MANUFACTURING TECHNOLOGY I SUB CODE: MEC230 Unit 2 Welding (Metal Joining) Processes & Metal Forming Processes

Unit 2 : Solid State Welding (SSW)

Solid State Welding (SSW):

Solid State Welding two pieces are joined under pressure & at a temperature essentially below the melting point Bonding of the materials is a result of diffusion of their interface atoms

Joining of parts is achieved by Pressure, or Heat & pressure

If both heat and pressure are used, Heat is not enough to melt work surfaces

For SSW processes, time is also a factor

No filler metal is added Each SSW process has its own way of creating a bond at the surfaces

Solid State Welding (SSW):

Essential factors for a successful solid state weld are Very clean surfaces

In very close physical contact with each other to permit atomic bonding

Advantages of Solid State Welding:

No Melting, then no heat affected zone, so metal around joint retains original properties
Weld is free from microstructure defects (pores, non-metallic inclusions, segregation of alloying elements) No consumable materials (filler material, fluxes, shielding gases) are required Dissimilar metals may be joined (steel - aluminum alloy steel copper alloy).

Disadvantages of Solid State Welding:

Thorough surface preparation is required (degreasing, oxides removal, brushing/sanding) Expensive equipment.

The following are Solid State welding processes :

Forge Welding (FOW) Cold Welding (CW)

Roll Welding (RW)

Diffusion Welding (DFW) Explosive Welding (EXW)

Friction Welding (FRW)

Ultrasonic Welding (USW) Hot Pressure Welding (HPW)

Forge Welding (FOW):

Welding process in which components to be joined are heated to hot working temperature range and then forged together by hammering or similar means Historic significance technology in development of manufacturing

Process dates from about 1000 B.C., when blacksmiths learned to weld two pieces of metal Prior to Forge Welding, the parts are joined by bevelling or notching them so that they fit over or into each other in order to prevent entrapment of oxides in the joint. Forge Welding is used in general blacksmith shops and for manufacturing metal art pieces and welded tubes.

Advantages of Forge Welding:

Good quality weld may be obtained Parts of intricate shape may be welded No filler material is required.

Disadvantages of Forge Welding:

Only low carbon steel may be welded

High level of the operators skill is required

Slow welding process Weld may be contaminated by the coke used in heating furnace

Forge Welding (FOW):

Cold Welding (CW):

SSW process done by applying high pressure between clean contacting surfaces at room temperature by deformation Intimate contact between these pure surfaces provide a strong and defectless bonding. Cleaning usually done by degreasing and wire brushing immediately before joining

No heat is applied, but deformation raises work temperature

At least one of the metals, preferably both, must be very ductile Soft aluminium and copper suited to CW

Applications: making electrical connections

Cold Welding (CW):

Aluminum alloys, Copper alloys, low carbon steels, Nickel alloys, and other ductile metals may be welded by Cold Welding. Cold Welding is widely used for manufacturing Bi-metal steel Aluminum alloy strips, for covering of aluminum alloy strips by other aluminum alloys or pure aluminum (Corrosion protection coatings).

Bi-metal strips are produced by Rolling technology

Presses are also used for Cold Welding Cold Welding may be easily automated

Roll Welding (ROW):

SSW process in which pressure sufficient to cause joining by means of rolls, either with or without external heat Variation of either forge welding or cold welding, depending on whether heating of workparts is done prior to process If no external heat, called cold roll welding If heat is supplied, hot roll welding

Roll Welding (ROW) Applications:

Covering stainless steel to mild or low alloy steel for corrosion resistance Bimetallic strips for measuring temperature "Sandwich" coins

Diffusion Welding (DFW):

SSW process uses heat and pressure, usually in a controlled atmosphere, with sufficient time for diffusion and joining to occur Temperatures 0.4 Tm Plastic deformation at surfaces is minimal

Primary joining mechanism is solid state diffusion

In order to keep the bonded surfaces clean from oxides and other air contaminations, the process is often conducted in vacuum. Limitation: time required for diffusion can range from seconds to hours

Advantages of Diffusion Welding:

Dissimilar materials may be welded (Metals, Ceramics, Graphite, glass) Welds of high quality are obtained (no pores, inclusions, chemical segregation, distortions)

No limitation in the work pieces thickness

Disadvantages of Diffusion Welding:

Time consuming process with low productivity

Very thorough surface preparation is required prior to welding process

The mating surfaces must be precisely fitted to each other

Relatively high initial investments in equipment

Diffusion Welding Applications:

Joining of high-strength and refractory metals in aerospace and nuclear industries 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

For joining dissimilar metals, a filler layer of different metal is often sandwiched between base metals to promote diffusion Diffusion Welding is used in rocket industries, electronics applications, manufacturing composite materials

Explosion Welding (EXW):

SSW process in which rapid joining of two metallic surfaces is caused by the energy of a detonated explosive No filler metal used No external heat applied

