Joining AND Assembly Processes:: Welding

JOINING
AND
ASSEMBLY
PROCESSES:
WELDING
JOINING AND
ASSEMBLY PROCESS
A. Joining
- general term for welding, brazing,
soldering and adhesive bonding
- form a permanent joint between the
parts
B. Assembly
- mechanical method of fastening parts
together
FUNDAMENTALS OF
WELDING
WELDING
 Materials joining process in
which two or more parts are
joined with a suitable application
of heat and pressure
 Most commonly associated
with metal parts, but also used in
joining plastics
 processes discussed would
focus on metals
FUNDAMENTALS OF
WELDING
ADVANTAGES DISADVANTAGES
 It provides a  Most welding
permanent joint operations are done
manually and are
 The welded joint can expensive (in terms of
be stronger than the labor)
parent materials  Welding processes are
 It is usually the most inherently dangerous
economical way of  It does not allow for
joining components convenient
disassembly
 Not restricted in a
factory environment,  Welded joint can
can be done “in the suffer from certain
quality defects
field”
TYPES OF WELDING
PROCESSES
A. Fusion Welding
1. Arc welding (AW)
2. Resistance welding (RW)
3. Oxyfuel gas welding (OFW)
4. Other types of fusion welding
B. Solid-State Welding
1. Diffusion welding (DFW)
2. Friction welding (FRW)
3. Friction stir welding (FSW)
4. Ultrasonic welding (USW)
5. Explosion welding (EXW)
A. FUSION WELDING
- These are the processes in which
use heat to melt the base metals
- Filler metal (added to the molten
pool to facilitate the process and
provide bulk and strength to the
welded joint)
- These processes are commonly
used: BACK
BACK
ARC WELDING
Fig. 1. Schematic illustration of the shielded
metal-arc welding process. About 50% of all
large-scale industrial welding operations use
this process.
Figure 2 Schematic illustration of the shielded

metal-arc welding operations (also known as
stick welding, because the electrode is in the
shape of a stick).
RESISTANCE BACK
WELDING
Figure 3 (a)
Sequence 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 process in
sheet metal
fabrication and in
automotive-body
assembly.
OXYFUEL GAS BACK
WELDING
OXYACETYLENE
WELDING
Figure 4. (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, acetylene
regulators red.
BACK
OTHER TYPES
A B
Fig. 5 (A) Laser welding of a gear (B) Electroslag

Welding equipment
B. SOLID-STATE BACK
WELDING
- It refers to the joining
process in which
applications of pressure
alone or a combination of
heat and pressure results
two metals to merge
- No filler metal is utilized
BACK
DIFFUSION WELDING
Figure 6. The sequence of operations in the fabrication of various structures by diffusion bonding and then superplastic forming of
(originally) flat sheets. Sources: (a) After D. Stephen and S.J.Swadling. (b) and (c) Rockwell International Corp.
BACK
FRICTION WELDING
Fig. 7. (A) Sequence of operations 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; flash begins to form. (4)
Left-hand component stops rotating; weld is completed. The flash can subsequently be removed by machining or
grinding. (B) Shape of fusion zone in friction welding, as a function of the force applied and the rotational speed.
FRICTION-STIR BACK
WELDING
Fig. 8. The principle

of the friction stir welding
process. Aluminum-alloy
plates up to 75 mm (3 in.)
thick have been welded by
this process. Source: TWI,
Cambridge, U.K.
ULTRASONIC BACK
WELDING
(a) (b)
(a) Components of an ultrasonic welding machine for 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. (c) An
ultrasonically welded part.
BACK
EXPLOSION WELDING
(a) (b)
Fig. 10 Schematic illustration of the

explosion welding process: (a)
constant interface clearance gap
and (b) angular interface clearance
gap. (c) and (d) Crosssections of
explosion-welded joints. (c) titanium
(top piece) on low-carbon steel
(bottom). (d) Incoloy 800 (an
ironnickel- based alloy) on
lowcarbon steel. Source: Courtesy
(c) (d) of E. I. Du Pont de Nemours & Co.
THE WELD JOINT:
TYPES OF JOINTS
WELD JOINT Types of Joints
-The junction of
two edges or
surface parts
that have been
joined by
welding
THE WELD JOINT:
WELD TYPES
THE WELD JOINT:
WELD TYPES
THE WELD JOINT:
WELD TYPES
A. Fillet weld
B. Groove weld
C. Plug or Slot
weld
D. Spot weld
E. Seam weld
F. Flange weld
G. Surfacing weld
WELD DEFECTS:
INCOMPLETE FUSION
Figure 11. Low-quality weld beads, the result of incomplete
fusion. Source: American Welding Society.
WELD DEFECTS:
DISCONTINUITIES
Figure 12. Schematic illustration of various discontinuities in
fusion welds. Source: American Welding Society.
WELD DEFECTS:
CRACKS
Figure 13
Types of
cracks (in
welded joints)
caused by
thermal
stresses that
develop during
solidification
and
contraction of
the weld bead
and the
surrounding
structure. (a)
Crater cracks.
(b) Various
types of
cracks in butt
and T joints.
INSPECTION &
TESTING METHODS
Figure 14 Two types of

specimens for tension-
shear testing of welded
joints.
Figure 15 (a) Wrap-around

bend test method. (b)
Three-point bending of
welded specimens
INSPECTION &
TESTING METHODS
Figure 16
(a)Tension shear
test for spot
welds. (b) Cross-
tension test. (c)
Twist test. (d)
Peel test
Thank you for
listening! 
REFERENCES
Groover, M. (2011) Principles of Modern Manufacturing. John
Wiley & Sons (Asia) Pte. Ltd.
Kalpakjian & Schmid. (2001) Manufacturing Engineering and
Technology. Prentice-Hall
(n.a.) [PDF document] Joining processes. Available from
http://www.ielm.ust.hk/dfaculty/ajay/courses/ieem215/
lecs/8_joining.pdf
(n.a) [PDF document] The Weld Joints and Weld Types. Available
from http://www.g-
w.com/pdf/sampchap/9781590708668_ch06.pdf

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JOINING

Figure 2 Schematic illustration of the shielded

Fig. 5 (A) Laser welding of a gear (B) Electroslag

Fig. 8. The principle

Fig. 10 Schematic illustration of the

Figure 14 Two types of

Figure 15 (a) Wrap-around

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