Dr.

Arman Shah Bin Abdullah,

B.Eng Hon.(Manuf. Eng), M.Eng. Adv. Manuf. Eng, Phd Mechanical
engineering
Coordinator
Research Management Unit
Research Management and Innovation Centre
Research Management Innovation Complex

Joining processes
Joining Processes
 Why Joining process
Some (even simple) products are too large to be made by individual processes ( 3-
D Hollow structural member, 5 m diameter)

Easier, more economical to manufacture & join individual components (Cooking

pot with handle)

Products to be disassembled for maintenance (Appliances; engines)

Varying functionality of product (Carbide inserts in tool steels; Brake shoes)
Transportation + assembly is less costly (Shelving units; Machinery)
Product Example
 Welding
Welding

Fusion Solid-state Brazing and

welding welding soldering.
 Fusion Welding
• Basically, fusion welding uses heat to dilute the metal over the melting
point of a metal during the merging process.

• Examples of fusion welding are

Arc welding,
Gas Welding,
Tungsten Inert Gas (TIG) and
Metal Inert Gas (MIG)
Fusion Welding
 Solid State Welding
• Solid state welding is a welding group that produces a coalescence under the
melting point of a material or metal to be welded.

• Examples of solid state welding are

 diffusion welding,
 friction welding and
 ultrasonic welding.
 Brazing and soldering
• Brazing uses filler metals and involves lower temperatures than welding.

• Soldering uses similar filler metals (solders) and involves even lower temperatures.
Brazing and soldering
 Shielded Metal Arc Welding (SMAW)

• SMAW is an arc welding process in which coalescence of metals is produced by

heat from an electric arc that is maintained between the tip of a consumable
covered electrode and the surface of the base metal in the joint being welded.
Principle of SMAW
 Advantages of SMAW
• Low cost equipment.

• Can weld many different metals.

• Welds can be performed in any position.

• Relatively portable and useful in confined space

• Can be performed under most weather condition.

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 Limitation of SMAW

• Not suitable for metal thickness less than 1/6 inch (1.5mm).

• The process is considered to be manual as it is not easily mechanized.

• Frequent stops and start during electrode changes provide the opportunity for weld
defects.

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Welding position

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Gas Metal Arc Welding (GMAW)
 Introduction
 Gas metal arc welding (GMAW), or also called metal inert gas (MIG) welding
or metal active gas (MAG) welding, is a welding process in which an electric
arc forms between a consumable wire electrode and the workpiece metal(s),
which heats the workpiece metal(s), causing them to melt, and join.

 A shielding gas feeds through the welding gun along with the wire electrode,
which shields the process from contaminants in the air. The process can be
semi-automatic or automatic.

 A constant voltage, direct current power source is most commonly used with
GMAW, but constant current systems, as well as alternating current, can be
used.
 Principle of GMAW
 With semi-automatic MIG welding, the electrode wire is fed through a welding gun
controlled by the operator. The operator starts the arc and controls the puddle.

 In automatic MIG welding, a robot or automated machine makes the weld. An arc digs into
the base metal much like water from a nozzle on a garden hose digs into the earth.

 The flow of the water is like welding current and water pressure is similar to voltage.
Molten metal forms a molten pool or crater and tends to flow away from the arc while
cooling and solidifying.

 A continuous even flow of shielding gas is needed to protect the molten weld metal from
atmospheric contaminants such as oxygen and nitrogen.

 The shielding gas comes from a gas cylinder and flows through the gun and cable assembly,
through the gas nozzle, and into the welding zone.

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 Advantages of GMAW

 Deposition rates higher than SMAW

 Productivity higher than SMAW with no slag removal and continuous welding
 Easily automated
 Welding can be done in all positions
 High welding speeds
 Less distortion of work piece

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 Disadvantages of GMAW
• Equipment is more expensive and complex than SMAW
• Process variants/metal transfer mechanisms make the process more complex and the process
window more difficult to control
• Restricted access
GMAW gun is larger than SMAW holder
• Wind or air flows may compromise gas shielding
• Reactive metals (i.e. titanium) may need special shielding provisions.
• High heat may be uncomfortable to welders
• Correct parameter selection learning needs dedicated training
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 Properties of Gases
Affect the performance of the welding process include:

1) Thermal properties at elevated temperatures.

2) Chemical reaction of the gas with the various elements in the base
plate and welding wire.

3) Effect of each gas on the mode of metal transfer.

