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Manufacturing Processes
MEEG 217
Biraj Singh Thapa
27, Aug, 2007
Basic Classification of MP
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.
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
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.
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
Welding Torch
Welding Torch
The End
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.
Soldering
Similar to the Brazing but the filler metal used has
melting point less than 450C.
The filler material is called solder.
END
Arc Welding
MEEG 217
Biraj Singh Thapa
31, Aug, 2007
Introduction
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:
MIG Operation
TIG Operation
TIG Contd
SAW Operation
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.
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.
END OF
ARC WELDING
Resistance Welding
MEEG 217
Biraj Singh Thapa
07, Sept, 2007
Introduction
Types:
1. Spot welding
2. Seam welding
3. Projection 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
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
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
Steel to tungsten;
Steel to niobium;
Stainless steel to titanium;
Gold to copper alloys.
Diffusion
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