Joining Processes Chapter Outline

Chapter
Chapter Outline
Outline
Joining
Joining Processes
Processes
R. Jerz
4/16/2006
R. Jerz
Welding
Welding Processes
Processes
4/16/2006
Welded
Welded Joints
Joints
Gas, electricity, or other heat source?

Is electrode consumed?
z Is a filler material used?
z Is flux used?
z Anything else?
z Video Introduction to welding
z
z
R. Jerz
4/16/2006
R. Jerz
Fusion
Fusion Welding
Welding Processes
Processes
z
4/16/2006
Oxyacetylene
Oxyacetylene Welding
Welding
Video Fusion welding processes
R. Jerz
Acetylene gas most common (6,000 F)

z Welding
z Cutting
z Straightening
z Can be with or without filler
z
4/16/2006
R. Jerz
4/16/2006
Page 1
1
Weld
Weld Joint
Joint Structure
Structure
Oxyacetylene Torch
Figure 30.2 (a) General view of
and (b) cross-section of a torch
used in oxyacetylene welding.
The acetylene valve is opened
first; the gas is lit with a spark
lighter or a pilot light; then the
oxygen valve is opened and the
flame adjusted. (c) Basic
equipment used in oxyfuel-gas
welding. To ensure correct
connections, all threads on
acetylene fittings are left-handed,
whereas those for oxygen are
right-handed. Oxygen regulators
are usually painted green, and
acetylene regulators red.
R. Jerz
Figure 30.17 Characteristics of a

typical fusion-weld zone in oxyfuelgas and arc welding.
4/16/2006
R. Jerz
Arc
Arc Welding
Welding Processes
Processes
z
Figure 30.18 Grain structure in (a) deep weld and

(b) shallow weld. Note that the grains in the
solidified weld metal are perpendicular to their
interface with the base metal (see also Fig. 10.3).
(c) Weld bead on a cold-rolled nickel strip produced
by a laser beam. (d) Microhardness (HV) profile
across a weld bead.
Gas-Tungsten
Gas-Tungsten Arc
Arc Welding
Welding
Nonconsumable electrode
Video TIG welding
Gas tungsten-arc (TIG)

Plasma arc (PAW)
z
Figure 30.4 (a) The gas

tungsten-arc welding
process, formerly known as
TIG (for tungsten inert gas)
welding. (b) Equipment for
gas tungsten-arc welding
operations.
Consumable electrode
Shielded metal arc (SMAW)

Gas metal arc (GMAW or MIG)
Flux-cored arc welding (FCAW)
Submerged arc welding (SAW)
R. Jerz
4/16/2006
4/16/2006
R. Jerz
Plasma-Arc
Plasma-Arc Welding
Welding Process
Process
10
4/16/2006
Shielded-Metal
Shielded-Metal Arc
Arc Welding
Welding
Video plasma arc welding

z 60,000 degrees F
z
Video shielded metal arc welding
Figure 30.7 Schematic illustration of the shielded metal-arc

welding process. About 50% of all large-scale industrial welding
operations use this process.
R. Jerz
11
4/16/2006
R. Jerz
12
4/16/2006
Page 2
2
Shielded-Metal
Shielded-Metal Arc
Arc Welding
Welding
Gas
Gas Metal-Arc
Metal-Arc Welding
Welding
z
Figure 30.8 A deep weld showing the

buildup sequence of eight individual weld
beads.
R. Jerz
13
4/16/2006
Videos gas metal arc welding
R. Jerz
Fluxed-Cored
Fluxed-Cored Arc-Welding
Arc-Welding
z
Video submerged-are welding
Figure 30.9 Schematic illustration of the submerged arc welding process and
equipment. The unfused flux is recovered and reused.
Figure 30.11 Schematic illustration of the flux-cored arc welding process. This
operation is similar to gas metal-arc welding, shown in Fig. 30.10.
15
4/16/2006
Submerged-Arc
Submerged-Arc Welding
Welding
Video flux core welding
R. Jerz
14
4/16/2006
R. Jerz
Other
Other Welding
Welding Processes
Processes
16
4/16/2006
Weld
Weld Design
Design
Electron beam - video

z Laser beam - video
z
Figure 30.29 Some design guidelines for welds. Source: After J.G. Bralla.
R. Jerz
17
4/16/2006
R. Jerz
18
4/16/2006
Page 3
3
Welded
Welded Joints
Joints
z
Defects
Defects in
in Fusion
Fusion Welds
Welds
Metallurgy concerns
Figure 30.19 Examples of
various discontinuities in fusion
welds.
Solidification process
z
Heat-affected zone weakest part of joint
Figure 30.20 Examples of

various defects in fusion welds.
R. Jerz
19
4/16/2006
R. Jerz
Cracks
Cracks in
in Welded
Welded Joints
Joints
21
4/16/2006
Distortion
Distortion of
of Parts
Parts After
After Welding
Welding
Figure 30.23 Distortion of parts after welding. (a) Butt joints and (b) fillet welds.
Distortion is caused by differential thermal expansion and contraction of different
regions of the welded assembly.
Figure 30.21 Types of cracks developed in welded joints. The cracks are caused
by thermal stresses, similar to the development of hot tears in castings (see also
Fig. 10.12).
R. Jerz
20
4/16/2006
R. Jerz
22
4/16/2006
Solid-state
Solid-state Processes
Processes
Weld
Weld Testing
Testing
z
Mechanical methods
Ultrasonic
Friction
Electrical
Resistance
Figure 30.26 (a) Specimen for longitudinal tension-shear testing; (b) specimen for
transfer tension-shear testing; (c) wraparound bend test method; (d) three-point
bending of welded specimens (see also Fig. 2.11).
R. Jerz
23
4/16/2006
R. Jerz
24
4/16/2006
Page 4
4
Ultrasonic
Ultrasonic Welding
Welding
Ultrasonic
Ultrasonic Welding
Welding
z
Video - ultrasonic
z
z
Vibrating tool at high frequency