 Shielding Gas
• Argon and helium first used for gas metal arc

• Continue to be basic gases

• Argon used more than helium on ferrous metals to keep spatter at minimum

• Also heavier than air so good weld coverage

• Carbon dioxide added to pure gases to improve arc stability, minimize undercut,
reduce porosity, and improve appearance of weld

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 Shielding Gas
• Helium added to argon to increase penetration

• Hydrogen and nitrogen used for only limited number of special applications

• Carbon dioxide has following advantages:

• Low cost

• High density, resulting in low flow rates

• Less burn-back problems because of its shorter arc characteristics

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Specific Metal Recommendations
• Aluminum alloys: argon

• Magnesium and aluminum alloys: 75 percent helium, 25 percent argon

• Stainless steels: argon plus oxygen

• Magnesium: argon

• Deoxidized copper: 75 percent helium, 25 percent argon preferred

• Low alloy steel: argon, plus 2 percent oxygen

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Specific Metal Recommendations
• Mild steel: 15 percent argon, 25 percent carbon dioxide (dip transfer); 100 percent
CO2 may also be used with deoxidized wire

• Nickel, and Inconel: argon

• Titanium: argon

• Silicon bronze: argon

• Aluminum bronze: argon

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Gas Tungsten Arc Welding (GTAW)
 Introduction
Gas Tungsten Arc Welding (GTAW)
Arc welding process uses a nonconsumable tungsten electrode and an inert
gas for arc shielding

• Melting point of tungsten = 3410C (6170F)

• Also called Tungsten Inert Gas (TIG) welding
• Used with or without a filler metal
• When filler metal used, it is added to weld pool from separate rod or
wire

• Applications: aluminum and stainless steel mostly

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 Advantages of GTAW
Advantages:

• High quality welds for suitable applications

• No spatter because no filler metal through arc

• Little or no post-weld cleaning because no flux

• High quality and precision

• Aesthetic weld beads

• No sparks or spatter

• No flux or slag

• No smoke or fumes

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 Disadvantages of GTAW
Disadvantages:

• Generally slower and more costly than consumable electrode arc welding processes.
• Lower filler metal deposition rates
• Good hand-eye coordination a required skill
• Brighter UV rays than other processes
• Slower travel speeds than other processes
• Equipment costs tend to be higher than other processes

kerja kimpalan dan fabrikasi logam

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 Principles of GTAW
• To strike the welding arc, a high frequency generator provides an electric spark
.

• This spark is a conductive path for the welding current through the shielding
gas and allows the arc to be initiated while the electrode and the workpiece are
separated, typically about 1.5–3 mm (0.06–0.12 in) apart.

• Once the arc is struck, the welder moves the torch in a small circle to create a
welding pool, the size of which depends on the size of the electrode and the
amount of current.

• While maintaining a constant separation between the electrode and the

workpiece, the operator then moves the torch back slightly and tilts it backward
about 10–15 degrees from vertical.

• Filler metal is added manually to the front end of the weld pool as it is needed.
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Principles of GTAW

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#4 Oxy-fuel welding
 Introduction
Oxy-fuel welding
Oxy-fuel welding (commonly called oxyacetylene welding, oxy welding, or gas welding) and oxy-fuel
cutting are processes that use fuel gases and oxygen to weld and cut metals, respectively.

In oxy-fuel welding, a welding torch is used to weld metals. Welding metal results when two pieces are
heated to a temperature that produces a shared pool of molten metal.

The molten pool is generally supplied with additional metal called filler. Filler material depends upon the
metals to be welded.

In oxy-fuel cutting, a torch is used to heat metal to its kindling temperature. A stream of oxygen is then
trained on the metal, burning it into a metal oxide that flows out of the kerf as slag.

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Advantages of oxy-fuel welding
• It's easy to learn.

• The equipment is cheaper than most other types of welding (e.g. TIG welding)

• Oxy-acetylene can be used on sites which have no power supply

• The equipment is more portable than most other types of welding (e.g. TIG
welding)

• Oxy-acetylene equipment can also be used to "flame-cut" large pieces of

material.

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Disadvantages of oxy-fuel welding
• Oxy-acetylene weld lines are much rougher in appearance than other kinds of
welds, and require more finishing if neatness is required.

• Oxy-acetylene welds have large heat affected zones (areas around the weld line
that have had their mechanical properties adversely affected by the welding
process)

• There are safety issues with oxy-acetylene as there is a naked flame present which
does not exist with electrical forms of welding.

welding and metal fabrication works

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Principles of oxy-fuel welding
During the welding, heat from the flame is
concentrated on the joint edges until the
metal melts and starts to flow. When the molten
metal from both sides melts it starts to fuse,
when the metal cools down the two parts
become Permanently joined
Additional Filler
Metal is fed in by
hand into the weld
pool, at regular
intervals where it
becomes molten
and joins with the
parent metal.
The Oxy-acetylene welding Flame
Reducing or Carburizing
Excess acetylene (0.9:1)
(Alloy steels and
aluminium alloys)

Oxidizing
Excess oxygen (1.5:1)
(Brasses, Bronzes, copper)

Neutral
Equal acetylene & oxygen
(low carbon steel, mild
steels).
Oxy-acetylene flames
The Oxy-acetylene welding Flame

Carburising Neutral Oxidising

Equipment used in Oxy-
Acetylene welding
The oxygen and acetylene hose
pipes
Gases used
Gas pressure Regulators
Flashback arrestor
Welding torch/Welding nozzle
Filler rods and fluxes
 The oxygen and acetylene hose pipes

Reinforced rubber hoses.

