Chapter

Chapter Outline
Outline
Joining
Joining Processes
Processes

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Welding
Welding Processes
Processes Welded
Welded Joints
Joints
z Gas, electricity, or other heat source?
z Is electrode consumed?
z Is a filler material used?
z Is flux used?
z Anything else?
z Video – Introduction to welding

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Fusion
Fusion Welding
Welding Processes
Processes Oxyacetylene
Oxyacetylene Welding
Welding
z Video – Fusion welding processes z Acetylene gas most common (6,000° F)
z Welding
z Cutting
z Straightening
z Can be with or without filler

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 Weld
Weld Joint
Joint Structure
Structure
Oxyacetylene Torch
Figure 30.2 (a) General view of
and (b) cross-section of a torch
used in oxyacetylene welding.
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 adjusted. (c) Basic
equipment used in oxyfuel-gas
welding. To ensure correct
connections, all threads on
acetylene fittings are left-handed,
whereas those for oxygen are Figure 30.18 Grain structure in (a) deep weld and
right-handed. Oxygen regulators Figure 30.17 Characteristics of a
(b) shallow weld. Note that the grains in the
are usually painted green, and typical fusion-weld zone in oxyfuel- solidified weld metal are perpendicular to their
acetylene regulators red. gas and arc welding. interface with the base metal (see also Fig. 10.3).
(c) Weld bead on a cold-rolled nickel strip produced
by a laser beam. (d) Microhardness (HV) profile
across a weld bead.

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Arc
Arc Welding
Welding Processes
Processes Gas-Tungsten
Gas-Tungsten Arc
Arc Welding
Welding
z Nonconsumable electrode z Video –TIG welding
• Gas tungsten-arc (TIG) Figure 30.4 (a) The gas
tungsten-arc welding
• Plasma arc (PAW) process, formerly known as
TIG (for tungsten inert gas)
welding. (b) Equipment for
z Consumable electrode gas tungsten-arc welding
operations.
• Shielded metal arc (SMAW)
• Gas metal arc (GMAW or MIG)
• Flux-cored arc welding (FCAW)
• Submerged arc welding (SAW)

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Plasma-Arc
Plasma-Arc Welding
Welding Process
Process Shielded-Metal
Shielded-Metal Arc
Arc Welding
Welding
z Video – plasma arc welding z Video – shielded metal arc welding
z 60,000 degrees F

Figure 30.7 Schematic illustration of the shielded metal-arc

welding process. About 50% of all large-scale industrial welding
operations use this process.

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 Shielded-Metal
Shielded-Metal Arc
Arc Welding
Welding Gas
Gas Metal-Arc
Metal-Arc Welding
Welding
Figure 30.8 A deep weld showing the
buildup sequence of eight individual weld
z Videos – gas metal arc welding
beads.

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Fluxed-Cored
Fluxed-Cored Arc-Welding
Arc-Welding Submerged-Arc
Submerged-Arc Welding
Welding
z Video – flux core welding z Video – submerged-are welding

Figure 30.11 Schematic illustration of the flux-cored arc welding process. This Figure 30.9 Schematic illustration of the submerged arc welding process and
operation is similar to gas metal-arc welding, shown in Fig. 30.10. equipment. The unfused flux is recovered and reused.
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Other
Other Welding
Welding Processes
Processes Weld
Weld Design
Design
z Electron beam - video
z Laser beam - video

Figure 30.29 Some design guidelines for welds. Source: After J.G. Bralla.

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 Welded
Welded Joints
Joints Defects
Defects in
in Fusion
Fusion Welds
Welds
z Metallurgy concerns
Figure 30.19 Examples of
• Solidification process various discontinuities in fusion
welds.
z Heat-affected zone -
weakest part of joint

Figure 30.20 Examples of

various defects in fusion welds.

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Cracks
Cracks in
in Welded
Welded Joints
Joints Distortion
Distortion of
of Parts
Parts After
After Welding
Welding

Figure 30.23 Distortion of parts after welding. (a) Butt joints and (b) fillet welds.
Distortion is caused by differential thermal expansion and contraction of different
regions of the welded assembly.
Figure 30.21 Types of cracks developed in welded joints. The cracks are caused
by thermal stresses, similar to the development of hot tears in castings (see also
Fig. 10.12).

