The document discusses heat transfer calculations related to various welding processes. It provides examples of calculating:
1) The power density required to melt metal from a circular heat source.
2) The heat required and generated for a fillet weld on steel.
3) Comparing two methods to calculate the unit melting energy of aluminum.
4) The travel speed required for an arc weld on aluminum given the power, heat transfer, and melting point.
5) The heat generation required for a spot weld on aluminum plates of a given size and time.
6) The heat generation and time required for a surfacing weld on a steel ring of given dimensions.
The document discusses heat transfer calculations related to various welding processes. It provides examples of calculating:
1) The power density required to melt metal from a circular heat source.
2) The heat required and generated for a fillet weld on steel.
3) Comparing two methods to calculate the unit melting energy of aluminum.
4) The travel speed required for an arc weld on aluminum given the power, heat transfer, and melting point.
5) The heat generation required for a spot weld on aluminum plates of a given size and time.
6) The heat generation and time required for a surfacing weld on a steel ring of given dimensions.
The document discusses heat transfer calculations related to various welding processes. It provides examples of calculating:
1) The power density required to melt metal from a circular heat source.
2) The heat required and generated for a fillet weld on steel.
3) Comparing two methods to calculate the unit melting energy of aluminum.
4) The travel speed required for an arc weld on aluminum given the power, heat transfer, and melting point.
5) The heat generation required for a spot weld on aluminum plates of a given size and time.
6) The heat generation and time required for a surfacing weld on a steel ring of given dimensions.
The document discusses heat transfer calculations related to various welding processes. It provides examples of calculating:
1) The power density required to melt metal from a circular heat source.
2) The heat required and generated for a fillet weld on steel.
3) Comparing two methods to calculate the unit melting energy of aluminum.
4) The travel speed required for an arc weld on aluminum given the power, heat transfer, and melting point.
5) The heat generation required for a spot weld on aluminum plates of a given size and time.
6) The heat generation and time required for a surfacing weld on a steel ring of given dimensions.
1. A heat source transfers 3000 J/sec to a metal part surface. The heated area is circular, and the heat intensity decreases as the radius increases: 75% of the heat is concentrated in a circular area having 3.5 mm diameter. Is the resulting power density enough to melt metal? 2. A fillet weld on low carbon steel has a cross-sectional area of 20.0 mm2 and is 250 mm long. Determine (a) the amount of heat (in joules) required to perform the weld, and (b) the amount of heat that must be generated by the heat source, if the heat transfer factor = 0.80 and the melting factor = 0.60 ? 3. It is desired to compare two methods of determining the unit melting energy (Um) for aluminum. The first method is by Equation 1, The second method is to compute Um as the sum of (1) the heat required to raise the temperature of the metal from ambient temperature to its melting point, which is the volumetric specific heat multiplied by the temperature rise; and (2) the heat of fusion. Take, specific heat, density, melting point and the heat of fusion for aluminum are as 0.21 Cal/g ᵒC, 2.7 g/cm3, 660 ᵒC and 398 kJ/kg 4. The power developed in an arc welding operation = 3000 W. This is transferred to the work surface with a heat transfer factor = 0.80. The metal to be welded is aluminium whose melting point 930K. Assume the melting factor = 0.40. A fillet weld is to be made with a cross-sectional area = 20.0 mm2. Determine the travel speed at which the welding operation can be accomplished. 5. In a spot-welding operation, two 1/16-in-thick aluminium plates are joined. The melted metal at each joint formed a disk-shaped nugget with a diameter of 1/4 in. The power is on for 0.4 sec. Assume the final nugget had the same thickness as the two aluminium plates (1/8-in thick), the heat transfer factor was 0.80, and the melting factor was 0.50. Determine the rate of heat generation that was required at the heat source to accomplish this weld. 6 A surfacing weld is applied to a ring-shaped plate made of low carbon steel. The outside diameter of the ring = 750 mm, and it’s inside diameter = 500 mm. The filler metal is a harder (alloy) grade of steel, whose melting point is assumed to be the same as the base metal. A thickness of 4.0 mm will be added to the plate, but with penetration into the base metal, the total thickness melted during welding = 7.0 mm, on average. The surface will be applied by rotating the ring while the welding head is fed from the outside toward the inside of the ring, thus creating a spiral welding path. The operation will be carried out automatically with the beads laid down in one long, continuous operation at a travel speed = 8.0 mm/s, using welding passes separated by 6 mm. Assume the welding bead is rectangular in cross section: 7 mm by 6 mm. The heat transfer factor = 0.8, and the melting factor = 0.65. Determine (a) the rate of heat that must be generated at the welding source, and (b) how long it will take to complete the surfacing operation.
𝑈𝑚 = 𝑘𝑇𝑚2 --- ----- ------ Eq 1
Where, K = constant whose value is 3.33 × 10–6 when the Kelvin scale is used
