What is arc welding?

Arc welding fuses parts permanently together by using a power supply to generate an electric arc between
an electrode mounted in a torch and a metal.

This arc is an electric current flowing between two electrodes through an ionized column of gas is able to produce a
heat intense enough to melt the metal.

The heat is produced through a negatively charged cathode and a positively charged anode. The negative and
positive ions are bounced off of each other in the plasma column at an accelerated rate.

The electrode is typically a specially prepared rod or wire that not only conducts the current but also melts and
supplies filler metal to the joint

The arc is formed between the actual work and an electrode (stick or wire) that is guided along the joint. It provides
the heat needed to melt the electrode and the base metal, and sometimes also supplies the means to transport the
molten metal from the tip of the electrode to the work.
This intense heat (around 6500F at the tip) applied at the joint between two parts is melted and caused to intermix
with an intermediate molten filler metal. This heat melts both the base metal and the electrode, creating molten
droplets that are detached and transported to the work through the arc column when the electrode is consumable.
In carbon or TIG welding there are no molten droplets to be forced across the gap and onto the work so filler metal
is melted into the joint from a separate rod or wire.

Regardless, this pool of molten metal is sometimes called a "crater." The crater solidifies behind the electrode (see
"slag" below) as it is moved along the joint. The result is a metallurgical fusion bond that produces a weldment that
has a similar strength to the metal of the parts. This is different than non-fusion processes of joining where the
mechanical and physical properties of the base materials cannot be duplicated at the joint.

This metal transfer can occur one of two ways: Surface Tension Transfer where a drop of molten metal touches the
molten metal pool and is drawn into it by surface tension or Spray Arc where the drop is ejected from the molten
metal at the electrode tip by an electric pinch propelling it to the molten pool (great for overhead welding).
Powering Arc Welding:
Below is a diagram of the basic arc-welding circuit that includes a power source. There must be an ionized path to
conduct electricity across a gap and then some sort of ignition in order to start the arc. This is usually caused by
supplying an initial voltage high enough to cause a discharge or by touching the electrode to the work and then
withdrawing it as the contact area becomes heated.

When welding, one can use a direct current (DC) with the electrode either positive or negative or alternating current
(AC). The choice of current and polarity depends on the process, the type of electrode, the arc atmosphere, and the
metal being welded. Whatever power source is necessary is fitted with necessary controls that are connected by a
work cable to the work piece.

photo courtesy of Lincoln Electric

Arc Shielding
Arc shielding is a necessary process in arc welding as any metal at high temperatures has a higher reactivity to
chemical elements in the air. So, the process has a means of covering the arc and molten pool with a protective
shield of gas. Shielding gas is used while the torch is joining parts together in order to prevent contamination. This
also confirms the strength of welds and minimizes post weld cleanup of a part.
photo courtesy of Lincoln Electric