Welding and Joining Guidelines
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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. -
Formation and Distribution of Porosity in Al-Si Welds
Formation and Distribution of Porosity in Al-Si Welds by Pierre-Alexandre LEGAIT A Thesis Submitted to the Faculty Of the WORCESTER POLYTECHNIC INSTITUTE In partial fulfillment of the requirements for the Degree of Masters of Science In Material Science and Engineering By May 2005 APPROVED: Diran Apelian, Howmet Professor of Mechanical Engineering, Advisor Richard D. Sisson Jr., George F. Fuller Professor of Mechanical Engineering Material Science and Engineering, Program Head ABSTRACT Aluminum alloys are the subject of increasing interest (in the automotive industry, as well as aircraft industry), aiming to reduce the weight of components and also allowing a profit in term of energy saving. Concerning the assembly, riveting has been widely used in the aircraft industry, whereas welding seems to be promising in the car industry in the case of aluminum alloys. Nevertheless, welding can generate defects, such as porosity or hot cracking, which could limit its development. One of the major problems associated with the welding of aluminum alloys is the formation of gas porosity. Aluminum alloy cleanliness remaining one of the aluminum industry’s primary concerns, this project focuses on the formation and distribution of porosity in Al-Si welds. A literature review has been performed, to identify the mechanisms of porosity formation in welds and castings. Porosity distribution in welds has been investigated, based on three different welding techniques: hybrid Laser/MIG welding process, the electron beam welding process, and the MIG dual wire welding process. Porosity distribution results provide information on to the porosity formation mechanisms involved during welding. A complete microstructure, microhardness and EDX analysis have been carried out, to describe and quantify the solidification process within the welds. -
MTI Friction Welding Technology Brochure
Friction Welding Manufacturing Technology, Inc. All of us at MTI… would like to extend our thanks for your interest in our company. Manufacturing Technology, Inc. has been a leading manufacturer of inertia, direct drive and hybrid friction welders since 1976. We hope that the following pages will further spark your interest by detailing a number of our products, services and capabilities. We at MTI share a common goal…to help you solve your manufacturing problems in the most Table of Contents efficient way possible. Combining friction welding Introduction to Friction Welding 2 with custom designed automation, we have Advantages of MTI’s Process 3 demonstrated dramatic savings in labor and Inertia Friction Welding 4 material with no sacrifice to quality. Contact us Direct Drive & Hybrid Friction Welding 5 today to find out what we can do for you. Machine Monitors & Controllers 6 Safety Features 7 Flash Removal 7 MTI Welding Services 8 Weldable Combinations 9 Applications Aircraft/Aerospace 10 Oil Field Pieces 14 Military 16 Bimetallic & Special 20 Agricultural & Trucking 22 Automotive 28 General 38 Special Welders & Automated Machines 46 Machine Models & Capabilities 48 Friction Welding 4 What It Is Friction welding is a solid-state joining process that produces coalescence in materials, using the heat developed between surfaces through a combination of mechanically induced rubbing motion and Information applied load. The resulting joint is of forged quality. Under normal conditions, the faying surfaces do not melt. Filler metal, flux and shielding gas are not required with this process. Dissimilar Materials Even metal combinations not normally considered compatible can be joined by friction welding, such as aluminum to steel, copper to aluminum, titanium to copper and nickel alloys to steel. -
Parameter Optimization of Gas Metal Arc Welding Process on Duplex 2205 Stainless Steel Using Irb1410 Arc Welding Robot
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 08 Issue: 03 | Mar 2021 www.irjet.net p-ISSN: 2395-0072 PARAMETER OPTIMIZATION OF GAS METAL ARC WELDING PROCESS ON DUPLEX 2205 STAINLESS STEEL USING IRB1410 ARC WELDING ROBOT Anand Jayakumar A1, Yash Nigam2, Vighneswaran C3, Surender S4 1Asst. Professor, Dept. of Mechanical Engineering, Sri Ramakrishna Institute of Technology, India 2,3,4Student, Dept. of Mechanical Engineering, Sri Ramakrishna Institute of Technology, India ---------------------------------------------------------------------***---------------------------------------------------------------------- Abstract - This review paper outline the recent research consumable MIG wire electrode and the workpiece metal(s), works on parameter optimization of duplex 2205 stainless which will heats the workpiece metal(s), causing them to steel using IRB1410 arc welding robot. Gas metal arc welding melt and join. Gas metal arc welding, also known as metal (GMAW) process has widely been employed due to the wide inert