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Chapter 30 Fundamentals of Welding Processes

This document discusses various joining processes with a focus on welding. It describes the different types of welding, including solid state and fusion welding. It discusses factors to consider for successful welding like joint design and defects to avoid. The document outlines various welding classifications and processes. It explains heat effects of welding and how they impact the material microstructure and properties. Welding can cause residual stresses and distortion that must be addressed during design.

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Nguyên Bành Quốc
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143 views28 pages

Chapter 30 Fundamentals of Welding Processes

This document discusses various joining processes with a focus on welding. It describes the different types of welding, including solid state and fusion welding. It discusses factors to consider for successful welding like joint design and defects to avoid. The document outlines various welding classifications and processes. It explains heat effects of welding and how they impact the material microstructure and properties. Welding can cause residual stresses and distortion that must be addressed during design.

Uploaded by

Nguyên Bành Quốc
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 28

Chapter 30:

Fundamentals of Joining
30.1 Introduction to Consolidation
Processes
 Consolidation Processes consist of
 Welding
 Brazing
 Soldering
 Fasteners
 Adhesives
 Shrink Fits
 Slots and Tabs
 Each Process has its own advantages and
disadvantages
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Welding

 Welding is the consolidation of two materials


by means of temperature and/or pressure to
cause the materials to melt or diffuse at the
joint.
 Welding can be done in a wide variety of
conditions and methods and is therefore on
of the most common consolidation processes.

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Welding

 There are two forms of welding


 Solid State welding where pressure and heat are
used to cause the diffusion at the joint, causing
the parts to fuse together
 Fusion welding where heat is applied to create
molten material at the joint, which fuses the parts
upon solidification
 Both process can cause changes in the
structure of the material, and must be
considered when selecting a process

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30.2 Classification of Welding and
Thermal Cutting Processes
 There are numerous Welding and Thermal
Cutting Process as shown on the next slide.
 Additional information on specific processes
are presented in:
 Chapter 31 presents gas and arc welding
processes
 Chapter 32 presents resistance and solid state
welding
 Chapter 33 presents other processes including
brazing and soldering

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Classification of Weld Process

FIGURE 30-1
Classification of
common welding
processes
along with their
AWS (American
Welding Society)
designations.

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30.3 Some Common Concerns

 Proper joint design is critical to a successful


weld
 Heating, melting, and resolidification can all
produce changes in microstructure of the material
and produce residual stress
 Welding can result in two basic types of defects
 Cracks Cavities
 Inclusions Unacceptable weld shape
 Incomplete fusion Incomplete penetration
 Arc strikes Spatter
 Metallurgical changes Excessive Distortion

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Common Weld Defects

FIGURE 30-3 Some common


welding defects.

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30.4 Types of Fusion Welds and Types of
Joints
 Bead welds (or surfacing weld): Limited
penetration so used on thin materials, or
surface modifications
 Groove welds: Used on thick materials,
requires joint preparation, used for single and
multiple passes
 Fillet welds: Use for tee, lap and corner joints
 Plug welds: Used a permanent replacement
for rivets or bolts
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Basic Fusion Welds

FIGURE 30-4 Four


basic types
of fusion welds.

FIGURE 30-6
Preferred shape and
the method of
measuring
the size of fillet welds.

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Basic Joint Designs of Fusion Welds

FIGURE 30-7 Five basic joint


designs for fusion welding.

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Weld Procedures

FIGURE 30-8 Various


weld procedures used
to produce welded
joints. (Courtesy
Republic Steel
Corporation,
Youngstown, OH).

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30.5 Design Considerations

 Welding produces monolithic, or one-piece,


structures
 Welded joints do not stop crack propagation,
cracks propagation typically does not travel
through a bolted joint
 Vibration stresses are transferred through a weld
joint, bolted joints adsorb some of the vibration
 Welded structure are more rigid than bolted
assemblies

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30.6 Heat Effects

 In fusion welding, the heat melts some of the


base material, which is then rapidly cooled,
creating changes in the granular structure.
 The pool of metal bonding the base material
is a blend of each material, and forms a cast
structure in the joint zone.
 Surrounding the pool of metal is the heat
affected zone, where metallurgical properties
have been changed.
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Butt Weld with Backing Plate

FIGURE 30-10 Schematic of a butt weld


between a plate of metal A and a plate of
metal B, with a backing plate of metal C and
filler of metal D. The resulting weld nugget
becomes a complex alloy of all four metals.

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Microstructure of a Fusion Weld

FIGURE 30-11 Grain structure


and various zones in a fusion
weld.

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Heat Effects (cont.)

 Deposition materials need as deposited properties


equal to the base metal.
 Solidification zone is subject to the all the problems
associated with casting.
 Heat affected zone is subjected to enough heat to
cause metallurgical changes, leading to phase
transformations, embrittlement, precipitation, or
cracking.
 The changes in properties are a function of the heat
input rate, which are a function of the weld process
used.

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Zone in a Fusion Weld

FIGURE 30-13 Schematic of a fusion weld in steel, presenting proper terminology for the
various regions and interfaces. Part of the heat-affected zone has been heated above the
transformation temperature and will form a new structure upon cooling. The remaining
segment of the heat-affected zone experiences heat alteration of the initial structure.
(Courtesy Sandvik AB, Sandviken, Sweden)

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Heat Rate of Welding Processes

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Heat Effects (cont.)

 Post weld heat treatment can be used to reduce the


impact of the heat affected zone.
 Size of HAZ will be increased with increased starting
temperature, decreased welding speed, increased the
thermal conductivity of the base metal and a decrease in
base metal thickness
 Welding techniques can be used to reduce the heat
distortion in welds
 Preheating the base metal also reduces weld
distortion
 Distortion is the result of thermally induced stresses
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Thermal Induced Residual Stress

 Thermal induced residual stress is the result of the


thermal expansion of the material and the
temperature gradient created during the welding
process.
 Thermal induced residual stress lead to part
distortion and cracking of the welds.
 Distortion can be reduced with the use of restraints,
though restraint in one direction is preferred.
 If parts are fully restrained during welding, additional
stresses, called reaction stresses are produced

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Stresses in a Weld

FIGURE 30-15 Shrinkage of a


typical butt weld in the transverse
(a) and longitudinal (b) directions as
the material responds to the induced
FIGURE 30-14 Schematic of stresses. Note that restricting
the longitudinal residual stresses transverse motion will place the
in a fusion-welded butt joint. entire weld in transverse tension.

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Warpage as a Result of Welding

FIGURE 30-16 Distortions or


warpage that may occur as a result
of welding operations: (a) V-groove
butt weld where the top of the joint
contracts more than the bottom;
(b) one-side fillet weld in a T-joint;
(c) two-fillet weld in a T-joint with a
high vertical web.

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Cracking as a Result of Welding

 The reaction stresses that contribute to


distortion are more often associated with
cracking during or immediately following the
welding operation.
 To minimize the possibility of fracture, welded
joints should be designed to keep restraint to
a minimum.

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Cracking as a Result of Welding

FIGURE 30-17 Various types and locations of cracking that can occur as a result of welding.

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30.7 Weldability or Joinability

 The weldability or joinability imply a reliable


measure of a material’s ability to be welded
or jointed, only a relative rating.
 The ability of a material to be welded
reliability is dependent upon the process
used and the skill of the operator.

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AWS Weldability

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Reference Problems

 Review Questions
 10, 23, 26, 29, 34

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