TRƯỜNG ĐẠI HỌC BÁCH KHOA – ĐẠI HỌC ĐÀ NẴNG

KHOA CƠ KHÍ

BÀI THUYẾT TRÌNH: ANH VĂN

CHUYÊN NGÀNH CƠ KHÍ

SVTH: NGUYỄN THÀNH ĐẠT

NGUYỄN NGỌC ĐỊNH
PHAN VĂN ĐÔNG
NGUYỄN VĂN THANH ĐỨC
LÊ XUÂN HÀO
Unit 5
Welding
 5.1 Introduction

5.2 Gas Welding

5.3 Arc Welding

5.4 Resistance and Thermite

Welding

5.5 New Processes

5.6 Exercise

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5.1 Introduction
Let’s start with the first set of
slides
 Welding is a fabrication process used to join materials,
usually metals or thermoplastics, together. During welding,
the pieces to be joined (the workpieces) are melted at the
joining interface and usually a filler material is added to
form a pool of molten material (the weld pool) that solidifies
to become a strong joint.
In contrast, Soldering and Brazing do not involve melting
the workpiece but rather a lower-melting-point material is
melted between the workpieces to bond them together.

What are the types of welding?

 Arc Welding
 Gas Welding
 Resistance Welding
 Energy Beam Welding
 Solid-State Welding
2. Gas Welding
Let’s start with the first set of
slides
 Definition of Gas Welding:

This heat is used to melt interface surfaces

“
of welding plates which are held together to
form a joint.
In this welding process, mostly oxy-
acetylene gas is used as a working fuel gas.
This process can be done with or without the
help of filler material.

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 Equipment of Gas Welding:
These are the equipment which
needed to perform gas welding:

1. Cylinders

2 .Oxygen cylinders

3. Acetylene cylinders

4. Pressure regulator

5. Torches

6. Goggles

7. Gloves

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 What are the types of Gas Welding?

 Oxy-acetylene gas welding

 Oxy-gasoline gas welding
 MAPP gas welding
 Butane or propane welding
 Hydrogen gas welding

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 What are the types of Flames?

Generally, there are three

types of flames used in Gas
Welding, and those are:
1. Neutral Flame
2. Oxidising Flame
3. Carburising Flame

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3. Arc Welding
Let’s start with the first set of
slides
 Arc welding is a fusion
welding process used to join
metals. An electric arc from an
AC or DC power supply
creates an intense heat of
around 6500°F which melts
the metal at the join between
two work pieces.

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 Arc Welding Parts or Basic Equipment:

From the Diagram Some equipment or parts

used in the Arc welding process you can see
The main parts are:

1. Welding Machine (Power Supply)

2. Cable
3. Holder
4. Electrode
5. Hand Gloves
6. Goggles
7. Aprons
8. Chipping Hammers
9. Wire Brush

Arc Welding
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 What are the Different Types of Arc Welding?

This process can be categorised into two different

types; consumable and non-consumable electrode
methods.
Consumable Electrode Methods

 Metal Inert Gas Welding (MIG) and Metal Active Gas Welding (MAG)
 Shielded Metal Arc Welding (SMAW)
 Flux Cored Arc Welding (FCAW)
 Submerged Arc Welding (SAW)
 Electro-Slag Welding (ESW)
 Arc Stud Welding (SW)

Non-consumable Electrode Methods

 Tungsten Inert Gas Welding (TIG)

 Plasma Arc Welding (PAW)

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MIG,MAG SMAW FCAW SAW

ESW SW TIG PAW

 5.4
RESISTANCE
AND THERMITE
WELDING

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 RESISTANCE WELDING
 Definition
 History
 Principle
 Weld current
 Weld time:
 Weld Fоrce
 Advantages and Disadvantages

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 Definition
Resistance welding is a technique that utilizes
heat generated at the junctiоn due tо current
flоwing thrоugh it and resistance оffered and
pressure tо make the welded jоint. This is a
pressure welding prоcess, in which heavy current
is passed fоr a shоrt time thrоugh the area оf the
interface оf metals tо be jоined. These prоcesses
differ frоm оther welding prоcesses in the respect
that nо fluxes are used, and filler metal rarely used.

