Dr. Ir. Winarto, M.Sc.

1
PROSES PENGELASAN PROSES PENGELASAN
LAINNYA LAINNYA
Departemen Metalurgi & Materials
Fakultas Teknik Universitas Indonesia
Lecture Lecture -- 05 05
Proses Pengelasan Lainnya
1. Las Oksi-asetilen (Oxy-Acetylene Welding )
2. Las Termit (Thermit Welding)
3. Las Sinar Elektron (Electron Beam Welding)
4. Las Sinar Laser(Laser Beam Welding)
5. Las Bawah Laut (Underwater Welding)
Dr. Ir. Winarto, M.Sc. 2
Lecture Lecture -- 05 05
1. Oxy-Acetylene Welding
Pengelasan dengan gas dilakukan dengan membakar bahan
bakar gas dengan oksigen sehingga menimbulkan nyala api
(flame) dengan suhu (sekitar 3000C) yang dapat
mencairkanlogaminduk dan logampengisi.
Api las atau nyala api pada las oksi-asetilen merupakan hasil
reaksi kimia sebagai berikut :
Tahap1 (blue reducing zone) : C
2
H
2
+ O
2
=== 2 CO + H
2
Tahap2 (pink envelope) : CO + H
2
+ O
2
=== CO
2
+ H
2
O
Lecture Lecture -- 05 05
Process OAW
Dr. Ir. Winarto, M.Sc. 3
Lecture Lecture -- 05 05
1. Oxy-Acetylene Welding
Jenis Nyala (Flame) :
1. Nyala Netral (untuk welding)
2. Nyala Oksidasi (untuk las brazing)
3. Nyala Karburisasi (untuk flame hardening)
Aplikasi: umumnya untuk reparasi
Plat Baja,
Besi Cor
Cu, Al dan Ni
Peralatannya :
Tabung Gas Oksigen & asetilen,
Pressure regulator,
Torch & Hoses.
Lecture Lecture -- 05 05
Dr. Ir. Winarto, M.Sc. 4
Lecture Lecture -- 05 05
Torch of OAW
Lecture Lecture -- 05 05
Types of Flame
Neutral Flame
Oxidizing Flame
Carburizing Flame
Dr. Ir. Winarto, M.Sc. 5
Lecture Lecture -- 05 05
Flame Temperature
Lecture Lecture -- 05 05
1. Oxy-Acetylene Welding
Fluks yang digunakanBorat atau campuranKlorida & Fluorida
Keunggulan :
Peralatannya Sederhana,
Portable
Murah
Kelemahannya :
Masukan panas terbatas,
kecepatan las lambat,
distorsinya tinggi.
Dr. Ir. Winarto, M.Sc. 6
Lecture Lecture -- 05 05
Flame vs Jenis Gas
Lecture Lecture -- 05 05
2. Thermit Welding
Teknik ini merupakan proses pengelasan berdasarkan
reaksi eksotermik dimana sejumlah oksida oksida logam
direduksi dengan misalnya aluminium yang membebaskan
sejumlah panas yang dapat mencairkan logam yang akan
disambung.
Reaksi kimia eksotermik sebagai berikut:
Fe
2
O
3
+ 2 Al -------- Al
2
O
3
+ 2 Fe
termit terak besi cair
Aplikasi : untuk penyambungan rel kereta api, frame dan poros
Dr. Ir. Winarto, M.Sc. 7
Lecture Lecture -- 05 05
Proses Penyambungan Rel KA
Lecture Lecture -- 05 05
Dr. Ir. Winarto, M.Sc. 8
Lecture Lecture -- 05 05
Jenis Logamyang Disambung
Lecture Lecture -- 05 05
3. Electron Beam Welding
Electron beam welding (EBW) merupakan proses pengelasan
yang melibatkan pencairan karena adanya enersi yang
disuplai dari hasil tumbukan berkas sinar elektron yang
terfokus. Sinar ini kemudian dipercepat dalam vakum
hingga ~60% kecepatan cahaya sehingga sewaktu
menumbuk ke benda kerja akan terbebaskan ~99% energi
kintetiknya menjadi panas dan timbul pengelasan lokal
Ciri ciri penting dari peralatan las sinar elektron adalah
electron gunyang memproduksi elektron, focusing and
beam-control systemdan working chamber.
