Assignment of Advanced welding process

Group members

 1 gobeze hafte
 2 desta g/silassie
 3 negasi hadush
 4 mebrahtom luel
Advanced
welding
process
INTRODUCTION

 Welding is an art of joining metals by heating. The process of joining may also take
place by other means of riveting or by fastening nut and bolts.

 If a joint can be dissembled then joining method is called temporary joining method. If
the formed cannot be dissembled without breaking it then the joint is called permanent
join
Continued

 Normally in welding operation joining of metal pieces is done by raising their

temperature to the fusion point so that they form a sort of pool of molten metal at the
ends to the joined, sometimes, the pool is supplemented with a filler metal (wire or rod)
which normally has almost same compositions as that of the work pieces.

 This way the pool form a homogeneous mixture. It is allowed to get solidify to have a
permanent joint.
 SUBMERGED ARC WELDING

Submerged arc welding is a method in which The heat

requierd to fuse the metal is generated by an arc Formed by
an electric current passing Between electrod and the work
piece.

Ther is no visible arc and no sparks,spatter or fume.

The electrod may be a solid or cored wire or astrip.

SAW is normally a mechanized process.

Main components of a Submerged Arc
Welding unit:
The wire electrode reel, the wire feed motor equipped with grooved
wire feed rolls which are suitable for the demanded wire diameters, a
wire straightener as well as a torch head for current transmission, Flux
supply is carried out via a hose from the flux container to the feeding
hopper which is mounted on the Depending on the degree of
automation it is possible to install a flux excess pick up behind the
torch.

Submerged arc welding can be operated using either an A.C. power

source or a D.C. power source where the electrode is normally
connected to the positive terminal. Welding advance is provided by
the welding machine or by work piece movement.
Key SAW process variables :

Wire feed speed (main factor in welding current control)

Arc voltage

Travel speed

Electrode stick-out(ESO) or contact tip to work (CTTW)

Polarity and current type (AC or DC) and variable balance AC current
Material applications:

Carbon steels (structural and vessel construction)

Low alloy steels

Stainless steels

Nickel-based alloys

Surfacing applications (wear-facing, buildup, and corrosion resistant overlay of

steels)
Advantages :
High deposition rates (over 45 kg/hr. have been reported).
High operating factors in mechanized applications.
Deep weld penetration.

Sound welds are readily made (with good process design and control).
High speed welding of thin sheet steels up to 5 m/min is possible.
Minimal welding fume or arc light is emitted.

Practically no edge preparation is necessary.

The process is suitable for both indoor and outdoor works.
Low distortion

Welds produced are sound, uniform, ductile, corrosion resistant and have good
impact value.
Single pass welds can be made in thick plates with normal equipment.
the arc is always covered under a blanket of flux, thus there is no chance of
spatter of weld.
50% to 90% of the flux is recoverable, recycled and reused.
Limitations:

Limited to ferrous (steel or stainless steels) and some nickel-based alloys.

normally limited to long straight seams or rotated pipes or vessels.

requires relatively trouble some flux handling systems.

Flux and slag residue can present a health and safety concern.
requires inter-pass and post weld slag removal.
ELECTRON BEAM WELDING

 EBW is a fusion welding in which coalescence is produced by heating and

consequently melting the work piece due to impingement of the concentrated
electron beam of high kinetic energy on the work piece.

 As electron beam impinges the work piece ,the kinetic energy of the electron
beam gets converted in to thermal energy resulting in melting and even
evaporation of the work material.
Major equipment of EBW

 The major equipment of EBW is as follows



 Electron gun

 Power supply

 Vacuum chamber

 Work piece handling device

Advantages

 Minimal distortion

 Narrow melt zone and narrow heat affected zone

 Deep weld penetration in single path

 Vacuum process yields in clean and reproducible

 environment
Disadvantages

 high equipment cost

 time delay when welding in vacuum

 high weld preparation cost

 rapid solidification rate can cause cracking in some material

Application
 Electron beam welding process is mostly used in joining of
refractive materials like columbium, tungsten, ceramics and
which are used in missiles.

 It is used in high precision welding for electronic components,

nuclear fuel elements

 It is particular useful in joining dissimilar materials equipment

of EBW
 Continued...

 Laser Beam Welding

Laser Beam welding is a method of joining the work
pieces using the laser beam as a heating source. The laser
beam delivers a focused high density of energy heat

source resulting in narrow affected heat zones and deep

welds. Laser welding is a quality, precision, and highspeed
welding and automation can be implemented in the
process.
 Continued…