Lap joints of thin materials
Figure 31.2 (a) Components of an ultrasonic welding machine for making lap welds. The lateral
vibrations of the tool tip cause plastic deformation and bonding at the interface of the
workpieces. (b) Ultrasonic seam welding using a roller as the sonotrode.
R. Jerz
25
4/16/2006
R. Jerz
Friction
Friction welding
welding
Resistance
Resistance (Spot)
(Spot) Welding
Welding (RW)
(RW)
Figure 31.6 (a) Sequence of
events in resistance spot
welding. (b) Cross-section of
a spot weld, showing the weld
nugget and the indentation of
the electrode on the sheet
surfaces. This is one of the
most commonly used
processes in sheet-metal
fabrication and in automotivebody assembly.
Rub two parts

together
z Video
z
R. Jerz
4/16/2006
26
27
4/16/2006
R. Jerz
Resistance
Resistance Welding
Welding
28
4/16/2006
Spot
Spot Welding
Welding Equipment
Equipment
Video
z Spot, projection, and seam
z Heating
z
H=I2RT, where
I=current
R=electrical resistance
T=time
Figure 31.7 (a) Schematic illustration of an air-operated, rocker-arm,
spot welding machine. (b) and (c) Two electrode designs for easy
access into components to be welded.
R. Jerz
29
4/16/2006
R. Jerz
30
4/16/2006
Page 5
5
Resistance
Resistance Projection
Projection Welding
Welding
Spot
Spot Weld
Weld Testing
Testing
Figure 31.13 (a) Schematic illustration of resistance projection welding. (b) A

welded bracket. (c) and (d) Projection welding of nuts or threaded bosses and
studs. (e) Resistance-projection-welded grills.
4/16/2006
31
R. Jerz
Figure 31.10 Test methods for spot welds: (a) tension-shear test, (b) cross-tension
test, (c) twist test, (d) peel test. (see also Fig. 32.9).
R. Jerz
Brazing
Brazing &
& Soldering
Soldering
32
4/16/2006
Joint
Joint Designs
Designs used
used in
in Brazing
Brazing
Video
Filler material
z Temperature below melting point of
metals
z Differences from welding
z
z
brazing alloy
strength of brazing alloy
capillary action
z
Soldering - lower temperature than

brazing
R. Jerz
33
Figure 32.3 Joint designs commonly used in brazing operations. The clearance
between the two parts being brazed in an important factor in joint strength. If the
clearance is too small, the molten braze metal will not penetrate the interface fully. If
it is too large, there will be insufficient capillary action for the molten metal to fill the
interface.
4/16/2006
R. Jerz
Joints
Joints
Should be clean
z Should have close tolerance
35
4/16/2006
Advantages
Advantages of
of Brazing
Brazing
Join a variety of metals
z Quick
z Low temperature
z Automation is possible
R. Jerz
34
4/16/2006
R. Jerz
36
4/16/2006
Page 6
6
Adhesives
Adhesives
Adhesives
Adhesives
Epoxies - most are 2 components

Cyanoacrylates - super glues
Anaerobics
Acrylics
Urethanes
Silicones - flexible joints

Hot melts
z
z
one component, cure when oxygen is removed

catalyst primer and adhesive
low temperatures
z
R. Jerz
37
4/16/2006
R. Jerz
z
z
z
z
z
z
z
z
z
Combination of materials
Low temperature
Joining of thin materials
Joining of heat sensitive materials
Inexpensive
Less assembly time
Unstable at higher temperature
Destructive testing required
Surface preparation
Cure time
R. Jerz
39
Many ideas
Function
z Cost
z Time
z DFM Video
z
z
4/16/2006
R. Jerz
DFM
DFM -- Concepts
Concepts
z
z
z
z
z
z
z
4/16/2006
Design
Design for
for Assembly
Assembly (DFM)
(DFM)
Advantages
Advantages &
& Disadvantages
Disadvantages
z
38
40
4/16/2006
DFM
DFM Examples
Examples
Reduce the number of parts

Reduce number of fasteners
Use modular designs
Reduce need to handle several components at
the same time
Limit number of directions
Use high quality components
Design fasteners that can be easily
automatically feed
R. Jerz
41
4/16/2006
R. Jerz
42
4/16/2006
Page 7
7

Joining Processes Chapter Outline

Uploaded by

Copyright:

Available Formats

Joining Processes Chapter Outline

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Joining Processes Chapter Outline

Uploaded by

Copyright:

Available Formats

Chapter

Gas, electricity, or other heat source?

Video Fusion welding processes

Acetylene gas most common (6,000 F)

Figure 30.17 Characteristics of a

Figure 30.18 Grain structure in (a) deep weld and

Video TIG welding

Gas tungsten-arc (TIG)

Figure 30.4 (a) The gas

Shielded metal arc (SMAW)

Video plasma arc welding

Video shielded metal arc welding

Figure 30.7 Schematic illustration of the shielded metal-arc

Figure 30.8 A deep weld showing the

Videos gas metal arc welding

Video submerged-are welding

Video flux core welding

Electron beam - video

Heat-affected zone weakest part of joint

Figure 30.20 Examples of

Vibrating tool at high frequency

Rub two parts

Figure 31.13 (a) Schematic illustration of resistance projection welding. (b) A

Soldering - lower temperature than

Epoxies - most are 2 components

Silicones - flexible joints

one component, cure when oxygen is removed

Reduce the number of parts

You might also like