Welding Technology a Suncam Continuing Education Course
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Fundamentals of Joining Processes
Outline ME3072 – MANUFACTURING ENGINEERING II BSc Eng (Hons) in Mechanical Engineering • Introduction to Welding Semester - 4 • Fusion-Welding Processes • Solid-State Welding Processes Fundamentals of Joining • Metallurgy of Welding Processes • Weld Quality • Brazing & Soldering Prepared By : R.K.P.S Ranaweera BSc (Hons) MSc Lecturer - Department of Mechanical Engineering University of Moratuwa 2 (for educational purpose only) Joining Processes Classification of Joining Processes 3 4 1 Introduction to Welding • Attention must be given to the cleanliness of the metal surfaces prior to welding and to possible • Is a process by which two materials, usually metals oxidation or contamination during welding process. are permanently joined together by coalescence, which is induced by a combination of temperature, • Production of high quality weld requires: pressure and metallurgical conditions. Source of satisfactory heat and/or pressure Means of protecting or cleaning the metal • Is extensively used in fabrication as an alternative Caution to avoid harmful metallurgical effects method for casting or forging and as a replacement for bolted and riveted joints. Also used as a repair • Advantages of welding over other joints: medium to reunite metals. Lighter in weight and has a great strength • Types of Welding: High corrosion resistance Fusion welding Fluid tight for tanks and vessels Solid-state (forge) welding Can be altered easily (flexibility) and economically 5 6 • Weldability has been defined as the capacity of • Steps in executing welding: metal to be welded under the fabrication conditions Identification of welds, calculation of weld area by stress imposed into a specific, suitably designed structure analysis, preparation of drawings & to perform satisfactorily in the intended service. -
Gas-Shielded Arc Welding TIG Welding
Gas-Shielded Arc Welding Gas-shielded welding can be divided into the tungsten gas-shielded welding and the metal gas-shielded welding processes. The tungsten gas-shielded welding covers the processes − Tungsten plasma arc welding (PAW) − Inert-gas tungsten-arc welding (TIG), whereby TIG welding is the most widely used fusion welding process for aluminium. The plasma welding consists only of the plasma-arc welding process which works with a transferred arc. The metal shielded-gas welding is limited to the metal inert-gas welding process operating with an inert gas as shield, as well as a process combination with plasma welding (plasma metal shielded-gas welding - PMIG). The abbreviations used are: GAW Gas-shielded arc welding GMGMMA Gas-mixture shielded metal-arc welding GTAW Gas-shielded tungsten arc welding (MAGM) GMAW Gas-shielded metal arc welding MAGC CO2-shielded metal-arc welding AHW Atomic hydrogen welding NGW Narrow-gap welding CAW Constricted arc welding EGW Electro -gas welding TIG Tungsten inert-gas arc welding PMIG Plasma MIG welding MIG Metal inert-gas arc welding MAG Metal active-gas arc welding p Pulsed arc PJW Plasma jet welding sh Short arc PAW Plasma arc welding sp Spray arc PJPW Plasma jet plasma arc welding l Long arc TIG Welding Principle of TIG Welding TIG welding equipment Watercooled TIG welding torch Torch forms for TIG welding Shielding gases for welding and cutting Flow meters Flow meter for torches Effect of current and inert gas Argon consumption for TIG welding Tungsten electrodes -
Welding Process Reference Guide
Welding Process Reference Guide gas arc welding…………………..GMAW -pulsed arc…………….……….GMAW-P atomic hydrogen welding……..AHW -short circuiting arc………..GMAW-S bare metal arc welding…………BMAW gas tungsten arc welding…….GTAW carbon arc welding……………….CAW -pulsed arc……………………….GTAW-P -gas……………………………………CAW-G plasma arc welding……………..PAW -shielded……………………………CAW-S shielded metal arc welding….SMAW -twin………………………………….CAW-T stud arc welding………………….SW electrogas welding……………….EGW submerged arc welding……….SAW Flux cord arc welding…………..FCAW -series………………………..