Why is it critical to match the welding process to the base material?

Matching the welding process to the base material is vital because it assures compatibility of thermal and mechanical properties. Each type of base material has specific characteristics, such as thermal conductivity, melting point, and tensile strength. The welding process must align with these properties to ensure effective fusion, avoid defects like cracking or warping, and achieve a strong and reliable weld joint.

When the welding method is not compatible with the base material, it can lead to issues such as improper melting, overheating, or insufficient penetration, which compromises the integrity of the weld. For instance, different materials may require distinct heat input levels or filler materials to optimize their performance and prevent thermal distortion. Therefore, selecting the appropriate welding process based on the material is crucial for ensuring the weld's success and longevity.