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Solid-State WeldingProcess
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Cold Welding Cold Weldin
g
Pressure is applied to theworkpieces through dies orrolls
Preferably both work piecesshould be ductile
The work pieces should
cleaned thoroughly
Can not join dissimilarmetals
Fig: The roll bonding or cladding process
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Ultrasonic Welding Ultrasonic Weld
ing
Surfaces of the twocomponents aresubjected to a staticforces and oscillating
shearing force
Produces a strong,solid-state bond
Versatile and reliablefor joining metals
Fig: a) Components of an ultrasonic welding machinefor lap welds.The lateral vibration of the tool tipcause plastic deformation and bonding at theinterface of the work piece b)Ultrasonic some welding using a roller c)An ultrasonically weldedpart
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Friction Welding Friction Weldin
g
Developed in the 194 !s
Parts are circular in shape
Can be used to join a wide variety of materials
Fig: e!uence of operation in the friction welding process ")#eft$hand component is rotated at high speed. %)&ight$hand component is brought into contact under an a'ial force ()A'ial force is increased the flash begins toform *) #eft$hand component stops rotating weld is completed.The flash can subse!uently be removed bymachining or grinding
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Friction Welding Friction Weldin
g
Process can be fully automated
Can weld solid steel bars up to "# mm in outside diameter
Fig: hape of friction +one in friction welding,as a function of the force applied and the rotational speed
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Inertia Friction Welding Inertia Friction Weldin
g $odi%cation of &riction 'elding
(nergy is supplied by a )y wheel
The parts are pressed together by a normal force
*s friction at the interface increases+ the )y wheel slows down
The weld is completed when the )ywheel stops
Fig : The principle of thefriction stir weldingprocess. Aluminum$alloy plates up to- mm /(in) thick havebeen welded by thisprocess
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Linear Friction Welding Linear Friction Weldin g
Parts are joined by a linear reciprocating motion
Parts do not have to be circular or tubular
,n this application+ one part is moved across the faceof the other part using a balanced reciprocatingmechanism
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Friction Stir Welding (FSW) Friction Stir Weld ing (FSW)
-ew Process for welding aerospace metals
.esearch is being directed towards using thisprocess for polymers
&/' uses a 0 rd nonconsumable tool insertedbetween the two bodies to heat the material tobe joined
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Resistance Welding Resistance We lding
Developed in the early 19 !s
* process in which the heat re uired for welding is
produced by means of electrical resistance acrossthe two components
.' does not requiring the following 2
Consumable electrodes
/hield gases
&lu3
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Resistance Spot Welding Resistance S pot Welding
./' uses the tips of two opposing solid cylindrical electrodes
Pressure is applied to the lap joint until the current is turnedo in order to obtain a strong weld
Fig: /a) e!uence in the resistance spot welding
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Resistance Spot Welding Resistance S pot Welding
/urfaces should be clean
*ccurate control of and timing of electric current and of pressureare essential in resistance welding
Fig: b)Cross$section of a spot weld,showing the weldnugget and the indentation of the electrode onthe sheet surfaces.This is one of the mostcommonly used process in sheet$metalfabrication and in automotive$body assembly
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Resistance Seam Welding Resistance Seam Weldin g ./($ is modi%cation of spot welding wherein the electrodes are replacedby rotating wheels or rollers
The electrically conducting rollers produce a spot weld
./($ can produce a continuous seam 5 joint that is li uid and gas tight
Fig : /a) eam$0elding 1rocess in which rotating rolls act as electrode /b)2verlapping spots in a seam weld. /c) &oll spot weld /d) &esistance$welded gasoline tank
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Resistance Projection Welding Resistance Pro jection Welding
.P' is developedby introducing highelectricalresistance at a jointby embossing one
or more projectionson the surface tobe welded
'eld nuggets aresimilar to spotwelding
Fig: a) &esistance pro3ection 0elding b)A welded bracket c) 4
d) 1ro3ection welding of nuts r threaded hosses and stack
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Resistance Projection Welding Resistance Pro jection Welding
The electrodes e3ert pressure to compressthe projections
-uts and bolts can be welded to sheet andplate by this process
$etal baskets+ oven grills+ and shopping
carts can be made by .P'
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Flash Welding Flash Weld ing 6eat is generated from the arc as the ends as the two memberscontacts
*n a3ial force is applied at a controlled rate
'eld is formed in plastic deformation
Fig : /a)Flash$welding process for end$to 5end welding of solid rods or tubular parts
/b) 4 /c) Typical parts made by flash welding /d)6esign 7uidelines for flash welding
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Stud Welding Stud Weldin g /mall part or a threaded rod or hanger serves as a electrode
*lso called as /tud arc weldingPrevent o3idation to concentrate the heat generation
Portable stud7welding is also available
Fig:The se!uence of operation in stud welding,which is used for welding bars threaded rods and variousfasteners onto metal plates
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