Non-Arc Welding Processes Continued

Introduction

Non-Arc Welding Processes

Resistive heating, chemical reactions, focused light
and electrons, sound waves, and friction can also
be used to join materials

Resistance welding
Oxy-Fuel Welding
Friction welding (&Solid State)
Laser and electron beam welding
Brazing and soldering
Plastics joining
Adhesive bonding

High Energy Density Processes

High Energy Density Processes

Focus energy onto a
small area
Laser
CO2 gas: fixed
position
Nd-YAG crystal:
fiber-optic delivery

Electron Beam

High Energy Density Processes

These processes focus the energy onto a
small area
Laser - 0.0001-inch thick stainless steel
sheet
Electron Beam - 0.030-inch weld width on
0.5 inch thick steel plate

0.1.1.2.1.T2.95.12

Laser Beam Welding (LBW)

Laser

0.1.1.2.1.T3.95.12

High Energy Density Processes

Laser Beam Welding (LBW)

shielding
gas nozzle
(optional)

Single pass weld

penetration up to 3/4 in
Laser beam
steel
Plasma plume
Materials need not be
Molten
conductive
material
Plasma
No filler metal required
keyhole
Low heat input produces
workpiece motion
low distortion
Does not require a
Keyhole welding
vacuum

High Energy Density Processes

Focusing the Beam

Heat
treatment

Surface
modification

Welding

Cutting

Advantages
Weld penetration, mm

12
6 kW CO2
10

2 kW Nd:YAG

8
6
4
2
0
1

Welding speed, m/min

Single pass weld

penetration up to 3/4
in steel
High Travel speed
Materials need not be
conductive
No filler metal required
Low heat input
produces low distortion
Does not require a
vacuum
0.1.1.2.1.T4.95.12

High Energy Density Processes

Limitations
High initial start-up costs
Part fit-up and joint tracking are
critical
Not portable
Metals such as copper and aluminum
have high reflectivity and are difficult
to laser weld
High cooling rates may lead to
materials problems

Electron Beam Welding (EBW)

EB Applications

0.1.1.2.1.T6.95.12

High Energy Density Processes

Electron Beam Welding (EBW)

Advantages

Deepest single pass

weld penetration of
the fusion processes
14-inch-thick steel

Fast travel speeds

Low heat input
welds produce low
distortion

High Energy Density Processes

Limitations

High initial start-up cost

Not portable
Part size limited by size of vacuum chamber
Produces x-rays
Part fit-up is critical
High cooling rates may lead to materials
problems

Turn to the person sitting next to you and discuss (1 min.):

In laser welding, materials with high reflectivity reflect the
beam right off the surface and no heat is absorbed and thus
they are difficult to weld. What might we do to make these
high reflectivity materials more weldable?

Introduction

Non-Arc Welding Processes

Resistive heating, chemical reactions, focused light
and electrons, sound waves, and friction can also
be used to join materials

Resistance welding
Oxy-Fuel Welding
Friction welding (&Solid State)
Laser and electron beam welding
Brazing and soldering
Plastics joining
Adhesive bonding

Brazing and Soldering

Brazing (B) and Soldering (S)

In these processes, the

base metals are heated
but do not melt; only
the filler metal melts
Brazing filler metals
having a melting point
above 840 F
(450C)
Soldering filler metals
have a melting point
below 840F (450C)

Brazing and Soldering

0.1.1.2.4.T18.95.12

Application of Low Thermal

Expansion Alloys
Thermal expansion
mismatch in metalceramic joints can lead
to cracks in the
ceramic
Thermal expansion
coefficients at 25C
(10-6 mm / mmC)

Alumina, 8.8
Nickel, 13.3
Iron, 11.8
Kovar, 5.0

Kovar lid
Silicon chip
Alumina substrate

Brazed joints

0.1.1.2.4.T20.95.12

Brazing and Soldering

Brazing Specifications
AWS A5.8 Specification for Brazing Filler Metal
8 well-defined groups (B) plus a vacuum grade (BV)
BAg-1
BAu-1
BCuP-1

(44-46 Ag, 14-16 Cu, 14-18 Zn, 23-25 Cd)

(37-38 Au, remainder Cu)
(4.8-5.2 P, remainder Cu)

Standard forms: strip, sheet, wire, rod, powder

Joint design tolerances, generally ~ 0.002 - 0.006 inches
Uses for each braze material

AWS C3.3 Standard Method for Evaluating the

Strength of Brazed Joints

Balchin & Castner, Health & Safety,

McGraw Hill, 1993

Brazing and Soldering

Advantages
Joins unweldable
materials
Base metals dont melt
Can be used on metals and
ceramics

Joined parts can be taken

apart at a later time
Batch furnace can easily
process multiple parts
Portable when joining
small parts

Brazing and Soldering

Limitations
Joint tolerance is
critical
Lower strength than a
welded joint
Large parts require
large furnaces
Manual processes
require skilled workers
Flux

Filler metal ring

surrounded by flux

Turn to the person sitting next to you and discuss (1 min.):

Why is joint tolerance so critical?
What happens if the joint space is too large?
What happens if the joint space is too small?
Turn to the person sitting next to you and discuss (1 min.):
What happens if we do not have sufficient flux?

