What is Carbon Arc Welding?

Carbon arc welding (CAW) was one of the first arc-welding processes that was developed, and while it is still used today, other variations predominate in various markets and applications. The process of carbon arc welding involves the heating of a non-consumable carbon or graphite electrode and a work piece. The welder is looking to form a bond between two separate pieces of metal, as is true with other forms of welding.

In CAW, an electric arc is formed between the electrode and the materials being welded. This arc can reach temperatures in excess of 5,432°F (3,000°C). High temperatures allow the separate metals to form a bond that, as it cools, solidifies to form a weld that joins them together into one piece. This strong bond is very useful for countless applications across various industries and it meets many manufacturing needs. Unlike other forms of welding, like shielded metal arc welding, carbon arc welding does not require shielding gasses. It is a simpler form of welding and is generally a cost-effective option for a range of applications.

Types Of Carbon Arc Welding

Different types of carbon arc welding are useful for different applications. These are four common options that you may encounter or require in your industry:

Single Carbon Arc Welding: This is the most basic form of carbon arc welding, and is as described above, the process of welding via an electric arc that runs between the electrode and the metal workpiece. The resulting molten metal forms the weld. Single carbon arc welding can be used with non-ferrous metals of different thicknesses and works well for smaller or medium-sized projects.

Twin Carbon Arc Welding: As the name implies, twin carbon arc welding uses two electrodes instead of just one. This is a more complex version of carbon arc welding that results in a more stable and intense heat source to form the weld. Otherwise, the process is the same as single carbon arc welding. When thicker materials are being used, or you need to create complex or intricate structures, the powerful heat available with twin carbon arc welding is a good option.

Air Carbon Arc Welding: This form of carbon arc welding uses a single carbon electrode but includes the use of an air jet system. It can also be used to cut metal, and is referred to as Carbon Arc Cutting when used for that purpose. Air carbon arc welding utilizes a jet of pressurized air along with the arc to drive molten metal away from the arc zone. This process is predominantly used to gouge or cut but can be used to weld, and can be done successfully with both ferrous and non-ferrous metals. Carbon arc cutting is often used in heavy industry settings.

Gas Carbon Arc Welding: Also known as Shielded Carbon Arc Welding, gas carbon arc welding is the same general process of carbon arc welding, paired with shielding gasses like helium or argon. These gasses prevent contamination from atmospheric conditions or components that could infiltrate the weld pool, protecting it from oxidation and impurities that lead to a weakened weld. If you are using reactive materials, such as some non-ferrous metals, that can readily suffer from oxidation, gas carbon arc welding is a great option.

Whichever type of carbon arc welding you opt for, there are some basic supplies you will need, including the graphite or carbon-coated electrode, a power source that can supply direct and alternating current (direct current is most commonly used), a carbon arc welding machine, electrode holder, and carbon arc welding torch.

Advantages And Disadvantages Of Carbon Arc Welding

Due to the relatively simple setup and minimal equipment needed to use carbon arc welding, it is seen as being a relatively clean, cost-effective and accessible option for most projects, from custom fabrication to mobile welding. It can be done with both ferrous and non-ferrous metals of varying thicknesses, which makes carbon arc welding more versatile than other options. It’s also an easily portable way to weld, and very convenient too, as it can be done using less than pristine materials.

All in all, carbon arc welding is an ideal place for beginning welders to start, but due to its ability to form high-quality reliable welds, it can also be used by advanced technicians as well and allows room for flexibility in technique, heat level, length of arc, and type of current, all while preventing warping and oxidation. Carbon arc welding can be used to create strong welds that are resistant to corrosion and high temperatures. The few disadvantages of carbon arc welding include the fact that it is noisier than other welding methods, it may present issues when using thinner materials, and blow holes on the edges of a workpiece can be more common. Carbon arc welding also can release fumes and light that can be damaging to a welder, so, as always is true, protective gear is vital for safety while welding.

What Is Carbon Arc Welding Used For?

As mentioned, carbon arc welding can produce welds that are resistant to corrosive environments and high temperatures. This makes it a perfect technique for welding in shipbuilding applications, such as the large, thick metal parts used in structural frames in shipyards.  It is also often used in applications within the aerospace and chemical industries. Carbon arc welding’s inherent flexibility and portability are key factors that make it a must in these settings. It can also be used for heavy equipment repair and anywhere that requires the ability to fuse steel, such as in repair and construction scenarios. Structural work, such as forming the infrastructure in buildings and bridges also relies heavily on carbon arc welding for strong, resistant welds. Its portability makes it ideal for use in remote locations, such as on pipelines during installation, repair, or maintenance work that requires mobile welding.

Custom Fabrication and Welding Services In Cleveland, Ohio

At M&M Certified Welding, our team of expert welders have extensive experience in all forms of welding, including carbon arc welding. We work with companies from various industries, and are happy to provide you with a free quote for your next custom fabrication project, truck body fabrication requirements, or our mobile welding services. Get in touch with us to learn more about our full array of welding supplies and welding services in Cleveland.