Discuss the details of Brazing, Soldering and -1

.Riveting Welding techniques

A) Brazing:
It's a welding process that involves melting a filler metal
between the material gabs.
Step 1: Good fit and proper clearances
Brazing, uses the principle of capillary action to distribute the
molten filler metal between the surfaces of the base metals.
Therefore, during the brazing operation, you should take care to
maintain a clearance between the base metals.
Step 2: Cleaning the metals
Capillary action will work properly only when the
surfaces of the metals are clean.
Step 3: Fluxing the parts
A coating of flux on the joint area, will shield the
surfaces from the air, preventing oxide
formation.
Step 4: Assembly for brazing
You want to be sure they remain in correct
alignment during the heating and cooling
cycles, so that capillary action can do its job.
Step 5: Brazing the assembly.
It involves heating the assembly to brazing
temperature, and flowing the filler metal through
the joint.
Step 6: Cleaning the brazed joint
First - removal of the flux residues.
Second - pickling to remove any oxide scale
formed during the brazing process.
B) Soldering:
Soldering has the same technique as Brazing of
1. Ensure fit and clearance
2. Clean metal
3. Flux prior to soldering
4. Fixturing of parts
5. Soldering the assembly
6. Cleaning the new joint
 Except that the filler metal (solder) melts at a lower
temperature.

C) Riveting:
1- Select the suitable rivet.
2- Determine the location of the rivets
3- Punch the holes especially if the metal is thin.
4- Set the rivet.
5- Head the rivet.
Use the flat face of the riveting hammer to strike the
shank squarely with several blows. The shank will
expand, filling the hole tightly while the top of the shank
will flatten a little.

6-
 With Full details demonstration discuss What are -2
the important and field applications of following
?Welding techniques

 Shielded Metal Arc Welding (SMAW) :

(SMAW) is one of the world's most popular
welding processes, Because of its
versatility and simplicity.
Applications:
1- the maintenance and repair industry.
2- In the construction of steel structures and
in industrial fabrication.
3- Now it's used in some factories with robots
technology for mass production.
4-  It's also used in underwater welding,
 Gas Metal Arc Welding (GMAW).
GMAW is one of the most popular welding
methods, especially in industrial
environments.

Applications:
1- It is used extensively by the sheet metal
industry.
2- The automobile industry,
replacing riveting or resistance spot
welding.
3- It is also popular for automated welding.

 Resistance Welding.
 Applications:
Resistance welding is used in :
1- Aero-space industeries, for materials that has high strength.
2- Automative industry, cars Motor-bikes and other automobiles.
3- Rail-way industries, gives high structural integrity.
4- joining different materials in railway switches.

 Stud Welding.
 Applications:
1- Food service equipment:
 stainless steel appliances....
microwaves, ovens, mixers
2- Architectural lighting.
3- Nameplates:
 brass nameplates commonly
found outside lawyers offices.
4- Shipbuilding:
 everything on board of ships is
held in place with weld studs.
5- Construction.
6- Elevator panels.
3- Submerged Arc Welding is the most applicable Arc
Welding in industrial field .discuss in details With full
schematic details .
(SAW) is a well established and
extremely versatile method of
welding. 
Theory :
It involves the formation of an arc between a
continuously fed electrode and the workpiece. A
blanket of powdered flux, which generates a
protective gas shield and a slag (and may also be
used to add alloying elements to the weld pool),
protects the weld zone.
Advantages :
1- The arc is submerged beneath the flux blanket.
2- SAW is normally operated in the automatic or
mechanized mode, however, semi-automatic (hand-held)
SAW guns with pressurized or gravity flux feed delivery
are available.
3- It has Deep weld penetration.
4- High speed welding of thin sheet steels up to 5 m/min
(16 ft/min) is possible.
4- In details With full Schematic illustration
Discuss the following:
A) Plasma Arc Welding ( PAW ):
 Theory :
PAW is a welding process
where the two metal
workpieces are joined due to
the formation of an arc
between the electrode and the
workpieces, the arc is basically
produced from the plasma
gas.
 Plasma gas formation:
The argon gas flows through
the welding torch and when it
comes in contact with the
current carrying electrode it
gets ionized, this ionized gas
is called plasma.
B) Ultrasonic Welding .
 Theory:
Ultrasonic welding is an industrial technique whereby high
frequency ultrasonic acoustic vibrations are locally applied to
workpieces being held together under pressure to create a solid-
state weld.

 Main parts :
1- Transducer: produces high
frequency ultra-sonic
vibrations.
2- Converter: Converts the
electrical signal into a
mechanical vibration.
3- Booster: Modifies the
amplitude of the vibration.
4- Sonotrode: Applies the
mechanical vibration to the
parts to be welded.
 Technique:
1- A static clamping force is applied prependicular to the interface
between the work pieces.
2- The contacting sonotrode oscillates on the interface.
3- Combined effect of static and oscillating force produces
deformation which promotes welding.
 MansouraUniversity
Faculty of engineering

Production engineering and mechanical

design department

Technical report

In

Welding process

:By
Ziad Sayed Fadali.