Chapter 30 Fundamentals of Joining. Materials Processing. Topics. MET Manufacturing Processes

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1 MET Manufacturing Processes Chapter 30 Fundamentals of Joining Before you begin: Turn on the sound on your computer. There is audio to accompany this presentation. Materials Processing Chapters Chapters Chapters Chapters Chapter 30-2 Topics Introduction to Consolidation Processes. Classification of Welding and Thermal Cutting Processes. Welding Basics and Common Concerns. Types of Fusion Welds and Joints. Design Considerations.. Weldability or Joinability. Chapter

2 Consolidation Processes Consolidation processes include: Welding, brazing and soldering involve solidification of molten metal. Discrete fasteners nuts, bolts, screws, rivets. Adhesive bonding any material can be bonded to any other material. Other techniques such as shrink fits, slots/tabs, and other mechanical methods. Chapter 30-4 Consolidation Processes Welding is the permanent joining of two materials, usually metals, by coalescence, which is induced by a combination of: Temperature Pressure Metallurgical conditions Welding has become the dominant method of joining in manufacturing, and a large of metal products would have to be drastically modified, or it would be far more costly if it were not available. Chapter 30-5 Introduction to Welding Process Coalescence is the merging of two or more particles into one Coalescence between two metals requires sufficient proximity and activity between the atoms of the pieces being joined to cause the formation of common crystals. Chapter

3 Introduction to Welding Process Ideal Metallurgical Bond, for which there would be no noticeable or detectable joint would require: Perfectly smooth, flat, or matching surfaces. Clean surfaces free from oxides, absorbed gases, grease, and other contaminants. Metals with no internal impurities. Two metals that are both single crystal with identical crystallographic structure and orientation. Chapter 30-7 Introduction to Welding Process Ideal metallurgical conditions are difficult to achieve under laboratory conditions and virtually impossible to achieve in normal production. Various joining methods have been designed to overcome or compensate for the various deficiencies. Surface roughness can be overcome either by: Force, causing plastic deformation and flattening of the high points, or Melting the two surfaces so that fusion occurs. Chapter 30-8 Introduction to Welding Process Methods to overcome ideal condition deficiencies also entail different approaches to cleaning the metal surfaces prior to welding and preventing further oxidation or contamination during the joining process. Examples: Solid State Welding Mechanical or chemical cleaning, or causing sufficient metal flow so that impurities are squeezed out. Fusion Welding Fluxing Agents. Chapter

4 Introduction to Welding Process Production of a high-quality welds require: Source of satisfactory heat. Means of cleaning and protecting the metals to be joined. Avoid and/or compensate for harmful metallurgical effects that can occur. Chapter Classification of Processes American Welding Society (AWS) has classified various welding process and assigned short letter symbols as designators (Figures 30-1 and 2). Chapter 31 Gas and arc processes. Chapter 32 Resistance and solid state processes. Chapter 33 Brazing, soldering and other processes. Chapter Classification of Processes Figure 30-1 Classification of common welding processes along with their AWS designations. Chapter

5 Classification of Processes Figure 30-2 Classification of thermal cutting processes along with their AWS designations. Chapter Common Concerns Proper selection of the correct welding process eliminates most inherent problems. Proper joint design is critical of quality welds. Heating and solidification can change properties of base and filler materials. Weld properties also affected by: Dilution of filler by melted base metal. Vaporization of alloy elements. Gas-metal reactions. Chapter Common Concerns Weld Defects can include: Cracks in various forms Gas and shrinkage cavities Inclusions slag, flux and oxides Arc strikes and weld splatter Metallurgical changes Excessive distortion Unacceptable weld shape or contour Incomplete fusion between weld and base metal Incomplete penetration insufficient depth Chapter

6 Common Concerns Examples of cracks due to welding. Chapter Types of Fusion Welds Figure 30-4 Four basic types of fusion welds. Chapter Types of Fusion Welds Bead Weld or Surfacing Weld Made directly onto a flat surface. Requires no edge preparation. Used primarily for: Joining thin sheets Building up surfaces Depositing hard-facing materials Chapter

