BTM4723

Advanced Manufacturing
Process

Lecturer: Dr. Mas Ayu Bt Hassan

Email: masszee@ump.edu.my
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Advanced Welding Processes 1

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Lesson Objectives:

After today’s lecture, students are expected to:

• Differentiate many types of fusion & solid-
state welding processes
• Identify the components or equipment
needed to conduct the processes and explain
their primary functions
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 Classification of joining processes

BMM 3643 Page 4

 Fusion Welding

Electric
(Arc Welding)

Consumable Non-consumable Electron beam welding Laser beam welding

Submerged-arc welding Plasma Arc Welding

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1. Ultrasonic welding (USW)
- Process is versatile & reliable
- Material can be used metallic
& nonmetallic materials
Solid state welding processes
2. Friction Welding (FRW)
- Can be used wide variety of
materials that has rotational
symmetry
- Solid or tubular parts
3. Resistance Welding (RW)
- Heat required for welding by
electrical resistance across 2
component
- Do not require consumable
electrode, shielding gases or
flux
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Fusion Welding Processes
 Introduction
• Fusion welding define as the melting together
and coalescing of materials by means of heat,
usually supplied by chemical or electrical means.
• Filler metals may or may not be used.
• Composed of consumable and non-consumable
electrode arc welding and high-energy-beam
welding processes.
• The welded joints undergoes important
metallurgical and physical changes which have
major influence on the properties & performance
of welded component or structure.
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Submerged arc welding (SAW)

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 Consumable electrode
Submerged arc welding (SAW) is a high-productivity
automatic welding method in which the arc is struck
beneath a covering layer of granular flux.
– The flux fed into the weld zone from a hopper flow through
a nozzle.
– This increases arc quality, since contaminants in the
atmosphere are blocked by the flux.
– The flux act as thermal insulator by promoting deep
penetration of heat into the w/p.
– Working conditions are much improved over other arc
welding processes since the flux hides the molten metal and
prevent spatter and sparks and suppresses the intense
ultraviolet radiation and fumes.
– Widely used in industry for large products such as pipes and
cylinders.
– SAW is automated and widely used to weld carbon and alloy
steel and stainless steel sheets or plates.

BMM 3643 Page 10

 SAW (cont.)
• The quality of weld is very hogh, with good
toughness, ductility and uniformity of
properties.
• Typical applications: Thick plate welding for
shipbuilding & pressure vessels.

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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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Plasma arc welding (PAW)

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 Non-consumable electrode

Plasma arc welding (PAW) a concentrated plasma

arc is produced and directed towards the weld
area (temp. 33,000 deg. Celcius)
– The plasma is initiated between the tungsten electrode
and the small orifice by a low-current pilot arc.
– Because of its stable current, less thermal distortion
and higher concentration, it 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.
– Proper training and skill are essential to use this
equipment.
BMM 3643 Page 14
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.
BMM 3643 Page 15
 PAW (cont.)
• Two methods of PAW:
1. Transferred-arc method – part welded is
electrical circuit. Arc transfers from electrode to
w/p.
2. Non-transferred method – Arc occurs between
the electrode and nozzle, heat by plasma is
carried to the w/p.

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Electron beam welding (EBW)
Laser beam welding (LBW)

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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
 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.
Electron Beam Welding vs Laser Welding

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Any questions??

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