What Is Welding And Fabrication?

You may think Fabrication and Welding are the same things. You may even hear the two words used interchangeably.

Fabrication and Welding are two essential processes in metalworking. But if you are in the industry, you’ll know there is a difference between the two.

To put it simply, Fabrication is the whole cycle in which a component or structure goes through. Welding is part of that cycle. Although, you can produce the final product without the need for Welding altogether.

Welding and Fabrication use different processes. As a result, they need different skill sets, but they can share many of the same activities.

Different Techniques

Welding is the art of fusing metal using heat or pressure.

There are a lot of different welding types used today. The four common ones we use at Varlowe are: 

• MIG (Metal Inert Gas) or GMAW (Gas Metal Arc Welding)

• TIG (Tungsten Inert Gas) or GTAW (Gas Tungsten Arc Welding)

• Stick Welding or SMAW (Shielded Metal Arc Welding)

• Electrofusion Welding

Fabricators share a few of the same techniques as Welders. They usually have their own set of methods to get the job done. These can be:

• Die-cutting

• Finishing

• Hydroforming

• Roll forming

• Shrinking

• Spinning

• Stamping

• Stretching 

Different Tools

The fabrication process usually starts with cutting metal down to size. Metals can be cut and shaped using various tools, for example:

• Saws

• Hammers

• Grinders

• Cutters

• Plasma Torch

Tools such as lathes and presses help shape and remove parts of the metal. These can be manual machines or using CNC. Also, tubing and pipe benders help shape pipework fabrications.

Welding tools are very different in comparison. For example, they can use:

• Welding Clamps

• Magnets

• Gauges 

• Vices 

• Electrodes

More safety equipment for Welding is needed—items such as heat resistant gloves, helmets, masks and safety glasses, to name but a few.

Welding helmets are required to have auto-darkening glass to protect the eyes. Also, they need to have built-in respirators to protect against welding fumes.

Both trades will use the same cleaning supplies to prepare the metal for work. Wire brushes, sandpaper and solvents such as acetone help wipe away any greasy deposits.

Different Skill Sets

Fabrication and welding both require a set of unique skills and tools.

Fabrication typically involves the use of portable hand and electrical tools, with equipment such as folders, rollers, shearing tools being used to manipulate the metal.

Welding, on the other hand, is conducted using stationary tools and largely done by hand.

Basic welds can usually be completed without requiring a specialist welder however more complex joins may need to be undertaken by experienced welders certified according to specific standards, e.g. Coded Welding.

Welding & Fabrication Safety Precautions

Both manufacturing forms need the same degree of safety precautions. They both work with hot metal and heavy machinery, each carrying its guidelines.

Each tradesperson should own or have provided the following:

• Protective Trousers

• Flame-Resistant Jacket

• Overalls

• Steel Toe Boots

• Gloves

• An Auto-Darkening Helmet

• Safety Goggles

• Hearing Protection

• Respirator

You should also have a safe workshop to work in to prevent injury. The workshop should have these in place at all times-

• Highlighted Walkways

• Fume Extraction

• Adequate Lighting

• Welding Screens

• First Aid Stations

To sum up

Fabrication and Welding are crucial professions. Both trades provides for almost every industry. From construction to transportation, you will find something that has been fabricated in some shape or form.

Varlowe has experienced metal fabricators and class 1 coded welders. We provide bespoke solutions for all industries. 

You can find more on our Welding Services page and Steel Fabrication page. You can also find what we offer on our services page. 

If you wish to speak to a member of the team, please call us on 01902 861042.

FAQ’s

What type of welding do fabricators use?

Fabricators can use various kinds of welding, depending on the materials being joined, the strength required, and the application. Some typical types of welding used by fabricators include MIG, TIG, Stick and Flux-Cored.

Is a welder and fabricator the same?

While welders may also have some fabrication skills, such as reading blueprints and using metalworking tools, their primary focus is welding. Fabricators, on the other hand, may have some welding skills, but their primary focus is on the broader process of creating metal structures and products from start to finish.

What is Steel Fabrication?

Steel fabrication creates metal structures and products from raw materials, primarily steel. This process involves cutting, bending, shaping, and welding steel components to make a final product that meets the intended design and engineering requirements.

Take a read of our comprehensive article here – “What Is Steel Fabrication?“

What is welding?

Welding is the metalworking process of combining two or more metal components using heat and pressure. The process involves melting the base metal and adding a filler material to create a solid and permanent joint between the components.

Take a read of our comprehensive article here – “What Is Welding?“

Welding Explained

In a nutshell, welding is the process of uniting two or more materials together. 

From hobbyists to large industrial environments, welding is one of the most critical steps in modern fabrication.

In this article, we will go over the basics, but let’s start at the very beginning.

Welding History

Welding dates back to 500BC, the Iron Age (perhaps even before that).

Scientists have discovered a two thousand year old tiny box of gold with pressure welded joints. Furthermore, there is data pointing to Ancient Egyptians knowing how to weld iron together.

However, the welding performed in those times was very simple. It was nothing but hammering together two metal pieces under heat.

Archivists believe the Egyptians began to manage fire to join copper. They think they moved on to other alloys like gold, silver, iron and bronze.

Welding developed over the decades, and in the 16th Century era, they began using the term “Weld”.

The form of welding that we use today dates back to the 19th Century, albeit with more modern equipment and techniques.

After the development of electrical power, welding torches were created for cleaner and more controlled welds. Then came along –

• Early 1900 – Gas Shielding and Flux
• 1940 – GMAW, MIG, and TIG 
• 1950 – Flux-Cored Arc Welding

Since their invention and as technology has advanced, these techniques have been improved. Today, engineers can weld Metals, plastics and even wood. 

