Professional Documents
Culture Documents
Welding
Jim Johnson
Zach Kirsch
Ross McKenzie
Topics to be Covered
Welding Topics:
MIG
TIG
Stick
Diffusion
Friction
Explosion
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6/1/2009
MIG Welding
MIG - History
Developed in 1940’s to
weld aluminum,
aluminum
magnesium, and other
non--ferrous alloys
non
Use in steel was originally
limited by cost of Inert gas
– It the early 1950’s carbon
dioxide was used as shielding
gas for steel greatly reducing
the cost
Further developments
through the 1960’s
increased the versatility of
the process
– Today GMAW is the most
commonly used industrial
welding process
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MIG - Equipment
(1) Welding Torch
– Controls
C t l arc, gas, wire
i feed
f d
(2) Workpiece
(3) Power Supply
-Typically constant voltage DC
(4) Wire Feed Mechanism
(5) Electrode
– Usually similar material as
workpiece
– Contains small amounts of
deoxidizing metals (Si, Mg, Al)
(6) Shielding Gas
– Typically argon-
argon-CO2 mix
MIG - Process
Arc creates weld p
pool to bond
material
– DC Constant Voltage with
positively charged electrode –
reverse polarity requires special
electrode
Shielding gas protects the
weld pool from atmospheric
gas effects
g
– Porosity and embrittlement
Technique
– Simple: electrode is fed
automatically
– Torch is guided along weld area
keeping a constant tip to
workpiece distance
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MIG – Capabilities
Inexpensive machines ($500)
R
Required
i d skill
kill level
l l is
i relatively
l ti l
low
Can weld many ferrous and non non--
ferrous materials
– Different results and requirements
must be expected (shielding gas,
technique, electrode, etc)
Power of machine will determine
what it can weld
– More power – thicker material
GMAW can be automated more
easily than other methods
MIG - Industries
Automotive
– Almost exclusive
Pressure Vessels
Heavy rail and
construction equipment
At Home
– Easy and inexpensive
Automobile/Agricultural
repair
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TIG - Welding
T
Tungsten
t IInertt G
Gas
(TIG) or Gas Tungsten
Arc Welding (GTAW)
AC or DC Electric Arc
Non--consumable
Non
tungsten electrode
l d
Shielding Gas
Hand fed filler
TIG - History
Early 1900’s
1900 s welding
non--ferrous materials
non
was difficult
– Reacted with air making
welds weak and porous
Process was improved
in the 1930’s and
1940’s
1940 s
– Gas shielding increased
weld quality
– AC machines allowed for
high quality welds on
aluminum and
magnesium
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TIG - Equipment
Welding Torch
– Di t shielding
Directs hi ldi gas and
d holds
h ld
electrode
Power Supply
– AC typically used for aluminum and
magnesium
– DC with a negatively charged
electrode is typically used for steels
Electrode
– Made from tungsten or tungsten
alloys
– ISO standards for each alloy
Filler Rod
Shielding Gas
– Argon is most common
– Helium is sometimes used when
welding aluminum and copper
TIG - Process
Arc creates weld pool to bond
material
– AC or DC used depending on
base material
Shielding gas protects the weld
pool from atmospheric gas
effects
– Porosity and impurities
Technique
– Requires
q two hands
– Torch is moved forward as filler
rod is dipped into the weld pool
– Filler rod must remain inside
the gas shield at all times
– Considered one of the most
difficult welding methods – low
melt alloys increase difficulty
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TIG – Capabilities
Produces welds with very similar material
properties of the base metal
GTAW can produce high quality welds on
materials such as aluminum, magnesium,
titanium, copper, nickel, steel.
