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Classification of

Manufacturing Processes

MEEG 217
Biraj Singh Thapa
27, Aug, 2007

Basic Classification of MP

Primary Shaping Process


Machining processes
Surface finishing processes
Joining processes
Processes affecting the change in
properties

Welding Technology

MEEG 217
Biraj Singh Thapa
27, Aug, 2007

Introduction
Welding is a process of joining two similar or
dissimilar metals by fusion,
with or with out the application of pressure,
and with or with out use of filler metal.

The fusion of metal take place by heat.


The heat may be obtained from:
electric arc,

electric resistance,
chemical reaction,
friction
or radiant energy

Classification of Welding

Classification of Welding

Gas Welding

MEEG 217
Biraj Singh Thapa
30, Aug, 2007

Introduction
Also called as oxy-fuel gas welding
Derives the heat from the combustion of a fuel gas in
combination with oxygen.
Fusion welding process is obtained by complete melting
of parent metals.
Filler rod may be used.
Useful fuel gases are:
Fuel Gas

Acetylene
Propylene
Propane
Hydrogen
Natural Gas

Chem Form.

C2H2
C3H6
C3H8
H2
CH4 + H2

Flame Tem (C)

3200
2500
2450
2390
2350

Oxy-Acetylene Welding
Acetylene mixed with oxygen in correct
proportion in welding torch and ignited gives the
flame of high temperature.

C2H2 + O2 = 2CO + H2 + Heat


2CO + H2 + 1.502 = 2CO2 + H2O + Heat

Types of Flame
Neutral Flame
5900F (3200C)
Mild Steel, Stainless Steel, Copper, Cast Iron
Oxidizing Flame
6300F
Copper based alloys for protective layer of slag
Reducing Flame
5500F
Lead and for Carburizing (Surface hardening)

Types of Flame

Types of Flame

Gas Welding Tools

Gas Welding Techniques


The flame is pointed in the
direction of welding.
This position permits uniform
preheating of the plate edges
immediately ahead of the
molten puddle.
Recommended for welding
material up to 1/8 in. (3.2
mm) thick.
A great deal of pipe welding
is done using this technique.

Gas Welding Techniques


The torch precedes the welding
rod, away from the direction of
welding.
The flame is directed at the
molten puddle.
The welding rod is between the
flame and the molten puddle.
Right hand welding may be used
with a slightly reducing flame,
increasing the carbon content,
which lowers the melting point of
a thin layer of steel and increases
welding speed.
This technique increases speed of
making pipe joints where the wall
thickness is 1/4 to 5/16 in. (6.4 to
7.9 mm).

Welding Torch

Welding Torch

The End

Brazing, Braze Welding &


Soldering

MEEG 217
Biraj Singh Thapa
31, Aug, 2007

Brazing
Process of joining two pieces of metals in which a nonferrous alloy is introduced in liquid state between workpiece. Heating source may be various types.
Melting point of filler metal is above 450C but less
than parent material.
Filler metal is distributed between the surfaces of the
joint by capillary action.
Fluxes (combination of borax, boric acid, chlorides,
fluorides and other wetting agents) are also added to
remove any of the oxide present.
Can join cast metals to wrought metals, dissimilar
metals and also porous components.
Used for pipe fittings, heat exchangers, electrical parts

Brazing
Common Filler metals:
Aluminum Silicon
Copper phosphorus
Copper Zinc
Silver
Magnesium
Nickel etc.
Advantages:
Less distortion, Quick finish, wide range of application
Limitations:
Tight mating parts, Proper cleaning, Limited size,
Costly, Poor color matching.

Braze or Bronze Welding


Similar to the Brazing but the joint is not
produced by the capillary or fusion, but by
adhesion.
Filler rod usually contain 60% copper and 40%
zinc.
Flux is applied to prevent oxidization.
Cheaper than Brazing but low in strength.
Both Brazing and Braze welding needs the pre
heating of the parent materials.
Both wildings are not successful at the elevated
temperatures.

Soldering
Similar to the Brazing but the filler metal used has
melting point less than 450C.
The filler material is called solder.

Composition of Some Solder are:

Soft solder: Lead 37% and Tin 63%


Medium solder: Lead 50% and Tin 50%
Electrician solder: Lead 58% and Tin 42%
Plumbers Solder: Lead 70% and Tin 30%

Some Fluxes are:


Inorganic (Corrosive): Zinc and Ammonium chloride
Organic (Mild): Latic Acid, Stearic Acid etc.
Rosins (Non Corrosive): Gum extruded from pine trees.

END

Arc Welding
MEEG 217
Biraj Singh Thapa
31, Aug, 2007

Introduction

Heat Source is Electric Arc (Plasma)


Without application of Pressure
With or without filler rod
AC Or DC Current supply can be used

Arc welding Equipment

AC / DC Machines
Step down transformers are used for AC
Machines to change the supply to 80-100
volts, 50-100 Amps.
DC machines are used for heavy works
and for the sites where AC source is not
available.
Straight and reverse polarity in DC
Machines (67% in +ve terminal)

Arc Crater
Small depression of
electric arc into parent
metal.
Can be adjusted by
operator.
Arc should not be broken.
The distance through the
center of the arc from the
tip of the electrode to the
bottom of arc is called arc
length. It should be 2-4
mm

Arc Blow
Wandering of arc due to electromagnetic
fields.
Present in DC Machines.
More at the ends of job.
Results porosity and other defects.
Ground connections should be placed as far
as possible.
Arc length and current should be reduced.