In this article, we will be focusing on metal and the techniques we use here at Varlowe Industrial Services.

You can read more about the history on Wikipedia.

Joining Metal

Metal welding starts by heating at a high temperature using electricity or gas.

The high heat causes a weld pool of molten material that cools to form the joint.

Usually, this joint is stronger than the parent metal.

Pressure can also produce a weld and work either alongside the heat or by itself.

Shielding gas can protect the melted/filler metals from becoming contaminated or oxidised.

Welding requires lots of work and practice. Best learned under the guidance of professional metal fabricators.

Once competent, you can progress your skills by going coded. Have a look at our “What is the meaning of “Coded Welding” blog post or our Coded Welding page.

Fabrication Welding

Steel fabricators can transform some of the world’s most robust materials into different shapes and sizes.

They produce products ranging from pipework to staircases. Or, in our case, a pipework-based staircase which you can view here “Our signature staircase”.

Drilling, cutting, bending and grinding metals are techniques used to create the basic shapes.

Once finished, you should have something that resembles Ikea’s flat-pack furniture.

Then comes the time to apply your chosen welding technique to fuse these pieces.

There are several types of techniques, manual and automated. Each offers different ways of uniting materials together.

The term “fabrication” and “welding” however are two separate methods of manufacturing. Check out our blog post “What Is The Difference Between Welding And Fabrication” to learn the difference between the two.

We will go over four types of welding techniques. These four are the most used methods we use here at Varlowe.

Welding Types

There are many types of welding processes, each serving its strengths and weaknesses.

Choosing the correct technique is dependent on the project. For example, you may need specific materials and welding positions factoring in.

The correct method is essential, so it’s necessary to understand the differences between them.

Today, processes have an automated option. Equipment such as robotic welding can, within a controlled environment, deliver high quality and repeatability with ease.

Yet, some projects need expert metal fabricators to produce a type of weld in a position not compliant with automated processes.

MIG (Metal Inert Gas) or GMAW (Gas Metal Arc Welding)

To Mig, or not to Mig, that is the question, which is usually yes.

This style is the most common industrial welding process.

A solid steel wire passes through the Mig Gun. The gun is electronically charged at the pull of the trigger, creating an arc, heating the two metals together.

It requires a constant voltage and direct-current power source.

Pros – MIG can weld in all positions – You do not have to chip off slag build-up – Its relatively easy to learn.

Cons – Large tank of shielding gas – the expensive cost of consumables.

TIG (Tungsten Inert Gas) or GTAW (Gas Tungsten Arc Welding)

A non-consumable tungsten electrode is used in this type of welding process.

This tungsten electrode, along with shielding gas, directs the arc in a controlled manner to heat the base metal. The heat created produces a molten weld puddle.

When you need a higher standard finish, TIG is usually the go-to method. It creates a very clean weld with little to no clean up required externally or internally.

Pros – Used in a wider variety of materials in all positions – Provides very high-quality welds – Does not produce toxic smoke – Minimal fumes – No slag produced.

Cons – TIG welding is a complex process – The torch held at the right angle – More complicated to master.

Stick Welding or SMAW (Shielded Metal Arc Welding)

Stick Welding is one of the easiest to learn and most common types of metal joining.

The electrode, or “stick”, covered with a flux coating that melts to form a gas shield as the heat rises.

Slag gets created when the molten flux solidifies on the surface of the weld.

Pros – No other consumables needed than rods – Achievable in all positions – Equipment is simple to use and inexpensive.

Cons – Stick Welding has a very rough appearance – Requires extra cleaning work – Difficult to weld thinner metals.

Electrofusion

Electrofusion welding is a form of resistive implant welding used to join pipes.

A fitting with embedded metal coils is placed around two ends of the pipes. A current passes through the coils, which creates the heat required.

The heating of the coils melts small amounts of the pipe and fitting. When the joint cools, the line will be fused and ready for commissioning.

Pros – A simple process capable of producing consistent joints – The contained process eliminates the risk of contamination – The process allows repair without the need to remove pipes.

Cons – More expensive method – extra parts required.

If you want more information on the different welding types, take a look at our blogpost “Welding Types“.

Welding Positions

You might assume a welder sits at a workstation and fuses the metal components on a table in front of them.

But in everyday work environments, joining metal can be much trickier.

Unremovable structures attached to the ceiling, the wall or embedded into the floor offer different challenges.

They need a different method, which is why welders need techniques to weld in any position.

There are four common positions are:

• Flat – As the name suggests, the welder passes over a flat placed piece of metal. The welder will move across the workpiece in a horizontal direction.

• Horizontal – The weld axis is horizontal, which requires a higher level of skill. How the position passes depends on the type of weld need.

• Vertical – Both the weld and plate will lie vertically. One of the problems performing this weld is the molten metal flowing downward and piling up.

• Overhead – The overhead position weld is the most challenging position to work on. Fighting against gravity is the main issue in this position. The welder will also have to angle themselves to reach the joints.

If you want to learn more about positions, take a look at our Welding Positions blog post.

Fabrication Services At Varlowe

Here at Varlowe, we have been providing metal fabrication services for over 17 years.

Our specialist area is in Pipework Fabrication, specifically high pressure pipework systems.

We also offer a class 1 coded service for a range of applications, nationwide.

Please visit our Welding Services and our Steel Fabrication page for more details.

You can call us on 01902 861042 or email info@varlowe.co.uk.