TAKORADI POLYTECHNIC

MECHANICAL ENGINEERING DEPT. MANUFACTURING TECHNOLOGY II GROUP (F) PRESENTING ON JOINING METHODS I 23rd MAY, 2011

GROUP MEMBERS
Acquah Gabriel Emmanuel Adjei Godson Awuyeh Frederick S. Danquah Moses Mensah Francis K Adiko 07098336 07098360 07098392 07098364 07098370 07098369

OBJECTIVES
At the end of the lesson students should: Identify types of joining methods. 1. fusion and pressure welding Describe with the aid of sketches the principles of joining methods., Distinguish between welding and brazing operations.

INTRODUCTION
Today, there are large numbers of techniques such as reverting, bolting, soldering and finally welding, and the problem is not how to join but how to select the best method of joining because each method has its own attributes and important factors such as strength, ease of manufacture, cost, corrosion, resistance and appearance. For any given material, there may be multiple accepted joining methods.

JOINING METHODS
Joining methods is a way or method of bringing together engineering material under heat and pressure.

WELDING
Welding is generally defined as the act of joining together two or more components by heating the parent metal surfaces with an electric arc or arcs.

CLASSIFICATION OF JOINING METHODS

WELDING PROCESS

FUSION WELDING

PRESSURE WELDING

ARC WELDING

LASER WELDING
GAS WELDING

FRICTION WELDING RESISTACE WELDING SPOT WELDING BUTT WELDING FLASH WELDING STUD WELDING

ELECTRON BEAM WELDING

SEAM WELDING
TUNGSTEN INERT GAS WELDING METAL INER GAS WELDING

METAL ARC WELDING

SUBMERG ARC WELDING

PROJECTION WELDING

FUSION AND PRESSURE WELDING

Fusion welding is a broad term for welding processes that rely upon melting to join materials of similar compositions and melting points Pressure welding involves processes in which external pressure is applied to produce heat as a means by which the weld is being form.

FUSION WELD
1. MANUAL SHIELDED ARC WELDING (MMAC) In this process an arc is drawn between a coated consumable electrode and the work piece, the metallic core-wire is melted by the arc and is transferred to the weld pool as molten drops as shown in figure(1a,b). The electrode coating also melts to form a gas shield around the arc and the weld pool as well as slag on the surface of the weld pool, thus protecting the cold weld pool from the atmosphere. The slag must be remove after each layer.

Fig(1a) SHOWS THE MSA WELDING

Fig(1b) SHOWS A MANUALSHIELDED ARC WELDING PROCESS

ADVANTAGES OF THE MSA WELDING The operation is flexible Low cost It is mobile Ideal for repairs DISADVANTADES It produce a toxic fumes which is harmful to human health. It cause burn to the human body if appropriate safety is not worn. It can not be used at a water log area. It can not be used were there is no electricity.

GAS WELDING
Is a type of welding in which the heat is produced by gases such as; oxy-acetylene gas, oxy-propane gas, oxy-hydrogen gas etc through the nozzle of a welding torch. Most often, metal is added to the joint with a filler rod which is usually made of the same material as the base metal.

fig(2) SHOWS THE EQUIPMENT IN GAS

WELDING

OXY- ACETYLENE GAS WELDING EQUIPMENTS OXYGEN CYLINDER: It is used to store the compressed oxygen gas. It is black in colour and is made of steel ACTYLENE CYLINDER: It is used to store acetylene gas. It maroon in colour and is made of steel. BLOW PIPE / TORCH: It is used to mix oxygen and acetylene gases and then to supply the gas mixture to a nozzle connected to its end. NOZZLE: It is a device screwed to the end of the blow pipe tip of the nozzle to facilitate burning. PRESSURE GAUGES: Each gas cylinder is provided with two pressure gauges of the gas inside the pressure of the gas supplied to the blow pipe.

 Chipping Hammer: Is a tool used in removing slag from the weld. Wire Brush: Used for cleaning the work and the weld. Wedges and Blocks: Use to position the work for welding. Clamps: Is a tool use in holding the work for welding. Pliers or Tongs: They are tools use for handling pieces of hot metal. Helmet or Face Shield: These are equipment used in protecting the face and eyes from the arc radiation which produces ultra-violet rays, infra-red rays and intense brilliant light rays and flying sparks which can cause severe injury to the eyes and face of the welder.

PRINCIPLES OF GAS WELDING

A mixture of burning gases at the tip of a special design nozzle. The flame is used to melt the parent metal to form a weld pool. Filler rod is added separately by feeding it manually into the leading edge of the weld pool. The welder moves the torch to achieve uniform progressive fusion.

A TYPE OF GAS WELDING

Oxy-acetylene Welding: A mixture of oxygen and acetylene is burnt at the tip of a special design nozzle which is fitted to a torch body. The flame is used to melt the parent metal to form a weld pool. Filler rod is added separately by manual feeding it into the leading edge of the weld pool. The welder moves the torch to achieve uniform progressive fusion. It is normally use for light fabrication such as ventilation dusts, small-bore pipe work for heating chemical systems and motor vehicle repair.