gas (MIG) welding, uses a continuous solid wire range of applications, cheap consumables and easy handling. A electrode that travels through the welding gun, which is suitable model is needed to investigate the characteristics of accompanied by a shielding gas to protect it from the effects of process parameters on the bead geometry in the contaminants. Gas metal arc welding (GMAW) is a welding GMA welding process in order to achieve a high level of processby an arc in which the source of heat is an arc is welding performance and quality. This paper is intended to formed between the consumable metal electrode and the represent new algorithms in the robotic GMA welding process work piece with an externally supplied gaseous shield of to predict process parameters on top-bead distance. -
GSS-124 Welding Fabrication for Gunsmiths 1.0 Unit
Lassen Community College Course Outline GSS-124 Welding Fabrication for Gunsmiths 1.0 Unit I. Catalog Description Students will select and fabricate gunsmith related projects using appropriate welding processes and techniques. Students will also have an opportunity to learn or improve welding skills related to the gunsmith vocation. Does Not Transfer to UC/CSU 50 Hours Lab Scheduled: II. Coding Information Repeatability: Take 1 Time Grading Option: Pass/No Pass Only Credit Type: Credit - Not Degree Applicable TOP Code: 095650 III. Course Objectives A. Course Student Learning Outcomes Upon completion of this course the student will be able to: Safely handle equipment to gas tungsten weld selected joint designs to critical industry standards. B. Course Objectives Upon completion of this course the student will be able to: 1. Explain the setup of both oxygen/acetylene welding and cutting. 2. Demonstrate correct project layout. 3. Demonstrate oxy/ace cutting. 4. Employ oxygen/acetylene welding to construct project. 5. Demonstrate setup of SMAW machine. 6. Identify and select correct electrodes. 7. Fabricate project using SMAW. 8. Demonstrate cleanup procedures. IV. Course Content A. Safety precautions 1. Electrical shock 2. Radiation hazards 3. Compressed gases 4. Air contamination 5. Emergency shop procedures B. Oxyacetylene welding 1. T-joints 2. Open butt joint - flat C. Shielded metal arc welding 1. T-joint - flat 2. T-joint - vertical GSS-124 Welding Fabrication for Gunsmiths Page 1 D. Gas metal arc welding 1. T-joint - flat 2. T-joint - vertical E. Gas tungsten arc welding 1. T-joint - flat 2. T-joint - vertical F. Cutting 1. -
Guidelines for the Welded Fabrication of Nickel-Containing Stainless Steels for Corrosion Resistant Services
NiDl Nickel Development Institute Guidelines for the welded fabrication of nickel-containing stainless steels for corrosion resistant services A Nickel Development Institute Reference Book, Series No 11 007 Table of Contents Introduction ........................................................................................................ i PART I – For the welder ...................................................................................... 1 Physical properties of austenitic steels .......................................................... 2 Factors affecting corrosion resistance of stainless steel welds ....................... 2 Full penetration welds .............................................................................. 2 Seal welding crevices .............................................................................. 2 Embedded iron ........................................................................................ 2 Avoid surface oxides from welding ........................................................... 3 Other welding related defects ................................................................... 3 Welding qualifications ................................................................................... 3 Welder training ............................................................................................. 4 Preparation for welding ................................................................................. 4 Cutting and joint preparation ................................................................... -
Keyhole Gas Tungsten Arc Welding: a New Process Variant Brian Laurence Jarvis University of Wollongong
