Chapter Outline. Joining Processes. Welding Processes. Oxyacetylene Welding. Fusion Welding Processes. Page 1. Welded Joints
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1 Joining Processes Chapter Outline R. Jerz 1 4/16/2006 R. Jerz 2 4/16/2006 Welding Processes Welded Joints Gas, electricity, or other heat source? Is electrode consumed? Is a filler material used? Is flux used? Anything else? Video Introduction to welding R. Jerz 3 4/16/2006 R. Jerz 4 4/16/2006 Fusion Welding Processes Video Fusion welding processes Oxyacetylene Welding Acetylene gas most common (6,000 F) Welding Cutting Straightening Can be with or without filler R. Jerz 5 4/16/2006 R. Jerz 6 4/16/2006 Page 1 1
2 Oxyacetylene Torch Weld Joint Structure Figure 30.2 (a) General view of and (b) cross-section of a torch used in oxyacetylene welding. The acetylene valve is opened first; the gas is lit with a spark lighter or a pilot light; then the oxygen valve is opened and the flame adjusted. (c) Basic equipment used in oxyfuel-gas welding. To ensure correct connections, all threads on acetylene fittings are left-handed, whereas those for oxygen are right-handed. Oxygen regulators are usually painted green, and acetylene regulators red. R. Jerz 7 4/16/2006 Figure Characteristics of a typical fusion-weld zone in oxyfuelgas and arc welding. Figure Grain structure in (a) deep weld and (b) shallow weld. Note that the grains in the solidified weld metal are perpendicular to their interface with the base metal (see also Fig. 10.3). (c) Weld bead on a cold-rolled nickel strip produced by a laser beam. (d) Microhardness (HV) profile across a weld bead. R. Jerz 8 4/16/2006 Arc Welding Processes Gas-Tungsten Arc Welding Nonconsumable electrode Gas tungsten-arc (TIG) Plasma arc (PAW) Consumable electrode Shielded metal arc (SMAW) Gas metal arc (GMAW or MIG) Flux-cored arc welding (FCAW) Submerged arc welding (SAW) Video TIG welding Figure 30.4 (a) The gas tungsten-arc welding process, formerly known as TIG (for tungsten inert gas) welding. (b) Equipment for gas tungsten-arc welding operations. R. Jerz 9 4/16/2006 R. Jerz 10 4/16/2006 Plasma-Arc Welding Process Video plasma arc welding 60,000 degrees F Shielded-Metal Arc Welding Video shielded metal arc welding Figure 30.7 Schematic illustration of the shielded metal-arc welding process. About 50% of all large-scale industrial welding operations use this process. R. Jerz 11 4/16/2006 R. Jerz 12 4/16/2006 Page 2 2
3 Shielded-Metal Arc Welding Gas Metal-Arc Welding Figure 30.8 A deep weld showing the buildup sequence of eight individual weld beads. Videos gas metal arc welding R. Jerz 13 4/16/2006 R. Jerz 14 4/16/2006 Fluxed-Cored Arc-Welding Video flux core welding Submerged-Arc Welding Video submerged-are welding Figure Schematic illustration of the flux-cored arc welding process. This operation is similar to gas metal-arc welding, shown in Fig R. Jerz 15 4/16/2006 Figure 30.9 Schematic illustration of the submerged arc welding process and equipment. The unfused flux is recovered and reused. R. Jerz 16 4/16/2006 Other Welding Processes Weld Design Electron beam - video Laser beam - video Figure Some design guidelines for welds. Source: After J.G. Bralla. R. Jerz 17 4/16/2006 R. Jerz 18 4/16/2006 Page 3 3
4 Welded Joints Metallurgy concerns Solidification process Heat-affected zone - weakest part of joint Defects in Fusion Welds Figure Examples of various discontinuities in fusion welds. Figure Examples of various defects in fusion welds. R. Jerz 19 4/16/2006 R. Jerz 20 4/16/2006 Cracks in Welded Joints Distortion of Parts After Welding Figure Types of cracks developed in welded joints. The cracks are caused by thermal stresses, similar to the development of hot tears in castings (see also Fig ). R. Jerz 21 4/16/2006 Figure Distortion of parts after welding. (a) Butt joints and (b) fillet welds. Distortion is caused by differential thermal expansion and contraction of different regions of the welded assembly. R. Jerz 22 4/16/2006 Weld Testing Solid-state Processes Mechanical methods Ultrasonic Friction Electrical Resistance Figure (a) Specimen for longitudinal tension-shear testing; (b) specimen for transfer tension-shear testing; (c) wraparound bend test method; (d) three-point bending of welded specimens (see also Fig. 2.11). R. Jerz 23 4/16/2006 R. Jerz 24 4/16/2006 Page 4 4
