Download - Welding process
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WELCOME YOU
FOR THE TOPIC ON:
by: C B Singh
SCIENCE & TECHNOLOGY OF WELDING
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It is needless to emphasize that the welding has become, now, the most efficient, economical & popular means of joining materials; Because:• It enables act as one . • It improves strength. •Reduces the over-all weight.•Reduces labor time & the cost.
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WELDING
Definition :A localized coalescence of material with or without the use of filler and also with or without the application of pressure.
or
Bringing two perfectly smooth & clean material surfaces to an intimate contact, which is an atomic distance, indeed, between the two, is known as welding.
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WELDING
Fusion
Diffusion
PressureNon-
pressure
* Soldering < 427 0C * Brazing > 427 0C * Braze-welding
&
* Resistance welding* Explosive welding
* Forge welding
* Friction/Inertia welding*Ultrasonic welding
* Cold welding* Thermit welding * Pressure gas
welding
* Oxy-Fuel gas welding* Electric Arc welding* Plasma Arc welding* Electron Beam welding* Laser Beam welding* Electro Slag / Gas
welding
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Ag100%
Cu100%
500
700
900
1100
0C
72%Ag + 28%Cu
Liquidus Solid +
Liquid
Solid
(Eutectic composition)
Silver–Copper Equilibrium Diagram
Molten liquid
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BRAZING & SOLDERING
Brazing & Soldering:
Low temp. Brazing 450-850 0C Medium temp. Brazing 850-950 0C High temp. Brazing > 950 0C
There is no bead formation, but only with capillary attraction.& diffusion.
Low temp. Soldering 427 0C Max.
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SteelSteel
Bronze
CopperCopperSteel
SteelCopper
Steel
Pb-Sn EutecticSteelCopper
Brazing & SolderingBrazing & Soldering
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Some Typical Brazing Applications:
Ring
Foil
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BRAZE WELDING
Braze welding: There is a bead formation, but without the fusion & capillary attraction.
An age-old joining technique
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OPERATION– Manual/ mechanized/ auto.
ADVANTAGE – Usually no distortion & heat damages; easy adaptability for the mass production of several intricate component parts. TYPICAL APPLICATIONS –Repair & maintenance, tool-tips, heat-exchangers, electrical switches, electric motor parts, gas turbine parts, bicycle frames, utensils & kitchen-wares etc.
BRAZE WELDING, BRAZING & SOLDERING
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An age-old metal joining techniques:
BRAZING & SOLDERING
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THERMIT WELDING (TW)
Thermit Powder
Molten Crucible
RAILS
Mould
Igniter
Molten metal flows down
developed in 1893
Flame heating gate
Thermit powder: Fe2O3 + 2Al = 2Fe + Al2O3
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THERMIT WELDING (TW)
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THERMIT WELDING (TW)
OPERATION – Manual skill .
TYPICAL APPLICATIONS – Confined to the railway tracks only, but can also be used for reinforced concrete bars & copper conductors & easy to use on site.
LIMITATIONS – Limited range of joints and materials., difficult to ensure consistency in it’s weld quality, slow & expansive, require a group of five people to work in tandem.
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Oxy-Acetylene Gas
Filler Rod
Gas
Flame
Weld Bead
OXY- FUEL GAS WELDING (OFW)
developed in 1904
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OPERATION – Manual skill.
ADVANTAGE –No power supply needed, low investment, highly - portable, excellent performance on Cast-iron, Cast-steel, depositing Tungsten-carbide & Stellite for hard surfacing.
TYPICAL APPLICATIONS – Repair & reclamation welding of motor vehicle parts, sheet metal & light fabrication welding.
OXY- FUEL GAS WELDING
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OXY-FUEL GAS CUTTING
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CARBON ARC WELDING (CAW)
Carbon electrode
AirFiller Rod Weld
Bead
Developed in 1884
1. Power source2. Holder cable3. Earth cable4. Work5. Carbon electrode & 6.Filler rod
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CARBON ARC GOUGING(C. A.
G.)
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CARBON/AIR ARC GOUGING (CAG)
1. Power source2. Holder cable3. Earth cable4. Work5. Carbon electrode & 6. Compressed Air.
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SHIELDED METAL ARC WELDING (SMAW)
_+_
1. Power source2. Holder cable3. Earth cable4. Work &5. Electrode
developed in 1907
MANUAL METAL ARC WELDING (MMAW)
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OPERATION – Manual skill. ADVANTAGE – Low capital investment, wide variety of application even in restricted areas.
TYPICAL APPLICATIONS – Ship building, Structural steel work, High-rise Buildings, Locomotive, Rail-road, Armament, Automotive, Transmission Pipeline, Mining, Repair & Construction of plant and machinery of all types. It is used for joining, rebuilding & hard-surfacing.
