INTRODUCTION TO JOINING PROCESSES

ADHESIVE BONDING, SOLDERING BRAZING WELDING-The joining of the two surfaces for achieving a metallurgical bond.It may be done by two methods fusion welding and pressure welding. Fusion welding-The two surfaces of metals melt either directly or along with filler and the intermixed molten metal

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Safety in welding & cutting

Possible hazards in welding & cutting-Burn injuries,Electrical shock,Eye injuries,Air pollution,Fire & explosion hazards,Heat effects,Back fire & flash back,Others like fall from height,Noise,Cuts etc. Burn injuries Causes-Hot spatters from welding,touching hot job,holder,electrode and its bits,burn due to short circuit or exposed cables,burn due to excessive heat. Remedial measures-Use personal protective 6/12/2013 2 equipments like gloves,safety shoes,protective

Heat Treatment
Annealing-Main purpose of annealing to reduce the hardness of steel or to produce a structure that facilitates the subsequent manufacturing operations. Full annealing raising the temperature to get the austenite phase,followed by slow cooling. Full annealing,Isothermal annealing,Intermediate annealing,Homocenizing annealing,Bright annealing,Solution annealing Full annealing-Austenitization of the steel followed by slow cooling in the furnace.The 6/12/2013 3 tempreture depend upon the carbon content in the

Full Annealing
Normalising,Annealing and Quenching-All these heat treatment involve heating the components above the

upper critical tempreture (AC3) tempreture for the steel.The thumb rule for fixing up the tempreture for normalising,annealing and hardening is AC3 tempreture read from the Iron-Carbon diagrame.However if the steel has alloying elements other than carbon the iron carbon diagrame can not be used for this purpose. The main difference is between normalising,annealing and hardening are mainly the rate of cooling from high tempreture In annealing very slow cooling,normally unfer stood to 6/12/2013 be furnace cooling,in normaling still in air,in hardening 4

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furnace cooling but in stainless steel 300 series might calls for rapid cooling.This slow and uniform cooling is necessary to prevent the addition of new internal stresses on cooling and to avoid the formation of cracks in stress relieved,welded components. Heating decrease the

Pre heating Post heating

Pre-heating-Heating the parent metal around the area to be welded to the specificified temp.Preheat is always specified as the min. temp. to which the parent metal must be heated before welding and maintained during welding. Purpose of preheating-To minimise the risk of cracking in weld and HAZ of steels. Reducing the rate of cooling,Allowing the hydrogen to diffuse away from the weld at a faster rate and also drives the moisture from the weld.Reducing the residual stresses induced in 6/12/2013 6 the weld region.Reducing the distortion.

Surface hardeningcarburising,nitriding,cyaniding,flame hardening,Induction hardening

Carburising-Heating the material in side a pack containing CO gas above 875-925 deg. C and soaking to be done.case depth depend upon soaking time and tempreture.Hardness can be achieve up to 60HRC,case depth 1-1.5mm Nitriding-Same as above using gas is NH3 at temp 495-565 deg c,Hardness can be achieve 60 HRC,case depth is 1000 micron. Cyaniding-By immersing the steel in molten bath containing 30% sodium cynide at 800-875 deg. C followed by water quenching. Case depth 1000 6/12/2013 7 micron.

BASIC ELECTRICITY,ARC PHYSICS,WELDING PARAMETER

Heat and light effect, Electric current, Concept of circuit, Electromagnetic force & Voltage, Ohm's law, Source of electricity, Direct current and Alternating current, Three phase AC Conduction of electricity in gases,Electric discharge phenomena,Arc discharge and its characteristics,Tempreture distribution,The welding arc,Metal transfer,The Pintch effect,Igniting the welding arc,Arc blow Welding current,voltage,speed etc.
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ARC WELDING POWER SOURCES

High voltage is hazardous Longer arc is difficult to manipulate Melting require high current Characteristics of power sources (I) Constant current characteristics (ii)Constant voltage characteristic Transformer power sources (AC)- The method to control the power circuit output by five methods (a) Movable coil (b) Moving shunt control (moving iron type) Series inductance (d) Tapped secondary coil (e) Magnetic amplifier 9 6/12/2013

Fundamental of materials,classification and properties of steels

Metals and alloys,Ceramics and glasses,Organic

polymers These material derive their inherent charecteristics because of the way of bonding takes places in them. (a) Electrovalent /Ionic bonding (b) Covalent bonding Metalic bonding (d) Vander walls bonding
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Arc Welding Submerged Arc Welding Electro Slag Welding Thermit Welding Resistance Welding Friction Welding Electron Beam & Laser Beam Welding Under Water Welding
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Welding process

Oxy Acetylene Welding- Process Fundamental Metal is heated by an intense flame (3300 degree centigrade) produced by burning proper quantities of oxygen and acetylene at the tip of welding torch. Welding may be done with or without filler metal. The table given below characteristics of different fuel gases and their ratio with oxygen. Combustion of acetylene is represented by 2C2H2+5O2=4CO2+2H2O+Heat Back fire-When the flame goes out with a loud 6/12/2013 12 pop.it is called back fire.it may be caused by

Shielded Metal Arc WeldingSMAW/MMAW

The welding system consist welding power source,welding cables,electrode holder,ground clamp,work piece & welding electrodes. Arc shielding Process capabilities and limitation Power sources-AC or DC Accessories-Electrode holder,Ground clamp,Welding cables,welding helmet,hand gloves,apron,leg sleeves,chipping hammer,wire brushes etc. 6/12/2013 Metals welded-Carbon steel,Low alloy

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