Aplikasi : untuk penyambungan :
- Logamkeras & TM tinggi (W, Mo, Nb, Ta)
- Logamreaktif (be, Ti, Zr)
- Yang membutuhkan kwalitas sambungantinggi
Dr. Ir. Winarto, M.Sc. 9
Lecture Lecture -- 05 05
Skematik Peralatan EBW
Lecture Lecture -- 05 05
3. Electron Beam Welding
Dr. Ir. Winarto, M.Sc. 10
Lecture Lecture -- 05 05
Electron Beam Welding
Lecture Lecture -- 05 05
Heat Intensity
Dr. Ir. Winarto, M.Sc. 11
Lecture Lecture -- 05 05
3. Electron Beam Welding
Keunggulan :
Penetrasinya dalam(rasio 1:20) & HAZ sempit
Distorsi kecil & hasil lasanbersih
Tidak ada kontaminasi
Prosesnya sangat cepat dan presisi
Energi (HI) yang diberikanrelatif kecil
Kelemahannya :
Peralatannya mahal (perlu ruang vakum),
Benda kerja tergantung ukuranchamber
Rentan terhadap retak (kecepatanpembekuantinggi)
Lecture Lecture -- 05 05
4. Laser Beam Welding
Laser beam welding (LBW) merupakan proses pengelasan
yang menggunakan enersi radiasi elektromagnetik untuk
mencairkan bagian logam yang akan di sambung. Laser
kepanjangannya adalah Light Amplification by Stimulated
Emission of Radiation.
LBW umumnya menggunakansistemsolidstatelaser (ruby
laser dan Yttrium-aluminium-garnet (YAG-laser) dan gas
laser (CO2 laser).
Aplikasi :
1. Industri pesawat terbang untuk pengelasankomponen
komponen yang sangat kecil sekali denganpresisi tinggi serta
distorsi yang sekecil mungkin.
2. Industri otomotif untuk pengelasangear cluster agar
distorsinya kecil.
Dr. Ir. Winarto, M.Sc. 12
Lecture Lecture -- 05 05
Comparison of Weld Bead Size
FIGURE 12.11 Comparison of the size of weld beads in (a) electron-beam or
laser-beam welding with that in (b) conventional (tungsten-arc) welding.
Source: American Welding Society, Welding Handbook, 8th ed., 1991.
Lecture Lecture -- 05 05
PrinsipSolid State Laser dan
AlatLas YAG Laser berdaya300W
Dr. Ir. Winarto, M.Sc. 13
Lecture Lecture -- 05 05
PrinsipGas Laser dan
AlatLas Fast Flow Laser berdaya2,5kW
Lecture Lecture -- 05 05
Peralatan LBW
Dr. Ir. Winarto, M.Sc. 14
Lecture Lecture -- 05 05
4. Laser Beam Welding
Keunggulan :
Masukanpanasnya kecil
HAZ sempit dan distorsi kecil
Tidak memerlukanelektroda
Proses tanpa kontak, & tanpa ruang vakum
Tidak dipengaruhi oleh medan maknit
Kelemahannya :
Sambungan harus diposisikansecara akurat,
Perlu clamping yang baik
Ketebalan yang di las terbatas (maksimum 19 mm),
Rentan Retak (kecepatanpembekuannya tinggi)
Lecture Lecture -- 05 05
Dr. Ir. Winarto, M.Sc. 15
Lecture Lecture -- 05 05
Lecture Lecture -- 05 05
5. Underwater Welding
Underwater welding can be divided into three main types:
1. Wet underwater welding, where manual metal arc welding
(MMA) is the most common process. Flux-cored arc welding
(FCAW) has been widely used
2. Coffer dam welding, which is carried out in the dry, in air,
where a rigid steel structure to house the welders is sealed
against the side of the structure to be welded, and is open to
the atmosphere.
3. Hyperbaric welding, in which a chamber is sealed around the
structure to be welded, and is filled with a gas (commonly
helium containing 0.5 bar of oxygen) at the prevailing
pressure.
Dr. Ir. Winarto, M.Sc. 16
Lecture Lecture -- 05 05
Skematik Underwater Welding
Lecture Lecture -- 05 05
Application & Benefit
l Aplication: to repair offshore structures in deeper
waters, fabricated from higher carbon equivalent steels.