TYPES OF FLAME IN OXY-ACETYLENE GAS WELDING

1. Neutral Flame: This flame burns equal quantities of oxygen and acetylene from the supply cylinders and is used for welding most materials, such as mild steel, cast iron, copper, aluminum and most magnesium. as shown in fig(3)

Fig(3)SHOWS THE NEUTRAL FLAME

2. Carburizing Flame: This has an excess of

acetylene which results in a carbon-rich zone around the cone. It is used for hard surfacing. As shown in the fig(4)

Fig(4)SHOWS THE CARBURIZING FLAME

3. Oxidizing Flame: This flame has an excess of oxygen which results in an oxygen-rich zone beyond the cone and its used for brazing, braze welding and fusion welding of brass. As shown in fig (5).

FIG(5) SHOWS THE OXIDIZING FLAME

SUBMERGED ARC WELDING (SAW)

This welding process requires a continuously fed consumable solid or tubular (flux core) electrode. The molten weld and the arc zone are protected from atmospheric contamination by being submerged under a blanket of granular fusible flux consisting of lime, silicon, manganese oxide, calcium fluoride, and other compounds as shown in fig(7). When welding, the flux becomes conductive, and provides a current path between the electrode and the work. This thick layer of flux completely covers the molten metal thus preventing spatter and sparks as well as suppressing the intense ultraviolet radiation and fumes that are a part of the process.

FIG (7) SHOWS THE SUBMERGE ARC WELDING DIAGRAM

ADVANTAGES OF SUBMERGED ARC WELDING

High operating factors in mechanized applications. Deep weld penetration. Sound welds are readily made (with good process design and control). Minimal welding fume or arc light is emitted. Distortion is much less.

DISADVANTAGES OF SUBMERGED ARC WELDING Limited to ferrous (steel or stainless steels) and some nickel based alloys. Normally limited to long straight seams or rotated pipes or vessels. Flux and slag residue can present a health & safety concern. Requires inter-pass and post weld slag removal.

SOURCES OF DANGERS IN GAS WELDING

Inadequate ventilation this prevents the escape of toxic fumes from the workshop, to prevent this toxic fumes the workshop must be well ventilated Bad conduction of oxygen and acetylene hoses these hoses should be in a good condition and of the correct colour. Oxygen - green or black. Acetylene - red.

 Incorrect connection of regulator and cylinder this causes leakages between the regulator and the cylinder. It must be correctly connected to prevent explosion.

LASER BEAM WELDING

It involves the act of using laser electromagnetic concentrated beam to weld. Heat is required to fuse the metals for any type of welding, in laser welding process the heat is obtained from the application of a concentrated coherent light beam which striking upon the weld metal and melts the metal, to obtain welding joint. Flux is added in this process to reduce fumes and replace metals which will loss as sparks of fire during the welding. The equipment is shown in figure(6)

FIG(6)SHOWS THE LASER BEAM WELDING

HOW IT WORKS
The focal spot is targeted on the workpiece surface which will be welded (fig 6). At the surface the large concentration of light energy is converted into thermal energy. The surface of the workpiece starts melting and progresses through it by surface conductance. For welding, the beam energy is maintained below the vaporization temperature of the workpiece material, because attaining the vaporization temperature of the material will result to hole drilling or cutting.(see video below)

ADVANTAGES OF LASER WELDING

1. Deep and narrow welds can be done. 2. Absence of distortion in welds created. 3. Minimal heat affected zones in weld created. 4. Ability to weld smaller, thinner components. 5. Increased travel speeds.

DISADVANTAGES OF LASER WELDING

1. The cost involve is too high.. 2 . Maintenance of equipment required a professional personnel which may not be as easy as the others.

FRICTION WELDING
This process uses friction to generate the welding heat. The welding machine rotates one of the parts being weld while applying pressure to force the other part which is clamp or held stationary for welding to take place. The friction obtained generates enough heat to soften the metal to plastic state. As shown in fig(8)

fig(8) SHOWS THE SEQUENCE IN FRICTION WELDING

TUNGSTEN INERT GAS WELDING

In tungsten inert gas arc welding, a tungsten electrode (non consumable electrode)is used in place of the metal electrode. A chemically inert gas, such as argon or helium, is used to shield the metal from oxidation. The heat from the arc formed between the electrode and the metal melts the edges of the metal. Metal for the weld may be added by placing a bare wire in the arc or the point of the weld. This process is an excellent process for fusion welding aluminum and its alloys. as shown in

Fig(9) SHOWS THE TUNSGTEN INERT GAS WELDING

METAL INERT GAS WELDING(MIG) In MIG welding process the electrode is a bear wire which is continuously fed into the welding gun by means of an electrode wire drive unit as the metal is transferred across the arc. The gas used in this process is the argon, helium and carbon dioxide as shown in fig(10)

Fig(10) SHOWS THE METAL INERT GAS WELDING

ELECTRON BEAM WELDING

Electron beam welding (EBW) is a fusion welding process in which a beam of high-velocity electrons is applied to the materials being joined. The work pieces melt as the kinetic energy of the electrons is transformed into heat upon impact, and the filler metal, if used, also melts to form part of the weld. The welding is often done in conditions of a vacuum to prevent dispersion of the electron beam. As shown in FIG(11) see video

FIG(11) SHOWS THE ELETRON BEAM WELDING(EBW)

Video of electron beam welding

ADVANTAGES OF ELECTRON BEAM WELDING(EBW)

Single pass welding of thick joints. Low distortion. Weld zone is narrow. Heat affected zone is narrow. Uses no filler metal.

