Welding Processes PDF
Welding Processes PDF
Welding Processes PDF
Welding Processes
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Department of Mechanical Engineering
Fusion Welding
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CE Welding Processes Fusion Welding
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CE Welding Processes Fusion Welding
Spattering
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CE Welding Processes Fusion Welding
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CE Welding Processes Fusion Welding
2. Gas Metal Arc Welding (GMAW)
Heavy spattering
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CE Welding Processes Fusion Welding
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CE Welding Processes Fusion Welding
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CE Welding Processes Fusion Welding
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NCE Welding Processes Fusion Welding
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NCE Welding Processes Fusion Welding
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NCE Welding Processes Fusion Welding
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Fusion Welding
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Fusion Welding
Resistance Welding
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Fusion Welding
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Fusion Welding
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Fusion Welding
H= I^2Rt
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Fusion Welding
No Sparking
Sparking
Coil does not make physical contact with pipe.
Heating is done due to induction process
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Fusion Welding
https://www.youtube.com/watch?v=Cy_R-iZpH8Q
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Fusion Welding
https://www.youtube.com/watch?v=Br_J9Ow-aMo
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Fusion Welding
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Fusion Welding
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Solid State Welding: Solid Sate Welding
1. Forge Welding
Components to be joined are heated to hot working
temperatures and then forged together by hammer or
other means.
It is oldest welding method, loosing use in industry
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Solid State Welding: Solid Sate Welding
2. Cold Welding
Surfaces are coalesced by applying high pressure b/w 02
clean surfaces at room temp
At least one of the welded metals must be very ductile
Soft metals such as Al, Cu can be readily welded
The applied compressive forces reduce thickness by 50%
due to plastic deformation
Heavy presses are used for large parts
Applications:
Making of electrical connections
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Solid State Welding: Solid Sate Welding
3. Roll Welding
Coalescence b/w the sheets is obtained by applying
pressure b/w the 02 sheets using rollers.
It can be done with/without application of heat
Application:
Cladding SS onto carbon steels to prevent corrosion
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Solid State Welding: Solid Sate Welding
4. Diffusion Welding
Coalescence b/w the parts is obtained by diffusion of
atoms
Diffusion is achieved by heating (0.5Tm) and application
of pressure with minimal plastic deformation of faying
edges.
- Sufficient time (could be 1hr) is given for diffusion
under pressure and Temp
Application:
- In aerospace/ nuclear industry for High strength &
refractory metals.
- Dissimilar metals: a filler layer of a different metal is
sandwiched b/w 02 different base metals to promote
diffusion
https://www.youtube.com/watch?v=IQYZHGSf_8E
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Solid State Welding: Solid Sate Welding
5. Explosive Welding
Necessary heat and pressure is provided by explosion of a
detonated explosive
No filler is used
Progressive welding at 8500m/sec
Metallurgical bonding takes place, as thin layer of metal at the
interface of faying surfaces undergoes melting
Application: https://www.youtube.com/watch?v=XMSaX-3tOUw
- For cladding sheets
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Solid State Welding: Solid Sate Welding
6. Friction Welding
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Rotation stopped
when temp reaches
hot working range https://www.youtube.com/watch?v=iG3t0Q7UuCU
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Solid State Welding: Solid Sate Welding
6. Friction Welding
Coalescence is achieved by friction heating combined with
pressure
Friction is induced by mechanical rubbing b/w the 02 surfaces
Then the parts are driven towards each other with sufficient
force to form a metallurgical bond
No shielding gas required
Low HAZ
Application:
- Welding of shafts & tubular parts in Automobile, Aircraft,
and Petroleum industry
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Homework
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Welding Defects
Cracks
Cavities
Solid inclusions
Imperfect shape or unacceptable contour
Incomplete fusion
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Welding Cracks
Fracture-type interruptions either in weld or in base metal
adjacent to weld
Serious defect because it is a discontinuity in the metal
that significantly reduces strength
Caused by
embrittlement
low ductility of weld and/or base metal
high restraint during contraction
high thermal stresses
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Welding Cracks
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Cavities
Two cavity types, similar to defects found in castings:
1. Porosity - small voids in weld metal formed by gases
entrapped during solidification
Caused by
inclusion of atmospheric gases
sulfur in weld metal
surface contaminants
2. Shrinkage voids - cavities formed by shrinkage during
solidification
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Solid Inclusions
Solid inclusions - solid material entrapped in weld metal
Most common form is slag inclusions generated during
AW processes that use flux
Instead of floating to top of weld pool, globules of slag
become encased during solidification
Metallic oxides that form during welding of certain metals
such Al2O3
Tungsten due to overheating melts down and becomes
the part of weldment
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Incomplete Fusion
Same joint but with several weld defects: (b) undercut, in which a portion of
the base metal part is melted away; (c) underfill, a depression in the weld
below the level of the adjacent base metal surface; and (d) overlap, in
which the weld metal spills beyond the joint onto the surface of the base
part but no fusion occurs.
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