How to Design Out Wire Form
Costs with Welding
When welding metal products,
there are advantages to using either spot welding or arc welding. The question
is, when do you use one over the other? Which will be the best fit for your
particular project? Which will save you the most money?
At Argo Products, we have
hundreds of years of combined welding expertise with our associates who have
mastered both Arc and Spot Welding and know the quickest, most efficient
technique to use for each individual project. This talent and experience has saved
our customers countless dollars.
Welding (Resistance Welding) is a process used to
permanently fuse two surfaces together by having an electrical current flow
through the parts while they are clamped together. Resistance welds can be butt welds, cross
welds, or projection welds.
Arc Welding (MIG Welding) is a process used to
permanently fuse two surfaces together using a wire-feeding welder in which heat is
generated from electricity to melt filler metal and base metals to form an
Listed below are some pros and cons of Arc and Spot Welding
Spot Welding Pros
Quickness of Weld - This
process adheres 2 pieces of metal together quickly, uniformly and efficiently,
giving your project a cleaner look than Arc Welding. Since it is quick, it does
not distort either of the two components.
Less Expensive - It
is much more cost effective to spot weld. It lends itself well to assembly line
More Energy Efficient - Typically,
it is a much more efficient process utilizing energy and electricity more
effectively than other types of welding processes.
Well Understood - Spot
welding is one of the oldest welding processes. The process is fully defined
and easily applies to many thin metals such as stainless steel, nickel alloys
Welds can be Weak - Spot
welding cannot be used for thicker metal materials because it will not
penetrate or form a good weld. Spot weld projects and finished jobs are easy to
break apart if necessary. The strength of a spot weld depends on the
force and temperature that has been applied and on the cleanliness of the
electrodes and metal.
The Process can be Dangerous
- Portable spot welding guns are difficult to handle, can be very heavy and
often require great strength. This makes spot welding very dangerous. High
amounts of heat and current are involved in the process.
on Materials - Spot Welding is not recommended for
aluminum, copper, or copper alloys. Use for steel and stainless steel only.
- MIG Welding adapts to different surfaces and does not always
require a great deal of fixturing.
Uninterrupted Welds - Used to fuse long surfaces
continuously such as bridge trusses and large truck assemblies.
Dissimilar Metals - MIG welding enables round rod, flat sheet
and tubular products to be welded at the same time.
Location - MIG Welds can be located anywhere along
- There is the need to replace the weld electrode in Arc Welding
and Care - It is necessary to remove the slag and spatter from the
- When welding, very bright light is produced. The welding
operator should wear eye protection. The welder should also wear protective
gear, so that he is protected from electric shock, burns and other problems
that might arise while welding due to high intensity of heat.
Appearance and Finishing - MIG Welding includes the
possibility of excessive melt-through and incomplete joint penetration or
fusion. MIG Welds are known to leave deposits that are heavily oxidized,
requiring surface preparation for finishing.
If your project
can be either spot or arc welded, there are definite pros and cons for both. In
general, we have found for volume projects that Arc Welding has more expensive
tooling costs (greater than 2X higher) and processing costs (greater than 20%
higher) than Spot Welding.