7 Types of Fusion Welds Groove Welds Used when full-thickness strength is desired on thicker material. Edge preparation between abutting edges is required. Used primarily for: When welding can occur from only one side. Pipeline welding. Chapter Types of Fusion Welds Groove Welds (continued) Common edge preparation configurations include: V, double-v, U and J. Chapter Types of Fusion Welds Fillet Welds Requires no special edge preparation. Used primarily for: Tee joints Lap joints Corner joints Figure 30-6 Preferred shape and the method of measuring the size of fillet welds. Chapter

8 Types of Fusion Welds Plug Welds Attaches one part on top of another and are often used to replace rivets or bolts. Chapter Types of Joints Joint design depends on: Type and amount of loading primary consideration. Cost and accessibility for welding: Secondary consideration to loading. Cost edge preparation. Type of equipment to be used. Speed and ease that the weld can be performed. Chapter Types of Joints Figure 30-7 Five basic joint designs for fusion welding. Chapter

9 Types of Joints Integrating the types of fusion welds and types of joint design. Chapter Design Considerations Monolithic or One Piece Structures Welding produces monolithic structures. When two pieces of material are welded together, they become one continuous piece. Significant complications: Cracking can propagate great distances through a structure resulting in failure. Large pieces of material behave differently compared to small pieces. Welded structures becoming too rigid. Chapter Design Considerations Figure 30-9 Effect of size on the transition temperature and energyabsorbing ability of a certain steel. While the larger structure absorbs more energy because of its size, it becomes brittle at a much higher temperature. Chapter

10 Design Considerations Liberty ship failures during early WWII is a famous example of monolithic structures becoming brittle to failure. Chapter Heating and cooling are integral to most welding processes. Fusion welding causes the base material to melt, followed by rapid cooling. Fusion welding can be thought of as a small metal casting in a large metal mold. Pool of molten metal is subject to all of the problems and defects associated with casting. Welding metallurgy is therefore an extensive and complex subject. Chapter Weld Pool or Fusion Zone Mixture of parent metals along with filler metal. The ratio of materials depends on the process used, the type of joint, and the edge preparation. Figure 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. Chapter

11 Heat-Affected Zone (HAZ): Adjacent to the fusion zone and wholly within the base material, is the undesirable heat-affected zone. The adjacent metal may well experience sufficient heat to bring about structure and property changes, such as phase transformations, recrystallization, grain growth, precipitation or precipitate coarsening, embrittlement or cracking. Chapter Heat-Affected Zone (continued): In steels, the structures can range from hard, brittle martensite all the way through coarse pearlite and ferrite. The HAZ may no longer possess the desirable properties of the parent material. Consequently, this is often the weakest area in the as-welded joint. Most welding failures originate in the HAZ. Chapter Figure Grain structure and the various zones in a fusion weld. Chapter

12 Figure 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. Chapter Rate of heat input significantly affects the metallurgy of the weld. Low rates of heat input tend to produce: Large total heat content Slow cooling rates Large HAZ Structures with lower strength and hardness. Structures with higher ductility. Chapter High rates of heat input tend to produce: Low total heat content Fast cooling rates Small HAZ Methods of controlling as-welded properties: Heat treatment after welding. Preheat base metal prior to welding. Chapter

13 Chapter Thermal-Induced Residual Stresses Residual are the result of thermal expansion and contraction restraint. Reaction residual stresses can contribute to cracking or failure during use. They can have magnitudes up to the yield strength of the parent metal. Chapter Residual stresses in a steel fusion weld measured using neutrons. The peak tensile stress is located at the weld center. Chapter

14 Effects of Thermal Stress: Distortion or Warping Control methods include: Minimizing total heat input to the weld. Oriented out of position so that distortion will move them to the desired final shape. Deposit weld metal in a specified pattern. Warping can be reduced by use of peening. Chapter Weldability or Joinability Not all joining processes are compatible with all engineering materials. Within a given process, the quality of results may vary greatly with variations in the process parameters, such as: Electrode material Shielding gases Welding speed Cooling rate Chapter Weldability or Joinability Chapter

15 The End See Oncourse for Videos Chapter

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