Professional Documents
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Joining Operations
Joining Operations
WELDING
WELDING
Definition: Material joining process. Two parts
connected at their contacting surfaces by suitable
heat and pressure.
Many welding processes are accomplished
by heat alone, some others by heat and pressure,
and some with pressure only.
In some welding operations a filler material
is used.
Welding operation usually applied to metals
but also used for plastics.
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Joining Processes
• Light
LASER
Three Specific Types of Welding Modules
• Spot Welding
–A process typically used in high-volume,
rapid welding applications.
• The pieces to be joined are clamped
between two electrodes under force,
and an electrical current is sent
through them.
Welding/Cutting Hazards
• Potential Hazards
– Fires may start by hot materials igniting nearby
combustibles.
– Burns to the operator may occur if unprotected
skin comes into contact with the extremely hot
work.
– Magnetic fields could easily
destroy/disrupt electronic
components, stored data if not
careful.
Welding/Cutting Hazards
• Potential Hazards Cont.:
– Metal fumes from vaporizing of the work with the
extremely hot arcs may be inhaled into the worker’s lungs.
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Oxygen-fuel gas welding & Cutting
– Storage of cylinders
• Storage area must be well ventilated
• Cylinders must be at least 20 feet from combustibles
• Valves must be closed
• Valve protection must be in place
• Inside storage must be limited to 2,000 cubic feet.
• Cylinders must be stored in upright position
• Oxygen must be at least 20 feet from fuel gas
or 5 feet with a 1/2 hour fire barrier
• Separate oxygen from fuel gas
Oxygen-fuel gas welding and cutting
• Cylinders Cont.:
– Operating Procedures
• Operation must emphasize the absence of
oily or greasy substances. Follow these rules
of operation:
– Cylinders, cylinder valves, couplings, regulators,
hose, and apparatus shall be kept free from oily or
greasy substances.
– Oxygen cylinders or apparatus shall not be
handled with oily hands or gloves.
– A jet of oxygen must never be permitted to strike
an oily surface, greasy clothes, or enter a fuel oil
or other storage tank.
Oxygen-fuel gas welding and cutting
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Types of weld
1. Fillet weld: Used in T joints,corner joints, lap joints.
2. Groove weld:Used in butt joints.
3. Plug weld: Used in lap joints.
4. Slot weld: Used in lap joints.
5. Spot weld: Used in lap joints.
6. Seam weld: Used in lap joints.
7. Flange weld:Used in edge joints.
8. Surfacing weld:Not a joining process, it is used to
increase the thickness of the plate, or provide a
protective coating on the surface.
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Fillet Weld Slot and Plug Weld
Groove weld
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Arc Welding
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Arc Welding and Cutting
• Definition:
– A fusion process wherein the coalescence of the
metals is achieved from the heat of an electric arc
formed between an electrode and the work.
• Application
• Installation
• Operation & Maintenance
t
Electric Arc Welding
- Classification -
• The Electrode
– Consumable: melts and serves as a filling material
– Non-consumable: does not melt, parent metal is used, or a
separate filler rod
– Coated or Uncoated
• Coating
– Provides a gaseous shield to prevent oxidation
– Lowers the voltage needed to establish the arc
– May provide slag-blanket to protect the joint
– Add alloying elements to enhance the properties of the joint.
Consumable Electrode Arc Welding Processes
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Thermit Welding
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Explosion Welding
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Resistance welding
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Forge welding
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PCB – printed circuit boards
Solder Pads
Soldering
Top View
Side View
Circuit Board
Resistor
Soldering
Iron
Move soldering iron until tip is
touching wire & solder pad
Move solder to touch edge of tip.
Solder
Hold until solder melts
on tip by wire
Solder
Move solder back to touch wire only
Solder
Move solder in to form a
small pocket
Solder
Move soldering iron tip up. This
will drag solder up with it.
Solder
Look for
shinny fillets
Brazing
• Definition:
– A process which a filler metal is placed at or between the
faying surfaces, the temperature is raised high enough to
melt the filler metal but not the base metal.
• The molten metal fills the spaces by capillary attraction.
• Torch Brazing
– Oxy-fuel torch with a carburizing flame
– First heat the joint then add the filler metal
Safe Work Practices
• Electric & Gas Welding
– Safety Check:
• Ensure electrical cord, electrode holder
and cables are free from defects
– No cable splices within 10 feet of electrode holder.
UW-Eau Claire
Facilities Planning & Management
Proper Ventilation for Welding
• Ventilation
– Proper ventilation can be obtained either naturally or
mechanically.
• Natural Ventilation is considered sufficient for welding and brazing
operations if the present work area meets these requirements:
– Space of more than 10,000 square feet is provided per welder
– A ceiling height of more than 16 feet.
• Mechanical ventilation options generally fall into two basic
categories.
– Low vacuum system which takes large volumes of air at low velocities.
– High vacuum system that are captured and extracted fumes as near to
the work as possible.
Fire Protection & Prevention
• Fire hazards must be removed, or
– Guards installed, or
– Welding/cutting must NOT take place
• Hot work permit should be used outside
designated areas to ensure that all fire
hazards are controlled
• Use of fire watch
– 1/2 hour after operation ceases
Proper Ventilation for Welding
• Ensure protection from fumes
and gases by one or a
combination of the following:
– Good general ventilation.
– Use of a booth.
– Local exhaust ventilation
on the hand piece.
– Air supply to the helmet.
Welding Operators Protection
• Welding involves specialized personal
protection that must be worn every time you
perform welding operations. The following is a
list of basic PPE:
– Fire-resistant gloves
– Aprons
– Safety shoes
– Helmet
– Ultraviolet radiation filter plate (arc welding)
– Goggles with filter lenses
U
Welding, Cutting and Brazing
• Summary
– Major hazards include:
• Fire
• Burns
• Shock
• Toxic Exposure
– Follow proper procedures to prevent fires
– Use appropriate engineering controls
– Wear appropriate PPE
Any Questions
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