Professional Documents
Culture Documents
metal joining
Subjects of Interest
Conventional joining techniques
Oxyacetylene welding
Electroslag welding
Resistance welding
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Objectives
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Gas welding
Oxyacetylene welding
Bolting
Arc welding
Riveting
Brazing
Soldering
Adhesive joining
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Power density
Deeper weld penetration
Higher welding speeds
Better weld quality
Less damage to the workpiece
Variation of heat input to the workpiece with
power density of the heat source.
Heat input
Weld strength
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www.arnoldsupplyinc.com
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www.engineeringyourfuture.com
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www.seas.upenn.edu
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Gas welding
Gas welding is a welding process that
melts and joints metals by heating them
with a flame caused by a reaction of fuel
gas and oxygen.
The most commonly used method is
Oxyacetylene welding, due to its high
flame temperature.
The flux may be used to deoxidize and
cleanse the weld metal.
The flux melts, solidifies and forms a
slag skin on the resultant weld metal.
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Oxyacetylene welding
There are three types of flame in oxyacetylene welding:
Neutral flame
Acetylene (C2H2) and O2 are mixed in
equal amounts and burn at the tip of the
welding torch. The inner cone gives 2/3
of heat whereas the outer envelope
provides 1/3 of the energy.
Reducing flame
The excess amount of acetylene is used,
giving a reducing flame. The combustion of
acetylene is incomplete (greenish) between
the inner cone and the outer envelope.
Good for welding aluminium alloys, high
carbon steels.
Oxidizing flame
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Disadvantages
Simple equipment
Portable
Inexpensive
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Deoxidation
Arc stabilization
Metal addition
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Disadvantages
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Shielding gases
Ar is heavier and offers more effective shielding and cheaper than He.
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Disadvantages
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Keyholing
Keyholing is a positive
indication of full penetration and
allow higher welding speed (for
thickness 2.5-6.4 mm).
Requires proper combinations
of the orifice gas flow, the travel
speed, and the welding current.
A wine cup shape is common in
PAW.
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Disadvantages
More complicated.
Full penetration.
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1. Globular transfer
Metal droplets travel across the arc gap under the
influence of gravity.
Often not smooth and cause spatter.
Low welding current (180A).
Globular transfer
2. Spray transfer
Occur above a critical current level (280-320A).
Small metal droplets travel across the gap under the
influence of the electromagnetic force at much higher
frequency and speed than in the globular mode.
More stable and spatter free.
Spray transfer
3. Short-circuit transfer
Molten metal droplets are transferred from electrode tip to the weld pool when it
touches the pool surface (short-circuit).
Require very low current and electrode diameter, giving small and fastfreezing weld pool desirable for welding thin section or out of position welding.
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Disadvantages
The GMAW gun is quite bulky
and difficult to reach small areas
or corners.
Ar shielding
75%He-25%Ar
shielding
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Disadvantages
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Electroslag welding
Electroslag welding (ESW) is a process that
melts and joins metals by heating them with a
pool of molten slag held between the metals and
continuously feeding a filler wire electrode into it.
The weld pool is covered with molten slag
and move upward as welding progresses.
A pair of water-cooled copper shoes keeps
the weld pool and the molten slag from
breaking out.
The molten slag protects the weld metal
from air and refine it.
The arc is only used during the initiation
process.
Electroslag welding
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Disadvantages
Very high heat input weld quality
could be poor due to coarse grain in
the fusion zone or heat affected
zone.
Strict to vertical position due to very
large weld pools.
Transverse cross
section of electroslag
weld in 70-mm thick
steel.
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Vacuum operation
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Disadvantages
Very high equipment cost.
High vacuum (10-3 10-6 torr) is
inconvenient. medium vacuum (10-3
25 torr) and non vacuum (1 atm) EBW
have also been developed.
Precise alignment of the joints and the
gun is required due to small beam size.
Missed jointed of dissimilar metal can
be obtained due to beam deflection.
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Laser beam welding with CO2 laser in 13-mm thick A633 steel.
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Disadvantages
Little distortion.
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Resistance welding
Resistance welding is used to join two or more metal parts together in a
localised area by the application of heat and pressure. The heat is
produced by the resistance of the material to carry a high amperage current.
There are at least seven different
types of resistance welding:
Electrode
Workpiece
Flash welding
High-frequency resistance welding
Percussion welding
Projection welding
Resistance seam welding
Resistance spot welding
Upset welding
Power
supply
www.fpe.co.uk
Projection welding
Spot welding
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Friction welding
Friction welding is a mechanical solid-phase
welding process in which heat generated by friction
is used to create high-integrity joint between similar
or dissimilar metals.
Can be used for round and
rectangular sections.
www.romanianbearings.ro
www.cetic.be
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public.ca.sandia.gov/
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Friction welding
Friction welding for rectangular sections
The heat generated due to frictional motions of the two workpieces, creating
a columnar microstructure as shown in figure.
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References
Kou, S., Welding metallurgy, 2nd edition, 2003, John Willey and
Sons, Inc., USA, ISBN 0-471-43491-4.
Gourd, L.M., Principles of welding technology, 3rd edition, 1995,
Edward Arnold, ISBN 0 340 61399 8.
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