popularity in mass production and construction projects.

3. Resistance Welding (Spot/Seam Welding)

Resistance welding bonds metals through strategically applied pressure and electrical current, creating intense localized heat at the contact points without requiring filler materials or shielding gas. This rapid, energy-efficient process excels in high-volume sheet metal fabrication - particularly for automotive body panels, battery connections, and household appliances - though its application is constrained by material compatibility issues, thickness limitations (typically under 3mm), and relatively imprecise weld quality compared to other methods. The technology's production speed makes it ideal for assembly lines where these trade-offs are acceptable.

4. Laser Welding

Laser welding delivers micron-level precision by focusing intense light energy to melt and fuse materials with minimal thermal spread, enabling deep, narrow welds ideal for delicate components. This automated process achieves remarkable speeds while maintaining exceptional accuracy, though it faces challenges with reflective surfaces and thicker sections. Its unique capabilities make it indispensable for manufacturing medical implants, microelectronics, and sensitive automotive parts where traditional methods would cause unacceptable distortion or damage. The technology's ability to work with tiny, heat-sensitive components comes with material limitations - particularly with highly conductive metals - requiring careful process optimization for each application.

5. Robot Welding

Robot welding utilizes automated robotic arms to execute precise, pre-programmed welding operations (MIG/TIG/laser) with unmatched consistency, making it ideal for high-volume production lines. While requiring substantial upfront investment in equipment and programming, this technology significantly reduces labor costs, enhances workplace safety by removing operators from hazardous environments, and delivers superior repeatability compared to manual welding. Robotic welding sacrifices flexibility for consistency, struggling with custom jobs human welders handle easily. This makes it ideal for high-volume settings like auto plants where standardization justifies the investment.

Carbon Steel Sheet Metal Welding：Carbon steel has good welding performance and is suitable for almost all welding methods. For example, MIG/MAG can be used for efficient welding of medium and thick plates, TIG can be used for welding high-quality thin and precision parts, resistance welding can be used for spot welding of thin plates, and SAW welding can be chosen for long welds of thick plates.

Stainless Steel Sheet Metal Welding：Stainless steel has certain difficulties in welding due to its special physical and chemical properties, such as high chromium content, thermal sensitivity, and easy deformation. TIG Welding is often chosen for SS304/SS316 (oxide-free precision welds) and MIG welding for thicker plates and laser welding for thin plates.

Aluminum Sheet Metal Welding: The thermal conductivity of aluminum is four times that of steel, and heat is rapidly dissipated. The dense Al₂O₃oxide film on the surface of aluminum (melting point 2050 ℃) is much higher than that of aluminum itself (660 ℃), which can easily lead to incomplete fusion. Recommend using TIG (AC) for welding high-quality thin plates and MIG (pulse) for welding medium thick plates, FSW does not melt and is suitable for high-strength aluminum alloys.

Copper Sheet Metal Welding: Copper has extremely strong thermal conductivity and requires high heat input or preheating. TIG welding of high thermal conductivity pure copper requires preheating, while bronze/brass can be directly welded. Laser welding of thin copper plates requires anti reflection treatment, and brazing (electrical joints to avoid high-temperature deformation) are recommended.

Galvanized Steel Sheet Metal Welding: Zinc coating on the galvanized steel vaporizes at high temps which will cause porosity so we need to adjust parameters or grind off zinc first before welding. Recommend using MIG welding (short-circuit transition) (requires ventilation, zinc vapor is toxic) and resistance welding (zinc layer has less impact during spot welding).