WELDING

BY T.MOHAN REDDY,SM(FQA)

WELDING PROCESS
WELDING PROCESS

SOLID PHASE

FUSION WELDING
JOINING AT BEYOND MELTING POINT

JOINING BELOW MELTING POINT

SOLID PHASE WELDING

FRICTION WELDING FLASH BUTT WELDING EXPLOSIVE WELDING DIFFSION WELDING

FRICTION WELDING
What Is Friction Welding? Friction Welding is a completely mechanical solid phase process in which heat is generated by friction to produce a high integrity welded joint between similar or dissimilar metals.

ADVANTAGES
The advantages are both metallurgical and physical. A bonded joint is formed using no filler metal, flux or shield gas. The process is environmentally clean; no arcs, sparks, smoke or flames are generated by clean parts. Surface preparation/cleanliness is not significant with most materials since the process burns through and displaces surface impurities. During the friction welding process there are narrow heat affected zones. The process is suitable for welding most engineering materials and is well suited for joining many dissimilar combinations. In most cases, the weld strength is as strong or stronger than the weaker of the two materials being joined. Operators are not required to have manual welding skills. Friction welding requires only simple integration into the manufacturing area. The process is easily automated for mass production. Welds are made rapidly compared to other welding processes. Plant requirements (space, power, special foundation etc.) are minimal for the friction welding process.

TYPICAL APPLICATIONS
ENGINE VALVES TRANSMISSION DRIVE SHAFTS DRILL RODS HYDRAULIC CYLINDERS FILTER CATRIDGES DRILL BITS ELECTRICAL CONNECTORS VIHICLE AIR BAGS

FLASHBUTT WELDING
Flash Butt Welding, also known as Flash Welding, uses an arc between the two mating parts as they begin to make contact. It is commonly used to join similar or dissimilar metals for end-to-end or edgeto-edge welds. The electrical resistance at the joint raises the temperature and plastic deformation forms the final weld. Impurities and contaminants are squeezed out during this operation resulting in an excellent weld, but a significant amount of material may be burnt off during the process. The joint may be machined later for improved appearance.

EXPLOSIVE WELDING
Explosion welding or bonding is a solid state welding process that is used for the metallurgical joining of dissimilar metals. The process uses the forces of controlled detonations to accelerate one metal plate into another creating an atomic bond. Explosion bonding can introduce thin, diffusion inhibiting interlayers such as tantalum and titanium, which allow conventional weld-up installation. Also explosive welding is considered a cold-welding process which allows metals to be joined without losing their prebonded properties.

APPLICATIONS
Dissimilar metal explosion bonded joints are applied anywhere a designer needs to make a high-quality transition between metals. Typical uses include ultra-high vacuum joints between aluminum, copper and stainless steel, corrosion resistant claddings on mild steel substrates, and alloy aluminum joined to low-expansion rate metals for electronic packages. Powder metal products such as Glidcop and AlSiC can be joined to wrought metal without thermal excursions. Difficult metals such as beryllium, Al-Be alloys and rhenium can be joined with explosion bonding.

DIFFUSION WELDING
DW, as a special technology, forms a contact on base of special bonding mechanism between metal and substrate. DW is the newest technology compared to standard (sputtering, evaporation, soldering) technologies for manufacturing of high quality contacts, especially on large areas The DW process has many advantageous, of which very important are: one-step high temperature process for manufacturing multi-layer contacts (low energy process); extra high adhesion between layers to be joined; minimum number of in homogeneities on large area (near defect free contacts); and the technology improves significantly the certain electrical characteristics of manufactured semiconductor devices compared to other technologies

 For formation of a bonding contact (DW technology), three major steps have to be made: To prepare suitable wafers and metal or ceramic films into one sandwich; To put the sandwich into a cassette and to transport it into the vacuum chamber; To apply a prescribed pressure for a certain time onto sandwich to promote a penetration of atoms of each material into neighbour layer (film) for getting extra high quality contacts

The DW technology is: One step high temperature process, which takes place in vacuum under mechanical pressure. Temperature does not exceed 500-600 Celsius degrees by the pressure about. 50 MPa and the manufacturing time are approximately from 5 to 10 minutes; The lateral homogeneity of the contact area will be higher compared to contacts manufactured by conventional deposited methods, which decreases the probability of hot spot creation in the contact during the device operation. The DW technology has been shown itself as a very effective method by manufacturing the high quality contacts to Si, GaAs, SiC, and other materials as well.

FUSION WELDING
OXY-ACETELENE GAS WELDING(100 WATTS, 3500 C) ARC WELDING (1000 WATTS, 6000 C) ELECTRONIC BEAM WELDING (1,00,000 WATTS, 10000 C) LASER BEAM WELDING (10000 WATTS, 10000 C)

OXYACETYLENE WELDING
Oxyacetylene welding, commonly referred to as gas welding, is a process which relies on combustion of oxygen and acetylene. When mixed together in correct proportions within a hand-held torch or blowpipe, a relatively hot flame is produced with a temperature of about 3,200 deg.C. The chemical action of the oxyacetylene flame can be adjusted by changing the ratio of the volume of oxygen to acetylene.