Acetylene hose has left hand thread couplings and colour
coded red.
Oxygen hose has right handed thread couplings and colour
coded blue
 Gases used

Oxygen extracted from air and compressed into

cylinders at high pressure. Cylinder is black. Oil
should never be brought into contact and should not
be used on fittings

Acetylene (C2H2) is a fuel gas. Cannot be compressed

directly as explodes at high pressures. Cylinders are
packed with porous material which is filled with
acetone. Acetone absorbs acetylene. Cylinder colour
coded maroon
 Oxy-Fuel Gases
Numerous gases are available for use in oxy-fuel operations.

• Oxygen
• Acetylene
• MAPP
• Natural Gas
• Propane
OXYGEN
• The presence of oxygen is required to support any
burning process.

• It is therefore necessary that oxygen be combined

with a “fuel” gas to produce the desired operating
flame.

• Oxygen itself is not flammable or harmful.

• However, the presence of pure oxygen will
drastically increase the speed and force with which
burning takes place.

• Pure oxygen can turn a small spark into a roaring

flame.
 OXYGEN Cont.
• Is a colorless, odorless gas
contained in the earth’s atmosphere
• When added to a fuel gas such as an
acetylene flame, the flame increases
in temperature and combustion rate
is more rapid.
• Oxygen will not combust or burn in
its natural state.
OXYGEN Cont.
• Oxygen must NEVER be allowed to
contact oil, grease or other petroleum-
based substances.

• Oil and/or grease in the presence of oxygen

becomes HIGHLY EXPLOSIVE.

• Full oxygen cylinders are pressurized

from 2000 to 2600 pounds per square
inch (PSI)

• Due to high pressure under which

oxygen is bottled and stored, cylinders
must always be handled with great care.
 ACETYLENE
• A colorless gas, with a strong garlic-like-putrid
smell.

• Is the most frequently used fuel gas.

• Is highly combustible when mixed with oxygen
• Produces one of the highest flame temperatures
available – 5,600 degrees Fahrenheit.

• Used for welding, cutting, brazing, heating, and

hard facing.

• Highly combustible and flammable gas – burns

rapidly.
 ACETYLENE Cont.
• Acetylene gas is a combination of carbon and
hydrogen (C2H2).

• It is produced when calcium carbide is submerged in

water.

• The escaping gas from the acetylene generator is then

trapped in a gas chamber to be compressed into
Acetylene cylinders or fed into piping systems.
Generator • IMPORTANT- Acetylene is an “unstable gas” when
compressed above 15 PSI.

• Therefore cannot be stored in a hollow cylinder under

high pressure, for example the way oxygen is stored.
 ACETYLENE Cont.
• Acetylene cylinders are filled with a
porous material creating in effect a
“solid” as opposed to a “hallow”
cylinder.

• The porous filling is then saturated with

liquid acetone.

• When acetylene is pumped into the

cylinder it becomes dissolved in the
liquid acetone throughout the porous
filling and is held in a stable condition.

• Full acetylene cylinders are pressurized

to about 250 PSI.
ACETYLENE Cont.
•Acetylene when combined with
oxygen has a flame temperature
of (5,589 degrees) or 5,600
degrees in the neutral flame.
•Acetylene makes a good
general purpose fuel gas - well
suited for numerous
applications like heating,
welding, cutting, brazing and
hardfacing.
 MAPP GAS
• MAPP Gas is a new fuel gas in the acetylene
family.

• Its components are methylacetylene, propadiene,

propylene and other related compounds.

• It can be readily liquefied and shipped in standard

L.P.G. containers at 60 PSI.

• Is a good fuel gas for heating and cutting.

However, special welding rod must be used to
combat the oxidizing characteristics of the flame
on the molten metal during the welding process.

• Has a neutral flame temperature of 5,300 Degrees

Fahrenheit.
 PROPANE
• Propane is an abundant and versatile fuel.
• When compressed, liquefied and confined, it
can develop a vapor pressure of 200 PSI.

• Is normally sold in liquid state.

• Propane cylinders range from 20-lb. to 100-lb.
• The neutral flame temperature is
approximately 5,200 Degrees Fahrenheit.

• Propane is most commonly used for cutting

and heating applications.
 Oxygen Cylinders
• Oxygen Cylinders are made from
seamless drawn steel and shaped by dies
into tanks.

• They provide strong, durable containers

with no joints or welded seams

• The thickness of the cylinder wall is at

least ¼”

• When fully charged, a standard cylinder

holds about 244 cu/ft. of oxygen at a
pressure of 2200 psi. at 70 degrees
 Acetylene Cylinders
• Low-temperature melting
fuse plugs at the top and
Fuse Plugs bottom of the cylinder allow
gas to escape if temperatures
exceed 212 degrees.

• Escaping gas may cause a

fire, but no explosion will
occur.

• A typical acetylene cylinder

contains about 280 cu./ft. of
gas at a pressure of 250 psi.