Manufacturing Processes

Definition:- The process of converting the raw material into finished products by using certain processes and/or machines.

Classification

Metal joining processes

Definition:-Small components are manufactured individually and then joined together to form the product.Such processes are called metal joining processes.

Types of Metal Joining Processes

Permanent Joints: Welding Brazing Soldering Adhesive bending Temporary Joints: Mechanical Fasteners (Nuts, bolts, rivets)

Welding

Definition:- The process of joining two metallic parts together by heating them to a plastic or semi molten state, with or without the application of a pressure and with or without a filler material.

Classification

Pressure Welding( Plastic welding) Parts to be joined are forced together by an external pressure Does not require filler material Non-pressure welding( Fusion welding) Metals parts to be joined are joined by heating without external pressure. Generally require filler material.

Pressure Welding
Forge Welding Resistance Welding Pressure Thermit Welding

(Electric) Resistance Welding

Heating is due to resistance of metal parts. The external pressure on the parts to be joined is applied by two electrodes. No filler material is used. Heat generated, H= I2RT

Classification
Spot welding Seam welding Projection welding

Resistance Welding (Spot)

Seam welding
Electrodes used are roller electrodes. Series of overlapping spots are obtained. Spot weld is made every time current reaches its peak during A.C. cycle (1/50th sec) resulting into continuous seam of overlapping weld spots. Suitable for thin metal sheets only.

Seam Welding

Resistance Welding

1)
2) 3) 4)

5)

Advantages:No filler material required. Fast and hence suitable for mass production Dissimilar materials can be welded. Process can be automated Does not require skilled worker

Resistance Welding
Disadvantages:1) Suitable only for parts 2) Cost is high Applications:1) Automobile bodies 2) Buiding of ships, aircrafts 3) Manufacturing of tubes, tanks

Non-Pressure (Fusion) Welding

Metals parts to be joined are joined by heating without external pressure. Generally require filler material. Types: Electric arc welding Gas Welding Non-pressure thermit welding

Electric arc welding

-ve terminal of power supply is attached to the electrode, while +ve terminal is attached to the workpieces. An electric arc is struck between an electrode and workpiece generating very high temperature.

Electric arc welding

Classification: Shielded metal arc welding (SMAW) Tungsten Inert Gas (TIG) arc welding Metal Inert Gas (MIG) arc welding Carbon arc welding

Electric arc welding

Electric arc welding

1)
2) 3) 4) 5)

Advantages:Suitable thin as well as thick jobs. Complecated shapes can be welded. Good quality and high strength. Less cost and simple. Does not require external pressure.

Electric arc welding

Disadvantages:1) Requires filler material 2) Time required is more as electrode is to be replaced after consumption. 3) Skilled worker is required. 4) Applications:1)Manufacturing of Bridges, towers, boilers, tanks, nuclear reactors. 2) Door, window frames, grills and other fabrication works.

Shielded Metal Arc Welding

Shielded Metal Arc Welding

Heating is done due to the electric arc between a flux coated consumable metal electrode and workpiece. No external pressure. Flux provides protective gas shield around the molten metal to avoid oxidation.

Tungsten Inert Gas (TIG) Arc Welding

Shielding around the molten metal is provided by the inert gas like helium, argon, etc. Tungsten electrode which is non-consumable. A separate filler material is used if required. Inert gas flows around the tungsten electrode through a nozzle. It removes contaminants from the workpieces.

Tungsten Inert Gas (TIG) Arc Welding

Tungsten Inert Gas (TIG) Arc Welding

Applications: Produces high quality welds for materials like Stainless steel, C.I., Cu and Al alloys, titanium, magnesium, etc. Used in food processing and pharmaceutical industries.

Metal Inert Gas (MIG) arc Welding

Heating due to Electric arc between Consumable metal electrode and the workpieces. Shielding around the molten metal is provided by the inert gas like helium, argon, etc. Inert gas flows around the consumable metal electrode through a nozzle. It removes contaminants from the workpieces.

Metal Inert Gas (MIG) arc Welding

Applications:- Similar to TIG welding

Comparison between TIG and MIG welding

Sr.No Parameter . 1. 2. Electrode Electrode TIG Non-consumable Tungsten wire MIG Consumable Metal wire similar to workpiece

3.
4. 5. 6. 7.

Electric arc
Filler material Speed Application Cost

Without melting wire

Separate Slow Thin metal section Low

Metal wire melts

Same Fast Thin as well as thick metals High

Comparison between Electric Resistance and Electric Arc Welding

Sr. Parameter No. 1. 2. Type Heating Resistance Pressure welding Due to resistance of metal parts Not required Thin parts Not skilled Arc Non-pressure welding Due to electric arc between electrode and workpieces Required Thin and thick parts Skilled

3. 4. 5.

Filler material Suitability Operator

6.

Application

Automobile bodies, ships, aircrafts

Bridges, Towers, fabrication works

Gas Welding
Non-pressure welding Heating is due to combustion of gases like acetylene, propane, butane, etc. Filler material is used.

Gas Welding

Gas Welding
Advantages:1)Controllable flame temp. 2)Portable equipment 3) Initial cost low. Disadvantages:1)Expensive gases 2)Safety problems 3)Not suitable for thick workpieces

Gas Welding
Applications: Sheet metal fabrication Automobile bodies Building of ships, aircrafts