Joining Processes

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Introduction
• Joining process is where two or more pieces of parts are
joined together to produce a single product of required
shape and size.
• The joining process can be classified as

a. Permanent joining process

It is done by fusing the metal together. The metal

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is heated to its melting state and then it is fused to
become one unit.
Ex. Welding, soldering and brazing

b. Semi – permanent or temporary joining process

In this the metal is not heated. Process is carried
out at room temperature. Temporary joining process can
be done using nuts, bolts, screws and adhesives.
 Welding Process

• Simple definition of welding -

"joining metals through heating them to a
molten state and fusing them together.“

• Technical definition of Welding -

“a localized coalescence of metals, wherein coalescence is

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obtained by heating to suitable temperature, with or
without the application of pressure and with or without the
use of filler material. This filler material has the melting
point same as the base material.”

It is also know as a metallurgical joining process of two

metal pieces, to produce a single piece of product.
Welding Terminologies

• Base Metal – Work pieces that are needed to be joined

• Weld Bead - A weld bead is a weld deposit produced by a
single pass of the welding processes. It is also known as bead
• Puddle – The molten base metal at the joint during the
welding operation

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• Weld pass – Movement of weld torch from one end of the
joint to the other end.
• Tack Weld – it is the temporary joint done before welding to
keep the work pieces to be welded in place during welding.
The joints are done at the ends of the work piece.
Classification of Welding Process

The welding process can be

classified based on the source of
energy to heat the metal and the

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state of metal at the joint.
• Pressure Welding
• Fusion Welding
Pressure Welding
• The surfaces of the joint to be welded is heated to a
plastic state and forced together with external pressure to
finish the joint.

• Depends on the application of pressures and temperature

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• ISO – 857 defines “Welding in which sufficient outer force
is applied to cause more or less plastic deformation of
both the facing surfaces, generally without the addition of
filler metal. Usually, but not necessarily, the facing
surfaces are heated in order to permit or to facilitate
bonding”
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Fusion Welding

• Heating in to molten state and allowed to

solidify to form joint with or without the
addition of filler material.
• The process is carried out with out the

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application of pressure.
• ISO – 857 defines “Welding without application
of outer force in which the facing surface must
be melted. Usually, but not necessarily, molten
filler metal is added”.
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 Advantages
• It is a high temperature process where the base
metals are heated above their melting temp.

• Strength of the joint obtained in welding is much

stronger than the parent metal

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• Welding produces stronger joints.Hence this
process is used for fabrication and structural
applications
Disadvantages
• Requires certain finishing operations like
grinding , filing etc

• Since welding is carried out at high temp,

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the metal adjacent to the weld portion
called the heat affected zone which is
affected to a large extent
 Applications
It can be employed in industry as a tool for,

Fabrication of automobile cars , Air- craft,

Refrigerators, Pressure vessels , Furnaces etc

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Repair and maintenance work
Joining broken parts
Rebuilding worn out components etc
Brazing
• it is a method of joining two similar or dissimilar metals using a
special fusible alloy called as “Spelters”.which is non ferrous
metal or alloy

• The base metals do not melt; they are heated above 450 deg
C but below their melting temperatures of base metal.

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• Some diffusion of the filler metal with base metal takes place.

• There are two types of spelters used:

• Copper and Copper base alloys
• Silver and silver base alloys
Butt Joint
When two metals are positioned in a head-to-head
arrangement for brazing, it will result in a Butt joint.

Lap Joints
Lap joint is the type of joint that have a larger surface area
because it is formed by overlapping of two metals.

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Butt-Lap Joint
It is a combination of both butt and lap type of joint and offers
the advantages of both. Butt-lap joint give the profitable
features of single thickness as well as of maximum strength
Advantages
• Dissimilar metals and parts having thin
sections can be joined easily.
• Brazing may avoid the metallurgical

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damage to the base metals.
• Strong joint can be obtained by brazing.
• It is economical and quick process
• Less heating is required than for welding.
 Soldering
• Soldering is a method of uniting two thin metal pieces
using a dissimilar metal or an alloy by application of
heat.
• The alloy is called as solder.
• Two types of solder are:

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• Soft solder
• Hard solder
• Usually the base metal is heated upto around 350 deg
C.
• Soldering is usually used for electrical & electronic
works and some low end sheet metal work.
Soft soldering is characterized by having a melting point of the
filler metal below approximately 400 °C (752 °F). Soft solder
filler metals are typically alloys (often containing lead) that have
liquidius temperatures below 350°C. Soft soldering can be done
with a heated iron whereas the other methods require a higher
temperature to melt the solder than can be achieved with a heated
iron.

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Hard soldering use higher temperatures, typically requiring a
flame or carbon arc torch to achieve the melting of the filler.
Hard soldering, as used by jewelers, machinists and in some
plumbing applications, requires the use of a torch or other high
temperature source and is much stronger than soft soldering.
 ADVANTAGES
• It is simple and economical process
• Since it done at relatively low temperature, no metallurgical
damage to the base metal.
• The soft soldered joints can easily be dismantled by simple heating
• Operator fatigue is less compared to welding process.

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• DISADVANTAGES
• 1. The process is limited to minimum thickness (3mm)
• 2. Skilled operator is required.
• 3. Strength of joint when compared to welding is low.
Difference between Soldering and Brazing
Sl no Brazing Soldering
1 Melting point of the filler Melting point of the filler material
material is about 600 degree. is below 450 degree.

2 Dissimilar metals can be Only similar metals can be joined.

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joined easily.

3 Good surface finish. Does not yield a good surface

finish

4 Stronger joints. Less stronger joint.

5 It is used for production of It is used for electrical and
heat exchangers and electronic applications.
radiators.
 Difference between Welding , Brazing and
Soldering
Sl no Parameter welding brazing soldering

1 Temperature Very high, about Melting point of the Melting point of

more than 5000 filler metal is above the filler metal is
degree c 600 degree c below 450 degree

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2 Type of metal Only similar metals Dissimilar metals Only similar
to be joined metals
3 Surface finish moderate good poor

4 strength Very high high weak