Most welders will be familiar with the concept of overlap in welding: the process of overlapping two materials in order to join them together. This common practice has been used in welding for hundreds of years, and is still one of the most reliable and secure methods available. Recent studies have shown that up to 75% of all welders use some form of overlap in their welding process, with a further 25% using multiple variations.
The use of overlap in welding provides superior strength and integrity, as well as giving welders the flexibility of having multiple methods at their disposal. This article explains the basics of what is overlap in welding, and the benefits of using it.
What is Overlap in Welding?Overlap in welding refers to an additional reinforcement of metal that is fused together for extra strength. It is often used when welding thick metal together, such as steel pipe and heavy duty structures, as additional reinforcement helps to increase bond strength and prevent cracking or buckling of the material.
Welders use a number of techniques to increase the bond strength, including lap, full and partial overlaps.
Techniques of Overlap Welding
- Lap Welding: This welding technique involves overlapping the edges of two metal pieces and fusing them together.
This technique is especially useful if structural stability is a priority, as lap welds are as strong as a single piece of metal.
- Full Overlap Welding: This welding technique involves completely covering the edges of two metal pieces with an additional metal piece. This technique provides maximum strength and is especially useful for welding pieces of metal together that are thicker than normal.
- Partial Overlap Welding: This welding technique involves partially covering the edges of two metal pieces with an additional metal piece. This technique is less strong than full overlap welding and is often used when welding thinner pieces of metal together.
Advantages of Overlap Welding
- Overlap welding increases bond strength and prevents cracking or buckling of the material.
- It can be used to weld pieces of metal together that are thicker or thinner than normal.
- It can be used in welding applications where other welding techniques are not practical.
- It can be used to weld both ferrous and non-ferrous metals.
- It can be used for both indoor and outdoor welding applications.