University of Wollongong Research Online University of Wollongong Thesis Collection University of Wollongong Thesis Collections 2001 Keyhole gas tungsten arc welding: a new process variant Brian Laurence Jarvis University of Wollongong Recommended Citation Jarvis, Brian Laurence, Keyhole gas tungsten arc welding: a new process variant, Doctor of Philosophy thesis, Faculty of Engineering, University of Wollongong, 2001. http://ro.uow.edu.au/theses/1833 Research Online is the open access institutional repository for the University of Wollongong. For further information contact the UOW Library: [email protected] Keyhole Gas Tungsten Arc Welding: a new process variant. tSS!1' This photograph is an end-on view of keyhole GTAW on 8mm wall-thickness stainless steel pipe. Certification I, Brian Laurence (Laurie) Jarvis, declare that this thesis, submitted in fulfilment of the requirements for the award of Doctor of Philosophy, in the Department of Mechanical Engineering, University of Wollongong, is wholly my own work unless otherwise referenced or acknowledged. The document has not been submitted for qualifications at any other academic institution. Brian Laurence Jarvis 15m July 2001. Keyhole Gas Tungsten Arc Welding: a new process variant By Brian Laurence Jarvis B.Sc. (Hons) Flinders University, 1975 Thesis Submitted in fulfilment of the requirements for the degree of Doctor of Philosophy in Mechanical Engineering, Faculty of Engineering, University of Wollongong June 2001. Wollongong, New South Wales 1 Dedication To my Mother and Father Acknowledgements I wish to thank my adviser and supervisor, Professor Michael West, for his support and direction during this investigation. Special thanks are also due to my co-supervisor, colleague and friend, Dr Nasir Ahmed for laying the foundations for this work, and for his continued encouragement and support. -
Analysis of Metal Transfer in Gas Metal Arc Welding
Analysis of Metal Transfer in Gas Metal Arc Welding This study shows that the transition of metal transfer mode in gas metal arc welding occurs much more gradually than is generally believed BY Y-S. KIM AND T. W. EAGAR ABSTRACT. Droplet sizes produced in transfer. These transfer modes show dif- metal transfer phenomenon. These have GMAW are predicted using both the ferent arc stabilities, weld pool penetra- had limited success. static force balance theory and the pinch tions, spatter production, porosity pop- In this study, the droplet size and instability theory as a function of weld- ulation and level of gas entrapment. droplet transfer frequency are analyzed ing current, and the results are compared Lesnewich (Ref. 1) showed that the mode both theoretically and experimentally. with experimental measurements. The of metal transfer depends on many op- In the first section of this paper, the equi- causes for the deviation of predicted erational variables such as welding cur- librium drop sizes are calculated using droplet size from measured size are dis- rent, electrode extension, electrode di- the static force balance analysis and the cussed with suggestions for modification ameter and polarity. Later, A. A. Smith pinch instability analysis. In the second of the theories in order to more accu- (Ref. 2) reported that an entirely differ- section of this paper, measurements of rately model metal transfer in GMAW. ent type of metal transfer mode is pro- droplet si'ze at different welding currents The mechanism of repelled metal trans- duced when using carbon dioxide gas are compared with the theoretical pre- fer is also discussed. -
Submerged Arc Welding
SAMPLE Welding Process Training Series Submerged Arc Welding 265558 Submerged Arc Welding CC 2014_EN.indd 1 4/17/15 15:35 SAFETY Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060 Arc Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (Phone: 800-463- Welding 6727, website: www.csa-international.org). Safe Practice For Occupational And Educational Eye And Face Protec- and Cutting tion, ANSI Standard Z87.1, from American National Standards Insti- tute, 25 West 43rd Street, New York, NY 10036 (Phone: 212-642-4900, the website: www.ansi.org). Safe Way! Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, Quincy, MA 02269 (Phone: 1-800-344-3555, website: www.nfpa.org.) OSHA, Occupational Safety and Health Standards for General Indus- try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart As in all occupations, safety is paramount. Because there are Q, and Part 1926, Subpart J, from U.S. Government Printing Of- numerous safety codes and regulations in place, we recommend fice, Superintendent of Documents, P.O. Box 371954, Pittsburgh, that you always read all labels and the Owner’s Manual carefully PA 15250-7954 (Phone: 1-866-512-1800) (There are 10 OSHA Re- before installing, operating, or servicing the unit. Read the safety gional Offices—phone for Region 5, Chicago, is 312-353-2220, information at the beginning of the manual and in each section. website: www.osha.gov). Also read and follow all applicable safety standards, especially Booklet, TLVs, Threshold Limit Values, from American Confer- ANSI Z49.1, Safety in Welding, Cutting, and Allied Processes. -
Laser Beams a Novel Tool for Welding: a Review