DISADVATAGES OF THE ELECTRON BEAM WELDING(EBW)

High equipment cost . Work chamber size constraints. Time delay when welding in vacuum . High weld preparation costs.

RESISTANCE WELDING
Resistance welding involves the generation of heat by passing current through the resistance caused by the contact between two or more metal surfaces. TYPES OF RESISTANCE WELDING. Butt Spot Flash Seam Stud Projection

BUTT RESISTANCE WELDING Butt welding is a metal welding process in which round or profile stock is welded end to end. It can be used to run a processing machine continuously, as opposed to having to restart such machine with a new supply of metals as in fig(12).

FIG(12) SHOWS THE BUTT RESISTANCE WELDING

SPOT RESISTANCE WELDING

Spot welding is a popular resistance welding method used to join overlapping metal sheets. Two electrodes are simultaneously used to clamp the metal sheets together and current is passed through the sheets.FIG(13)

FIG(13) SHOWS THE(SPOT RESISTANCE WELDING)

FLASH RESISTANCE WELDING

Flash welding is a type of resistance welding that involves pressing two ends together, while simultaneously running a current between them. This has the effect of forming a joint between the two metals that is free of oxides as the surfaces of the two joining parts is forced out the sides of the joint as shown in fig(14).

Fig(14) SHOWE THE FLASH RESISTANCE WELDING

SEAM WELDING
The seam welding process involves making a series of overlapping spot welds by means of rotating copper alloy wheel electrodes to form a continuous leak tight joint as shown in fig(15a,b)see video

Fig(15a) SHOWS THE SEAM WELDING

Fig(15b) SHOWS THE SEAM WELDING.

RESISTANCE PROJECTION WELDING

Projection welding is a development of resistance spot welding. In spot welding, the size and position of the welds are determined by the size of the electrode tip and the contact point on the work pieces, whereas in projection welding the size and position of the weld or welds are determined by the design of the component to be welded. The force and current are concentrated in a small contact area which occurs naturally, as in cross wire welding or is deliberately introduced by machining or forming. As shown in FIG(16)

FIG(16) SHOWS THE (RESISTANCE PROJECTION WELDING)

LASER CUTTING
Laser cutting refers to the use of directed high-power laser output to cut a material as shown in fig(17).

Fig (17) SHOWS THE LASER CUTTING

PRINCIPLES OF LASER CUTTING

Laser cutting takes direct input in the form of electronic data from a CAD drawing to produce flat form parts of great complexity. Laser cutting is an industrial application obtained by the use of a laser device to emit the generated electromagnetic radiation via stimulated emission. The resultant 'light' is emitted through a low-divergence beam. Laser cutting refers to the use of directed high-power laser output to cut a material. The result is quicker smelting and melting of the material. (See video the laser cutting)

BRAZING
Brazing is a joining process that produces coalescence of metals by heating the components to a suitable temperature and then using a filler metal whose melting point is below that of the parent metal. In brazing, a torch is used which blends oxygen and a fuel gas together and burns them at the tip of the torch. The socket and the inserted tube to be joined are heated to the brazing temperature with the

torch, and the filler metal is fed into the gap between the socket and the tube. A properly brazed joint is stronger than the pipe or tube being joined. As shown in the fig.(18)

Fig(18) SHOWS THE BRAZING PROCESS

Welding is generally defined as the act of joining together two or more components by heating the parent metal surfaces with an electric arc or arcs, and producing coalescence (a solid connection) with or without the use of a filler metal.

DIFFERENCES BETWEEN WELDING AND BRAZING

WELDING 1. In welding, the two parts of the materials are joined together by melting the base metal and then adding the filler material into it. 2. Welding can be done more precisely on the material, materials are joined more powerfully with welding materials. BRAZING 1. in brazing the base metal is not melted.

2. Not as powerful as welding.

DIFFERENCES BETWEEN WELDING AND BRAZING

WELDING 3. It requires high temperature 4. Welding would melt the base metal and filler metal`

BRAZING
3. It is done at low temperature. 4. brazing only melts the filler metal.

CONCLUSION
From the topic discussed we have got to appreciate the study of joining methods in relation to manufacturing technology. We have got to know the principles of joining methods and various types MMA, SMA, EBW, Laser cutting and welding and brazing etc. Joining methods should therefore be encouraged in industries in order to meet the need of production.

REFRENCES
WWW.AWS.ORG WWW.MHHE.COM Wikipedia TAKORADI POLYTECNIC (MECHANICAL ENGINEERING DEPT.) PRESENTASION ON JOINING PROCESS. 17TH MAY 2011. WELDING PRINCIPLES AND PRACTICSES THIRD EDITION(SACKS AND BOHNART)