BTM4723

Advanced Manufacturing
Process

Lecturer: Dr. Mas Ayu Bt Hassan

Email: masszee@ump.edu.my
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Advanced Welding Processes

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Lesson Objectives:

After today’s lecture, students are expected to:

• Differentiate many types of fusion welding
processes
• Identify the components or equipment
needed to conduct the processes and explain
their primary functions
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Fusion Welding Processes
 Classification of joining processes

Resistance Welding

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1. Soldering
- Temperature below 450oC
- Used for electronic assembly
Solid/Liquid state joining
2. Brazing
- Temperature above450oC
- Used for metal joining
3. Adhesive Bonding
- NO heating required
- Used for either
metal/electronic assembly
- Adhesive materials must be
Strong, Tough and resistance to
fluid
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 Fusion Welding

Electric
(Arc Welding)

Consumable Non-consumable

2 GMAW / MIG
1. SMAW 3. FCAW 4. SAW 1. GTAW / TIG
Gas Metal Arc 2. Plasma Arc
Shielded Metal Flux-cored Arc Submerged Arc Gas Tungsten Arc Welding
Welding / Metal
Arc Welding Welding Welding Welding
Inert Gas

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 Electric arc Welding
• In arc welding or electric welding, the heat
required is obtained from electrical energy.
• It involves electrodes.
• An arc is produced between the tip of the
electrodes and the workpiece to be welded,
by the use of an AC or a DC power supply.

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 Electric arc Welding (cont.)

• A pool of molten metal is formed near

electrode tip
• As electrode is moved along joint, molten
weld pool solidifies in its wake.
• This arc produces temperatures of about 30
000 °C, much higher than those developed
in oxyfuel gas welding.

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 Arc Welding

The basic configuration and electrical circuit of an arc

welding process

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 Two Basic Types of AW Electrodes

• Consumable – consumed during welding process

– Source of filler metal in arc welding
• Nonconsumable – not consumed during welding
process
– Any filler metal must be added separately

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 The difference between consumable and non-
consumable electrodes in welding?
Consumable electrodes
Consumable electrodes become part of
the weld bond itself. The electrode serves
as the filler metal and melts along with
the metals to be welded together.
For example, in typical electric arc
welding, the consumable electrode is the
filler metal welding rod and contains a
flux that contributes to producing a
barrier to protect the weld from any
contamination.
The selection of electrode material is
critical. This is because the electrode
material must be compatible with the
metals that are being welded together;
that is, they must be chemically
compatible.
Non-consumable elctrodes
Electrodes are not consumed during
welding, with a separate welding rod
serving as the filler metal that melts and
joins the metals together.
For instance, non-consumable electrodes
are used in TIG welding. Here, the
electrode is made of tungsten, which has
a high melting point of about 6,000˚ F, so
it isn’t consumed during welding.
No issue about the type of electrode
material. Common electrode materials
include carbon or graphite in addition to
either pure tungsten or tungsten alloys.
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 Consumable electrode methods
• Few types of consumable electrode methods
available;
1. Shielded metal arc welding (SMAW), or
manual metal arc welding (MMA) or stick
welding.
– An electric current is used to strike an arc
between the base material and a consumable
electrode rod or 'stick'.

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Shielded-Metal Arc Welding

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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Consumable electrode methods (cont.)

2. Gas metal arc welding (GMAW) uses a continuous

wire feed as an electrode and an shielding gas to
protect the weld from contamination.
– When using an inert gas as shield it is known as Metal
Inert Gas (MIG) welding.
– GMAW welding speeds are relatively high due to the
automatically fed continuous electrode, but is less
versatile because it requires more equipment than the
simpler SMAW process.

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 Gas Metal-
Arc Welding

(a) Schematic illustration of the gas metal-arc welding process,

formerly known as MIG (for metal inert gas) welding. (b) Basic
equipment used in gas metal-arc welding operations.
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Consumable electrode methods (cont.)
3. Flux-cored arc welding (FCAW), uses similar
equipment but uses wire consisting of a steel
electrode tube surrounding a powder fill
material.
– This cored wire is more expensive than the
standard solid wire and generates extra shielding
gas and/or slag, but it permits higher welding
speed and greater metal penetration.

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Fluxed-Cored Arc-Welding

Schematic illustration of the flux-cored arc welding process. This

operation is similar to gas metal-arc welding as shown before.

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Consumable electrode methods (cont.)
4. Submerged arc welding (SAW) is a high-
productivity automatic welding method in which
the arc is struck beneath a covering layer of flux.
– This increases arc quality, since contaminants in the
atmosphere are blocked by the flux.
– The slag that forms on the weld generally comes off by
itself and, combined with the use of a continuous wire
feed, the weld deposition rate is high.
– Working conditions are much improved over other arc
welding processes since the flux hides the arc and no
smoke is produced.
– Widely used in industry for large products.

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Submerged-Arc Welding

Schematic illustration of the submerged arc welding process and

equipment. The unfused flux is recovered and reused.

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 Non-consumable electrode methods
• Few types of non-consumable electrode methods
available;
1. Gas tungsten arc welding (GTAW), or tungsten inert gas
(TIG) welding, uses a non-consumable electrode made of
tungsten, an inert or semi-inert gas mixture, and a
separate filler material.
– useful for welding thin materials,
– characterized by a stable arc and high quality welds, but it
requires significant operator skill and can only be accomplished at
relatively low speeds.
– used on nearly all weldable metals, though it is most often
applied to stainless steel and light metals.
– often used when quality welds are extremely important, such as
in bicycle, aircraft and naval applications.
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Gas-Tungsten Arc Welding

(a) The gas tungsten-

arc welding process,
formerly known as TIG
(for tungsten inert gas)
welding. (b) Equipment
for gas tungsten-arc
welding operations.

