Unit Iii Solid State Welding

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UNIT III

SOLID STATE WELDING


CONTENT
 Cold welding
 Diffusion bonding
 Explosive welding
 Ultrasonic welding
 Friction welding
 Forge welding
 Roll welding
 Hot pressure welding
 Advantages, Limitations and applications
SOLID STATE WELDING

 SSW process in which coalescence is achieved by


frictional heat combined with pressure When properly
carried out, no melting occurs at faying surfaces
 No filler metal, flux, or shielding gases normally used
 Process yields a narrow HAZ
 Can be used to join dissimilar metals
 Widely used commercial process and mass production
Cold welding or Contact Welding
COLD PRESSURE WELDING
ROLE OF DIES
• The dies play an important role in the cold butt weld process.
Firstly, they must grip the material firmly and, therefore, the
inside of the cavity is either etched or made with an electric
pencil
• The gap between the two faces, or noses, of the die is also
extremely important. If it is too large, the material will just
collapse or bend away. This dimension is taken care of during
manufacture and cannot be changed.
ROLE OF DIES
Advantages

• As the process is performed at ambient


temperature, there are no thermal effects on the
parts being joined
• The process is fast
• It is simple and inexpensive to operate once dies
have been produced.
• The ends of the wire or rod need no preparation
to welding and the alignment of the two butt ends
is automatic as the material is placed in the die
Disadvantages
• Highly specialized with respect to joint design
and materials to be welded (soft iron that has
no carbon content)
• welds are made in the 'solid state' they are
difficult to inspect
Application
• Butt joints: Are primarily used for joining wires
and rods in diameters from 0.5mm up to
12mm
Diffusion Bonding
• Diffusion bonding is a solid-state welding technique,
wherein coalescence of the faying surfaces is
produced by the application of pressure and
temperature to carefully cleaned and mated metal
surfaces so that they actually grow together by
atomic diffusion.
• The process can join either like or dissimilar metals
with or without the use of another material
between.
• Any surface to be diffusion welded is never
extremely smooth.
• It has a number of peak points and valleys.
Moreover, this surface may have,
• (i) An oxidized layer (ii) Oil, grease, dirt etc.,
(iii) Absorbed gas, moisture.
Diffusion welding process involves two steps:
DIFFUSSION PROCESS
Diffusion Bonded Methods

1. Gas pressure bonding (815 oC.)

2. Vacuum fusion bonding (1150 oC and 700 Kg/cm2)

3. Eutectic bonding
Limitations of diffusion bonding
 A major difficulty is the removal of oxide and the
contaminating layers present on practically all metals exposed
to natural or industrial environment.

Diffusion welding requires a relatively long, time consuming


thermal cycle.

Diffusion welding is not classified as a mass production


process.
Application of Diffusion bonding
1. Fabrication of reactor components in atomic energy industries.

2. Fabrication of honeycomb, rocket engines, helicopter rotor hub, turbine


components, etc., in aerospace missile and rocketry industries.

3. Fabrication of composite materials.

4. It is most commonly used to join sheet metal structures in nuclear and


electronics industries.
Explosive welding
• Explosion welding is a solid-state welding process
that uses a controlled application of large
pressure generated by the detonation of applied
explosives.
• Welded parts are metallurgically bonded as a
result of oblique impact pressure exerted on them
by a controlled detonation of an explosive charge.
• Explosion welding is also a solid state welding
process. Welding occurs without application
of external heat.
• No addition of filler material.
• It is mainly used to join large surface area of
dissimilar materials.
TERMINOLOGY
Ultrasonic Welding
Ultrasonic welding is a solid state welding process in
which two work pieces are bonded as a result of a pressure
exerted to weld parts combined with application of high
frequency acoustic vibration (ultrasonic).
It uses the principle of conversion of high frequency
electrical energy into high frequency mechanical energy.
The components to be joined are held together under
pressure and subjected to vibrations, usually at a frequency
of 15 to 60 kHz.
The vibrations produced by a welding sonotrode or
sonometer or horn are used to soften or melt the
thermoplastic material at the joint line.
Welding times are lower than 3 seconds.
WORKING OF ULTRASONIC
WELDING
Step I:
The parts to be welded are placed into a locating holder.
Step II:
The ultrasonic tool descends to apply a clamping pressure between
the weld parts.
Step III:
When ultrasonic power flows for a given time, the tool then
vibrates at a certain frequency.
Step IV:
The base metals are then mechanically mixed causing a
metallurgical bond between parts. The parts are immediately
welded. There is no hold time or curing time required.
Step V:
Force is removed and machine is unloaded.
Friction welding (FW)
• Friction welding (FW) is a class of solid state
welding processes that generates heat
through mechanical friction between a
moving work piece and a stationary
component, with the addition of a lateral
force called "upset" to plastically displace
and fuse the materials.
Principles:
• Friction Welding (FRW) is a solid state welding process .
• In Friction Welding process heat is required to produce a
joint between two objects.
• One of the parts to be joined is rotated at a high speed
around 3000 revolutions per minute (rpm) and the other
part is axially aligned with the second one and pressed
tightly against it.
• The friction between the two parts raises the temperature
of both ends, then the rotation of the part is stopped
abruptly and the pressure on the fixed part is increased so
that the joining takes place.
STAGES OF 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
STAGES OF FW
UPSET LENGTH
Application
• Drill pipes and drill rods – welding of
connectors to pipes and rods.
• To fabricate piston rods.
ADVANTAGES
 Friction welding has become industry standard in
a number of applications.
 Weld monitoring can insure 100% weld quality
 Friction welding produces a 100% cross sectional
weld area
 Far superior weld integrity compared to MIG
welding
 Limited operator training require – full
automation also possible
Limitations

