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This welding technique is mostly used in the automotive industry. process in order to prevent the w/p from oxidation
It works on the principle that when electrons of an atom gets 1. Gas lasers: It uses mixtures of gases as a lasing medium
to produce laser. Mixtures of gases such as nitrogen,
excited by absorbing some energy. And then after some time helium, and co2 are used as the lasing medium.
2. Solid-state laser: it uses several solid media such as
when it returns back to its ground state, it emits a photon of light. synthetic ruby crystal (chromium in aluminum oxide),
neodymium in glass (Nd: glass), and neodymium in
The concentration of this emitted photon increased by stimulated yttrium aluminum garnet (Nd-YAG, most commonly used).
emission of radiation and we get a high energy concentrated laser Fiber laser: The lasing medium in this type of laser is optical fiber
itself.
beam.Light amplification by stimulated emission of radiation is
Characteristics of Laser Beam
called laser. The main parts or equipment of laser beam welding are:
Welding
1. Laser Machine: It is a machine that is used to produce a 1. The power density of laser beam welding is high. It is of the
laser for welding. The main components of the laser order 1 MW/cm2. Because of this high energy density, it has
machine are shown below. small heat-affected zones. The rate of heating and cooling
2. Power Source: A high voltage power source is applied is high.
across the laser machine to produce a laser beam.
2. The laser beams produced are coherent ( having the motion of the laser and workpiece table during the
same phase) and monochromatic ( i.e. having the same welding process.
wavelength).
3. It is used to weld smaller sizes spot, but the spot sizes can As the laser beam strikes the cavity between the two metal pieces
vary from .2mm to 13 mm. to be joined, it melts the base metal from both the pieces and
fuses them together. After solidification, we get a strong weld.This
The depth of penetration of the LBW depends upon the amount of is how a laser Beam Welding Works
power supply and location of the focal point. It is proportional to
Advantages
the amount of power supply.
• It produces high weld quality.
• LBW can be easily automated with robotic machinery
for large volume production.
• No electrode is required.
easily accessible.
Working
• It has the ability to weld metals with dissimilar physical
required.
velocity electrons is applied to the materials being joined or fused. When these • The electron beam welding process eliminates the atmospheric
contamination of both the weld zone and the weld bead, as it is
high velocity electrons impact the workpieces, the kinetic energy of the electrons performed in the vacuum.
• Electron beam welding consumes low power, therefore, its operating
is transformed into heat, which melts the workpieces. cost is low.
• It produces narrow electron beam that reduces the distortion of the
workpiece.
The first practical electron beam welding machine was developed by a • Electron beam welding is the only process that can be used to join high
temperature metals like columbium.
German physicist Karl-Heinz Steigerwald in 1958. In order to prevent the
• Electron beam welding has high deposition rate. Therefore, its single
distortion of the electron beam, the electron beam welding is performed in pass can produce welds of excellent quality.
vacuum Electron beam welding produces deep penetration with very less distortion.
Working Principle of Electron Beam Welding Applications of Electron Beam Welding
In electron beam welding, when a cathode in a vacuum is heated by a filament, it Some of the applications of the electron beam welding are given as follows −
emits a beam of high velocity electrons. These electrons are further accelerated by
• The adjustment of penetration can be controlled by controlling the
voltage and are converged by an electromagnetic coil. When the electron beam
electron beam output, thus the electron beam welding is applicable to
strikes the workpiece, the kinetic energy of the electrons is converted into heat. This
a wide variety of base materials, from thick to thin sheets.
heat energy generated is then utilized for welding process.
• Metals having high melting points like tungsten can also be welded by
using the electron beam welding.
• Electron beam welding can be used for active metals such as titanium
which may oxidize during the welding process.
Equipment’s:
• Electron beam welding is widely used in various industrial applications
such as for welding of electronic components, bridges, aircraft parts, .
ship’s shells, etc.
Power Supply:
Disadvantages: The ultrasonic welding needs high frequency and high voltage power supply. This
• High capital or set up cost. power is needed by the transducer to generate vibrations
• High skilled labor required.
•
•
Frequently maintenance required.
Work pieces size is limited according to vacuum chamber.
Transducer:
• It cannot do at site due to vacuum 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.
Advantages:
▪ This welding can be easily automated and fast.
▪ This produces high strength joint without applying external heat.
▪ This is clean and provides good surface finish after welding.
▪ Ultrasonic process used to weld wide variety of dissimilar metal.
It does not develop high heat so there is no chance of expel molten metal form joint.
Disadvantages:
▪ It does not weld thick harder metal. The thickness of welds about 2.5 mm for
aluminum.
▪ Tooling cost for fixture is high and they also need special design.
▪ The vibration generates through transducer, can damage electronic component.
Applications:
▪ This welding is used in fabrication of nuclear reactor components.
▪ It is used in automotive industry for key, head lamp parts, button and
switches etc.
▪ Ultrasonic is used in electronic industries like armature winding, switches
etc.
▪
▪ melting of work piece or using filler metal.
