Solid State Welding Process

Solid-State Welding
Process
Cold Welding
Pressure is applied to the

workpieces through dies or rolls
Preferably both work pieces

should be ductile
The work pieces should cleaned

thoroughly
Fig: The roll bonding or cladding process
Can not join dissimilar metals

Ultrasonic Welding
Surfaces of the two

components are
subjected to a static
forces and oscillating
shearing force
Produces a strong,
solid-state bond Fig: a) Components of an ultrasonic welding machine
for lap welds.The lateral vibration of the tool tip
cause plastic deformation and bonding at the
interface of the work piece b)Ultrasonic some
welding using a roller c)An ultrasonically welded
Versatile and reliable part
for joining metals
Friction Welding
Developed in the 1940s
Parts are circular in shape
Can be used to join a wide variety of materials
Fig: Sequence of operation in the friction welding process 1)Left-hand component is rotated at high speed. 2)
Right-hand component is brought into contact under an axial force 3)Axial force is increased;the flash begins to
form 4) Left-hand component stops rotating;weld is completed.The flash can subsequently be removed by
machining or grinding
Friction Welding
Process can be fully automated
Can weld solid steel bars up to 250mm in outside diameter
Fig:Shape of friction zone in friction welding,as a function of the force applied and the rotational speed
Inertia Friction Welding
Modification of Friction Welding
Energy is supplied by a fly wheel
The parts are pressed together by a normal force
Fig : The principle of the

As friction at the interface increases, the fly wheel slows down friction stir welding
process. Aluminum-
alloy plates up to
75mm (3in) thick have
The weld is completed when the flywheel stops been welded by this
process
Linear Friction Welding
Parts are joined by a linear reciprocating motion
Parts do not have to be circular or tubular
In this application, one part is moved across the face of the

other part using a balanced reciprocating mechanism
Friction Stir Welding (FSW)
New Process for welding aerospace metals
Research is being directed towards using this process

for polymers
FSW uses a 3rd nonconsumable tool inserted between

the two bodies to heat the material to be joined
Resistance Welding
Developed in the early 1900s
A process in which the heat required for welding is produced by

means of electrical resistance across the two components
RW does not requiring the following:

Consumable electrodes
Shield gases
Flux
Resistance Spot Welding
RSW uses the tips of two opposing solid cylindrical electrodes
Pressure is applied to the lap joint until the current is turned off in order
to obtain a strong weld
Fig: (a) Sequence in the resistance spot welding

Resistance Spot Welding
Surfaces should be clean
Accurate control of and timing of electric current and of pressure are

essential in resistance welding
Fig: 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 process in sheet-metal
fabrication and in automotive-body assembly
Resistance Seam Welding
RSEM is modification of spot welding wherein the electrodes are replaced by rotating
wheels or rollers
The electrically conducting rollers produce a spot weld
RSEM can produce a continuous seam & joint that is liquid and gas tight
Fig : (a) Seam-Welding Process in which rotating rolls act as electrode (b)
Overlapping spots in a seam weld. (c) Roll spot weld (d) Resistance-welded gasoline tank
Resistance Projection Welding
RPW is developed by
introducing high
electrical resistance at
a joint by embossing
one or more
projections on the
surface to be welded
Weld nuggets are

similar to spot welding
Fig: a) Resistance projection Welding b)A welded bracket c) &

d) Projection welding of nuts r threaded hosses and stack
Resistance Projection Welding
The electrodes exert pressure to compress the

projections
Nuts and bolts can be welded to sheet and plate by

this process
Metal baskets, oven grills, and shopping carts can be

made by RPW
Flash Welding
Heat is generated from the arc as the ends as the two members contacts
An axial force is applied at a controlled rate
Weld is formed in plastic deformation
Fig : (a)Flash-welding process for end-to end welding of solid rods or tubular parts
(b) & (c) Typical parts made by flash welding (d)Design Guidelines for flash welding
Stud Welding
Small part or a threaded rod or hanger serves as a electrode
Also called as Stud arc welding
Prevent oxidation to concentrate the heat generation
Portable stud-welding is also available
Fig:The sequence of operation in stud welding,which is used for welding bars threaded rods and various
fasteners onto metal plates
THE END

Solid State Welding Process

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Solid-State Welding

Pressure is applied to the

Preferably both work pieces

The work pieces should cleaned

Can not join dissimilar metals

Surfaces of the two

Parts are circular in shape

Can be used to join a wide variety of materials

Can weld solid steel bars up to 250mm in outside diameter

Energy is supplied by a fly wheel

The parts are pressed together by a normal force

Fig : The principle of the

Parts are joined by a linear reciprocating motion

Parts do not have to be circular or tubular

In this application, one part is moved across the face of the

New Process for welding aerospace metals

Research is being directed towards using this process

FSW uses a 3rd nonconsumable tool inserted between

Developed in the early 1900s

A process in which the heat required for welding is produced by

RW does not requiring the following:

Fig: (a) Sequence in the resistance spot welding

Surfaces should be clean

Accurate control of and timing of electric current and of pressure are

Fig: b)Cross-section of a spot weld,showing the weld

The electrically conducting rollers produce a spot weld

Weld nuggets are

Fig: a) Resistance projection Welding b)A welded bracket c) &

The electrodes exert pressure to compress the

Nuts and bolts can be welded to sheet and plate by

Metal baskets, oven grills, and shopping carts can be

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