5 Ultrasonic Welding Video - ultrasonic Ultrasonic Welding Vibrating tool at high frequency Lap joints of thin materials Figure 31.2 (a) Components of an ultrasonic welding machine for making lap welds. The lateral vibrations of the tool tip cause plastic deformation and bonding at the interface of the workpieces. (b) Ultrasonic seam welding using a roller as the sonotrode. R. Jerz 25 4/16/2006 R. Jerz 26 4/16/2006 Rub two parts together Video Friction welding Resistance (Spot) Welding (RW) Figure 31.6 (a) Sequence of events in resistance spot welding. (b) Cross-section of a spot weld, showing the weld nugget and the indentation of the electrode on the sheet surfaces. This is one of the most commonly used processes in sheet-metal fabrication and in automotivebody assembly. R. Jerz 27 4/16/2006 R. Jerz 28 4/16/2006 Video Resistance Welding Spot, projection, and seam Heating H=I 2 RT, where I=current R=electrical resistance T=time Spot Welding Equipment Figure 31.7 (a) Schematic illustration of an air-operated, rocker-arm, spot welding machine. (b) and (c) Two electrode designs for easy access into components to be welded. R. Jerz 29 4/16/2006 R. Jerz 30 4/16/2006 Page 5 5
6 Resistance Projection Welding Spot Weld Testing Figure (a) Schematic illustration of resistance projection welding. (b) A welded bracket. (c) and (d) Projection welding of nuts or threaded bosses and studs. (e) Resistance-projection-welded grills. R. Jerz 31 4/16/2006 Figure Test methods for spot welds: (a) tension-shear test, (b) cross-tension test, (c) twist test, (d) peel test. (see also Fig. 32.9). R. Jerz 32 4/16/2006 Brazing & Soldering Joint Designs used in Brazing Video Filler material Temperature below melting point of metals Differences from welding brazing alloy strength of brazing alloy capillary action Soldering - lower temperature than brazing R. Jerz 33 4/16/2006 Figure 32.3 Joint designs commonly used in brazing operations. The clearance between the two parts being brazed in an important factor in joint strength. If the clearance is too small, the molten braze metal will not penetrate the interface fully. If it is too large, there will be insufficient capillary action for the molten metal to fill the interface. R. Jerz 34 4/16/2006 Should be clean Joints Should have close tolerance Advantages of Brazing Join a variety of metals Quick Low temperature Automation is possible R. Jerz 35 4/16/2006 R. Jerz 36 4/16/2006 Page 6 6
7 Adhesives Adhesives Epoxies - most are 2 components Cyanoacrylates - super glues Anaerobics one component, cure when oxygen is removed Acrylics catalyst primer and adhesive Urethanes low temperatures Silicones - flexible joints Hot melts R. Jerz 37 4/16/2006 R. Jerz 38 4/16/2006 Advantages & Disadvantages Combination of materials Low temperature Joining of thin materials Joining of heat sensitive materials Inexpensive Less assembly time Unstable at higher temperature Destructive testing required Surface preparation Cure time R. Jerz 39 4/16/2006 Design for Assembly (DFM) Many ideas Function Cost Time DFM Video R. Jerz 40 4/16/2006 DFM - Concepts DFM Examples Reduce the number of parts Reduce number of fasteners Use modular designs Reduce need to handle several components at the same time Limit number of directions Use high quality components Design fasteners that can be easily automatically feed R. Jerz 41 4/16/2006 R. Jerz 42 4/16/2006 Page 7 7
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