Welding Methods Employed In Industrial

Applications
 M.Mohsin Rasheed
Gulam Fareed Ali Shan
University of Lahore
University of Lahore University of Lahore
Electrical Engineering Department
Electrical Engineering Department Electrical Engineering Department
Lahore,Pakistan
Lahore,Pakistan Lahore,Pakistan
mohsinrasheed1602@gmail.com
gfareed0086@gmail.com shan79786@gmail.com
BSEE02163002
BSEE01153086 line 1: 6th Given Name Surname
 I. INTRODUCTION

Welding history can find from ancient times. The earliest

examples of welding come from the Bronze Age. Small gold
circular boxes were made by pressure welding lap joints
together. It is estimated that these boxes were made more
than 2,000 years ago. During the Iron Age the Egyptians and
people learned to weld pieces of iron together. Many tools
were found that were made in approximately 1000 B.C.
During the Middle Ages, many items of iron were produced
that were welded by hammering. It was not until the 19th Fig1.1 Time and Temperature
century, so technique developed named as welding. Edmund
Davy of England discovered acetylene in 1836. Gas welding The temperature of the parts during this phase can be
and cutting developed in 1800. Arc welding with the carbon modeled by assuming a constant temperature boundary
condition and using the one-dimensional heat equation
arc and metal arc was developed also in 1800. Auguste De
Meritens, used the heat of an arc for joining lead plates for
storage batteries in the year 1881. Coffin of Detroit awarded
for an arc welding process using a metal electrode in 1890.
Strohmenger introduced a coated metal electrode in Great
Britain in 1900. In 1920, automatic welding was introduced.
P.O. Nobel invented automatic welding. Stud welding was
Low Temperature:
developed in 1930 at the New York Navy Yard. The gas
metal arc welding (GMAW) process was successfully 1. Temperatures less than 500°F
developed at Battelle Memorial Institute in 1948. In 1953, 2. Low temperature tools require Teflon coated heat
Lyubavskii and Novoshilov announced the use of welding platen inserts or Teflon cloth.
with consumable electrodes in an atmosphere of carbon
dioxide gas. Another variation was use of inert gas with 3. Typically, coating/cloth needs replacement every
small amounts of oxygen that provided the spray-type arc 1500-8000 cycles.
transfer. It became popular in the 1960s. Gage invented 4. Typical cycle time is 20-40seconds.
plasma arc welding in 1957. This process uses a constricted
arc. The electron beam welding process, which uses a High Temperature:
focused beam of electrons as a heat source in a vacuum 1. Temperatures higher than 500°F
chamber, was developed in France. The majority of everyday
products contain a joint of some description, with even small 2. High temperature tools are typically manufactured
items such as mobile phones, cars, bikes, machinery etc. So using P-20 tool steel.
welding has important role in our daily life and for emerging 3. No melt release coatings typically required
industries.
4. Melt residue smokes away or requires brush
cleaning(Nylon)
Different methods of welding 5. Smoke/Fumes present: requires exhaust/smoke
There are many methods of welding which used in removal or air cleaning
industries. Every day we see things, which are made up of 6. Typical cycle time is 10-30 seconds.
joints. Things are join together by different methods of
welding. Here we discuss many methods of welding which
industries are using nowadays.
B. Hot gas welding
A. Hot plate welding Hot-gas welding is a manual plastic welding process for
Hot plate welding, also called heated tool welding, is a joining thermoplastic materials. A hot-gas torch is used to
thermal welding technique for joining thermoplastics. heated direct hot air to both the joint surface and weld rod that is
tool is placed against or near the two surfaces to be joined in heating the materials to their softening temperature. Weld
order to melt them. Then, the heat source is removed, and the rod joint surfaces, bonds the materials together to form a
surfaces are brought together under pressure. To heat the part completed weld. This process, invented in the mid 20th
joint area, a thermally heated plate is placed between the century.
parts to be join. Thermal heat continues to conduct into the
material even though compression and displacement have
minimum. After the joint area reaches molten temperature,
the holding open and the heat platen is removed. The holding
fixtures then close, forcing the two parts together until
fixtures come into contact with one another.
Critical Hot Plate Welder Parameters:
Time and Temperature:
The platen temperature to melt the part interface depends
on the type of material being joined. Each material has a
characteristic melt time/temperature curve, and a weld can be Fig1.2 Hot Gas Welding
produced at any temperature on the curve range is 300° to
950°F. Welding parameters:
There are four main welding parameters in the hot gas
welding process.
1. Temperature
Temperature is the most important of the four parameters,
since the temperature at the interface between the rod and
the substrate is not only controlled by the setting on the gun,
but also by the gun travel speed and the gun position with
respect to the substrate. The temperature for welding is set
between 80 and 100°C above the melting point of the
material being welded.