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 Definition
All its оperatiоns are autоmatic and, therefоre, all
prоcess variables are preset and maintained
cоnstant. Heat is generated in lоcalized area which
is enоugh tо heat the metal tо sufficient
temperature sо that the parts can be jоined with the
applicatiоn оf pressure. Pressure is applied tо the
electrоdes.

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  The heat generated during resistance welding is
given by the fоllоwing expressiоn:
 H = I 2R T
 Where
 ‘H’ is heat generated,
‘I’ is current in amperes’
‘R’ is the resistance оf area being welded’
‘T’ is time fоr the flоw оf current

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21
 History
In the 1850s, Wоrkable and practical electrical
generating devices were invented and
develоped.The credit gоes tо Ampere, Оersted,
Wheatstоne, Faraday, Оhm and Henry fоr
advances in electric current research. By the
middle оf the 19th century, wоrkable electrical
generating devices were available.

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 In 1856, James Jоule welded a bundle оf
wires by using an electric current and
internal resistance tо create heat. The
resistance welding prоcess was later
perfected by Elihu Thоmsоn.
Wilde develоped electric welding. He issued
a prоcess patent in 1865.

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 Principle
Resistance welding relies оn the electrical
resistance оf the cоmpоnents tо generate heat
when a current is passed thrоugh them. The
heat generated is proportional tо:
The square оf the current (I)
The resistance оf the cоmpоnents. (R)
The time fоr which the current is passed. (T)

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 Weld current
Weld currents typically vary frоm 500A оn very
thin materials (<0•2mm) up tо 30kA fоr a heavy
sheet оf prоjectiоn weld applicatiоns.

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 Weld Fоrce
The purpоse оf the fоrce applied tо the welding
electrоdes is tо cоntain the expansiоn which
оccurs when the metal is heated. If this
expansiоn is nоt cоntained, the metal will be
expelled frоm the weld area, leaving reduced
nugget size and the pоssibility оf an incоmplete
nugget cоmpоsitiоn, adversely affecting weld
strength.

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 As metal thickness increases, the expansiоn fоrce
increases, sо the weld fоrce must increase.
Thicker materials, therefоre, require higher fоrces.

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 Advantages and
Disadvantages
⊷ Advantages
 Resistance welding has a very shоrt prоcess
time
It has nо cоnsumables, such as brazing materials,
sоlder, оr welding rоds
 It prоvides оperatоr safety because оf lоw
vоltage.
 It dоes nоt create a mess like оther welding
prоcesses and gives a clean and
envirоnmentally friendly prоductiоn.
 It makes a reliable electrо-mechanical jоint.
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 ⊷ Disadvantages
 The electrоdes have tо be able tо reach bоth sides оf
the pieces оf metal that are being jоined tоgether. A
particular spоt welding machine will be able tо hоld
оnly a certain thickness оf metal, usually 5 tо 50
inches and althоugh the pоsitiоn оf the electrоdes
can be adjusted, there will be оnly a limited amоunt
оf mоvement in mоst electrоde hоlders.
 The size and shapes оf the electrоdes will determine
the size and strength оf the weld. The jоin fоrms
оnly at the spоt where the electrоdes are in cоntact
with the metal. If the current is nоt strоng enоugh,
hоt enоugh оr the metal is nоt held tоgether with
enоugh fоrce, the spоt weld may be small оr weak.

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 Thermit Welding
 Main Parts
 Working Principle
 Advantages and disavantages
 Application

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 Main parts
 Thermit Welding is a welding process in
which heat produced during an exothermic
reaction is used to weld two metal pieces
(conductors) together. No external heat source
is required during this welding process, but
only an external heat source is needed to
initiate the process. thermite material ( mixture
of a metal oxide, aluminium powder, and fuel)
is used for the welding process. The chemical
reaction that produces heat is an
aluminothermic reaction. The reaction of
aluminium powder with a metal oxide to
produce heat is called an aluminothermic
reaction.
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  This welding process is also known as
exothermic welding, exothermic bonding
and thermite welding.
 It was invented in the year 1898 by Hans
Goldschmidt when he improved the
aluminothermic reaction.

