Preparation: Before welding, the surfaces of the materials to be joined must be cleaned and prepared to ensure proper bonding. This may involve removing any rust, dirt, or contaminants using wire brushes, grinders, or chemical cleaners. Additionally, the edges of the materials may be beveled or chamfered to facilitate proper penetration and fusion during welding.

Fixture or Jig Setup: In many cases, the materials to be welded are held in position using fixtures or jigs to ensure accurate alignment and joint geometry. This helps to prevent distortion and misalignment during welding and ensures that the finished weld meets the desired specifications.

Heat Source: Welding is typically performed using a heat source to melt the base metals and create a molten pool that fuses them together. The heat source may be an electric arc, a gas flame, a laser, or a high-intensity beam of light, depending on the welding process being used.

Consumable Material: In some welding processes, a consumable material such as welding wire or welding rod is used to facilitate the bonding process. This material melts along with the base metals to form the weld joint. In other cases, no consumable material is required, and the base metals themselves are fused together.

Application of Heat: The heat source is applied to the joint area, raising the temperature of the materials to their melting point or above. As the materials melt, they form a molten pool that fuses together to create the weld joint.

Cooling and Solidification: Once the welding process is complete, the weld joint is allowed to cool and solidify, forming a strong and permanent bond between the materials. The cooling rate and post-welding treatments may influence the mechanical properties and integrity of the weld.

Inspection and Quality Assurance: After welding, the finished weld is inspected to ensure that it meets the specified quality standards and requirements. This may involve visual inspection, non-destructive testing (such as X-ray or ultrasonic testing), and mechanical testing to assess the strength, integrity, and dimensional accuracy of the weld joint.