…….SAW-S coextrusion welding……………...CEW Arc brazing……………………………..AB cold welding…………………………..CW Block brazing………………………….BB diffusion welding……………………DFW Diffusion brazing…………………….DFB explosion welding………………….EXW Dip brazing……………………………..DB forge welding…………………………FOW Flow brazing…………………………….FLB friction welding………………………FRW Furnace brazing……………………… FB hot pressure welding…………….HPW SOLID ARC Induction brazing…………………….IB STATE BRAZING WELDING Infrared brazing……………………….IRB roll welding…………………………….ROW WELDING (8) ultrasonic welding………………….USW (SSW) (AW) Resistance brazing…………………..RB Torch brazing……………………………TB Twin carbon arc brazing…………..TCAB dip soldering…………………………DS furnace soldering………………….FS WELDING OTHER electron beam welding………….EBW induction soldering……………….IS SOLDERING PROCESS WELDNG -high vacuum…………………….EBW-HV infrared soldering…………………IRS (S) -medium vacuum………………EBW-MV iron soldering……………………….INS -non-vacuum…………………….EBW-NV resistance soldering…………….RS electroslag welding……………….ESW torch soldering……………………..TS -
UNIT-IV Metal Joining Processes
Manufacturing Process - I UNIT –IV Metal Joining Processes Prepared By Prof. Shinde Vishal Vasant Assistant Professor Dept. of Mechanical Engg. NDMVP’S Karmaveer Baburao Thakare College of Engg. Nashik Contact No- 8928461713 E mail:- [email protected] Website:- www.vishalshindeblog.wordpress.com 06/09/2016 PROF.V.V.SHINDE NDMVP'S KBTCOE NASHIK JOINING PROCESSES • Joining includes welding, brazing, soldering, adhesive bonding of materials. • They produce permanent joint between the parts to be assembled. • They cannot be separated easily by application of forces. • They are mainly used to assemble many parts to make a system. • Welding is a metal joining process in which two or more parts are joined or coalesced at their contacting surfaces by suitable application of heat or/and pressure. • Some times, welding is done just by applying heat alone, with no pressure applied • In some cases, both heat and pressure are applied; and in other cases only pressure is applied, without any external heat. • In some welding processes a filler material is added to facilitate coalescence(Joining)06/09/2016 PROF.V.V.SHINDE NDMVP'S KBTCOE NASHIK Joining Processes: Welding, Brazing, Soldering 1. Brazing and Soldering: Melting of filler rod only • Brazing: higher temperature, ~brass filler, strong • Soldering: lower temp, ~tin-lead filler, weak 2. Welding: Melting of filler rod and base metals 06/09/2016 PROF.V.V.SHINDE NDMVP'S KBTCOE NASHIK Advantages of welding: • Welding provides a permanent joint. • Welded joint can be stronger than the parent materials if a proper filler metal is used that has strength properties better than that of parent base material and if defect less welding is done. -
Lecture: 3 Classification of Welding Processes II Apart from Technical
Lecture: 3 Classification of Welding Processes II Apart from technical factors, welding processes can also be classified on the fundamental approaches used for deposition of materials for developing a joint. This chapter presents the classification of welding processes as welding processes and allied process used for developing a joint Keywords: Welding and allied processes, approach of classification, cast weld, resistance weld, fusion weld, solid state weld 3.1 Classification of welding processes There is another way of classifying welding and allied processes which is commonly reported in literature. Various positive processes involving addition or deposition of metal are first broadly grouped as welding process and allied welding processes as under: 1. Welding processes i. Cast weld processes ii. Fusion weld processes iii. Resistance weld processes iv. Solid state weld processes 2. Allied welding processes i. Metal depositing processes ii. Soldering iii. Brazing iv. Adhesive bonding v. Weld surfacing vi. Metal spraying This approach of classifying the welding process is primarily based on the way metallic pieces are united together during welding such as Availability and solidification of molten weld metal between components being joined are similar to that of casting: Cast weld process. Fusion of faying surfaces for developing a weld: Fusion weld process Heating of metal only to plasticize then applying pressure to forge them together: Resistance weld process Use pressure to produce a weld joint in solid state only: Solid state weld process 3.2 Cast welding process Those welding processes in which either molten weld metal is supplied from external source or melted and solidified at very low rate during solidification like castings. -