In view of the high weld metal diffusible hydrogen
levels generated in wet underwater welding, there is a
risk of hydrogen-assisted cracking which increases with
increasing carbon equivalent. Underwater welders
perform installation and repairs on aging bridges,
pipelines, nuclear power plants, and vessels
l Benefits : Underwater welding provides a means of
assembly or repair underwater. Alternatives, which
include clamped and grouted repairs (which may
introduce unacceptably high loading on offshore
structures), and the use of bolted flanges for tie-ins, are
not necessarily always satisfactory.
Dr. Ir. Winarto, M.Sc. 17
Lecture Lecture -- 05 05
Underwater Welding
Lecture Lecture -- 05 05
Electroda for Underwater Welding
Dr. Ir. Winarto, M.Sc. 18
Lecture Lecture -- 05 05
RISK
For the humans involved, the risks are of three main types.
l There is a potential risk to the welder/diver of electric
shock. Precautions include achieving adequate electrical
insulation of the welding equipment, shutting off the
electricity supply immediately the arc is extinguished,
and limiting the open-circuit voltage of MMA (SMA)
welding sets.
l Hydrogen and oxygen are produced by the arc in wet
welding and cutting. Precautions must be taken to aviod
the build-up of pockets of gas which are potentially
explosive.
l The life or health of the welder/diver from nitrogen
introduced into the blood steam during exposure to air at
increased pressure.
Lecture Lecture -- 05 05
Underwater Welding
Dr. Ir. Winarto, M.Sc. 19
Lecture Lecture -- 05 05
Requirement
l AWS D3.6 Standard and the qualifications generally
recognized.
l "Welder-diver: A certified welder who is also a
commercial diver, capable of performing tasks
associated with commercial sub-sea work, weld setup
and preparation, and who has the ability to weld in
accordance with the AWS D3.6, Specification for
Underwater Welding Specification for Underwater
Welding (i.e., wet or dry), and other weld-related
activities
Lecture Lecture -- 05 05
Description
l An experienced welder-diver must possess: commercial
diving skills (i.e., be familiar with the use of specialized
commercial diving equipment, have an understanding
of diving physiology, diving safety, rigging, the
underwater environment, communication, etc.); weld
setup and preparation skills (i.e., the ability to perform
tasks typically assigned to a fitter or rigger, such as
materials alignment and materials preparation including
beveling, stripping of concrete, fitting a steel patch or
repair plate, etc.,); and the ability to certify to a
required underwater weld procedure
Dr. Ir. Winarto, M.Sc. 20
Lecture Lecture -- 05 05
Limitations
l Underwater welding has historically been restricted in
its use by the very factor that makes it so unique - the
water. Water can cause underwater repairs to become
brittle. Hydrogen, a component within water, can
chemically react with newly welded material to create
a brittle weld, or can cause delayed cracking in the
welded area hours or days after repair. This limits the
longevity of the repair. Water also induces rapid
cooling of the area, causing detrimental
microstructures to form and brittleness to occur if the
weld is not properly treated after welding.
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Dr. Ir. Winarto, M.Sc. 21
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Dr. Ir. Winarto, M.Sc. 22
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Dr. Ir. Winarto, M.Sc. 23
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Dr. Ir. Winarto, M.Sc. 24
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Dr. Ir. Winarto, M.Sc. 25
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Home Work
1. JelaskanPrinsip kerja EBW & LBW beserta gambar.
2. Jelaskan mekanisme tahapanpenyambunganpada Thermit
Welding dan gambarkan grafik skematisnya?
3. Jelaskanpersyaratan untuk personel underwater welding
4. Jelaskan jenis dari underwater welding dan manakah metoda
yang umum diaplikasikan.
5. Sebutkanketerbatasandan resiko dalam under water
welding?
6. Jelaskankeuntungandan keterbatasandari EBW dan LBW.
7. Apa yang disebut Hybrid Welding Process dan sebutkan
beberapa contohproses hybrid welding process serta
keuntungandari proses tersebut.
8. Sebutkanjenis nyala api pada proses OAW beserta rasio dari
2 gas yang dicampur dan jelaskanaplikasi dari masing2
nyala api tersebut.