IOSR Journal of Applied Physics (IOSR-JAP) e-ISSN: 2278-4861.Volume 8, Issue 6 Ver. III (Nov. - Dec. 2016), PP 08-26 www.iosrjournals.org Laser Beams A Novel Tool for Welding: A Review A Jayanthia,B, Kvenkataramananc, Ksuresh Kumard Aresearch Scholar, SCSVMV University, Kanchipuram, India Bdepartment Of Physics, Jeppiaar Institute Of Technology, Chennai, India Cdepartment Of Physics, SCSVMV University, Kanchipuram, India Ddepartment Of Physics, P.T. Lee CNCET, Kanchipuram, India Abstract: Welding is an important joining process of industrial fabrication and manufacturing. This review article briefs the materials processing and welding by laser beam with its special characteristics nature. Laser augmented welding process offers main atvantages such as autogenous welding, welding of high thickness, dissimilar welding, hybrid laser welding, optical fibre delivery, remote laser welding, eco-friendly, variety of sources and their wide range of applications are highlighted. Significance of Nd: YAG laser welding and pulsed wave over continuous wave pattern on laser material processesare discussed. Influence of operating parameter of the laser beam for the welding process are briefed including optical fibre delivery and shielding gas during laser welding. Some insight gained in the study of optimization techniques of laser welding parameters to achieve good weld bead geometry and mechanical properties. Significance of laser welding on stainless steels and other materials such as Aluminium, Titanium, Magnesium, copper, etc…are discussed. I. INTRODUCTION Welding is the principal industrial process used for joining metals. As materials continue to be highly engineered in terms of metallic and metallurgical continuity, structural integrity and microstructure, hence, welding processes will become more important and more prominent. -
Tendencies in Development of Plasma-Arc Welding of Aluminium Alloys*
MAIN TENDENCIES IN DEVELOPMENT OF PLASMA-ARC WELDING OF ALUMINIUM ALLOYS* A.A. GRINYUK2, 3, V.N. KORZHIK1, 2, V.E. SHEVCHENKO1, 2, A.A. BABICH2, S.I. PELESHENKO4, V.G. CHAJKA2, A.F. TISHCHENKO2 and G.V. KOVBASENKO2 1Chinese-Ukrainian E.O. Paton Welding Institute (Guangdong General Research Institute of Industrial Technology) (Guangzhou Research Institute of Non-Ferrous Metals, PRC) 2E.O. Paton Electric Welding Institute, NASU 11 Bozhenko Str., 03680, Kiev, Ukraine. E-mail: [email protected] 3NTUU «Kiev Polytechnic Institute» 6/2 Dashavskaya Str., 03056, Kiev, Ukraine. E-mail: [email protected] 4South China University of Technology 510641, Guangzhou, PRC. E-mail: [email protected] Publications, describing the characteristic technologies of aluminium alloy welding by an arc constricted by high-velocity inert gas flow were analyzed. It is shown that plasma-arc welding (PAW) is further development of the process of nonconsumable-electrode inert-gas welding. It is established that during development of PAW of aluminium alloys, there was a transition from alternating sinusoidal current to reverse polarity direct current, and furtheron to variable polarity asymmetrical current with rectangular current waveform. A more promising direction of improvement of PAW equipment is transition from specialized power sources to modular design of PAW system, based on power sources applied for noncon- sumable electrode welding and plasma modules. Further path of improvement of the processes of aluminium alloy PAW is combined or hybrid application of several heat sources, including the constricted arc and consumable-electrode arc. In the authors’ opinion, hybrid consumable-electrode PAW with hollow anode and axial wire feed in the most promising variant. -
Metal Casting and Welding (17ME45A)
[METAL CASTING AND WELDING – 17M45-A] Metal Casting and Welding (17ME45A) Prepared by: Prof. Sachin S Pande Dept of Mechanical Engineering, SECAB I E T-586109 Page 1 [METAL CASTING AND WELDING – 17M35-A] METAL CASTING AND WELDING [AS PER CHOICE ASED CREDIT SYSTEM (CBCS) SCHEME] SEMESTER – III Subject Code 17 ME 35 A IA Marks 20 Number of Lecture Hrs / Week 04 Exam Marks 80 Total Number of Lecture Hrs 50 Exam Hours 03 CREDITS – 04 COURSE OBJECTIVE 1) To provide detailed information about the moulding processes. 2) To provide knowledge of various casting process in manufacturing. 3) To impart knowledge of various joining process used in manufacturing. 4) To provide adequate knowledge of quality test methods conducted on welded and casted components. MODULE -1 INTRODUCTION & BASIC MATERIALS USED IN FOUNDRY Introduction: Definition, Classification of manufacturing processes. Metals cast in the foundry-classification, factors that determine the selection of a casting alloy. Introduction to casting process & steps involved. Patterns: Definition, classification, materials used for pattern, various pattern allowances and their importance. Sand molding: Types of base sand, requirement of base sand. Binder, Additives definition, need and types Preparation of sand molds: Molding machines- Jolt type, squeeze type and Sand slinger. Study of important molding process: Green sand, core sand, dry sand, sweep mold, CO2 mold, shell mold, investment mold, plaster mold, cement bonded mold.Cores: Definition, need, types. Method of making cores, concept of gating (top, bottom, parting line, horn gate) and risering (open, blind) Functions and types. 10 hours MODULE -2 MELTING & METAL MOLD CASTING METHODS Melting furnaces: Classification of furnaces, Gas fired pit furnace, Resistance furnace, Coreless induction furnace, electric arc furnace, constructional features & working principle of cupola furnace.