2. Welding speed
The gun travel speed is normally between 0.1 and 0.3m/min,
again, depending upon the material being welded.
3. Pressure
The welding pressure is applied via the toe of the welding
nozzle. The welding pressure is applied via the toe of the
welding nozzle and is achieved by holding the welding gun
grip firmly and pushing down into the weld.
C. Hand Welding:
Hand welding is a process in which contacting metal
surfaces are joined by the heat obtained from resistance to
electric current. Projection welding is a modification of spot
or hand welding.
Fig1.5 Made with (a) Tool T2 (b) Tool T1, T2, T3
E. Vibration Welding
Linear vibration welding physically moves one of two
parts horizontally under pressure, creating heat through
surface friction that melts and welds the parts together.
Compared to ultrasonic welding, vibration welders operate
at much lower frequencies, higher amplitudes and much
greater clamping force. Vibration welding may be
performed on almost any thermoplastic material. Vibration
welding is feasible for composites but a higher force is
required and fibre damage at the joint can be a problem.
Direction of Vibration
The vibration welding process vibrates one
component relative to another in a linear side-to-side
motion. Take a second to rub your hands together like you
are trying to warm up from the cold. You are making the
same motion that a vibration welder does with two parts.
The friction between the two objects generates the heat used
for welding.

Fig1.3 Hand Welding

D. Friction stir spot welding:

Friction stir spot welding is a solid-state joining process,
which is a derivative of friction stir welding no linear
movement of the tool occurs. In friction stir spot welding,
individual spot welds are created by pressing a rotating tool
Fig1.6 Direction of Vibration
with high force onto the top surface of two sheets that
overlap each other in the lap joint. The shoulder applies a Frequency of vibration
high forging pressure, which bonds the components Frequency is the measure of how many vibratory
metallurgically without melting. The tool consists of a oscillations are completed in one second. The vibration
rotating pin and a shoulder. The pin is the part of the tool welding process vibrates approximately 120-240 times per
that penetrates into the materials. second, or 120-240 Hz, depending on the size of the parts
It has been mainly used to join heat treatable aluminum being welded. This frequency is well within the human
alloys, without and with surface protection. hearing range, so vibration equipment uses sound
Examples dampening enclosures to protect machine operators from the
a) Shipbuilding and Marine deafening fog-horn-like sound.
b) Railway tankers
c) Car body structures

Fig1.4 Friction Stir Spot Welding Fig1.7 Frequency over Time

Amplitude of vibration
Amplitude is the distance between the two furthest
points of vibratory motion. In vibration welding, the Where q is the heat generation rate, f is the coefficient of
amplitude is typically between 0.4 and 1.8 mm in high- friction, r is the radius of the parts being welded.
frequency machines and 1.8 and 4.0 mm in low-frequency
machines. The lower the amplitude, the higher the
frequency.

Where qy is viscosity of the molten polymer, r is the part

radius, ω is related to the RPM as above, and 2h is the
thickness of the melt layer.

Spin Welding Characteristics of Semi-Crystalline Polymers

Fig1.8 Amplitude of Vibration

Applications
a) Instrument panels
b) Glove boxes
c) Power tools
d) Surgical instruments
e) Filters
f) Home appliances

F. Spin Welding
The process of spin welding consists of generating heat
by rotational friction to weld thermoplastic parts with
circular joints. The spin welding machine applies force
axially while rotating one part against its stationary mate.
The resulting friction generates heat that melts the parts at Advantages
the interface. Once rotation stops, the material cools and Advantages of the spin welding process include
solidifies, forming a welded assembly. For cases where the high quality permanent joints, hermetic seals, lower
parts must be oriented in a particular manner with respect to equipment costs compared to other processes, ease of
each other, the welder stops the rotation at a precise angular assembly, energy efficient operation, immediate handling,
orientation. entrapment of other parts, far-field welding capability and
elimination of additional materials, such as adhesives.

Applications
a) High quality permanent joints
b) Hermetic seals
c) Twin-wall drinking cups

G. Ultrasonic Welding
Ultrasonic plastic welding is the joining or
reforming of thermoplastics through the use of heat
Fig1.9 Spin Welding generated from high-frequency mechanical motion. It is
accomplished by converting high-frequency electrical
Material Considerations
energy into high-frequency mechanical motion. That
Materials suitable for spin welding are generally
mechanical motion, along with applied force, creates
the same as those that can be joined by other friction
frictional heat at the plastic components’ mating surfaces
welding processes, such as vibration welding. Semi
(joint area) so the plastic material melts and forms a
crystalline thermoplastics are more readily joined using spin
molecular bond between the parts.
welding. Using compatible polymers, spin welding is
capable of making reliable hermetic seals.
The ultrasonic welding needs high frequency and
Weld pressure
high voltage power supply. This power is needed by the
Pressure also plays a role in heat generation.
transducer to generate vibrations.
Mathematical Analysis of Heat Generation
Transducer is a device which can convert high
frequency electric signal into high frequency mechanical
vibration. This is connected with the welding head. The
converter or piezoelectric transducer used in this welding
process.

Fig1.10 Ultrasonic Welding Process

Principle
It works on the basic principle of energy of
ultrasonic wave. Ultrasonic vibration creates a dynamic
shear stress between the contacts of two work piece. Due to
local plastic deformation and heat generate due to friction
between contact surfaces, joint formation will take place at
the interface.
During the ultrasonic welding process mechanical
vibrations with defined amplitude, force and duration are
applied to the materials to be welded. Due to intermolecular
and surface friction heat is generated and melts the material.

Fig1.11 Amplitude-Wavelength Waveform

Applications
a) This welding is used in fabrication of
nuclear reactor components.
b) It is used in automotive industry for key,
head lamp parts, button and switches etc.
c) Ultrasonic is used in electronic industries
like armature winding, switches etc.
d) This is clean welding process so it is used
in medical industries to make parts like
filters, masks etc.
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