No diffusion occurs - time is too short

Bonding is metallurgical, combined with mechanical interlocking that results from a rippled or wavy interface between the metals

Commonly used to bond two dissimilar metals

Explosion Welding (EXW):

(1) Setup in parallel configuration, and

(2) during detonation of the explosive charge

Explosion Welding (EXW):

One of the welded parts (base plate) is rested on an anvil, the second part (flyer plate) is located above the base plate with an angled or constant interface clearance. Explosive charge is placed on the flyer plate. Detonation starts at an edge of the plate and propagates at high velocity along the plate. The slags (oxides, nitrides and other contaminants) are expelled by the jet created just ahead of the bonding front. Most of the metals and alloys may be bonded (welded) by Explosive Welding.

Advantages of Explosive Welding

Large surfaces may be welded

High quality bonding: high strength, no distortions, no porosity, no change of the metal microstructure
Low cost and simple process

Surface preparation is not required

Disadvantages of Explosive Welding:

Brittle materials (low ductility and low impact toughness) cannot be processed Only simple shape parts may be bonded: plates, cylinders Thickness of flyer plate is limited - less than 2.5 (63 mm) Safety and security aspects of storage and using explosives

Explosion Welding (EXW) Applications:

Dissimilar metals may be joined by Explosive Welding:

Copper to steel
Nickel to steel Aluminum to steel

Tungsten to steel
Titanium to steel Copper to aluminum

Explosive Welding is used for manufacturing tubes and pipes, pressure vessels, aerospace structures, heat exchangers, bimetal sliding bearings, ship structures, corrosion resistant chemical process tanks.

Friction Welding (FRW):

SSW process in which joining is achieved by frictional heat combined with pressure When properly carried out, no melting occurs at faying surfaces No filler metal, flux, or shielding gases normally used

Process yields a narrow HAZ

Can be used to join dissimilar metals Widely used commercial process, agreeable to automation and mass production

Friction Welding (FRW):

(1) Rotating part, no contact (2) parts brought into contact to generate friction heat (3) rotation stopped and axial pressure applied and (4) weld created

Friction Welding (FRW) Limitations:

At least one of the parts must be rotational

Flash must usually be removed (extra operation)

Upsetting reduces the part lengths (which must be taken into consideration in product design)

Friction Welding (FRW)Applications:

Shafts and tubular parts Industries: automotive, aircraft, farm equipment, petroleum and natural gas Carbon steels, Alloy steels, Tool and die steels, Stainless steels, Aluminum alloys, Copper alloys, Magnesium alloys, Nickel alloys, Titanium alloys may be joined by Friction Welding.

Friction Stir Welding (FSW):

SSW process in which a rotating tool is fed along a joint line between two work-pieces, generating friction heat and mechanically stirring the metal to form the weld seam Distinguished from FRW because heat is generated by a separate wear-resistant tool rather than the parts Applications: butt joints in large aluminum parts in aerospace, automotive, and shipbuilding

Friction Stir Welding (FSW):

(1) Rotating tool just before entering work, and

(2) partially completed weld seam

Advantages and Disadvantages of Friction Stir Welding: Advantages

Good mechanical properties of weld joint Avoids toxic fumes, warping, and shielding issues Little distortion or shrinkage Good weld appearance

Disadvantages
An exit hole is produce when tool is withdrawn
Heavy duty clamping of parts is required

Ultrasonic Welding (USW)

Two work pieces are bonded as a result of a pressure exerted to the welded parts combined with application of high frequency acoustic vibration.

Oscillatory shear stresses of ultrasonic frequency are applied to interface to cause joining

Oscillatory motion breaks down any surface films to allow intimate contact and strong metallurgical bonding between surfaces

Ultrasonic Welding (USW)

Ultrasonic cycle takes about 1 sec. The frequency of acoustic vibrations is in the range 20 to 70 KHz. Thickness of the welded parts is limited by the power of the ultrasonic generator. Temperatures are well below Tm No filler metals, fluxes, or shielding gases Generally limited to lap joints on soft materials

Ultrasonic Welding (USW)

(a) General setup for a lap joint; and

(b) close-up of weld area

Ultrasonic Welding (USW) Applications:

Wire terminations and splicing in electrical and electronics industry Eliminates need for soldering Assembly of aluminum sheet metal panels

Welding of tubes to sheets in solar panels

Assembly of small parts in automotive industry Bonding of work pieces in electronics For manufacturing communication devices Medical tools, watches, automotive industry

Advantages of Ultrasonic Welding:

Dissimilar metals may be joined

Very low deformation of the work pieces surfaces

High quality weld is obtained The process may be integrated into automated production lines Moderate operator skill level is enough

Disadvantages of Ultrasonic Welding:

Only small and thin parts may be welded Work pieces and equipment components may fatigue at the reciprocating loads provided by ultrasonic vibration Work pieces may bond to the anvil