Arc Welding • Electric Arc Is Produced When Current Flows Across the Air Gap Between the End of Metal Electrode and Work Surface
Arc welding • Electric arc is produced when current flows across the air gap between the end of metal electrode and work surface. • Electric discharge occurring in the air gap. • The temperature at centre of arc is 6500C. • Only 3600C is utilized for melting of metal. • Arc welding is a welding process that is used to join metal to metal by using electricity to create enough heat to melt metal, and the melted metals when cool result in a binding of the metals. • Equipments: • Transformer: To change high voltage and low amperage to a low voltage 20-80 V and high 80- 500 amps. • In arc welding, the voltage is directly related to the length of the arc, and the current is related to the amount of heat input. • Generator: Driven by motor. Generates D.C. • Rectifier: The output of step down transformer is to rectifier to converts A.C. to D.C. • Electrode: Metal stick to create arc. A.C.plant: • Simple, less cost, No moving parts, low maintenance cost, no change of polarity. • Gives smoother arc when using high current. • Not suitable for non-ferrous and thin sheets. • Electric shock is more intense. • D.C.Plant • Can be used for ferrous ,non-ferrous & thin sheets • Stable arc, fine settings are possible • Easy of operation, suitable for over head welding. • Safer to use. • More expensive, high maintenance cost, arc blow(arc is forced away from weld point). • Polarity: It indicates the direction of current flow in D.C. In D.C. 2/3 of heat is liberated from + end and 1/3 of heat is liberated from - end. -
Boilermaking Manual. INSTITUTION British Columbia Dept
DOCUMENT RESUME ED 246 301 CE 039 364 TITLE Boilermaking Manual. INSTITUTION British Columbia Dept. of Education, Victoria. REPORT NO ISBN-0-7718-8254-8. PUB DATE [82] NOTE 381p.; Developed in cooperation with the 1pprenticeship Training Programs Branch, Ministry of Labour. Photographs may not reproduce well. AVAILABLE FROMPublication Services Branch, Ministry of Education, 878 Viewfield Road, Victoria, BC V9A 4V1 ($10.00). PUB TYPE Guides Classroom Use - Materials (For Learner) (OW EARS PRICE MFOI Plus Postage. PC Not Available from EARS. DESCRIPTORS Apprenticeships; Blue Collar Occupations; Blueprints; *Construction (Process); Construction Materials; Drafting; Foreign Countries; Hand Tools; Industrial Personnel; *Industrial Training; Inplant Programs; Machine Tools; Mathematical Applications; *Mechanical Skills; Metal Industry; Metals; Metal Working; *On the Job Training; Postsecondary Education; Power Technology; Quality Control; Safety; *Sheet Metal Work; Skilled Occupations; Skilled Workers; Trade and Industrial Education; Trainees; Welding IDENTIFIERS *Boilermakers; *Boilers; British Columbia ABSTRACT This manual is intended (I) to provide an information resource to supplement the formal training program for boilermaker apprentices; (2) to assist the journeyworker to build on present knowledge to increase expertise and qualify for formal accreditation in the boilermaking trade; and (3) to serve as an on-the-job reference with sound, up-to-date guidelines for all aspects of the trade. The manual is organized into 13 chapters that cover the following topics: safety; boilermaker tools; mathematics; material, blueprint reading and sketching; layout; boilershop fabrication; rigging and erection; welding; quality control and inspection; boilers; dust collection systems; tanks and stacks; and hydro-electric power development. Each chapter contains an introduction and information about the topic, illustrated with charts, line drawings, and photographs. -
Red Rocks Community College 1997-98 Catalog
