Object XMLDocument
Object XMLDocument
1. 2. 3. 4. 5. 6. 7. 8. Arc Welding Resistance Welding Oxyfuel Gas Welding Other Fusion Welding Processes Solid State Welding Weld Quality Weldability Design Considerations in Welding
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Arc Welding
A pool of molten metal is formed near electrode tip, and as electrode is moved along joint, molten weld pool solidifies in its wake
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Consumable Electrodes
Forms of consumable electrodes Welding rods (a.k.a. sticks) are 9 to 18 inches and 3/8 inch or less in diameter and must be changed frequently Weld wire can be continuously fed from spools with long lengths of wire, avoiding frequent interruptions In both rod and wire forms, electrode is consumed by the arc and added to weld joint as filler metal
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Nonconsumable Electrodes
Made of tungsten which resists melting Gradually depleted during welding (vaporization is principal mechanism) Any filler metal must be supplied by a separate wire fed into weld pool
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Arc Shielding
At high temperatures in AW, metals are chemically reactive to oxygen, nitrogen, and hydrogen in air Mechanical properties of joint can be degraded by these reactions To protect operation, arc must be shielded from surrounding air in AW processes Arc shielding is accomplished by: Shielding gases, e.g., argon, helium, CO2 Flux
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Flux
A substance that prevents formation of oxides and other contaminants in welding, or dissolves them and facilitates removal Provides protective atmosphere for welding Stabilizes arc Reduces spattering
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
SMAW Applications
Used for steels, stainless steels, cast irons, and certain nonferrous alloys Not used or rarely used for aluminum and its alloys, copper alloys, and titanium
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Electrogas Welding
Electrogas welding using flux-cored electrode wire: (a) front view with molding shoe removed for clarity, and (b) side view showing molding shoes on both sides
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Little or no post-weld cleaning because no flux Disadvantages: Generally slower and more costly than consumable electrode AW processes
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Figure 31.12.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Resistance Welding
Resistance welding, showing components in spot welding, the main process in the RW group
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Cross-Wire Welding
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Oxyacetylene Welding
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Acetylene (C2H2)
Most popular fuel among OFW group because it is capable of higher temperatures than any other Up to 3480C (6300F) Two stage reaction of acetylene and oxygen: First stage reaction (inner cone of flame) C2H2 + O2 2CO + H2 + heat Second stage reaction (outer envelope) 2CO + H2 + 1.5O2 2CO2 + H2O + heat
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Oxyacetylene Torch
Maximum temperature reached at tip of inner cone, while outer envelope spreads out and shields work surface from atmosphere Shown below is neutral flame of oxyacetylene torch indicating temperatures achieved
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
High voltage (e.g., 10 to 150 kV typical) to accelerate electrons Beam currents are low (measured in milliamps) Power in EBW not exceptional, but power density is
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Thermit Welding
(1) Thermit ignited; (2) crucible tapped, superheated metal flows into mold; (3) metal solidifies to produce weld joint
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
TW Applications
Joining of railroad rails Repair of cracks in large steel castings and forgings Weld surface is often smooth enough that no finishing is required
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Forge Welding
Welding process in which components to be joined are heated to hot working temperature range and then forged together by hammering or similar means Historic significance in development of manufacturing technology Process dates from about 1000 B.C., when blacksmiths learned to weld two pieces of metal Of minor commercial importance today except for its variants
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Roll Welding
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
DFW Applications
Joining of high-strength and refractory metals in aerospace and nuclear industries Can be used to join either similar and dissimilar metals For joining dissimilar metals, a filler layer of different metal is often sandwiched between base metals to promote diffusion
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Explosive Welding
Commonly used to bond two dissimilar metals, in particular to clad one metal on top of a base metal over large areas
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Explosive Welding
Commonly used to bond two dissimilar metals, e.g., to clad one metal on top of a base metal over large areas (1) Setup in parallel configuration, and (2) during detonation of the explosive charge
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Friction Welding
(1) Rotating part, no contact; (2) parts brought into contact to generate friction heat; (3) rotation stopped and axial pressure applied; and (4) weld created
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Ultrasonic Welding
(a) General setup for a lap joint; and (b) close-up of weld area
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
USW Applications
Wire terminations and splicing in electrical and electronics industry Eliminates need for soldering Assembly of aluminum sheet metal panels Welding of tubes to sheets in solar panels Assembly of small parts in automotive industry
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Weld Quality
Concerned with obtaining an acceptable weld joint that is strong and absent of defects Also concerned with the methods of inspecting and testing the joint to assure its quality Topics: Residual stresses and distortion Welding defects Inspection and testing methods
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Welding Defects
Cracks Cavities Solid inclusions Imperfect shape or unacceptable contour Incomplete fusion Miscellaneous defects
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Welding Cracks
Fracture-type interruptions either in weld or in base metal adjacent to weld Serious defect because it is a discontinuity in the metal that significantly reduces strength Caused by embrittlement or low ductility of weld and/or base metal combined with high restraint during contraction In general, this defect must be repaired
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Welding Cracks
Various forms of welding cracks
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Cavities
Two defect types, similar to defects found in castings: 1. Porosity - small voids in weld metal formed by gases entrapped during solidification Caused by inclusion of atmospheric gases, sulfur in
weld metal, or surface contaminants 2. Shrinkage voids - cavities formed by shrinkage during solidification
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Solid Inclusions
Nonmetallic material entrapped in weld metal Most common form is slag inclusions generated during AW processes that use flux Instead of floating to top of weld pool, globules of slag become encased during solidification Other forms: metallic oxides that form during welding of certain metals such as aluminum, which normally has a surface coating of Al2O3
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Incomplete Fusion
A weld bead in which fusion has not occurred throughout entire cross section of joint Several forms of incomplete fusion are shown below
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Weld Profile in AW
(a) Desired profile for single V-groove weld joint, (b) undercut - portion of base metal melted away, (c) underfill - depression in weld below adjacent base metal surface, and (d) overlap - weld metal spills beyond joint onto part surface but no fusion occurs
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Visual Inspection
Most widely used welding inspection method Human inspector visually examines for: Conformance to dimensions, wWarpage Cracks, cavities, incomplete fusion, and other surface defects Limitations: Only surface defects are detectable Welding inspector must also decide if additional tests are warranted
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Destructive Testing
Tests in which weld is destroyed either during testing or to prepare test specimen Mechanical tests - purpose is similar to conventional testing methods such as tensile tests, shear tests, etc Metallurgical tests - preparation of metallurgical specimens (e.g., photomicrographs) of weldment to examine metallic structure, defects, extent and condition of heat affected zone, and similar phenomena
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Weldability
Capacity of a metal or combination of metals to be welded into a suitable structure, and for the resulting weld joint(s) to possess the required metallurgical properties to perform satisfactorily in intended service Good weldability characterized by: Ease with which welding is accomplished Absence of weld defects Strength, ductility, and toughness in welded joint
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e