ADVANCED JOINING

PROCESSES

1
CONTENTS:-
1,INTRODUCTION
2.TYPES OF JOINING
3. Oxy-Fuel GasWelding
4.Shielded Metal Arc Welding
5. Submerged ArcWelding
6. GasMetal Arc Welding
7. Flux-Cored Arc Welding
8.Soldering & Brazing
9.Adhesive bonding
10.References
 WHY JOINING?

 Ease of manufacturing part bypart.

 Manufacture as a single then assembling.
 To take part apart for repair or maintenance.
 Different properties for functional purpose.
 Ease of transporting as individual part.
 Joining

Fusion Solid-state Brazing & Adhesive Mechanical

Welding Welding Soldering Bonding Fastening
Fusion Welding
Oxy-fuel Gas
Welding
Arc Welding-
Consumable
Arc Welding-
Nonconsumable
High-Energy-
Beam Welding
 Oxy-Fuel GasWelding

Fuel gas is used as the source of heat.

The most common used gas is acetylene.
For structural sheet-metal fabrication
automotive bodies and various other repairworks.
Hydrogen and methyl acetylene propadiene can also
used for oxy-fuelgas welding.
Arc Welding- Consumable Electrode
• Shielded Metal ArcWelding

• Submerged Arc Welding

• Gas Metal Arc Welding

• Flux-Cored Arc Welding

 Shielded Metal Arc Welding

T h e oldest, simplest and the most versatile joining process.

Suited for work piece thicknesses of 3-19 mm this range
extend can by using multiple passtechnique.
Slag should be cleaned after each weld bead.
 Submerged Arc Welding

 The weld arc is shielded by granular flux.

 Flux prevents molten metal from spatter, sparks and
fumes.
 Used in shipbuilding and pressure vessels
 Quality of weld is very high with good toughness,
ductility and uniformity of properties.
 Gas Metal Arc Welding

 Known as MIG welding (for

metal inert gas)
 The weld zone is shielded
by external source of gas.
 Multiple layers can be
deposited at thejoint.
 Rapid, versatile &
economical
 Its productivity is double of
SMAW process.
 Flux-Cored Arc Welding
Tubular electrode
filled with flux isused.
M a n y different base
metals can be melded.
Economical & usedfor
different thicknesses.
Specific weld metal
chemistries can be
developed.
Easy to automate and
adaptable to flexible
manufacturing systems
and robotics
Arc Welding-Non-Consumable Electrode

• Gas Tungsten Arc Welding

• Atomic Hydrogen ArcWelding

• Plasma Arc Welding

 Gas Tungsten Arc Welding

 Known as TIG welding(for tungsten inertgas)

 Flux is not needed.
 In close-fit joints filler wire is not required.
 The cost of inert gas makes this process expensive.
 Atomic Hydrogen Welding

Energy is gathered by atomic formed hydrogen.

The energy can be varied by changing distance
between arc andworkpiece.
High-Energy Beam Welding

• Electron Beam Welding

• Laser Beam Welding

 Electron Beam Welding

 Heat is generated by electron beams.

 Vacuum and special equipment areneeded.
 High quality, deep and narrow welded joints.
 Minimal distortion andshrinkage.
 Laser Beam Welding

Source:http://www.ustudy.in/sites/default/files/images/laser%20welding.jpg

High-power laser is used for source of heat.

Good quality welding.
Can be easily automated.
The major advantages of LBW over EBW:-

The LB can be transmitted through air, hence

a vacuum is not required.
Because laser beam can be shaped, manipulated
and focused optically the process easily be
automated.
The laser beam do not generate X-rays
unlike electron beams.
The quality of the weld is better with laser beam
welding with less tendency for incomplete fusion -,
spatter, porosity and distortion.
 Solid –State Welding
• Cold Welding
• Ultrasonic Welding
• Friction Welding
• Resistance Welding
• Explosion Welding
• Diffusion Welding
 BRAZING AND SOLDERING
 Only filler metal is melted, not base metal
 Lower temperatures than welding
 Filler metal distributed by capillary action
 Metallurgical bond formed between filler & base metals

Strength of joint typically

stronger than filler metal itself
weaker than base metal
gap at joint important (0.001 – 0.010”)

 Pros & Cons

Can join dissimilar metals
Less heat - can join thinner sections (relative to welding)
Excessive heat during service can weaken joint
 BRAZING AND SOLDERING
Brazing:-
•Use of low melt point filler
metal to fill thin gap between
mating surfaces to be joined
utilizing capillary action
• Filler metals include Al, Mg &
Cu alloys (melt point typically
above 840 F)
•Flux also used
•Types of brazing classified by heating method:
-- Torch, Furnace, Resistance
Applications:-
•Automotive - joining tubes, Pipe/Tubing joining (HVAC)
• Electrical equipment - joining wires, Jewelry Making
 Soldering
Solder = Filler meta
- Alloys of Tin (silver, bismuth, lead)
- Melt point typically below 840 F

Flux used to clean joint & prevent oxidation.

separate or in core of wire (rosin-core)

Tinning = pre-coating with thin layer of solder

Applications:-
• Printed Circuit Board (PCB) manufacture
• Pipe joining (copper pipe)
• Jewelry manufacture
• Typically non-load bearing
 Adhesive bonding

Bookbinding, labeling, home furnishing, packaging andfootwear.

Used in aerospace, automotive, appliances and building products.
Types of Adhesives:-
Natural:Starch, dextrin, soya flour
Inorganic: sodium silicate and magnesium oxy-chloride
Synthetic: thermoplastics and thermosetting polymers.
Process Capabilities;
 Similar and dissimilar, metallic and non-metallic materials can
be easily bonded.
 Curing time : few seconds at high temperatures, several
hours at room temperature.
Advantages,
Provides a bond at the interface
Reduces vibration and noise at the joints
Eliminate localized stresses
The external appearances of joined components is
unaffected Very thin and fragile components can bebonded
Limitations,
 The service temperature are relatively low
 The bonding time can be long
 Surface preparation is essential
 It is difficult to test adhesively bonded joints
 REFERENCES:-
1.Wikipedia

2. Richard Little, Welding and Welding Technology,

McGraw Hill, (2001), 1st edition

3. Welding handbook, American Welding Society, (1983),

7th edition, volume 1 & 2, USA

4. http://www.everlastgenerators.com/importance-of-
welding-in-manufacturingindustries.php

5. http://en.wikipedia.org/wiki/Metal_fabrication