For different alloys and metals like steel, iron, cast iron, and aluminum, various techniques of welding are used. The selection of the welding method basically depends on the composition of metal, shape, and the required robustness you need. For instance, when you are welding steel, you mainly go for stick welding, arc welding, resistance spot welding, and DC-TIG welding. These methods may not be as helpful for welding cast iron. So, similar is the case for alloys.
Here we will deeply check what the best methods to weld Inconel are. If you use the best way of welding, it is promising that your welds will last forever. So, let the original debate begin without any further postponement.
- What is Inconel?
- Properties of Inconel
- Applications of Inconel
- How to Weld Inconel?
- Common Mistakes to avoid while Welding Inconel
- Frequently Asked Questions
What is Inconel?
Inconel is an alloy made up of nickel, chromium, and iron. It is known for its great heat tolerance and its anti-corrosive qualities. This is the reason it is used in most industrial works.
It has a lot of qualities to make it a part of the list of expensive metals and alloys. Not only the heat resistance but it is also known for the tensile strength it holds.
Properties of Inconel
- Inconel can withstand the highest temperatures. It holds excellent integrity and strength even when heated to the end limit.
- When Inconel is heated, an oxidative layer is formed, which makes it highly resistant to corrosion.
- The formation of a specific intermetallic compound is the reason that it can withstand the highest temperature and will not collapse like steel.
- You will get Inconel alloy in the form of strips, rods, plate, rolled, Annealed, tube, and pipe.
- The composition of nickel in Inconel divides it into several grades. Each grade varies in composition and properties.
- Even some grades of Inconel are acid and nuclear-resistant.
- You can use Inconel alloys in the hottest areas with extreme exposure to sun and the areas with excessive moisture. In both cases, you will get a breathtaking response, i.e., it will remain intact.
Applications of Inconel
Inconel is an expensive alloy, so it is used in areas with a harsh environment or great exposure to heat or corrosion. Well, here are some of the applications of Inconel.
Jet Engines and some parts as well
As you know, jet engines are the functional part of giant airplanes and jets, so they need to be non-corrosive and heat resistant. Too much workload means excessive heating. So Inconel is the preferred alloy for their making.
Automotive or car engines
The same is the case with car engines. Work leads make the machine go hot, so if it is made up of cheaper metal, the chances of engine explosion are there. So to be on the safer side, Inconel is used to build engines.
Extraction of oil and gas
The temperature inside the earth is more than enough to melt and collapse any other metal out there. So, Inconel is used in the making natural resources extraction machinery.
How to Weld Inconel?
Because of the high heat resistance, people often think that it may be difficult or impossible to weld Inconel, but that’s not true. All you need to do is to learn the exact technique and practice a lot. Once you get expertise in welding Inconel, it is the easiest thing to do. Here is the exact technique to weld Inconel.
Usually, nickel-containing alloys have a tendency to craft after they are welded, so you need to be careful.
Also, the filler and the metal may give a collective uglier look, but you have to look at the amazing benefits it is offering you.
The following techniques are used to weld Inconel:
- Using TIG welding
- Using Automated machines
- Using Inconel 625 alloy as a filler material
As it is a bit hard to weld or directly join two pieces of metal with excessively high melting points, experts prefer tungsten inert gas welding, which usually doesn’t require filler. But remember to get outstanding results, filler combined with TIG welding is used to avoid cracking.
Nowadays, automated machines are primarily in fashion to weld Inconel because the safety ratio is increased up to a significant scale. Also, quality increases and the error ratio decreases because robots are not made to get tired or show less interest in their work.
While keeping all of these points in mind, many steel and automobile companies are investing in getting automatic machinery to complete their projects.
Common Mistakes to avoid while Welding Inconel
Undoubtedly, welding Inconel seems to be an easy task, but the smallest of mistakes may make your project collapse. So always take good care of the welding equipment and try to stay safer by avoiding the silly errors below.
Thick materials: Excessively thick metals may not get accurate results with welding.
Poor preparation: You forget to clean the metal surface and remove contaminations from the surface.
Wrong technique: Some people may opt for the improper process for the wrong metal or alloy. So you need to be careful while selecting the welding technique.
Worn-out metal: Using a worn-out metal in anything means you are wasting your money and time as it will collapse as soon as possible.
Electrode and wire selection: Always select a good wire so that you may not get to face electrical hazards or power shortages while welding
Frequently Asked Questions
1. Is welding Inconel toxic?
Welding Inconel occasionally means the least inhalation, but when this inhalation reaches chronic levels, it may cause pneumoconiosis. Deposition of iron in body tissues causes toxicity which may lead to death.
Some of the symptoms associated with Inconel toxicity are pink urine, vomiting, diarrhea, liver damage, and black stool. If you get any of these, consult a physician immediately.
2. What are the points we need to remember before we start welding Inconel?
Here are the essential points that welders need to remember at their fingertips:
- Permanently weld at an area with good ventilation.
- Keep fire extinguishers and safety equipment near you.
- Use all the safety equipment like welding shoes, gloves, and suits.
- Don’t forget to wear glasses and a face shield.
- Never touch a naked wire by hand.
3. What are the hazards of welding?
Welding is a life-saving technique as the majority of appliances we use in our homes still result from some hazards associated with this helpful technique. We divide these hazards into seven categories, i.e., electric current, Heat and fire hazards, Fumes and respiratory issues, gas and suffocation hazards, and many other related threats.
If you want to stay safe from these hazards, don’t forget to follow the safety rules.
No doubt, a metal or alloy with an excessively high melting point and tendency to crack gets challenging to work with, but if done with expertise, it will give you uncountable benefits. The same is the case with the welding of Inconel. You need to be accurate with your decisions and techniques.
Also, we recommend you go for automated welding of Inconel as it is the best way to weld this alloy perfectly.