Fusion Welding Processes

Welding Processes

Consumable Electrode
SMAW Shielded Metal Arc Welding GMAW Gas Metal Arc Welding SAW Submerged Arc Welding

Non-Consumable Electrode
GTAW Gas Tungsten Arc Welding PAW Plasma Arc Welding

High Energy Beam

Electron Beam Welding Laser Beam Welding

SMAW Shielded Metal Arc Welding

Welding Processes

Consumable electrode Flux coated rod Flux produces protective gas around weld pool Slag keeps oxygen off weld bead during cooling

General purpose weldingwidely used

Thicknesses 1/8 3/4 Portable

Power... Current I (50 - 300 amps) Voltage V (15 - 45 volts) Power = VI 10 kW

Electric Arc Welding -- Polarity

Welding Processes

SMAW - DC Polarity
Straight Polarity Reverse Polarity

() (+)
Shallow penetration (thin metal)

(+) ()
Deeper weld penetration

AC - Gives pulsing arc

- used for welding thick sections

GMAW Gas Metal Arc Welding (MIG)

Welding Processes
DC reverse polarity - hottest arc AC - unstable arc

Gas Metal Arc Welding (GMAW) Torch

MIG - Metal Inert Gas Consumable wire electrode Shielding provided by gas Double productivity of SMAW Easily automated

Groover, M., Fundamentals of Modern Manufacturing,, p. 734, 1996

SAW Submerged Arc Welding

Welding Processes

300 2000 amps (440 V)

Consumable wire electrode Shielding provided by flux granules Low UV radiation & fumes Flux acts as thermal insulator Automated process (limited to flats) High speed & quality (4 10x SMAW) Suitable for thick plates
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Gas Metal Arc Welding (GMAW) Torch

GTAW Gas Tungsten Arc Welding (TIG)

Welding Processes

Current I (200 A DC) (500 A AC) Power 8-20 kW

a.k.a. TIG - Tungsten Inert Gas Non-consumable electrode With or without filler metal

Shield gas usually argon

Used for thin sections of Al, Mg, Ti. Most expensive, highest quality

Laser Welding Laser beam produced by a CO2 or YAG Laser High penetration, high-speed process Concentrated heat = low distortion Laser can be shaped/focused & pulsed on/off Typically automated & high speed (up to 250 fpm) Workpieces up to 1 thick

Welding Processes

Typical laser welding applications :

Catheters & Other Medical Devices Small Parts and Components Fine Wires Jewelry Small Sensors Thin Sheet Materials Down To 0.001" Thick

Solid State Welding Processes

Welding Processes

Friction Welding Diffusion Welding Ultrasonic Welding Resistance Welding

Friction Welding (Inertia Welding) One part rotated, one stationary

Welding Processes

Stationary part forced against rotating part Friction converts kinetic energy to thermal energy Metal at interface melts and is joined When sufficiently hot, rotation is stopped & axial force increased

Resistance Welding

Welding Processes

Resistance Welding is the coordinated application of electric current and mechanical pressure in the proper magnitudes and for a precise period of time to create a coalescent bond between two base metals.

Heat provided by resistance to electrical current (Q=I2Rt) Typical 0.5 10 V but up to 100,000 amps! Force applied by pneumatic cylinder Often fully or partially automated - Spot welding - Seam welding

Resistance Welding

Welding Processes

Resistance Welding is the coordinated application of electric current and mechanical pressure in the proper magnitudes and for a precise period of time to create a coalescent bond between two base metals.

