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Metal Joining Processes
Metal Joining Processes
Subjects of Interest Conventional joining techniques Oxyacetylene welding Shielded metal arc welding Gas-tungsten arc welding Gas-metal arc welding Flux-core arc welding Plasma arc welding Submerged arc welding Electroslag welding Electron beam welding Laser beam welding Resistance welding Friction (stir) welding
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Sep-Dec 2007
Objectives
This chapter provides information on metal joining processes, for example, fusion welding and other high energy beam welding techniques. Students are required to indicate advantages and disadvantages of different methods of metal joining. Students should be able to select appropriate methods of metal joining for the required applications.
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Types of metal joining Power density of heat source Type of joint and weld position Welding processes and materials
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Power density
Deeper weld penetration Higher welding speeds Better weld quality Less damage to the workpiece
Variation of heat input to the workpiece with power density of the heat source.
Variation of weld strength with unit thickness of workpiece heat input per unit length of weld.
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The surface of the weld is called the face. The two junctions between the face and the workpiece surface are called the toes. The portion of the weld beyond the workpiece surface is called the reinforcement.
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www.arnoldsupplyinc.com
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www.engineeringyourfuture.com
www.arnoldsupplyinc.com
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www.seas.upenn.edu
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Gas welding
Gas welding is a welding process that melts and joints metals by heating them with a flame caused by a reaction of fuel gas and oxygen. The most commonly used method is Oxyacetylene welding, due to its high flame temperature. The flux may be used to deoxidize and cleanse the weld metal. The flux melts, solidifies and forms a slag skin on the resultant weld metal.
Sep-Dec 2007
Oxyacetylene welding
There are three types of flame in oxyacetylene welding:
Neutral flame
Acetylene (C2H2) and O2 are mixed in equal amounts and burn at the tip of the welding torch. The inner cone gives 2/3 of heat whereas the outer envelope provides 1/3 of the energy.
Reducing flame
The excess amount of acetylene is used, giving a reducing flame. The combustion of acetylene is incomplete (greenish) between the inner cone and the outer envelope. Good for welding aluminium alloys, high carbon steels.
Oxidizing flame
The excess amount of O2 is used, giving an oxidizing flame. Good for welding brass.
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The secondary combustion is also called the protection envelope since CO and H2 here consume the O2 entering from surrounding air, thereby protecting the weld from oxidation.
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Disadvantages
Limited power density Very low welding speed High total heat input per unit length Large heat affected zone Severe distortion Not recommended for welding reactive metals such as titanium and zirconium.
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Deoxidation
Provide deoxidizers and fluxing agent to deoxidize and cleanse the weld metal. The solid slag also protects the weld metal from oxidation. Provide arc stabilizers which are compounds such as potassium oxalate and lithium carbonate. They readily decompose into ions in an arc, which increase electrical conductivity. Provide alloying elements (for composition control) and metal powder (increase deposition rate) to the weld pool.
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Arc stabilization
Metal addition
Sep-Dec 2007
Simple welding equipment Portable Inexpensive Used for maintenance, repair, and field construction
Not clean enough for reactive metals such as aluminium and titanium. The deposition rate is limited because the electrode covering tends to overheat and fall off. The electrode length is ~ 35 mm and requires electrode changing lower the overall production rate.
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Shielding gases
Ar is heavier and offers more effective shielding and cheaper than He.
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Disadvantages
Deposition rate is low. Excessive welding current causes melting of the tungsten electrode and results in brittle tungsten in the weld pool. Multiple passes Low welding speed
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Keyholing
Keyholing is a positive indication of full penetration and allow higher welding speed (for thickness 2.5-6.4 mm). Requires proper combinations of the orifice gas flow, the travel speed, and the welding current. A wine cup shape is common in PAW.
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Disadvantages
More complicated. Require proper electrode tip configuration and positioning and orifice selection. Equipment is more expensive.
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1. Globular transfer
Metal droplets travel across the arc gap under the influence of gravity. Often not smooth and cause spatter. Low welding current (180A).
Globular transfer
2. Spray transfer
Occur above a critical current level (280-320A). Small metal droplets travel across the gap under the influence of the electromagnetic force at much higher frequency and speed than in the globular mode. More stable and spatter free.
Spray transfer
3. Short-circuit transfer
Molten metal droplets are transferred from electrode tip to the weld pool when it touches the pool surface (short-circuit). Require very low current and electrode diameter, giving small and fastfreezing weld pool desirable for welding thin section or out of position welding.
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Disadvantages
The GMAW gun is quite bulky and difficult to reach small areas or corners.
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Disadvantages
Cannot weld in a flat-position and circumferential (pipe). High heat input can reduce the weld quality and increase distortions.
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Electroslag welding
Electroslag welding (ESW) is a process that melts and joins metals by heating them with a pool of molten slag held between the metals and continuously feeding a filler wire electrode into it. The weld pool is covered with molten slag and move upward as welding progresses. A pair of water-cooled copper shoes keeps the weld pool and the molten slag from breaking out. The molten slag protects the weld metal from air and refine it. The arc is only used during the initiation process.
Electroslag welding
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Disadvantages
Very high heat input weld quality could be poor due to coarse grain in the fusion zone or heat affected zone. Strict to vertical position due to very large weld pools.
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Welds in 13 mm-thick 2219 aluminium (a) Electron beam weld and (b) gas tungsten arc weld. Dispersion of electron beam at various ambient pressures.
Vacuum operation
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Disadvantages
Very high equipment cost. High vacuum (10-3 10-6 torr) is inconvenient. medium vacuum (10-3 25 torr) and non vacuum (1 atm) EBW have also been developed. Precise alignment of the joints and the gun is required due to small beam size. Missed jointed of dissimilar metal can be obtained due to beam deflection.
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Laser beam welding with CO2 laser in 13-mm thick A633 steel.
Surface melting produces a full penetration. High reflectivity can cause problems in LBW Surface modifications, i.e., roughening, oxidizing and coating can significantly reduce reflectivity. Laser beam can be used in combination with arc welding such as GMAW to provide greater penetration.
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Disadvantages
Very high reflectivity of a laser beam by the metal surface. High equipment cost. Require precise joint and laser beam alignment.
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Resistance welding
Resistance welding is used to join two or more metal parts together in a localised area by the application of heat and pressure. The heat is produced by the resistance of the material to carry a high amperage current. There are at least seven different types of resistance welding:
Electrode Workpiece Power supply
Flash welding High-frequency resistance welding Percussion welding Projection welding Resistance seam welding Resistance spot welding Upset welding
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Projection welding
Spot welding
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Friction welding
Friction welding is a mechanical solid-phase welding process in which heat generated by friction is used to create high-integrity joint between similar or dissimilar metals. Can be used for round and rectangular sections.
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public.ca.sandia.gov/
www.mtiwelding.com
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Friction welding
Friction welding for rectangular sections
The heat generated due to frictional motions of the two workpieces, creating a columnar microstructure as shown in figure.
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High cost of welding machines. Can use to join dissimilar metals. Very small distortion. Limited to non-round and non-complex component.
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References
Kou, S., Welding metallurgy, 2nd edition, 2003, John Willey and Sons, Inc., USA, ISBN 0-471-43491-4. Gourd, L.M., Principles of welding technology, 3rd edition, 1995, Edward Arnold, ISBN 0 340 61399 8.
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