Module-II of Manufacturing Science-ILecture Notes of Chinmay Das
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2. JOINING PROCESSES
According to American Welding Society (AWS), all joining processes can be classified into threecategories. They are a) welding, brazing & soldering, b) adhesive bonding and c) mechanical fastening.Welding processes are in turn divided into three basic categories: a) fusion welding, b) solid-state welding,and c) brazing and soldering. Some types of welding processes can be classified into both the fusion andsolid-state categories.Welding was using in ancient (3,000 yearsago) times by pouring molten metal into acast located on another metal part. Sandcasting is still used today.Figure 2.1: Ancient welding process
Fusion welding
is defined as the melting together and coalescing of materials by means of heat (usuallyprovided by chemical or electrical means); filler metals may or may not be used. This process constitutes amajor category of welding; it comprises consumable or non consumable electrode arc welding and highenergy beam welding processes .The welded joint undergoes important metallurgical and physical changeswhich in turn have a major effect on the properties and performance of the welded component or structure.In
solid-state welding
joining takes place without fusion; consequently thee is no liquid (molten)phase in the joint. The basic categories are
diffusion bonding, ultrasonic, cold, friction, resistance, andexplosive welding
. Diffusion bonding, combined with super plastic forming, has become an importantmanufacturing process for complex shapes.
Brazing and soldering
use filler metals and involve lowertemperatures than welding; the heat required is supplied externally.Another classification of welding processes is given below:1.
Heating the metal joint to a temperature below the solidus temperature and applying pressure.
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Forge welding2.
Melting of the metal at the joint (fusion welding).
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Gas welding
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Arc welding
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Thermit welding
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Flow welding3.
Melting the metal at the joint and applying pressure.
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Pressure-gas welding
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Stud welding
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Flash welding
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Resistance welding
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Induction welding4.
Applying pressure only to the metal joint (done at room temperature).
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Cold weldingAnother criterion used for a classification of the welding process is based on the composition of the joint.According to this scheme, all joining processes can be grouped into three different categories, namely,
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