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    Lectures 7-10

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    ranasb.2005
    Lecture 7 to 10

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    Lectures 7-10

    Uploaded by

    ranasb.2005
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    Lecture 7 to 10

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    Lecture 7 to 10

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    5 views59 pages

    Lectures 7-10

    Uploaded by

    ranasb.2005
    Lecture 7 to 10

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
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    Workshop Practice

    Lecture 7-10
    By Mansoor Dawson
    Machine Shop
    Welding

    • A welded join is a
    permanent joint,
    obtained by the
    fusion of the edges of
    the two parts to be
    joined together, with
    or without the
    application of
    pressure and a filler
    material
    Welding Classification

    1. Fusion welding - coalescence is accomplished by melting


    the two parts to be joined, in some cases adding filler
    metal to the joint
    Examples: arc welding, resistance spot welding,
    oxyfuel gas welding

    2. Solid state welding - heat and/or pressure are used to


    achieve coalescence, but no melting of base metals
    occurs and no filler metal is added

    Examples: forge welding, diffusion welding, friction


    welding
    Welding Classification
    Welding Classification
    Arc Welding (AW)

    A fusion welding process in which coalescence of the metals


    is achieved by the heat from an electric arc between an
    electrode and the work.

    Electric energy from the arc produces temperatures ~


    10,000 F (5500 C), hot enough to melt any metal

    Most AW processes add filler metal to increase volume


    and strength of weld joint
    Arc Welding (AW)
    What is an Electric Arc?

    An electric arc is a discharge of electric current across


    a gap in a circuit

    It is sustained by an ionized column of gas


    (plasma) through which the current flows

    To initiate the arc in AW, electrode is brought into


    contact with work and then quickly separated from it
    by a short distance
    Arc Welding (AW)

    A pool of molten metal is formed near electrode tip,


    and as electrode is moved along joint, molten weld
    pool solidifies in its wake
    Two Basic Types of AW Electrodes

    Consumable – consumed during welding process

    Source of filler metal in arc welding

    Nonconsumable – not consumed during welding


    process

    Filler metal must be added separately if it is added


    Consumable Electrodes

    Forms of consumable electrodes

    Welding rods (a.k.a. sticks) are 9 to 18 inches and 3/8


    inch or less in diameter and must be changed
    frequently
    Weld wire can be continuously fed from spools with
    long lengths of wire, avoiding frequent interruptions

    In both rod and wire forms, electrode is consumed


    by the arc and added to weld joint as filler metal
    Nonconsumable Electrodes

    Made of tungsten which resists melting

    Gradually depleted during welding (vaporization is


    principal mechanism)

    Any filler metal must be supplied by aseparate wire


    fed into weld pool
    Arc Shielding
    At high temperatures in AW, metals are chemically
    reactive to oxygen, nitrogen, and hydrogen in air

    Mechanical properties of joint can be degraded by these


    reactions

    To protect operation, arc must be shielded from


    surrounding air in AW processes

    Arc shielding is accomplished by:


    Shielding gases, e.g., argon, helium, CO2
    Flux
    Flux

    A substance that prevents formation of oxides and


    other contaminants in welding, or dissolves them
    and facilitates removal

    Provides protective atmosphere for welding

    Stabilizes arc

    Reduces spattering
    Power Source in Arc Welding

    Direct current (DC) vs. Alternatingcurrent (AC)

    AC machines less expensive to purchase and operate,


    but generally restricted to ferrous metals

    DC equipment can be used on all metals and is


    generally noted for better arc control
    Consumable Electrode AW Processes

    Shielded Metal ArcWelding

    Gas Metal Arc Welding (GMAW or MIG)

    Flux-Cored ArcWelding

    Electrogas Welding

    SubmergedArc Welding
    Shielded Metal Arc Welding
    (SMAW)
    Uses a consumable electrode consisting of a filler
    metal rod coated with chemicals that provide flux
    and shielding

    Sometimes called "stick welding"

    Power supply, connecting cables, and electrode


    holder available for a few thousand dollars
    Welding Electrode or Stick
    Composition of filler metal usually close to base metal

    Coating: powdered cellulose mixed with oxides and


    carbonates, and held together by a silicate binder

    Welding stick is clamped in electrode holder connected to


    power source

    Disadvantages of stick welding:


    Sticks must be periodically changed
    High current levels may melt coating prematurely
    SMAW Applications

    Used for steels, stainless steels, cast irons,


    and certain nonferrous alloys

    Not used or rarely used for aluminum and its


    alloys, copper alloys, and titanium
    Weld Appearances
    Weld Appearances
    Gas Metal Arc Welding (GMAW)