• At least one of the parts must be rotational


• Flash must usually be removed (extra
operation)
• Upsetting reduces the part lengths (which
must be taken into consideration in product
design)
FORGE WELDING
 Forge welding is a solid state welding process in
which components to be joined are heated to red
hot working temperature and then hammered
them together.
 The temperature required to forge weld is
typically 50% to 90% of the melting temperature.
 Before forge welding is done, the parts are
cleaned to prevent entrapment of oxides in the
joint.
• It is used to join both similar and dissimilar metals.
• Similar metal joints – By a solid state diffusion.
• Dissimilar metal joints – By the formation of a
lower melting temperature eutectic materials.
Metals which can be forge welded:
i. Wrought iron and low carbon steels (with C
content less than 0.2%)
ii. Forge welding can be carried out with metal
thickness up to about 30 mm.
Fuels and furnaces required:
Coal, coke, charcoal, gas and oil can be used in
furnaces required to heat objects to the plastic
state.
Heating must be uniform and neither too much
nor too little.
Surface Preparation:
Surfaces of the metal pieces to be forge – welded
are prepared by upsetting the pieces at the ends.
FORGE WELDING PROCEDURE
The parts to be forge welded are given an edge
or joint preparation
Then, the parts are heated to over 1000oC until
they are plastic. In this condition, the parts are
placed on the anvil end to end and are
hammered together, either using a power
hammer or manually, until they form a solid
structure of metal.
 An important requirement is that during heating
the absorption of sulphur from the coke of the fire
and scaling of the pieces(to be welded) should be
prevented or that if scale is formed, the hammering
should be done in such a way as to squeeze this out
of the joint and permit metal to metal contact.
 Besides being united by blows from a hammer, the
work pieces may also be welded by being rolled,
drawn or squeezed together.
• Types of forge welding:
– Fire welding: In which pieces to be joined are heated
in the fire by blacksmith. He with draws them at the
appropriate time and joints them by a hammer blow.
– Water gas welding: Edges of the plate (to be
converted into a pipe) are heated by water gas flame
(consisting essentially of hydrogen, carbon monoxide
and nitrogen) and as the attain appropriate
temperature, they are welded together under the
hammer or by means of pressure rollers.
APPLICATIONS
• Forge welding finds use in blacksmith shops, rail
road shops and repair shops of general
character.
• It is used in the production of pattern welded
blades.
• It is used in the manufacture of shotgun barrels.
• It is used for making pipes from plates by rolling
the plate to cylindrical form
ROLL WELDING

 In which pressure sufficient to cause coalescence


is applied by means of rolls either with or
without external heat.
 If the welding is done without applying heat, it
is called cold roll welding and if the heat is used
for welding, it is called hot roll welding.
 Coalescence occurs at the interface between two
parts by means of diffusion at the faying
surfaces.
 Parts to be welded should be ductile and free of
work hardening.
 If the parts to be welded are small, the pressure
applied by rolls is done by using simple hand
operated tools. For heavier sizes of parts, power
presses are used to apply pressure.
 One of the major uses of this process is the
cladding of mild steel or low-alloy steel with a
high-alloy material such as stainless steel. It is
also used for making bimetallic materials for the
instrument industry.
Advantages:
 The operation is easy and uses simple equipment.
 There is no need of using flux and filler metal.
 Less time is required
 No fumes, gases or smoke is generated.
Disadvantages:
 It needs extreme pressure to perform the welding process.
 The cost of equipment is high.
 Weld quality is less as compared to fusion welding.
 It is limited to welding of flat shapes.
Applications:
 Metals such as soft aluminium, copper, gold and silver can be easily
welded by roll welding.
 Roll welding is used to produce sandwich strips to convert into
coins.
 It is used in making bimetallic strips.
HOT PRESSURE WELDING PROCESS

 Hot pressure welding is a solid state welding process which produces


coalescence of materials with heat and the application of pressure
sufficient to produce macro deformation of the base metal.
 During welding, the coalescence occurs at the interface between parts
because of pressure and heat applied to produce an appreciable
deformation.
 The deformation of surface crashes the surface oxide film and it
increases the areas of clean metal. Welding this metal to the clean metal
is accomplished by diffusion across the interface. Therefore the
coalescence of the faying surface occurs.
 This type of operation is normally carried in closed chambers where
vacuum or a shielding medium may be used.
 The pressure is applied by means of a hot inert gas in a pressure
vessel. Generally heat is applied by flames of oxy-fuel torches
directed on the end surfaces of solid bars or hollow sections to be
joined.
 It is similar to both friction welding and flash welding although
source of heating is different.
 The materials to be welded must exhibit hot ductility or forgeability.
Therefore Cast Iron cannot be hot pressure welded.
 Carbon steels, low alloy steels and certain non ferrous metals can be
joined.
• There are five cycles that hot pressure welding
undergoes as follows
I. Load Phase
II. Melt Phase
III. Open Phase
IV. Seal Phase
V. Unload Phase
Advantages:
 Welding process is simple.
 It needs simple joint preparation.
 It ensures quick weld production.
 High quality joints are produced.
 No filler metal needed.
Limitations:
 Not all metals are weldable.
 Length of cycle is dependent on time for heating.
 Removal of flash and bulge are required after welding
Applications:
 It is used in aerospace industry.
 It is used in plastic welding.
 It is used in ship building.
 It is used for producing medical devices.
 It is used in automotive industries.

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