Professional Documents
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EQUIPMENT
Note:
Study each manufacturing process under the
following headings;
1.
2.
3.
4.
5.
INTRODUCTION
Joining Processes: Processes by which individual
components are attached to other components and
assemblies
Common Joining processes include:
Welding
Brazing
Soldering
Adhesive bonding
Mechanical fastening
CLASSIFICATION OF JOINING
PROCESSES
WELDING
Welding is a materials joining process in which two or more
parts are coalesced( bring together to form a single mass) at
their contacting surfaces by a suitable application of heat and/or
pressure. Many welding processes are accomplished by
heat alone, with no pressure applied; others by a combination
of heat and pressure; and still others by pressure alone, with no
external heat supplied.
Filler In some welding processes a material is added to
facilitate coalescence.
Weldment The assemblage of parts that are joined by welding
is called a weldment.
Faying Surface is one of the surfaces that are in contact at a
joint. Faying surfaces may be connected to each other by bolt
or rivet or by adhesive or welding. Example, steel pipe flanges.
TYPES OF WELDING
We can divide the welding processes into two major groups:
(1) fusion welding and
(2) solid-state welding.
Fusion Welding: Fusion-welding processes use heat to melt the
base metals. In many fusion welding operations, a filler metal is
added to the molten pool to facilitate the process and provide
bulk and strength to the welded joint. A fusion-welding
operation in which no filler metal is added is referred to as an
autogenous weld.
The fusion category includes the most widely used welding
processes, which can be organized into the following general
groups:
SOLID-STATE WELDING
Solid-state welding refers to joining processes in which
coalescence results from application of pressure alone or a
combination of heat and pressure. If heat is used, the
temperature in the process is below the melting point of the
metals being welded. No filler metal is utilized.
Diffusion welding (DFW). Two surfaces are held together under
pressure at an elevated temperature and the parts coalesce by
solid-state diffusion.
Friction welding (FRW). Coalescence is achieved by the heat of
friction between two surfaces.
Ultrasonic welding (USW). Moderate pressure is applied
between the two parts and an oscillating motion at ultrasonic
frequencies is used in a direction parallel to the contacting
surfaces. The combination of normal and vibratory forces
results in shear stresses that remove surface films and achieve
atomic bonding of the surfaces.
TYPES OF WELDS
Cont
A welding fixture is a device for clamping and holding the
components in fixed position for welding. It is custom-fabricated
for the particular geometry of the weldment and therefore must
be economically justified on the basis of the quantities of
assemblies to be produced.
A welding positioner is a device that holds the parts and also
moves the assemblage to the desired position for welding. This
differs from a welding fixture that only holds the parts in a single
fixed position.
The desired position is usually one in which the weld path is flat
and horizontal.
JOINING PROCESSES
TYPES OF JOINTS
2CO + H2 + Heat
OXYACETYLENE TORCH
The acetylene valve is opened first; the gas is lit with a spark lighter or
a pilot light; then the oxygen valve is opened and the flame is adjusted.
To ensure correct connections, all screw threads on acetylene fittings are lefthanded, whereas those for oxygen are right-handed. Oxygen regulators are
usually painted green, and acetylene regulators red.
FILLER METALS
Filler metals: Filler metals are used to supply additional
metal to the weld zone during welding, They are available
as filler wire or rods as shown in the figure. They are
usually coated with flux.
Cont.
Shielded metal arc welding is usually performed manually.
Common applications include construction, pipelines,
machinery structures, shipbuilding, job shop fabrication,
and repair work. It is preferred over oxyfuel welding for thicker
sectionsabove 5 mm (3/16 in)because of its higher power
density. The equipment is portable and low cost,making SMAW
highly versatile and probably the most widely used of the AW
processes. Base metals include steels, stainless steels, cast
irons, and certain nonferrous alloys. It is not used or seldom
used for aluminum and its alloys, copper alloys, and titanium.
A disadvantage of shielded metal arc welding as a production
operation is the use of the consumable electrode stick. As the
sticks are used up, they must periodically be changed. This
reduces the arc time with this welding process. Another
limitation is the current level that can be used.
Submerged arc welding demonstration at the Essen Welding Fair in Germany, 2005. The welding head moves
from right to left. The flux (powder) is supplied on the left hand side, then follow three filler wire guns and finally a
vacuum cleaner.
Figure (a): gas metal-arc-welding process, formerly known as MIG (metal inert
gas) welding and (b): Basic equipment used in gas metal-arc-welding operations.
electrode)
includes
Figure (a): Gas tungsten-arc-welding process, formerly known as tungsten inert gas (TIG)
welding and Figure (b): Equipment for gas tungsten-arc-welding operations.
Tungsten
electrode
RESISTANCE WELDING
Resistance welding (RW) is a group of fusion-welding
processes that uses a combination of heat and pressure to
accomplish coalescence, the heat being generated by electrical
resistance to current flow at the junction to be welded. The
principal components in resistance welding are shown in Figure
30.12 in next slide for a resistance spot-welding operation, the
most widely used process in the group.
The components include work parts to be welded (usually sheet
metal parts), two opposing electrodes, a means of applying
pressure to squeeze the parts between the electrodes, and an
AC power supply from which a controlled current can be
applied. The operation results in a fused zone between the two
parts, called a weld nugget in spot welding. By comparison to
arc welding, resistance welding uses no shielding gases, flux,
or filler metal; and the electrodes that conduct electrical power
to the process are nonconsumable.
ContRESISTANCE WELDING
Success in resistance welding depends on pressure as well as
heat. The principal functions of pressure in RW are to
(1) force contact between the electrodes and the workparts and
between the two work surfaces prior to applying current, and
(2) press the faying surfaces together to accomplish
coalescence when the proper welding temperature has been
reached.