Introduction

Non-Arc Welding Processes

Resistive heating, chemical reactions, focused light
and electrons, sound waves, and friction can also
be used to join materials

Resistance welding
Oxy-Fuel Welding
Friction welding (&Solid State)
Laser and electron beam welding
Brazing and soldering
Plastics joining
Adhesive bonding

Welding of Plastics

Joining Plastics
Polymer - a single building
block (mer) is repeated to
form a long chain molecule
Thermoplastic polymers
soften when heated, harden
when cooled
2-liter bottles

Thermosetting polymers
dont soften when heated
Car tires, caulking compound

(Poly)ethylene

H
H
C=C
H
H
add H2O2

HH
-C-C-
HH

Joining of Plastics
Plastic (polymer) is a material in which single building
blocks (mers) join to form a long chain or network
molecule
Thermoplastic polymers soften when heated and harden
when cooled
Foam cups (polystyrene), 2-liter bottles (polyethylene),
Leisure suits (polyester)

Thermosetting polymers become permanently hard when

heat is applied and do not soften upon subsequent
heating
Car tires (isoprene, isobutene), Epoxy, Caulks (silicones)
0.1.1.2.5.T22.95.12

Hot Plate, Hot Gas, Infrared

Advantages
Provide strong joints
Reliable
Used on difficult to join
plastics

Limitations
Slow
Limited temperature
range
0.1.1.2.5.T23.95.12

Welding of Plastics

Hot Plate, Infrared Welding

Hot plate welding

Welding of Plastics

Hot Gas Welding

Thermoplastics
(hotmelts)
Adhesive is heated
until it softens, then
hardens on cooling

Hot gas softens filler

and base material
Filler is pulled or fed
into the joint

Vibration
Advantages
Speed
Used on many
materials

Limitations
Size
Requires fixturing
Equipment costly
0.1.1.2.5.T24.95.12

Ultrasonic
Advantages
Fast
Can spot or seam weld

Limitations
Equipment complex,
many variables
Only use on small parts
Cannot weld all plastics

0.1.1.2.5.T25.95.12

Turn to the person sitting next to you and discuss (1 min.):

Make a list of some thermoplastic items you have recently
seen that have been wlded.

Introduction

Non-Arc Welding Processes

Resistive heating, chemical reactions, focused light
and electrons, sound waves, and friction can also
be used to join materials

Resistance welding
Oxy-Fuel Welding
Friction welding (&Solid State)
Laser and electron beam welding
Brazing and soldering
Plastics joining
Adhesive bonding

Adhesives
Thermosets form long polymer chains by
chemical reaction (curing)
Heat is the most common means of curing
Ultraviolet light, oxygen - acrylics
Moisture - cyanoacrylates

Thermoplastics (hotmelts)
Adhesive is heated until it softens, then hardens
on cooling -Polyethylene, PVC
0.1.1.2.6.T26.95.12

Adhesive Bonding

Curing of Adhesives
Thermosets form
long polymer
chains by chemical
reaction (curing)
Heat (epoxy)
Ultraviolet light,
oxygen (acrylics)
Moisture
(superglue)

Stress Modes - Best to Worst

1. Compression

4. Peel

2. Shear

3. Tension

5. Cleavage

0.1.1.2.6.T29.95.12

Adhesive Bonding

Why Adhesive Bonding?

Dissimilar materials
Plastic to metal

Materials that can be damaged by

mechanical attachments
Shock absorption or mechanical dampening
Laminate structures
Skin to honeycomb structure

Adhesive Bonding

Adhesive Selection
Adhesive selection is based primarily on
Type of substrate
Strength requirements, type of loading, impact
requirements
Temperature resistance, if required

Epoxy
Cyanoacrylates
Anaerobics - metals
Urethanes
Silicones
Pressure sensitive adhesives (PSAs)

Process Selection

Factors that Influence Process

Selection

Material joining needs

Capabilities of available processes
Cost
Environment
Required welding speed
Skill level
Part Fit-up

Advantages
Joining dissimilar materials - plastic to metal
Materials that can be damaged by mechanical
attachments
Blind joints
Shock absorption or mechanical dampening
Temporary alignment
Laminated structures
Thin substrates - skin-to-honeycomb construction
Stress distribution
0.1.1.2.6.T27.95.12

Adhesive Bonding

Limitations
Adhesives dont do work, they distribute
work; they are not structural materials
Environmental degradation
Temperature
Oxidation

Difficult to repair
Curing or setting time
Surface preparation

Do Homework Assignment 3 on More Welding Processes

and Turn in by next class period.