Module 4

UNIT 1: MECHANICAL POWER TRANSMISSION

Engineering Materials: The materials which can be engineered and helpful for the human society. In modern age, man
developed numerous materials which are used in many applications including domestic use, industrial use, medicinal use, use
in automotive, marine, and aerospace divisions etc.

Classification (Types) of Engineering Materials:

Engineering Materials are broadly classified as Metals and Non Metals.

Metals: These are the elements which is opaque in nature, good conductor of electricity and heat.

Non Metals: These are the elements which may be transparent (glass) or may be opaque (wood), may be semi conductor
(silicon) or may be bad conductor (wood) of electricity, and bad conductor of heat.
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UNIT 2: METAL JOINING PROCESSES

Methods of Metal Joining Process:

1. Soldering: It is a method of joining two thin metal pieces using a dissimilar metal or an alloy by the application of heat. The
alloy of lead and tin, is used as a solder. Soldering technique is used for sheet metal work, plumbing work and electrical
junctions. The melting temperature of the solder ranges between 150℃ 𝑡𝑜 350℃ . Flux material is used to clean the joint
surfaces and to prevent the oxidation while soldering.

Method of Soldering (Soldering Iron Method):

• Application of Flux: Joining surfaces are coated with a flux (usually borax or rosin is used as flux material). Flux material
cleans the surfaces chemically and helps the solder in making a bond.

• Tinning of Surfaces to be Soldered: Before carrying out soldering operation, soldering iron must be coated with tin and this
process is called as tinning. It removes a thin film of oxide that forms on copper bit, otherwise bit will not allow the job to be
heated and thus it becomes difficult to solder. In tinning, the copper bit is heated and then rubbed with a file to clean it properly
and then rotating with solder using resin. This causes the formation of thin film of solder over the copper bit.

• Heating: Soldering iron is then heated and the flowing molten filler metal fills the joint interface. Allow the solder area to cool
and then solidify thus making the joint.

• Final Clean-Up: After completing the soldering, and the joints are formed. Cleaning the soldered surface with steel wool or
solvent to remove left over flux.
Types of Soldering:

1. Torch Soldering: In this type of soldering, the heat required for soldering operation is supplied by the flame of an oxy-
acetylene gas torch. Blow torch consists of a mixing chamber, where acetylene and oxygen are mixed in required
proportions and flame is directed towards the workpiece. The workpiece are then heated to the required temperature and
solder is fed into the joint area and due to heat it melts and flows into the gap between the joining workpieces. Upon
cooling, the joint is formed.

2. Wave Soldering: It is a large scale soldering process by which electronic components are soldered to a printed circuit
boards to form an electronic assembly. Here molten solder is pumped out of a narrow slot thus creating a waves, hence the
name wave soldering. The PCB is moved and the solder sticks to the component and solder pad by surface tension.

Advantages of Soldering:

• Low cost and easy to use.

• Soldered joints are easy to repair and solder joint can last for many years.

• Low energy is required to solder.

• Soldering does not change the microstructure of base material.

• Very low strength because soldering is applied for low melting point alloys.
3. Welding: It is the process of joining two metal pieces together to produce essentially single piece of metal. This process is
extensively used in fabrication work in which metal plates, rolled steel sections, castings of ferrous materials are joined
together. This process is also used for repairing broken, worn-out and defective metal parts.

Principle of Welding: It is the process in which the junction of the two parts to be joined are heated and then fused together with or
without the application of pressure to produce a continuity of the homogenous material of the same composition and the
characteristics of the parts which are being joined.

Types of Welding:

• Pressure Welding: In this type the parts to be joined are heated only up to the plastic state and then fused together by applying
the external pressure.

• Fusion Welding: In this type, the parts to be joined are heated to the molten state and allow to solidify. This type of welding is
also called as non-pressure welding.
Classification of Welding Process:

1. Arc Welding:

Principle of Welding

• When two conductors of an electric circuit are touched together momentarily and then instantaneously separated slightly,
assuming that there is sufficient voltage in the circuit to maintain the flow of current, and electric arc is formed.

• Concentrated heat is produced throughout the length of the arc at a temperature of about 5000 to 6000℃.

• Usually the parts to be welded are wired as one pole of circuit and electrode held by operator forms other pole.

• When the arc is produced, the intense heat quickly melts the workpiece metal, which is directly under the arc, forming small
molten metal pool,
• At the same time, the tip of the electrode at the arc also melts, and this molten metal of electrode is carried over by the arc to the
molten metal pool of the workpiece.

• The molten metal in the pool is agitated by the action of arc, thoroughly mixing the base and filler metal.

• Solid joint is formed, when the molten metal cools and solidifies.

• The flux coating over the electrode produces an inert gaseous shield surrounding the arc and protects the molten metal from
oxidizing by coming in contact with the atmosphere.

Components Used During Arc welding:

1. Arc Welding Machine:

• AC Welding Machine: It uses a stepdown transformer. Transformer receives the AC supply between 200 to 440 volts and
transforms it in to the required low voltage I the range of 80 to 100 volts. High current of 100A to 400A will be suitable for
general arc welding work.

• DC Welding Machine: Here workpiece is connected to the positive pole of DC generator and the electrode is connected to the
negative pole, in order to melt greater mass of metal in the base material. This kind of setup is said to have straight polarity.
When the less heat is required at the base material, the polarity is reversed.
2. Arc Welding Electrode:

• Consumable Electrode: It is an electrode which melts along with the workpieces and fill the joint. These are made up of
various metals depending upon their purpose and the chemical composition of the workpieces. The consumable either will be
bare or coated. When bare electrode is used, the molten metal while passing from electrodes absorbs oxygen and nitrogen from
the air to form non-metallic constituents, which gets trapped in the solidifying weld metal and thereby, decreasing the strength
of the joint. Where as coated electrodes facilitates protection from oxygen and nitrogen to the molten metal by providing
gaseous shield around the arc and molten metal pool. It forms slag over the joint thus protects from rapid cooling.

• Non-Consumable Electrode: Here along with electrode additional filler material is also required separately. The advantage of
using this type of electrode is that the amount of metal deposited by the filler rod can be controlled, which is not possible in
consumable type of electrodes.
2. Oxy-Acetylene Gas Welding:
Definition: When right proportion of oxygen and acetylene are mixed in the welding torch and then ignited, the flame produced at
the nozzle tip is called oxy-acetylene flame. This flame is used to join the two workpiece by melting them at high temperature is
called oxy-acetylene welding.

Working Principle:

• Components to be welded are checked for safety and correctness of setup.

• Pressure regulators fitted to the oxygen and acetylene cylinders are adjusted to correct pressure to draw the oxygen and acetylene
gas in required proportions from the cylinders respectively.

• Pressure regulator in each of the cylinder is fitted with two gauges. One gauge indicates the gas pressure inside the cylinder and
other gauge indicates the reduced pressure at which gas goes out.

• The respective gases from cylinders are carried from pressure regulators to the welding torch using rubber hose pipes.

• When gases reach the welding torch, these gases are allowed to mix in the mixing chamber and then gases are led out of the torch
through the blow pipe.

• High temperature of about 3200℃ is used to melt the work pieces.

• Flux material is used to dissolve and remove metal oxides formed during welding.

• The technique used to weld can be leftward or rightward.

• In leftward welding technique, the flame from torch preheats the material yet to be welded.

• In rightward welding technique, the flame from torch post heats the weld bead.

• The molten metal pool, that contains molten metal of the filler rod and workpiece solidifies to form a welded joint.