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 Non-consumable electrode methods

2. Plasma arc welding, uses a tungsten electrode but

uses plasma gas to make the arc.
– The arc is more concentrated than the GTAW arc,
– Because of its stable current, the method can be used
on a wider range of material thicknesses and is much
faster.
– applied to all of the same materials as GTAW except
magnesium; automated welding of stainless steel is
one important application of the process.
– A variation of the process is plasma cutting, an efficient
steel cutting processs.

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Plasma-Arc Welding Process

Two types of plasma-arc welding processes: (a) transferred, (b)

nontransferred. Deep and narrow welds can be made by this
process at high welding speeds.
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 Power Source in Arc Welding

• Direct current (DC) vs. Alternating current

(AC)
– AC machines less expensive to purchase
and operate, but generally restricted to
ferrous metals
– DC equipment can be used on all metals
and is generally noted for better arc
control.
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Power Source in Arc Welding
For DC current, the polarity can be:
• Straight polarity ( electrode -ve) Workpiece is
positive
• Reverse polarity (electrode +ve) Workpiece is
negative

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 Straight Polarity Reverse Polarity

Produces less heat at 2/3 heat is

electrode concentrated in
Shallow Penetration small cross section
of electrode
Used for easy to High current density
weld material and
position
Sheet Metal Out of position
welding and work
piece not parallel to
ground
Thick sections
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Power Source in Arc Welding

The effect of polarity and current type on weld beads: (a)

dc current straight polarity; (b) dc current reverse
polarity; (c) ac current.

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 High Energy Beam
• Electron Beam Welding (EBW) is a fusion welding process
in which a beam of high-velocity electrons is applied to two
materials to be joined. The workpieces melt and flow
together as the kinetic energy of the electrons is
transformed into heat upon impact. EBW is often
performed under vacuum conditions to prevent dissipation
of the electron beam.

• Laser Beam Welding (LBW) is a welding technique used to

join pieces of metal or thermoplastics through the use of a
laser. The beam provides a concentrated heat source,
allowing for narrow, deep welds and high welding rates.
The process is frequently used in high volume applications
using automation, as in the automotive industry. It is based
on keyhole or penetration mode welding.
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 Electron Beam Welding
• Performed in a vacuum environment as the
presence of gas can cause the beam to scatter.
• Due it being a vacuum process and because of
the high voltages used, this welding method is
heavily automated and computer controlled.
• As a result, specialized fixtures and CNC tables
are used to move the workpiece inside the
welding vacuum chamber.

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 Laser Beam Welding (LBW)

• Laser beam produced by a CO2 or YAG Laser

• High penetration, high-speed process
• Concentrated heat = low distortion
• Laser can be shaped/focused & pulsed on/off
• Typically automated & high speed (up to 250
fpm)
• Workpiece up to 1” thick

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Typical laser welding applications :

1. Catheters & Other Medical Devices

2. Small Parts and Components
3. Fine Wires
4. Jewelry
5. Small Sensors
6. Thin Sheet Materials Down To 0.001" Thick

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 Example Laser welding of razor blades

A closeup of the Gillette Sensor™ razor cartridge. Each of the two

narrow, high-strength blades has 13 pinpoint welds—11 of which
can be seen (as darker spots, about 0.5 mm in diameter) on each
blade in the photograph. You can inspect the welds on actual
blades with a magnifying glass or a microscope.
The welds are made with a Nd:YAG laser equipped with fiber-optic
delivery. This equipment provides very flexible beam manipulation
and can target exact locations along the length of the blade. With a
set of these machines, production is at a rate of 3 million welds per
hour with accurate and consistent weld quality.
Example Laser welding of razor blades
Electron Beam Welding vs Laser Welding

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 Friction Welding (Inertia Welding)
Welding Processes

1. One part rotated, one stationary

2. Stationary part forced against rotating part
3. Friction converts kinetic energy to thermal
energy
4. Metal at interface melts and is joined
5. When sufficiently hot, rotation is stopped &
axial force increased

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FRICTION WELDING
RESISTANT SEAM WELDING
RESISTANT SEAM WELDING
RESISTANT PROJECTION WELDING
1. Coalescence occurs at one or
more relatively small contact
points.
 Diffusion Welding
1. Parts forced together at high temperature (<
0.5Tm absolute) and pressure
2. Atoms diffuse across interface
3. After sufficient time the interface disappears
4. Good for dissimilar metals
5. Heated in furnace or by resistance heating
6. Bond can be weakened by surface impurities

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Surface bonding
in diffusion
welding.

Kalpakjian, S., Manufacturing Engineering & Technology, p. 889, 1992

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 Weldability
• It is a distinct measure of a material’s ability to be
welded.
• The quality of results may vary greatly with
variations in the process parameters, such as
electrode material, shielding gases, welding speed
and cooling rate.
• Also influencing weldability are mechanical and
physical properties of welded materials e.g.
strength, toughness, ductility, melting point etc.

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 Weldability (cont.)
• Here is a brief summary of the general
weldability characteristics of metals and
alloys:
– Plain-carbon steels: weldability is excellent for
low-carbon steel, fair to good for medium
carbon steel, poor for high carbon steel.
– Aluminium alloys: these are weldable at high
rate of input. Aluminium alloys containing Zn
and Cu are considered unweldable.
– Tungsten: this is weldable under well-controlled
conditions.
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Any questions??

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 Class Activity

Form 5 groups: AW Types Main Advantage

Grp 1: features
Grp 2:
1
Grp 3:
Grp 4:
Grp 5:
2
Compare all AW types that use
consumable electrodes.
Write your findings in table
form.
etc

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