Specialized welding: The importance of precision and quality in industrial components
Nicro is a leading company in the field of metal alloy processing and transformation, with solid expertise in high-precision industrial welding. Founded on values of quality, innovation, and sustainability, Nicro stands out for its use of cutting-edge technologies and a customized approach tailored to clients’ needs.
Specializing in the production of metal components for various industrial sectors, including mechanical, aerospace, automotive, construction, chemical, and oil & gas industries, Nicro ensures reliable and durable components through the use of advanced nickel-based and other special metal alloys, along with high-performance welded solutions.
In this article, we explore the main welding processes used at Nicro and how each contributes to the production of precise, high-quality industrial components.
Choosing the welding process: materials, dimensions, and thickness
At Nicro, the selection of the welding process is never random. It depends on several key factors that determine the quality, efficiency, and feasibility of the joint. Each welding method, whether TIG, submerged arc, MIG, MAG, or PLASMA, is chosen based on specific component characteristics such as size, material, and thickness.
The use of semi-automatic or mechanized processes is a common strategy, as it simplifies work, reduces human intervention, and increases production speed without compromising quality. However, in cases where precision is critical, fully automated solutions are employed, such as plasma welding on complex components.
Nicro’s team has in-depth knowledge and extensive experience with various welding processes, ensuring the highest quality and final results that meet customer requirements.
Welding processes used at Nicro
Welding is a crucial aspect in the production of high-precision, high-strength industrial components. At Nicro, the focus on product quality and durability is reflected in the adoption of various welding techniques, each selected according to the specific needs of the project.
The welding processes used by Nicro include TIG welding, submerged arc welding, MIG and MAG continuous wire welding, and plasma welding. Each of these can be applied in manual, semi-automatic, or mechanized modes to optimize time and cost.
The ability to combine the precision of manual processes with the efficiency of semi-automatic and mechanized methods is one of Nicro’s strengths. The company is constantly working to improve its techniques and meet the growing demands of its clients.
TIG Welding (Tungsten Inert Gas)
TIG welding (Tungsten Inert Gas) is one of the most precise and versatile processes used at Nicro. This method employs a non-consumable tungsten electrode and an inert gas (such as argon or helium) to shield the weld area from oxidation. TIG welding is particularly suited for creating high-quality joints that require great precision and constant temperature control throughout the process.
At Nicro, the TIG process is applied in three main modes, each suited to specific production needs:
- Manual mode: This allows the welder to have direct control over the torch and tungsten electrode. It is ideal for small joints or complex components where meticulous, hands-on intervention is required.
- Partly mechanized mode: In this mode, the welder uses a TIG torch assisted by semi-automatic equipment to improve welding speed and precision while reducing the margin for human error. Semi-automatic welding is suitable for medium-sized components and productions that require consistent quality.
- Mechanized mode: In the mechanized mode, the TIG welding process is fully automated through the use of advanced mechanical equipment. This mode is ideal for large-scale production and for components that require long, uniform welds. Mechanized welding ensures high levels of precision and repeatability, optimizing production times and minimizing the risk of errors.
The TIG welding process is particularly advantageous for materials such as stainless steel and nickel alloys, which require smooth, clean, and durable welds without the need for excess filler material.
Submerged arc welding
Submerged arc welding is a highly specialized process used to ensure high-quality welds on thick materials such as steel and special alloys. This welding method is characterized by the use of an electric arc that melts both the base material and the filler wire, while the entire process is carried out under a layer of fine flux powder. This flux protects the weld from exposure to air, preventing oxidation and contamination.
At Nicro, submerged arc welding is mechanized, meaning the entire process is performed using advanced equipment and automated systems that ensure precise control and high repeatability. This results in extremely strong and durable welds, ideal for industrial applications requiring robust and structurally sound joints, such as those in the steel industry.
MIG and MAG continuous wire welding
Continuous wire welding is one of the most common processes for creating fast and reliable joints. In its MIG (Metal Inert Gas) and MAG (Metal Active Gas) variants, the process involves the use of a continuous metal wire as filler material, which is melted to join the base materials. Depending on the type of gas used, inert gas for MIG or active gas for MAG, this process can be adapted to a wide range of metals, including steels, stainless steels, and aluminum. It can be applied in both semi-automatic and mechanized modes for welding medium to large components, such as metal structures.
- Partly mechanized mode: In this mode, the welder manually moves the torch, while the wire feed and shielding gas flow are controlled automatically by the machine. This mode is ideal for applications requiring a balance between precision and speed, and for welding joints in medium-sized components.
- Mechanized mode: In the mechanized mode, the entire welding process is automated. This mode is suitable for series production or for welding large components where repeatability and efficiency are essential. Mechanized welding minimizes human error and ensures continuous, clean, and high-quality welds.
Plasma welding
Plasma welding is one of the most advanced processes for ensuring high-quality joints on materials that are difficult to weld or on small components that require extremely precise control, such as those used in the aerospace industry and the production of parts for industrial plants.
This process uses a high-temperature electric arc to melt the filler and base materials, employing ionized gas (plasma) to shield the weld and enhance arc stability.
- Mechanized mode: In this mode, the process is carried out using systems that precisely control the filler wire feed rate, shielding gases, and weld execution based on the joint geometry. It is ideal for series production of components that require high-precision welding and a high degree of uniformity. The machine is programmed to follow exact paths, minimizing errors and ensuring consistently high-quality results.
- Automatic mode: In the automatic mode, the entire welding process is managed by intelligent machines that continuously monitor parameters to ensure quality remains consistent throughout the production cycle. This type of welding is used for applications that demand the highest level of precision and repeatability, such as welding complex or serial components, where each joint must be identical and compliant with strict quality standards.
If you’d like to learn more about our specialized welding services and discover how we can support your project, contact us today for a personalized consultation. Our team is ready to provide the most suitable solution for your needs, always ensuring the highest levels of quality and precision.
