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    Lecture4 - Power Density in Welding

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    Zundali Firdaus
    This document discusses power density and its relationship to welding processes and weld quality. It begins by explaining that fusion welding processes can be categorized based on their range of energy density, and that higher energy density processes allow for faster welding speeds. It then provides a table comparing typical energy densities and temperatures of different welding techniques. The remainder of the document discusses how higher power density decreases heat input requirements but can also increase thermal damage, and that there is an optimal power density range for developing sound weld joints without excess distortion or reduced mechanical properties.

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    Lecture4 - Power Density in Welding

    Uploaded by

    Zundali Firdaus
    474 views5 pages
    This document discusses power density and its relationship to welding processes and weld quality. It begins by explaining that fusion welding processes can be categorized based on their range of energy density, and that higher energy density processes allow for faster welding speeds. It then provides a table comparing typical energy densities and temperatures of different welding techniques. The remainder of the document discusses how higher power density decreases heat input requirements but can also increase thermal damage, and that there is an optimal power density range for developing sound weld joints without excess distortion or reduced mechanical properties.

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    This document discusses power density and its relationship to welding processes and weld quality. It begins by explaining that fusion welding processes can be categorized based on their range of energy density, and that higher energy density processes allow for faster welding speeds. It then provides a table comparing typical energy densities and temperatures of different welding techniques. The remainder of the document discusses how higher power density decreases heat input requirements but can also increase thermal damage, and that there is an optimal power density range for developing sound weld joints without excess distortion or reduced mechanical properties.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    474 views5 pages

    Lecture4 - Power Density in Welding

    Uploaded by

    Zundali Firdaus
    This document discusses power density and its relationship to welding processes and weld quality. It begins by explaining that fusion welding processes can be categorized based on their range of energy density, and that higher energy density processes allow for faster welding speeds. It then provides a table comparing typical energy densities and temperatures of different welding techniques. The remainder of the document discusses how higher power density decreases heat input requirements but can also increase thermal damage, and that there is an optimal power density range for developing sound weld joints without excess distortion or reduced mechanical properties.

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    Lecture: 4

    Power density and welding process


    In this chapter, energy density and temperature associated with different welding
    processes have been presented. Further, the influence of energy density on the
    performance parameters of the weld joints has also been described.
    Keywords: Power density, temperature of heat source, heat input, distortion,
    mechanical properties
    4.1

    Introduction

    Fusion welding processes can be looked into on the basis of range of energy density
    which they can apply for melting the faying surfaces of base metal for joining. Heat
    required for fusion of faying surfaces of components being welded comes from
    different sources in different fusion welding processes (gas, arc and high energy
    beam). Each type of heat source has capability to supply heat at different energy
    densities (kW/mm2). Even for a given arc power (arc current I X arc voltage V),
    different welding processes provide heat at different energy densities due to the fact
    that it is applied over different areas on the surface of base metal in case of different
    processes. Energy density (kW/mm2) is directly governed by the area over which
    heat is applied by a particular process besides welding parameters. Power density in
    ascending order from gas welding to arc welding to energy beam based welding
    processes is shown in table 4.1. Typical values of energy densities and approximate
    maximum temperature generated during welding by different processes are shown in
    Table 4.1.
    Table 4.1 Heat intensity and maximum temperature related with different
    welding processes

    Sr. No.

    Welding process

    Heat density (W/cm2) Temperature (0C)

    Gas welding

    102 -103

    2500-3500

    Shielded meta arc welding

    104

    >6000

    Gas metal arc welding

    105

    8000-10000

    Plasma arc welding

    106

    15000-30000

    Electron beam welding

    107 -108

    Laser beam welding

    >10

    20,000-30000
    >30,000

    4.2 Effect of power density


    Energy density associated with a particular welding process directly affects amount
    of heat required to be supplied for fusion of the faying surfaces. An increase in power
    density decreases the heat input required for melting and welding of work pieces
    because it decreases time over which heat is to be applied during welding for
    melting. The decrease in heat application time in turn lowers the amount of heat
    dissipated away from the faying surfaces to the base metal so the most of the heat
    applied on the faying surfaces is used for their fusion only. However, it is important to
    note that heat required for melting the unit quantity of a given metal is constant and
    is a property of material. Heat for melting comprises sensible heat and latent heat.
    Latent heat for steel is 2 kJ/mm3.
    Fusion welding processes are based on localized melting using high-density heat
    energy. To ensure melting of base metal in short time it is necessary that energy
    density of welding process is high enough (Fig. 4.1). Time to melt the base metal is
    found inversely proportional to the power density of heat source i.e. power of (arc or
    flame) / area of work piece over which it is applied (W/cm2). Lower the energy
    density of heat source greater will be the heat input needed for fusion of faying
    surface welding as a large amount of heat is dissipated to colder base material of
    work piece away from the faying surface by thermal conduction (Fig. 4.2).

    Fig. 4.1 Effect of energy density and time on energy input

    Heat input to workpiece

    increasing
    Increasingthermal
    damagedamage
    to
    workprices
    to workpiece

    Gas
    welding
    Arc
    welding
    High energy
    beam welding

    Increasing penetration,
    welding speed, weld
    quality and equipment
    cost

    Power density of heat source


    Fig. 4.2 Effect of power density of heat source on heat input required for welding
    [Kou S, 2003]

    4.3

    Need of optimum power density of welding process

    As stated, low power density processes need higher heat input than high power
    density processes. Neither too low nor too high heat input is considered good for
    developing a sound weld joint. As low heat input can lead to lack of penetration and
    poor fusion of faying surfaces during welding while excessive heat input may cause
    damage to the base metal in terms of distortion, softening of HAZ and reduced
    mechanical properties (Fig. 4.3). High heat input has been reported to lower the
    tensile strength of many aluminium alloys of commercial importance due to thermal
    softening of HAZ and development of undesirable metallurgical properties of the
    weldment (Fig. 4.4). Moreover, use of high power density offers many advantages
    such as deep penetration, high welding speed and improved quality of welding joints.
    Welding process (where melting is required) should have power density
    approximately 10(W/mm2). Vaporization of metal takes place at about 10,000W/mm2
    power-density. Processes (electron and laser beam) with such high energy density
    are used in controlled removal of metal for shaping of difficult to machine metals.
    Welding processes with power density in ascending order are shown in Fig. 4.5.

    Distortion (degree)

    GTAW
    6

    EBW

    20

    10

    30

    40

    Thickness (mm)

    Fig. 4.3 Effect of welding process on angular distortion of weld joint as a function of
    plate thickness[Kou S, 2003]

    Tensile strength

    Al-Mg-Si

    Al-Cu-Mg

    Al-Mg-Si

    Heat input

    Fig. 4.4 Schematic diagram showing effect of heat input on tensile strength of
    aluminium alloy weld joints (magnfication of micrograph in figure is 200 X) [Kou S,
    2003]

    EBW

    LBW

    PAW
    GMAW
    SMAW
    GW

    Fig. 4.5 Power densities of different welding processes

    References and books for further reading

    Welding handbook, American Welding Society, 1983, 7th edition, volume 1 &
    2, USA.

    Sindo Kou, Welding metallurgy, John Willey, 2003, 2nd edition, USA.

    S V Nadkarni, Modern Arc Welding Technology, Ador Welding Limited, 2010,


    New Delhi.

    http://www6.conestogac.on.ca/~ffulkerson/MANU1060_files/solutions_ch31.pdf

    http://eagar.mit.edu/EagarPapers/Eagar061.pdf

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