Electrodes
Consumable
Electrode melts along with parent metal and
get mixed to form a joint.
Sevres as heat source and filler rod.
Electrode material is close to that of parent
material

Non Consumable
Separate filler rod required if necessary
Better control of heat input and filler material
Carbon Graphite for DC
Tungsten for both AC and DC

Electrodes Cont
Bare Electrodes:
Additional flux is added if necessary
For carbon and Tungsten.
Striking of arc is difficult.

Coated Electrodes:

Available in form of stick of length 350 or 450 mm.


Gas forming flux: Starch, wood pulp etc
Slag forming flux: Manganese, Titanium ores
Reducing components, Alloys, Stabilizing and
binding components are also present.

Flux Shielded Metal Arc Wielding


Flux coated consumable electrodes produces
the heat by electric arc (750 Am.)
Temperature is
in range 2400C2700C
AC or DC may
be used
Simple & cheap
Limited length of
electrode
Chances of
moisture and
slag entrapment.

Carbon Arc Welding


Heat is obtained by electric struck in between a
non consumable carbon electrode and the work
piece. Graphite rod is also used.
Welding carried out in air or inert atmosphere
with or with out filler rod.
DC is usually used (Polarity!).
Twin carbon electrode arc welding has better arc
control. Arc is maintained between two carbon
electrodes held in special holder. (Movibility!)
Used for cast iron, steel, copper, bronze, rough
cutting material.
Simple & better control. But high arc blow and
chances of carbon infiltration in base metal.

Carbon Arc Welding Cont..

Metal Inert Gas (MIG)


Welding heat is produced from continuously fed
metal electrode and the job.
Ar, He, Co2 or mixture gas shields the arc and
molten metal.
The current from the welding machine is
changed by changing the rate of feeding of the
electrode wire:
If arc length decreases, voltages decreases and
current increases. Increased current melts the
electrode at the faster rate normalizing arc length
(Self adjusted arc).
Electrode feeding motor is controlled by the arc
voltage, change in arc length is thus adjusted by
change in feed rate (Self controlled arc).

MIG Operation

MIG Operation Contd

MIG Operation Contd

Advantages, Disadvantages &


applications of MIG

Tungsten Inert Gas (TIG)


Welding heat is produced from an electric arc
established between the non-consumable
tungsten electrode and the job.
A shielding gas (argon, helium, nitrogen etc.) is
used to avoid oxidation.
Argon requires a lower arc voltage, easier arc
starting.
Carbon dioxide is used for low temp, economical.
Helium can withstand higher arc voltage.
Filler material if required is fed separately.
Arc is struck either by touching the electrode with
a scrap tungsten or by using high frequency unit.
Both AC and DC power source can be used
(Polarity)

TIG Operation

TIG Contd

Submerged arc Welding (SAW)


Welding heat is produced from an electric arc
set up between bare metal electrode and job.
Arc, end of electrode and molten metal remain
submerged under a granular material
Initially flux is insulator but once melted it acts
as good conductor to maintain the electricity.
Continuously fed bare metal acts as filler rod.
For very faster rate welding (5m/min), with large
electrodes (12mm), for plates with 75mm thick
in butt at a single pass.
4000 A current can deposit metal up to 20kg/hr
Economical for larger works only.

SAW Operation

SAW Operation Contd

Electroslag Welding
Welding heat is produced by the molten slag,
which melts the filler metal and welding
surface.
Arc initiated between electrode and the work
is extinguished after flux is melted and the
molten conditions maintained by the its
resistance to current flow between electrode
and work.
Temperature of molten slag is 1650 -1950.
Water-cooled shoe or dam plate fastened to
the sides of the workpeice prevents the
molten metal from running off.

Electroslag Welding Operation

Electroslag Welding Operation

Advantages, Disadvantages &


applications of Electroslag Welding

Electrogas Welding
Similar process
electroslag welding, but
an inert gas is used for
shielding.
Flux cores wire is
automatically fed to the
molten weld pocket and
an electric arc is
continuously maintained.
Welding Shoes are used
to confine the weld metal
for the vertical positions.

Electrogas Welding Operation

Plasma Arc Welding


Plasma is formed when inert gase get ionized
after passing through arc and nozzle.
Welding heat is obtained from a constricted arc
set up between a tungsten electrode and water
cooled nozzle (non-transferred arc) or between
the electrode and job (transferred arc).
The process employs two inert gases, one forms
the arc plasma and the second shields the arc
plasma.
Filler metal may or may not be used.
Temeperature of the order 11000 C can be
obtained.