▪ ▪
▪
High maintenance cost.
Transferred plasma arc welding:
▪
▪
▪ This process also uses straight polarity DC current. In this process, the tungsten electrode
Explosive welding
is connected to the negative terminal and the work piece is connected to the positive
terminal. The arc is produces between tungsten electrode and work piece. In this process Explosive welding is the type of solid-state welding in which two dissimilar
both plasma and arc transferred to the work piece which increases the heating capacity metals are welded together by using a higher impact force generated by the
of process. It is used to weld thick sheets. explosion of explosive materials.
Working It is the type of solid-state welding in which the material is not melted for the
welding and also it does not use any filler material.
▪ First the work pieces are properly cleaned. The power source supply power which
produces arc between tungsten electrode and nozzle, or tungsten electrode and
workpiece. The process is also known as the explosive cladding process as it is used to
▪ The tungsten electrode gives a high intense arc which is used to ionization of gas apply the cladding material layer onto the base material. The explosive
particles and converts orifice gases into plasma. This hot ionized gas is supplied welding can be used for protecting corrosive material like carbon steel by
to the welding plates from a small orifice. covering it with a layer of non-corrosive material like stainless steel.
▪ The shielding gases like argon etc. are supplied through pressure valve and
regulating valve to the outer nozzle of welding torch. These gases create a shield
around the welding area which protect it from atmospheric gases like oxygen, working principle
nitrogen etc.
▪ The plasma strikes the welding plates and fuses it into one piece. Next the welding ▪ in explosion welding, the flyer plate is arranged at a certain distance
torch is moved in the direction of welding.
from the base plate for getting momentum to the flyer plate.
▪ If the welding required filler material, it is fed by the welder manually.
▪ The flyer plate is accelerated by the use of explosives, therefore it hits
Application: the base plate at a higher velocity and due to this highest impact,
the plastic deformation and molecular diffusion are happened in
▪ This welding is used in marine and aerospace industries. between two plates. And hence it can create the weld joint between the
▪ It is used to weld pipes and tubes of stainless steel or titanium. two dissimilar metals.
▪ It is mostly used in electronic industries.
▪ ) Target plate/ Base metal: It is the plate on which the cladding has to
▪ It is used to repair tools, die and mold.
▪ It is used to welding or coating on turbine blade be done. The target plate is mounted onto the anvil.
▪ 2) Flyer plate: The flyer plate is made up of cladding material and it has
Advantages: less thickness in comparison with the target plate.
▪ High welding speed. The flyer plate may be parallel to the base plate or kept at a certain
▪ High energy available for welding. It can be easily used to weld hard and thick angle with the base plate.
work pieces. ▪ 3) Buffer plate: It protects the flyer plate from erosion due to the
▪ The distance between tool and work piece does not effects the arc formation. explosion.
▪ Low power consumption for same size weld. ▪ 4) Explosive material: The explosive material used for explosive
▪ More stable arc produced by PAW method. welding is maybe RDX or TNT or any other explosives. The selection of
▪ High intense arc or high penetration rate. explosive material is based on the magnitude of impact to be generated
▪ It can work at low amperage. for welding.
▪ 5) Stand-off distance: The stand-off distance is the distance between
the base plate and flyer plate kept for the movement of the flyer plate
Disadvantages: ▪
over the base plate.
6) Stand-off angle: In the case of material that can not weld by using
▪ Higher equipment cost. constant stand-off distance, therefore for this material the flyer plate is
▪ Noisy operation. kept at a certain angle over the base plate. This angle is known as a
▪ More radiation. stand of angle.
▪ High skill labor required.
Construction disadvantages
The target plate/base plate is fixed over the anvil to support it during the ▪ It is used only for a ductile material.
explosion. 2) Fire safety precautions are required due to the use of explosives.
3) It is used only for simple geometric shapes.
2) The surface of the target plate and flyer plate are made clean from all 4) The method is not useful for brittle material.
impurities to avoid the generation of oxides. 5) Licence is necessary for using explosives.
6) The explosion creates a high level of noise and ground vibration.
3) After that the flyer plate is kept over the base plate by keeping stand-off 7) This method is not suitable for thick flyer plates.
distance and stand-off angle between these two plates. the standoff distance
is about 0.5 to 1 times the thickness of the flyer plate.
applications
4) The buffer plate is placed over the flyer plate to protect it from erosion.
1.Welding of large flat plates
2) Cladding of plates for prevention against corrosion.
5) After that the layer of explosive material is placed over the buffer plate with 3) To join pipes and tubes of dissimilar metals
the detonator arranged at one end. 4) Joining of cooling fins
advantages
▪ It is easy to weld dissimilar metals which can not weld by using other
methods.
2) The welding takes place in a solid state of materials.
3) In this process, the parent properties of the material are not affected.
4) It is useful for welding large surfaces.
5) it is useful in the cladding of a protective layer over a base metal.
6) For explosive welding, highly skilled labor is not required.
7) It requires minimum fixtures.
8) The process of explosive welding is simple.