Red Rocks Community College 1997-98 Catalog CollegeSource Career Guidance Foundation • 1-800-854-2670 • http://www.cgf.org Copyright & Disclaimer Information Copyright© 1994, 1995, 1996,1997 Career Guidance Foundation CollegeSource digital catalogs are derivitave works owned and copyrighted by Career Guidance Foundation. Catalog content is owned and copyrighted by the appropriate school. While the Career Guidance Foundation provides information as a service to the public, copyright is retained on all material. This means you may NOT: · distribute the material to others, · "mirror" or include this material on an Internet (or Intranet) server, or · modify or re-use material without the express written consent of the Career Guidance Foundation and the appropriate school. You may: · print copies of the information for your own personal use, · store the files on your own computer for personal use only, or · reference this material from your own documents. The Career Guidance Foundation reserves the right to revoke such authorization at any time, and any such use shall be discontinued immediately upon written notice from the Career Guidance Foundation. Disclaimer CollegeSource digital catalogs are converted from either the original printed catalog or electronic media supplied by each school. Although every attempt is made to ensure accurate conversion of data, the Career Guidance Foundation and the schools which provide the data do not guarantee that the this information is accurate or correct. The information provided should be used only as reference and planning tools. Final decisions should be based and confirmed on data received directly from each school. What do our students learn? First, they learn about learning. -
05/09/16 05/09/16 Rc-Upf Dmc Rc
UPF PROJECT PROCEDURE Title: UPF WELDING AND CUTTING SAFETY Document Number: UPF-CP-225WCS Revision: 000 Page: 1 of 13 Prepared by: . 05/09/16 . Brian Garrett, Date BNI UPF ES&H Lead Approved by: . 05/09/16 . Ed Kelley, Date BNI UPF ES&H Manager Approved by: . 05/09/16 . Gary Hagan, Date UPF ES&H Manager Concurrence by: . 05/09/16 . Lynn Nolan, Date UPF Manager of Construction . 05/10/16 . James W. Sowers, Date UPF Quality Assurance Manager 05/11/16 Effective Date RC-UPF DMC This document has been reviewed by a Y-12 DC / RC-UPF DMC UCNI-RO and has been determined to be 05/10/16 15:15 UNCLASSIFIED and contains no UCNI. This review 05/10/16 15:32 does not constitute clearance for Public Release. Name:________________________ Date:__________05/09/16 UPF-CP-225WCS Revision 00 Page 2 of 13 UPF Welding and Cutting Safety Revision History Revision Reason/Description of Change Initial issue. 000 UPF-CP-225WCS Revision 00 Page 3 of 13 UPF Welding and Cutting Safety Table of Contents 1.0 PURPOSE ..................................................................................................................................4 2.0 GENERAL ..................................................................................................................................4 Description ....................................................................................................................4 Acronyms .......................................................................................................................4 Definitions ......................................................................................................................4 -
Kabila, Laurent-Desiré (1939–2001). Congolese Politician. a Guerilla and Bandit for 30 Years, His Forces Overthrew *Mobutu In
1912 and 1917, he had a relationship with Felice Bauer (1887–1960). They were twice engaged but never married. (He wrote her 500 letters but they only met 17 times.) Kafka had the smallest output of any K major writer, three short novels (all unfinished), one novella, 23 short stories, diaries and five collections of Kabila, Laurent-Desiré (1939–2001). Congolese letters, almost all published posthumously. He lived politician. A guerilla and bandit for 30 years, his forces briefly with two unhappily married women. overthrew *Mobutu in July 1997 and he became The novella Metamorphosis (Die Verwandlung), President of the Democratic Republic of the Congo published in 1915, is famous for the image of the (formerly Zaire). Assassinated in January 2001 by his central character Gregor Samsa waking to find bodyguard, 135 people were tried, mostly convicted himself transformed into ‘a monstrous vermin’, which but apparently not executed. His son Joseph is usually rendered in English as an insect or beetle. Kabila Kabange (1971– ) was President