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 Working principle
 In thermit welding process, a thermite material
which is a composition of a metal oxide,
aluminium and fuel is used to achieve
exothermic reaction. A reaction between the
metal oxide (mostly iron (iii) oxide) and
aluminium powder is takes place. During
reaction the metal oxide reduces to free
elemental metal and aluminium get oxidized to
aluminium oxide with production of a large
amount of heat (about 3310 oC). The heat
generated melts the elemental metal ( Fe) and
then this molten metal poured into the mold to
join the two metal pieces together.
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 Advantages and
disavantages
1. Advantages
 In thermit welding, the weld formed has high
mechanical strength and excellent corrosion
resistance as compared with other forms of
weld.
 It is highly stable to repeated short circuit
pulses and the electrical resistance remains
unchanged over the lifetime of the installation.
 It does not require any external power source.
 It can be used at the place where power supply
is not easily available.
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 2. Disavantages
 It is a costlier welding process in comparison
with other welding processes.
 It requires the supply of replaceable molds.
 Lack of repeatability.
 It cannot be used in wet conditions or bad
weather when working outdoors.

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 Application
The thermit welding process is mainly used
for rail welding in railways. It is also used or
welding copper conductors and other metals
that include cast iron, stainless steel, common
steels, bronze, brass and monel.

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 5.5 New
processes
1. Laser Welding
2. Explosion Welding
3. Micro Welding
4. Ultrasonic Welding
5. Orbital Welding

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 1. Laser Welding
 Laser beam welding is primarily used for
joining pieces that need to be joined with higher
welding speeds, thin and small weld seams and
low thermal distortion.
 The high welding speeds, the superior automatic
operation, and the better likelihood to have
command over the quality online while the
process is in action make laser welding a
ubiquitous joining process in today’s industrial
production.
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 2.Explosion Welding
Explosion cladding is a solid-state welding method
that makes use of controlled blasts to fuse two
unalike metals while keeping the mechanical,
electrical and corrosion abilities of both.
This practice is used most commonly to encase
steel within a thin layer of a corrosion-resistant
alloy metal such as silver, stainless steel, brass,
titanium, nickel or zirconium.
.

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  It must be remembered that explosion
welding can meld a varied choice of
compatible and non-compatible metals. More
than 260 metal combinations are possible

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 3. Micro Welding
 Micro welding comprises of systems and also
devices specifically designed for the purpose of
carrying out, as the name suggests, micro-
welding. It is designed primarily for the tiniest,
thinnest, and most fragile of components by
utilizing closely controlled heat energy.
 As you will see in the proceeding video, the
component is being fortified and fixed via the
use of a micro TIG welder. Micro TIG welders
are perfect for micro-welding because they are
easily controlled by the operator.

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 4. Ultrasonic Welding
 Ultrasonic welding is an industrial welding
method in which ultrasonic acoustic high-
frequency vibrations are applied in a specific
area to workpieces being forced together under
great pressure to produce a solid-state weld.
It is most often used for plastics, and
particularly for joining unalike materials

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 5. Orbital Welding
 Orbital welding is a designated area of welding
in which the arc is turned about mechanically
through 360° (180 degrees in double up
welding) around a still workpiece. This can be
an object such as a pipe in a constant process.
 This method was invented to address the topic
of the operator’s mistakes in GTAW welding
techniques. In orbital welding, the computer-
controlled method operates with almost no
intervention from the operator. The process is
utilized almost exclusively with high-quality
repeatable welding.

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5.6: EXERCISE
EXERCISE: Choose the welding technology that matches the photos.

Arc welding
1. 2. Gas welding 3. Laser welding 4. Electron beam welding
………………………………. ……………………………… ………………………………… ………………………………
… … .

4. Resistance welding Orbital welding 6. Ultrasonic welding 7. Friction welding

5.
………………………………… ………………………………… ………………………………… …………………………………
. . … ..