Dissimilar materials – copper and stainless
at Zak
Requires a skilled welder – considered to be
one of the more difficult types of welding
Automation is possible, but not as common
as GMAW due to the increase complexities
TIG - Industries
Aircraft
Spacecraft
Bicycles
Crack repair
– Aluminum wheels and
engine blocks
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http://atpwelding.com/welding.jpg
Basic Principles
Arc created between
metal and electrode
Metal is melted and
coalesces to form weld
http://www.twi.co.uk/j32k/protected/band_3/jk2.html
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Coating
Different coatings for
different applications
Cellulosic, Rutile, and
Limestone are common
Coatings ease process
through slag creation,
and help to strengthen
weld
http://www.twi.co.uk/j32k/twiimages/jk82f1.jpg
Advantages/Disadvantages
Advantages: Disadvantages:
Simple Limited shielding
Portable Limited Deposition rates
Versatile Usually done by hand
Inexpensive Highly trained labor
equipment
q p required
q
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6/1/2009
Diffusion Welding
Also known by:
diffusion bonding, solid
state bonding
Can be used to join
metals and ceramics
that otherwise can’t be
joined
http://www.turktoz.gazi.edu.tr/en_makale_files/image037.jpg
Diffusion Welding
“Diffusion
Diffusion Welding is a solid
solid--state welding process
that produces a weld by the application of
pressure at elevated temperature with no
macroscopic deformation or relative motion of the
work pieces.”
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6/1/2009
Basic Principles
Two materials are
heated and pressed
upon one another
Pressure causes heated
atoms to diffuse into
surface, creating a
bond upon
recrystalization
D=D0e-(Q/KT) Messler 1999
Equipment
A press is needed,
needed
which can create
pressure in a variety of
ways
Heat needs to be
generated as well
Fixturing system
required
http://frisch-gmbh.de/images/sinteranlage.jpg
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6/1/2009
Advantages/Disadvantages
Advantages Disadvantages
“Perfect” weld possible Only perpendicular
Special material surfaces
properties Specially designed
Even weld properties components
throughout material Requires inert
Close tolerances atmosphere
Expensive materials Expensive
Friction Welding
(FW)
Solid state welding
process
Generates heat through
friction between moving
surfaces
Heat in combination
with lateral force called
“upset” fuses two
materials together
First Patent for the
development of FW was
applied for in 1891
http://www.fortunecity.com/village/lind/247/weld_book/fig10-79.gif
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Spin Welding
Involves the rotation of one
surface relative to another
while applying pressure along
the axis of rotation
Work pieces are held by
chucks in spin welding
machines
Flywheel is used to store the
energy
gy produced
p byy the motor
Requires circular joining points
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6/1/2009
Image: http://www.twi.co.uk/j32k/twiimages/spswksep99f9.gif
Image: http://www.eurotradeglobal.com/content/1124976586.jpg
Image: http://www.boeing.com/news/frontiers/archive/2004/september/
photos/sept_i_tt.jpg
Image: http://www.hitachi-cable.co.jp/ICSFiles/afieldfile/2005/12/26/1_1.gif
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Friction Surfacing
Coatingg of material applied
pp
to surface of another
material
Rod composed of coating
material is rotated under
pressure across the surface
of a separate material
Closely resembles a hot
forging
g g process
p so
problems associated with
more traditional welding
process are avoided
Image: http://www.frictec.co.uk/frictec-whatisfr.html
Advantages/Disadvantages
Fast jjoining
g times Uneconomical for short
Small heat affected zones production runs due to high
Joined with little preparation of equipment costs
surfaces Excludes delicate and intricate
Believed that “flash” carries part
away dirt and debris from
surfaces
Welding of dissimilar metals
Aerospace - Aluminum and Steel
Nuclear - Copper and Steel
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Explosion Welding
(EXW)
Welding Process
Image:http://content.edgar-online.com/edgar_conv_img/2007/03/08/0001104659-07-017391_G57151FCI001.JPG
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Advantages/Disadvantages
Large surfaces may be welded Brittle materials cannot be
Produces a high quality bond processed
Low cost Only simple shapes
Simple - Plates and Cylinders
Common Bi-
Bi-Metals
Produced
Copper
pp to Steel
Nickel to steel
Aluminum to steel
Tungsten to steel
Titanium to steel
Copper to aluminum
Other
SS/Al Ring
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Chart: http://www.aps.anl.gov/Facility/Technical_Publications/lsnotes/ls237/Images/ls237_t2.gif
Videos
http://video.google.com/videoplay?docid=-
http://video.google.com/videoplay?docid=
p // g g / p y -
7051110735654059178&q=friction+stir+welding&total=8&sta
rt=0&num=10&so=0&type=search&plindex=0&hl=en
http://video.google.com/videoplay?docid=8072096915190997
688&q=friction+welding&total=25&start=0&num=10&so=0&t
ype=search&plindex=2&hl=en
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