of the DRC Kafka does not explain why the transformation 2001–19. In 2018, a corrupt and violent election was occurred. won by an opposition candidate Félix Tshisekedi; a bizarre result that appeared to be a democratic He suffered from tuberculosis of the larynx, died transition but was engineered to guarantee Kabila’s —essentially of starvation—in a sanatorium at continuing influence and preservation of his family’s Klosterneuburg, near Vienna, and was buried in wealth. Prague. He left instructions that his literary works be burnt, unread, but his friend and executor Max Brod Kaczyński, Jarosław (1949– ) and Lech Aleksander (1882–1968) ignored the direction and published Kaczyński (1949–2010). -
Basic Metallurgy
Welding Welding or more generally Joining involves putting two or more pieces together in such a way that they behave as a single piece. This may involve applying some kind of pressure or heat or both to the pieces to be joined together. Welding provides metallurgical continuity, while mechanical joining process like riveting does not provide metallurgical continuity. Definition Localized coalescence of metals produced either by heating the material to the required welding temperature, with or without the application of pressure or by the application of pressure alone, with or without the use of filler materials.” Advantages of Welding • Welding has proved to be most efficient way of creating new shapes. There is maximum saving of the material. • It is suitable for single or one off piece or for large numbers of similar jobs. • Individual components produced by different shaping route such as forging, rolling or casting can joined together by welding. • Very large to small components can be made by welding. • Riveting and bolting involves material wastages as it leads to heavier structures. • Riveted joints are prone to fatigue failures and crevice corrosion attack. • Welding methods are open for automation and use of ROBOTS. Classification of Welding a) Fusion Welding processes: Fusion welding is carried out by simultaneous melting of the edges of the pieces to be joined, allowing the molten metal to mix together and solidify as a single piece to bridge the gap between two components, thus melted and solidified metal becomes part of the joint. Additional molten metal can be added either through electrodes or through filler metal. -
Chapter 6 Arc Welding
Revised Edition: 2016 ISBN 978-1-283-49257-7 © All rights reserved. Published by: Research World 48 West 48 Street, Suite 1116, New York, NY 10036, United States Email: [email protected] Table of Contents Chapter 1 - Welding Chapter 2 - Fabrication (Metal) Chapter 3 - Electron Beam Welding and Friction Welding Chapter 4 - Oxy-Fuel Welding and Cutting Chapter 5 - Electric Resistance Welding Chapter 6 - Arc Welding Chapter 7 - Plastic Welding Chapter 8 - Nondestructive Testing Chapter 9 - Ultrasonic Welding Chapter 10 - Welding Defect Chapter 11 - Hyperbaric Welding and Orbital Welding Chapter 12 - Friction Stud Welding Chapter 13 WT- Welding Joints ________________________WORLD TECHNOLOGIES________________________ Chapter 1 Welding WT Gas metal arc welding ________________________WORLD TECHNOLOGIES________________________ Welding is a fabrication or sculptural process that joins materials, usually metals or thermoplastics, by causing coalescence. This is often done by melting the workpieces and adding a filler material to form a pool of molten material (the weld pool) that cools to become a strong joint, with pressure sometimes used in conjunction with heat, or by itself, to produce the weld. This is in contrast with soldering and brazing, which involve melting a lower-melting-point material between the workpieces to form a bond between them, without melting the workpieces. Many different energy sources can be used for welding, including a gas flame, an electric arc, a laser, an electron beam, friction, and ultrasound. While often an industrial process, welding can be done in many different environments, including open air, under water and in outer space. Regardless of location, welding remains dangerous, and precautions are taken to avoid burns, electric shock, eye damage, poisonous fumes, and overexposure to ultraviolet light.