Heat provided by resistance to electrical current (Q=I2Rt) Typical 0.5 10 V but up to 100,000 amps! Force applied by pneumatic cylinder Often fully or partially automated - Spot welding - Seam welding

Diffusion Welding

Welding Processes

Parts forced together at high temperature (< 0.5Tm absolute) and pressure
Heated in furnace or by resistance heating Atoms diffuse across interface After sufficient time the interface disappears Good for dissimilar metals

Bond can be weakened by surface impurities

Kalpakjian, S., Manufacturing Engineering & Technology, p. 889, 1992

Soldering & Brazing Soldering & Brazing

Metal Joining Processes

Only filler metal is melted, not base metal

Lower temperatures than welding Filler metal distributed by capillary action Metallurgical bond formed between filler & base metals Strength of joint typically stronger than filler metal itself weaker than base metal gap at joint important (0.001 0.010)

Pros & Cons

Can join dissimilar metals Less heat - can join thinner sections (relative to welding) Excessive heat during service can weaken joint

Soldering Soldering Solder = Filler metal Alloys of Tin (silver, bismuth, lead) Melt point typically below 840 F Flux used to clean joint & prevent oxidation separate or in core of wire (rosin-core) Tinning = pre-coating with thin layer of solder Applications: Printed Circuit Board (PCB) manufacture Pipe joining (copper pipe) Jewelry manufacture Typically non-load bearing

Metal Joining Processes

Easy to solder: copper, silver, gold Difficult to solder: aluminum, stainless steels (can pre-plate difficult to solder metals to aid process)

PCB Soldering Manual PCB Soldering

Metal Joining Processes

PTH - Pin-Through-Hole connectors

Soldering Iron & Solder Wire

Heating lead & placing solder

Heat for 2-3 sec. & place wire opposite iron

Trim excess lead

PCB Reflow Soldering Automated Reflow Soldering

Metal Joining Processes

SMT = Surface Mount Technology

Solder/Flux paste mixture applied to PCB using screen print or similar transfer method

Solder Paste serves the following functions: supply solder material to the soldering spot, hold the components in place prior to soldering, clean the solder lands and component leads prevent further oxidation of the solder lands.
Printed solder paste on a printed circuit board (PCB)

PCB assembly then heated in Reflow oven to melt solder and secure connection

Brazing Brazing

Metal Joining Processes

Use of low melt point filler metal to fill thin gap between mating surfaces to be joined utilizing capillary action
Filler metals include Al, Mg & Cu alloys (melt point typically above 840 F) Flux also used Types of brazing classified by heating method: Torch, Furnace, Resistance Applications: Automotive - joining tubes Pipe/Tubing joining (HVAC) Electrical equipment - joining wires Jewelry Making Joint can possess significant strength

Brazing Brazing

Metal Joining Processes

Use of low melt point filler metal to fill thin gap between mating surfaces to be joined utilizing capillary action
Filler metals include Al, Mg & Cu alloys (melt point typically above 840 F) Flux also used Types of brazing classified by heating method: Torch, Furnace, Resistance Applications: Automotive - joining tubes Pipe/Tubing joining (HVAC) Electrical equipment - joining wires Jewelry Making Joint can possess significant strength

Brazing Brazing Figuring length of lap for flat joints.

X = Length of lap T = Tensile strength of weakest member W = Thickness of weakest member C = Joint integrity factor of .8 L = Shear strength of brazed filler metal Lets see how this formula works, using an example.

Metal Joining Processes

Problem: What length of lap do you need to join .050" annealed Monel sheet to a metal of equal or greater strength? Solution: C = .8 T = 70,000 psi (annealed Monel sheet) W = .050" L = 25,000 psi (Typical shear strength for silver brazing filler metals) X = (70,000 x .050) /(.8 x 25,000) = .18" lap length

Soldering & Brazing Brazing

Metal Joining Processes

Figuring length of lap for tubular joints.

X = Length of lap area W = Wall thickness of weakest member D = Diameter of lap area T = Tensile strength of weakest member C = Joint integrity factor of .8 L = Shear strength of brazed filler metal Again, an example will serve to illustrate the use of this formula. Problem: What length of lap do you need to join 3/4" O.D. copper tubing (wall thickness .064") to 3/4" I.D. steel tubing? Solution: W = .064" D = .750" C= .8 T = 33,000 psi (annealed copper) L = 25,000 psi (a typical value) X = (.064 x (.75 .064) x 33,000)/(.8 x .75 x 25,000) X = .097" (length of lap)