SHIELDED METAL ARC WELDING (SMAW)MANUAL METAL ARC WELDING (MMAW)
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An arch-bridge on river Chenab in Kashmir by Konkan Rly, Usage 26,000 Tons of steel,
1.3K.M. long & 359 M high > Affil tower (324M)
This will be the tallest bridge made within 30Months
Ref: www.bbchindi.com – dated 17th, Apr, 2006
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Mechanized wire feed
Mechanized arc tracking
SUBMERGED ARC WELDER (SAW)
Granulated SAW flux
developed in 1936
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SUBARC WELDER
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SUBARC WELDER
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WELDING POSITIONERS
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REBUILDING BY SAW
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SUBMERGED ARC WELDER (SAW)
OPERATION – Usually mechanized or automatic. ADVANTAGE – High deposition rate, high quality radiographic sound weld, invisible arc underneath the flux granules causes least fatigue to the operator.
TYPICAL APPLICATIONS – High quality pressure vessel, chemical plant, ship building, structural engineering component parts, and also for rebuilding & surfacing.
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Mechanized wire feed
FCAW - with or without external gas shield
Flux Cored Electrode
FLUX CORED ARC WELDING (FCAW)
developed in 1955
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OPERATION – Usually semi-automatic but also mechanized or automated, if the need arises. ADVANTAGE –High deposition rate, high quality weld for shop & site welding, it causes lesser fatigue than GMAW to the welder.
TYPICAL APPLICATIONS– Pressure vessel, chemical plant, pipe work, structural work, ship building, and also popular for rebuilding & surfacing on shop and site.
FLUX CORED ARC WELDING (FCAW)
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GAS-SHIELDED METAL ARC WELDING (GMAW)
GMAW , SIGMA, MIG/MAG or CO2/MIG Welding
Mechanized wire
feeding
Consumable
ElectrodeInert/active gas
feed
MIG developed in 1950 & MAG welding during 1953
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GAS-SHIELDED METAL ARC WELDING (GMAW)
OPERATION–Usually semi-automatic but also mechanized or robotic. ADVANTAGE – Continuous process with reduced finishing operation, high quality weld including in vertical down with extra low hydrogen.
TYPICAL APPLICATIONS – Light, medium & heavy fabrication such as ship-containers, light and heavy vehicle, earth movers, heavy machinery fabrication etc.
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GAS-SHIELDED METAL ARC WELDING (GMAW)
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Filler Rod
H2 gas
Tungsten Electrodes
~~
ATOMIC HYDROGEN WELDING (AHW)
developed in around 1940, but it was made to disappeare soon
OPERATION – Usually manual but also mechanized.
ADVANTAGE – Similar to those of GTAW process.
TYPICAL APPLICATIONS – Welds in thin materials particularly stainless steel; mechanized thin sheet welding.
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GTAW / TIG Welding
Inert gas feed
Filler rod
Non-consumable Tungsten Electrode
GAS-SHIELDED TUNGSTEN ARC WELDING (GTAW)
developed in 1942
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GAS-SHIELDED TUNGSTEN ARC WELDING
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OPERATION – Usually manual but also scarcely mechanized for tube to tube sheet & orbital welding. ADVANTAGE – Wide range of metals, produces high quality standard weld with extra low hydrogen.
TYPICAL APPLICATIONS– High quality weld in stainless steel for nuclear reactors, chemical & fertilizer plants, industrial piping, nickel alloys for aircraft engines, aluminum alloys for food industry.
GAS-SHIELDED TUNGSTEN ARC WELDING (GTAW)
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PAWFiller rod
Plasma gas
Shielding Gas
PLASMA ARC WELDING (PAW)
+
developed in 1959
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TRANSFER & NON-TRANSFER PLASMA ARC
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PLASMA ARC WELDING (PAW)
OPERATION – Usually mechanized. ADVANTAGE – Wide range of metals, produces high quality deep penetration weld with extra low hydrogen.
TYPICAL APPLICATIONS– High quality weld in stainless steel sheet foil butt welds, electronics cans, thermo couples, bellows, capsuls, filters by MPW and high speed tube manufacturing, high speed unprepared butt joint making in chemical plant.
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E.B.W. Gun
Beam alignment coil
Optics
Vacuum Chamber
Deflection Coil
Focus Coil
Work
ELECTRON BEAM WELDER (EBW)
developed in 1960
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OPERATION –Fully mechanized. ADVANTAGE – Excellent penetration; Low distortion; Non-contaminated weld; High speed welding; Ability to weld several non-weld-able materials. Any metal may be welded compatible with the vacuum while in molten state.
TYPICAL APPLICATIONS –Gear clusters/shafts joint; Turbine blade root joint; Fully mechanized.
ELECTRON BEAM WELDER (EBW)
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LASER BEAM WELDER (LBW)
Capacitor Bank
Flash tube
Focusing lens
Work
Laser beam
developed in 1967
OPERATION:Fully mechanized. ADVANTAGE: Wide range of materials.
TYPICAL APPLICATIONS:Continuous laser for the develop-mental activities; Pulsed laser for reputed application to some small assemblies such as electronic component parts.