Plasma Arc Welding


Operation

Plasma Arc Welding Operation

Plasma Arc Welding Operation

Plasma Arc Welding Types

Plasma Arc Welding

Comparison Between PAW &


TIG

END OF
ARC WELDING

Resistance Welding

MEEG 217
Biraj Singh Thapa
07, Sept, 2007

Introduction

Welding heat is obtained from resistance of the


work to the flow of electric current and by the
application of pressure.
No filler metal or flux is added.
Heat balance is essential: Sizing electrode
proportional to thickness and thermal
conductivity.

Types:
1. Spot welding
2. Seam welding
3. Projection welding

4. Resistance butt welding


5. Flash butt welding
6. Percussion welding

Spot Welding
Overlapping sheets
are joined by local
fusion at one or more
spots by the heat and
pressure is applied by
the electrodes one
above and another
below the workspace.
Low cost, no edge
preparation, semiautomatic.
Used for automobiles,
house hold furniture's,
containers etc.

Spot Welding Operation

Spot
Welding
Operation

Seam Welding
Overlapping sheets are joined by local fusion
progressively along a joint by rotating the
circular electrodes.

Seam Welding

Projection Welding
Advancement of
spot welding.
One of the electrode
is provided with
number of
projections to help
to localize the
current at a
predetermined spot.
Projections of the order of 0.8 mm can be
obtained.
All the projections should be of same height

Resistance Butt Welding


(UPSET)
Job pieces to be
joined are held
tightly together and
current is applied
heating the entire
surface area.
Pressure is
increased when the
welding temperature
is reached.
For butt joints of
pipes, tubes etc.

Resistance
Butt
Welding

Flash Butt Welding


Similar to upset,
except the heat
required for melting
is obtained by
means of an arc
rather than simple
resistance heating.
Cheap, faster and
consumes less
current

Flash Butt
Welding

Percussion Welding
Welding heat is obtained
by arc produced by rapid
discharge of stored
electrical energy, using
capacitors.
Higher temp, Costly
devices

END

Other Welding

MEEG 217
Biraj Singh Thapa
7, Sept, 2007

Solid State Welding


Unlike the fusion welding, no molten phase is
present in the joint.
Two clean surfaces are brought into atomic
contact with each other under sufficient pressure
to form the bond and strong joint.
Strength depends upon pressure, temp and time
of contact.
Forge Welding:
The ends of the parts to be joined are heated to a
temperature slightly below the solidus temp and
pressure is applied to obtain the fusion.
Popular with black smiths works
For low carbon steels; flux is needed to prevent
oxides

Solid State Welding


Friction Welding:

Welding heat is obtained


by the friction between
the ends of the two parts
to be joined.
Center Lathe like
machine is used.
Used for joining different
metals, Aerospace
engineering, Tools
manufacture

Solid State Welding


Diffusion Welding:

Strength of joint results primarily from diffusion and


secondarily from plastic deformation.
Required temp is 0.5 MP, Usually Vacuum is preferred
Bonded interface has same mechanical and physical
properties.
Diffusion Welding is able to bond dissimilar metals,
which are difficult to weld by other welding processes:

Steel to tungsten;
Steel to niobium;
Stainless steel to titanium;
Gold to copper alloys.

Diffusion
Welding

Thermo Chemical Welding


Fusion takes by heat from exothermic reaction.
Atomic Hydrogen welding:
Welding heat is obtained from electric arc
maintained between two tungsten electrodes in
an atmosphere of hydrogen, which also acts as
shielding gas.
Electric current breaks down molecular hydrogen
into atomic hydrogen, which reforms molecule as
touches relatively cold surface producing large
heat.
Filler metal may or may not be used.

Atomic Hydrogen welding


Operation

Radiant Energy Welding


The heat for fusion is obtained from the kinetic
energy of a dense beam.
Electron Beam Welding:
Heat of fusion is obtained from high velocity narrow
beam electrons.
The kinetic energy of the electrons is converted into
heat as they strike the work piece.
Depth to width ratio is between 10:1 to 30:1
No filler metal or flux is needed.
Can be done in Hard / Partial vacuum or in
atmosphere.
Used for reactive metals as titanium, tungsten etc.
Chances of x-ray exposure.

Electron Beam Welding Operation

Radiant Energy Welding


Laser beam Welding:
Utilizes a high power laser beam as the source of
heat.
Very high energy density and deep penetrating
capability.
Welding can be done inside plastic or glass casing.
Laser as light can be conversed, focused and
reflected.
Slow process and dangerous for health.
Used for cutting and joining: wires, sheets etc
Used for welding: Copper, nickel, titanium, tungsten

Laser beam Welding

Assignment 1
Prepare a table (in a chart paper) to show:
Classification,
Working principle,
Working temperature and materials,
Advantages and disadvantages,
Operation figures of all the welding systems
studied.
Identify welding defects, their causes and remedies.
Dead line: Friday, 21, September, 2006

End of chapter 2 (Welding) (7hrs.)


Next chapter Foundry (8 hrs.)

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