PROCESS
Welding is generally carried out using the neutral flame setting which has equal quantities of oxygen and acetylene. The oxidising flame is obtained by increasing just the oxygen flow rate while the carburising flame is achieved by increasing acetylene flow in relation to oxygen flow. Because steel melts at a temperature above 1,500 deg.C, the mixture of oxygen and acetylene is used as it is the only gas combination with enough heat to weld steel. However, other gases such as propane, hydrogen and coal gas can be used for joining lower melting point non-ferrous metals, and for brazing and silver soldering

EQUIPMENT
Oxyacetylene equipment is portable and easy to use. It comprises oxygen and acetylene gases stored under pressure in steel cylinders. The cylinders are fitted with regulators and flexible hoses which lead to the blowpipe. Specially designed safety devices such as flame traps are fitted between the hoses and the cylinder regulators. The flame trap prevents flames generated by a 'flashback' from reaching the cylinders; principal causes of flashbacks are the failure to purge the hoses and overheating of the blowpipe nozzle. When welding, the operator must wear protective clothing and tinted coloured goggles. As the flame is less intense than an arc and very little UV is emitted, general-purpose tinted goggles provide sufficient protection.

ELECTRON BEAM WELDING

Electron Beam Welding (EBW) is a fusion joining process that produces a weld by impinging a beam of high energy electrons to heat the weld joint. Electrons are elementary atomic particles characterized by a negative charge and an extremely small mass. Raising electrons to a high energy state by accelerating them to roughly 30 to 70 percent of the speed of light provides the energy to heat the weld. An EBW gun functions similarly to a TV picture tube. The major difference is that a TV picture tube continuously scans the surface of a luminescent screen using a low intensity electron beam to produce a picture. An EBW gun uses a high intensity electron beam to target a weld joint. The weld joint converts the electron beam to the heat input required to make a fusion weld.

ELECTRON BEAM WELDING

The electron beam is always generated in a high vacuum. The use of specially designed orifices separating a series of chambers at various levels of vacuum permits welding in medium and nonvacuum conditions. Although, high vacuum welding will provide maximum purity and high depth to width ratio welds

ADVANTAGES
Single pass welding of thick joints Hermetic seals of components retaining a vacuum Low distortion Low contamination in vacuum Weld zone is narrow Heat affected zone is narrow Dissimilar metal welds of some metals Uses no filler metal

LIMITATIONS
High equipment cost Work chamber size constraints Time delay when welding in vacuum High weld preparation costs X-rays produced during welding Rapid solidification rates can cause cracking in some materials

ARC WELDING
ARC WELDING FLUX SHIELDED (FSAW) GAS SHIELDED (GSAW)

GAS SHIELDED ARC WELDING

GSAW

GTAW (GAS TUNGSTON ARC) NON-CONSUMABLE

GMAW (GAS METAL ARC) CONSUMABLE

TIG WELDING

PLASMA WELDING

MIG (METAL INERT GAS) NON-FERROUS

MAG (METAL ACTIVE GAS0 FERROUS

ARGON, HELIUM

CO2, CO2+ARGON O2+ARGON

GTAW
TIG Welding (GTAW or Gas Tungsten Arc) - Often called TIG welding (Tungsten Inert Gas), this welding process joins metals by heating them with a tungsten electrode which should not become part of the completed weld. Filler metal is sometimes used and argon inert gas or inert gas mixtures are used for shielding. Consumables: tungsten electrode, filler metal, shielding gas.

GAS METAL ARC WELDING

MIG (GMAW or Gas Metal Arc Welding) - An arc welding process which joins metals by heating them with an arc. The arc is between a continuously fed filler metal (consumable) electrode and the workpiece. Externally supplied gas or gas mixtures provide shielding. Common MIG welding is also referred to as short circuit transfer. Metal is deposited only when the wire actually touches the work. No metal is transferred across the arc. Another method of MIG welding, spray transfer moves a stream of tiny molten droplets across the arc from the electrode to the weld puddle. Consumables: contact tips, shielding gas, welding wire.

FLUX SHIELDED ARC WELDING

FLUX SHIELDED ARC

SHIELDED METAL ARC

SUBMERGED ARC

FLUX CORED ARC

FLUX CORED ARC WELDING

Flux Cored Arc Welding (FCAW) - An arc welding process which melts and joins metals by heating them with an arc between a continuous, consumable electrode wire and the work. Shielding is obtained from a flux contained within the electrode core. Depending upon the type of flux-cored wire, added shielding may or may not be provided from externally supplied gas or gas mixture. Consumables: contact tips, flux cored wire, shielding gas (if required, depends on wire type).

SAW
Submerged Arc Welding Submerged arc welding (SAW) is a high quality, very high deposition rate welding process. Submerged arc welding is a high deposition rate welding process commonly used to join plate. Submerged Arc Welding Benefits Extremely high deposition rates possible High quality welds Easily automated Low operator skill required

SMAW
Stick Welding Shielded Metal Arc Welding (SMAW) is frequently referred to as stick or covered electrode welding. Stick welding is among the most widely used welding processes. The flux covering the electrode melts during welding. This forms the gas and slag to shield the arc and molten weld pool. The slag must be chipped off the weld bead after welding. The flux also provides a method of adding scavengers, deoxidizers, and alloying elements to the weld metal.

SMAW
Stick Welding Benefits Equipment used is simple, inexpensive, and portable Electrode provides and regulates its own flux Lower sensitivity to wind and drafts than gas shielded welding processes All position capability

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