    Uses a consumable bare metal wire as electrode


    with shielding by flooding arc with a gas

    Wire is fed continuously and automatically from as pool


    through the welding gun

    Shielding gases include argon and helium for


    aluminum welding, and CO2 for steel welding

    Bare electrode wire plus shielding gases eliminate


    slag on weld bead
    No need for manual grinding and cleaning of slag
    GMAW Torch
    GMAW Advantages over SMAW
    Better arc time because of continuous wire electrode

    Sticks must be periodically changed in SMAW

    Better use of electrode filler metal than SMAW

    End of stick cannot be used in SMAW

    Higher deposition rates

    Eliminates problem of slag removal

    Can be readily automated


    Weld Appearances
    Nonconsumable Electrode Processes

    Gas Tungsten Arc Welding (TIG Welding)

    Plasma Arc Welding

    Carbon Arc Welding

    Stud Welding
    Gas Tungsten Arc Welding
    (GTAW/ TIG)
    Uses a nonconsumable tungsten electrode and an inert gas
    for arc shielding

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

    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


    Advantages and Disadvantages

    Advantages:

    High quality welds for suitable applications

    No spatter because no filler metal througharc

    Little or no post-weld cleaning because noflux

    Disadvantages:

    Generally slower and more costlythan consumable electrode


    AW processes
    Welding Positions
    Welding Defects

    Cracks

    Cavities

    Solid inclusions

    Imperfect shape or unacceptable contour

    Incomplete fusion

    Miscellaneous defects
    Welding Defects
    Welding Defects
    Welding Joints

    • Butt
    • Corner
    • Lap
    • Tee
    • Edge
    Butt Joint
    Tee Joint
    Lap Joint
    Corner Joint
    Resistance Welding (RW)

    A group of fusion welding processes that use a


    combination of heat and pressure to accomplish
    coalescence

    Heat generated by electrical resistance to current


    flow at junction to be welded

    Principal RW process is resistance spot welding


    (RSW)
    Resistance Welding

    Resistance welding,
    showing components
    in spot welding, the
    main process in the
    RW group
    Components in Resistance Spot
    Welding

    Parts to be welded (usually sheet metal)

    Two opposing electrodes

    Means of applying pressure to squeeze parts


    between electrodes

    Power supply from which a controlled current


    can be applied for a specified time duration
    Resistance Spot Welding (RSW)

    Resistance welding process in which fusion of faying


    surfaces of a lap joint is achieved at one location by
    opposing electrodes

    Used to join sheet metal parts

    Widely used in mass production of automobiles, metal


    furniture, appliances, and other sheet metal products

    Typical car body has ~ 10,000 spot welds


    Spot Welding Cycle

    (a) Spot welding cycle


    (b) Plot of force and
    current
    Cycle: (1) parts
    inserted between
    electrodes, (2)
    electrodes close, (3)
    current on, (4) current
    off, (5) electrodes
    opened
    Advantages and Drawbacks of
    Resistance Welding
    Advantages:
    No filler metal required
    High production rates possible
    Lends itself to mechanization and automation
    Lower operator skill level than for arc welding
    Good repeatability and reliability

    Disadvantages:
    High initial equipment cost
    Limited to lap joints for most RW processes
    Oxyfuel Gas Welding (OFW)

    Group of fusion welding operations that burn various


    fuels mixed with oxygen

    OFW employs several types of gases, which is the primary


    distinction among the members of this group

    Oxyfuel gas is also used in flame cutting torches


    to cut and separate metal plates and other parts

    Most important OFW process is oxyacetylene


    welding
    Oxyacetylene Welding (OAW)
    Fusion welding performed by a high temperature
    flame from combustion of acetylene (ethyne) and
    oxygen

    Flame is directed by a welding torch

    Filler metal is sometimes added

    Composition must be similar to base metal

    Filler rod often coated with flux to clean surfaces


    and prevent oxidation
    Acetylene (C2H2)

    Most popular fuel among OFW group because it is capable


    of higher temperatures than any other

    Up to 3480C (6300F)

    Two stage reaction of acetylene and oxygen:

    First stage reaction (inner cone of flame)


    C2H2 + O2 → 2CO + H2 + heat
    Second stage reaction (outer envelope)
    2CO + H2 + 1.5O2 → 2CO2 + H2O + heat
    Oxyacetylene Torch

    Maximum temperature reached at tip of inner cone, while


    outer envelope spreads out and shields work surface from
    atmosphere

    Shown below is neutral flame of oxyacetylene torch


    indicating temperatures achieved
    Safety Issue in OAW
    Together, acetylene and oxygen are highly flammable

    C2H2 is colorless and odorless

    Storage cylinders are packed with porousfiller material saturated


    with acetone (CH3COCH3)

    Acetone dissolves about 25 times its own volume of acetylene

    Different screw threads are standard on C2H2 and O2 cylinders


    and hoses to avoid accidental connection of wrong gases
    Alternative Gases for OFW

    Methylacetylene-Propadiene (MAPP)
    Hydrogen
    Propylene
    Propane
    Natural Gas

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