 The Process
Laser beam welding (LBW) is a process that melts and
joins metals by heating them with a laser beam. The laser beam
can be produced either by a solid- state laser or a gas laser. In
either case, the laser beam can be focused and directed by
optical means to achieve high power densities. In a solid-state
laser, a single crystal is doped with small concentrations of
transition elements or rare earth elements. For instance, in a
YAG laser the crystal of yttrium– aluminum–garnet (YAG) is
doped with neodymium. The electrons of the dopant element
can be selectively excited to higher energy levels upon exposure
to high-intensity flash lamps as shown in Figure 1
 Continued…
 Lasing occurs when these excited electrons return to their normal energy state, as
shown in Figure 1.The power level of solid-state lasers has improved
significantly, and continuous YAG lasers of 3 or even 5 kW have been developed.
In a CO2 laser, a gas mixture of CO2, N2, and He is continuously excited by
electrodes connected to the power supply and lases continuously. Higher power
can be achieved by a CO2 laser than a solid-state laser, for instance, 15kW. Figure
2 shows LBW in the keyholing mode. Figure 3 shows a weld in a 13-mm-thick
A633 steel made with a 15-kW CO2 laser at 20mm/s . Besides solid-state and gas
lasers, semiconductor-based diode lasers have also been developed. Diode lasers
of 2.5kW power and 1mm focus diameter have been demonstrated . While
keyholing is not yet possible, conduction mode (surface melting) welding has
produced full-penetration welds with a depth–width ratio of 3 : 1 or better in 3-
mm-thick sheets.
 Figure 2

Figure 1

Figure 3
Figure 4
Conti…
Advantages and Disadvantages
 LBW can produce deep and narrow welds at high welding
speeds, with a narrow heat-affected zone and little
distortion of the workpiece. It can be used for welding
dissimilar metals or parts varying greatly in mass and size.
 vacuum and x-ray shielding are not required in LBW.
However, the very high reflectivity of a laser beam by the
metal surface is a major drawback, as already mentioned.
Like EBW, the equipment cost is very high, and precise
joint fit-up and alignment are required.
Ultrasonic welding

 It is solid state welding process,which is no

external heat is added
 Ultrasonicwaves or vibrations are used to generate
heat for welding
 It used frequency from 20000 to 30000 Hz .
 Principle

 It works based on the principles of energy of

ultrasonic wave . ultrasonic vibration creates a
dynamic shear stress between the contacts of two
work piece, due to local plastic deformation heat
generate due to friction between contact
surface ,joint formation will takes place at the
interface.
Equipment used
 Advantages
• Easily automated and fast
• Produce high strength joint without applying external heat
• Provides clean and smooth surface finish after welding
• Able to weld dissimilar metal
 Disadvantages
Itdoes not weld hard and thick metal
Tooling cost for fixture is high and also need
special design
The vibration generates through transducer, can
damage electronic component
 Application
 Used in fabrication and nuclear reactor component
 Used in automotive industry for key, head lamp parts,
buttons and switches
 Used in electronic industries
 Alsoused in medical industries to make parts like filters,
masks
Some examples of ASSW processes include:

Frictionwelding (FRW)
Ultrasonic welding (USW)
Electron beam welding (EBW)
Laser beam welding (LBW)
Resistance welding (RW)
Advanced solid-state welding (ASSW)

is a processes that join materials without

melting them. ASSW process uses;
pressure,
heat,
 combination of both to create a strong
bond between the two materials.
Cont
 The specific working principle of ASSW
varies depending on the specific process
being used. However, all ASSW processes
involve the use of pressure and/or heat to
create a strong bond between the two
materials.
Friction welding (FRW)


1 Rotational friction welding; involves
rotating one part against a stationary component
2 Linear friction welding; moving part oscillates
laterally
3 Orbital friction welding; parts may not have
rotationally symmetric.
 the friction heat is due to relative movement of the joining parts.


and movement could circular vibratory motion of one or both parts.
Cont…..
Advantage
 High strength welds
 Excellent fatigue and corrosion resistance
 Ability to join a wide range of materials, including
dissimilar metals
 Low heat-affected zone
 Minimal distortion
 Fast cycle times
 Environmentally friendly
 Disadvantage

Complex and challenging processes

Can be expensive to implement
Requires specialized equipment and
expertise
May require post-weld heat treatment
in some cases
 Advanced explosive welding
AEW; is a solid-state welding process that uses controlled
explosions to join two or more metals together.
 can be used to join a wide range of materials,
including dissimilar metals.
 it uses a number of advanced techniques; Like lasers
and other advanced sensors
Working principle of advanced explosive
welding (AEW)

AEW works by using a controlled explosion

to create a high-velocity impact between two
metal plates.
The impact force plastically deforms the
surfaces of the plates.
this resulting deformation creates a strong
bond between the two materials.
General steps of working principle of
AEW
1. The two metal plates to be welded are placed in close proximity
to each other.
2. A controlled explosion is initiated, which creates a high-
velocity impact between the two plates.
3. The impact force plastically deforms the surfaces of the
plates.
4. The resulting deformation creates a strong bond
between the two materials.
Cont….
Laser-assisted explosive welding (LAEW):
 LAEW uses a laser to heat one of the metal plates before the
explosion.
 This helps to improve the quality of the weld by reducing the
amount of deformation that occurs.
 Shock wave explosive welding (SWEW):
 SWEW uses a shock wave generator to create a high-pressure
pulse that accelerates one of the metal plates.
 This helps to produce a weld with a very low heat-affected zone
Cont..
toimprove the quality and consistency of the welds
uses precision tool.

Application area;
aerospace, defense, automotive, and energy
Examples of AEW are;
Advantage
High strength welds
Excellent fatigue and corrosion resistance
Ability to join a wide range of materials,
including dissimilar metals
Low heat-affected zone
Fast cycle times
Minimal preparation required
Disadvantages

Complex and challenging process

Requires the use of explosives
Can be expensive to implement
Requires specialized equipment
and expertise