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Weld
Weld Testing
Testing Solid-state
Solid-state Processes
Processes
z Mechanical methods
• Ultrasonic
• Friction
z Electrical
• Resistance

Figure 30.26 (a) Specimen for longitudinal tension-shear testing; (b) specimen for
transfer tension-shear testing; (c) wraparound bend test method; (d) three-point
bending of welded specimens (see also Fig. 2.11).

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 Ultrasonic
Ultrasonic Welding
Welding Ultrasonic
Ultrasonic Welding
Welding
z Video - ultrasonic z Vibrating tool at high frequency
z Lap joints of thin materials

Figure 31.2 (a) Components of an ultrasonic welding machine for making lap welds. The lateral
vibrations of the tool tip cause plastic deformation and bonding at the interface of the
workpieces. (b) Ultrasonic seam welding using a roller as the sonotrode.
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Friction
Friction welding
welding Resistance
Resistance (Spot)
(Spot) Welding
Welding (RW)
(RW)
Figure 31.6 (a) Sequence of
z Rub two parts events in resistance spot
welding. (b) Cross-section of
together a spot weld, showing the weld
nugget and the indentation of
the electrode on the sheet
z Video surfaces. This is one of the
most commonly used
processes in sheet-metal
fabrication and in automotive-
body assembly.

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Resistance
Resistance Welding
Welding Spot
Spot Welding
Welding Equipment
Equipment
z Video
z Spot, projection, and seam
z Heating
• H=I2RT, where
• I=current
• R=electrical resistance
• T=time
Figure 31.7 (a) Schematic illustration of an air-operated, rocker-arm,
spot welding machine. (b) and (c) Two electrode designs for easy
access into components to be welded.

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 Resistance
Resistance Projection
Projection Welding
Welding Spot
Spot Weld
Weld Testing
Testing

Figure 31.13 (a) Schematic illustration of resistance projection welding. (b) A Figure 31.10 Test methods for spot welds: (a) tension-shear test, (b) cross-tension
welded bracket. (c) and (d) Projection welding of nuts or threaded bosses and test, (c) twist test, (d) peel test. (see also Fig. 32.9).
studs. (e) Resistance-projection-welded grills.
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Brazing
Brazing &
& Soldering
Soldering Joint
Joint Designs
Designs used
used in
in Brazing
Brazing
z Video
z Filler material
z Temperature below melting point of
metals
z Differences from welding
• brazing alloy
• strength of brazing alloy
Figure 32.3 Joint designs commonly used in brazing operations. The clearance
• capillary action between the two parts being brazed in an important factor in joint strength. If the
clearance is too small, the molten braze metal will not penetrate the interface fully. If
it is too large, there will be insufficient capillary action for the molten metal to fill the
z Soldering - lower temperature than 4/16/2006
interface.
4/16/2006
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brazing

Joints
Joints Advantages
Advantages of
of Brazing
Brazing
z Should be clean z Join a variety of metals
z Should have close tolerance z Quick
z Low temperature
z Automation is possible

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 Adhesives
Adhesives Adhesives
Adhesives
z Epoxies - most are 2 components
z Cyanoacrylates - “super glues”
z Anaerobics
• one component, cure when oxygen is removed
z Acrylics
• catalyst primer and adhesive
z Urethanes
• low temperatures
z Silicones - flexible joints
z Hot melts
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Advantages
Advantages &
& Disadvantages
Disadvantages Design
Design for
for Assembly
Assembly (DFM)
(DFM)
z Combination of materials z Many ideas
z Low temperature
z Function
z Joining of thin materials
z Cost
z Joining of heat sensitive materials
z Inexpensive z Time
z Less assembly time z DFM Video
z Unstable at higher temperature
z Destructive testing required
z Surface preparation
z Cure time
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DFM
DFM -- Concepts
Concepts DFM
DFM Examples
Examples
z Reduce the number of parts
z Reduce number of fasteners
z Use modular designs
z Reduce need to handle several components at
the same time
z Limit number of directions
z Use high quality components
z Design fasteners that can be easily
automatically feed

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