ASSIGNMENT-5 ENMT610029 WELDING

ANDARADHI NARARYA/1206291992

1. Explain the principle of cold welding. What type of materials can be joined by this
method and mention some requirements to be joined by this method.
Cold welding is one of the solid
state welding process in which
the working principle of the
pressure generated in the form of
the connection of two materials
at

room

temperature.

This

process requires no heat at all either from the outside or generated by the welding process.
The principle of cold welding is basically two workpieces both ends facing each other
(butt), clamped by forceps, then pressure is applied on both ends of the resulting splicing
process. This process requires a force large enough to contact a good interface.

The main requirement for the material can be joined by this method such as
o Least one metal which will have a resilient characteristic/very tough.
o The material not undergo drastic strain hardening.

2. Explain what the meaning of Threshold Deformation. Explain the relationship

between the deformation threshold deformations with the surface preparation for
cold welding process.
Threshold deformation is a very important parameter that is used to determine the
maximum force that can be achieved from cold welding process. The usability threshold
deformation is to determine the minimum limit that the material has a bond during cold
deformation.

The relationship between the threshold deformation by pressure and surface

preparation for cold welding process:
o High pressure on the material, the threshold deformation would be lower
and strength of the connection would be higher.
o The better the surface preparation, the threshold deformation would be
lower.

METALLURGY AND MATERIALS ENGINEERING

ASSIGNMENT-5 ENMT610029 WELDING

ANDARADHI NARARYA/1206291992

3. Calculate the minimum value of threshold deformation on aluminum material if they

joined by cold welding.
0 1
100%
t0

% =

Suppose:
Initial thickness (t0) = 30 mm
Final thickness (t1) = 12 mm
Thus,
% =

30 12
100%
30

% = 60%

4. Explain the principle of explosive welding with schematic drawings. Give an example
of application for this process.
Explosion welding is a
solid state welding process
in which a connection is
produced by the collision
(impact)

of

high-speed

workpiece by an explosion (detonation). The principle works using three components,

namely the base metal, prime metal, explosive. In detail, its working principle is:

Three components are arranged in which the prime component is placed on the
middle layer and a detonator at the top.

With detonator detonates the prime component will pound the base metal to plastic
deformation occurs and the two plates are connected.

METALLURGY AND MATERIALS ENGINEERING

ASSIGNMENT-5 ENMT610029 WELDING

ANDARADHI NARARYA/1206291992

Examples of such applications in the field at the time of the cladding material. Moreover,
usually explosive welding can be performed on material carbon steel with stainless steel,
titanium on low carbon steel, and iron-nickel base alloys in low carbon steel.

5. Explain the principle of ultrasonic welding with schematic drawings. Explain the
relationship between the energy used to heat the material properties and give the
examples of this application in the engineering field.
Ultrasonic welding is a solid state welding process in which a connection is produced by
air-frequency vibrational energy is high and the pressure on the workpiece. Bonding
connection (bonding) occurs in the absence of the parent metal smelting.
The principle of ultrasonic vibration generated by the transducer which is transmitted to
the tip of the sonotrode so that the two metal sheets which are connected will arise heat and
subsequent rupture of the oxide layer with the pressure of clamping will result in material
connected.

METALLURGY AND MATERIALS ENGINEERING

ASSIGNMENT-5 ENMT610029 WELDING

ANDARADHI NARARYA/1206291992

In ultrasonic welding method is the relationship between the energy needed and
weldability, which can be seen from the following formula:

Where:
E = Electrical Energy

H = Vickers Hardness Number

K = Constants from welding system

T = Thickness of workpiece sonotrode contact

From the formula can be the relationship that the harder a material is the energy required
would be even greater. This is also evidenced by the picture below.

Examples of the use of ultrasonic welding applications in the field is shown as the picture
below

METALLURGY AND MATERIALS ENGINEERING

ASSIGNMENT-5 ENMT610029 WELDING

ANDARADHI NARARYA/1206291992

6. Explain the principle of friction welding with schematic drawings. As well as the
advantages and limitations of the friction welding. Give an example of application in
the field of industry.
Friction welding is a solid state welding process in which a connection is obtained due to
the compressive force between the workpiece surface contacts with each other and rotating
relative to each other to generate heat and the plastic deformation of the surface of both
ends.

Principal:
o Two workpiece is pressed and rotated so that both will arise due to friction
heat.
o Furthermore is used for joining process.

Advantages
o Without molten metal
o Friction heating is localized thus there is no dispersion of heating
o Can be used to joining two different materials
o The process is faster

Limitations
o It is used for similar type of metal and similar geometry shape
o Usually for material which has a rod-like
o High cost
o The welding result depends on the preparation

METALLURGY AND MATERIALS ENGINEERING

ASSIGNMENT-5 ENMT610029 WELDING

ANDARADHI NARARYA/1206291992

Examples of the use of friction welding applications in the field are:

7. Explain the principle of friction-stir welding with schematic drawings. Give an

example of the material types to be joined with this method. Mention the advantages
for this process.
The principle of friction-stir welding:

The rotating pin at a speed of 3000-4000 rpm is placed on material

Material is heated due to friction

The material that has been heated to reach a plasticizer temperature (800F for
aluminum)

Plasticizer material draped back to pin

The material cooling with the formation of finer grain compared with parent
materials

METALLURGY AND MATERIALS ENGINEERING

ASSIGNMENT-5 ENMT610029 WELDING

ANDARADHI NARARYA/1206291992

Some metals generally applicable with friction-stir welding such as:

Aluminum and aluminum alloy

Magnesium

Copper

Zinc

lead

Advantages

More powerful and cleaner when compared to fusion welds

High tenacity in welding

Efficient energy

Simple and clean (no fume, arcs, or spatter)

Treatment after straightening is not necessary

Low distortion and shrinkage

There is no porosity, no lack of fusion, and no changing of material composition

METALLURGY AND MATERIALS ENGINEERING

ASSIGNMENT-5 ENMT610029 WELDING

ANDARADHI NARARYA/1206291992

8. Compare between the capabilities of the resistance spot welding with ultrasonic
welding on material.
Spot resistance welding
Has a melting areea

Ultrasonic welding
There is no melting area

In metals with high conductivity requires Be able to connect the different metals
high energy

(dissimilar)

even

metal

plated

(plating/coating)
The heat did not get to the center

For the metal having high conductivity (Cu,

Al) only requires lower energy

There are sparks that can cause a fire or Small pressure and heat needed to middle
explosion
Electrical shock susceptible

Generally used for relatively small-sized

metal

There is smoke on the welding process

Quality connection for the transfer uniform

energy and constant residual heat released
and limited to the connection area.

When using the current density is too high,

it can cause molten metal thrown and the
impact on the formation of cavities, cracks
and degrade the mechanical properties of the
weld results

METALLURGY AND MATERIALS ENGINEERING