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ELECTRO SLAG WELDER (ESW)
Electrode wire
Copper shoe
Weld metal
Work
Developed in 1956
OPERATION–Mechanized only. ADVANTAGE –Fast completion of thick joint in singular run.
TYPICAL APPLICATIONS – Thick wall pressure vessels; Thick civil engineering & structural fabric-ation work and Ship-building.
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CONSUMABLE GUIDE ESW
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COLD WELDING (CW)
Split die
Split die
ADVANTAGE – Large area of weld made in high conducting materials such as copper and aluminum; Low cost welding.
TYPICAL APPLICATIONS:Welding of copper overhead conductors for electric traction; Aluminum - copper joints for electric cables.
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FORGE WELDING (FOW)
Force
An age-old welding technique
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FORGE WELDING (FOW)
TECHNIQUE –Pressure welding .
OPERATION –Manual or mechanized. APPLICATION – Black-smith’s artistic iron ware only; dimensions not easily controlled and difficult to assure quality. Limited low carbon & some alloy steels only.
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~
~
ELECTRIC RESISTANCE SPOT WELDER (ERW)Developed in
1887
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RESISTANCE SPOT WELDER (ERW)
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OPERATION – Mechanized or robotized.ADVANTAGE – Consumable & skill is not required thus consistent weld quality with high productivity. Commonly used ferrous & non-ferrous metals but difficult to weld copper.
TYPICAL APPLICATIONS – Light fabrication from pressed sheet parts such as motor vehicle bodies, domestic washing machines, and cabinets for refrigerators etc.
ELECTRIC RESISTANCE SPOT WELDER (ERW)
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PROJECTION SPOT WELDER (RPW) ~
~Step-1
Step-2
Ideal for making multiple spots, where the spacing may be the designers constraint.
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RESISTANCE SEAM WELDER (RSEW)
~
~
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RESISTANCE FLASH-BUTT WELDER (FW)
~ ~
Developed in 1927
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RESISTANCE UPSET- BUTT WELDER (UW)
Upsetting
~ ~
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H.F. RESISTANCE BUTT WELDER (HFRW)
~ ~
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INDUCTION BUTT WELDER (IW)
~ ~
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CD STUD - WELDER
Step-1Step-2
~~
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ARC STUD – WELDER (SW)
Stud
Weld metal
Ceramic ferrule
Step-1
Step-2~ ~
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FRICTION WELDER (FRW)Developed in
1955
OPERATION – Mechanized. ADVANTAGE – Produces consistently high quality welds; Fast joining of large area; Suitable for wide range of materials; Mechanized & works on simple principle; & Consumable is not required.
TYPICAL APPLICATIONS –Internal combustion engin valves; Head to stem joint of dissimilar metals; Stud welding; Rear axle casings; Transmission and steering components for vehicles and Electrical part connections .
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EXPLOSIVE WELDING (EXW)
Flyer plate
Explo-siveBuffe
r
APPLICATIONS – Manufacture of steel to aluminum or copper transition pieces for fabrication; Cladding steel parent plate; Tube - to -tube sheet joints. The wide range of metals studied to date give good results The process is particularly suited to dissimilar metals.
ADVANTAGE –Cladding large plates without preheat; Suitable for wide range of dissimilar metals; Fast as a large area is joined in single shot.
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PROCESSES & THEIR LETTER DESIGNATIONS
LETTER DESIGNATION
WELDING PROCESS
GROUPArc welding
Carbon Arc Flux Cored ArcGas Metal ArcGas Tungsten ArcPlasma Arc Shielded Metal ArcStud ArcSubmerged Arc
CAW FCAWGMAW GTAWPAW SMAWSWSAW
Brazing
Diffusion Brazing Dip Brazing Furnace BrazingInduction Brazing Infrared BrazingResistance BrazingTorch Brazing
DFBDBFB IB IRBRB TB
Continued …
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Oxyfuel Gas Welding
Oxyacetylene WeldingOxyhydrogen Welding Pressure Gas Welding
OAWOHW PGW
Resistance Welding Flash Welding High Frequency Resistance Percussion WeldingProjection Welding Resistance-Seam WeldingResistance-Spot Welding Upset Welding
FWHFRW PEWRPW RSEWRSW UW
Solid State Welding
Cold WeldingDiffusion Welding Explosion WeldingForge WeldingFriction WeldingHot Pressure WeldingRoll Welding Ultrasonic Welding
CW DFW EXW FOWFRW HPWROW USW
PROCESSES & THEIR LETTER DESIGNATIONS
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Soldering
Other Welding Processes
Dip SolderingFurnace SolderingInduction SolderingInfrared SolderingIron Soldering Resistance SolderingTorch Soldering Wave Soldering
DSFS IS IRSINSRSTS WS
Electron Beam Welding Electro Slag Welding Induction Welding Laser Beam WeldingThermit Welding
EBW ESWIWLBW TW
PROCESSES & THEIR LETTER DESIGNATIONS
Ref: AWS