494

t Aagh wlding :
poudeng 2 olps
biUs +so elechode holdu powee Supry
uiU be ai¯eni B}w
BBo the
the tuo
tu Sufacea
niHay hecr con be produce by
genaing ele c c
ConHnoue.the-rC
roe.
S u ç n t ETs
In ord to

Fes.
mauntain klwthe tuo wPs
-Heailbe geneaec
AFe ehg sUfiuent amount of
bec of eleekik

heaur
by suith the powoe Suppy éx
ex tenay
prress Can beapplied to pro duce Join
APPlfcaion For boH:
the objeF end to end shich
Joining oP
re made do ofF high cabonsteey,
Los coarbonSteels, C loyed stee
(Sto 2s mm
aluminium and is a y
dta ony) fle lecha
consunable
# ELECTROS LAG---WELDING:
S more Hen

DCRP, lehed
isreid
>High
thrckneg
JPS otwldir
cam be
deu

** Thicknss: So 2somm
Lcu, plate
To noinimie
{000A
 425
31
Ave is eneated bBw consumable lechode
|and wlP Aftex aeting Sufflcient amount
OF L mea by hea geneiaion Fx
be acded. It wiu pro duce sio by, ne
tthe. height oF iq mnetel ohen it is'contac
jhelectrode ue to Short-Cycut rc
be extingust. But heargneeaion
l be conHnue. frr thcue.to ReSStan,
of the Stag by Suppying the Same rrent.
Welding will be takes PLace Veicaly
|up-wrd d ix ,n.
tAPPLICATION to
Joining oF hih thìckness objet edge
edge Vecticalyin ship bilding
Fabrication of press franes and Roilin
misstands:
IWORkBook
t O SSec.
m
t=2mm t ÷ 6oo0
d=smm and t=2. S mm
--H.= 29.Imms

2
Hm= 2.4xy908 he2S
-S m

Hs = J'Rt 4
y9-o8 mm

4os JOwe
|42-33.
E3S.]4"/
 2m m

t = 10XJ6 Sec.
= x2 3 små
m=exV.

2:34*I61x fg00 soo + 300x1

3S1-15 fowe
Hs= I²RT

lm Hm
Hs

31) t = s mm d z s mm
I=l0O90 A
t.2See
L÷ 1200erl
R=100x/6
S= 2000 Im 4

=xs*3
m= SV S8 9mn

'. Hm=
(C=0 Not giun)
s6Ss 9 j o e .

Hs =1'RT
:%Heas l0s= Hs-Hm17
Hs =12 .
 427
f=25oO0A, Eoos sc. 39

l9smma. R=?
o j = . lox UOm lox

m= Hs
’1oA6 = 2soooxRx0-00s R= 362
R=l.
=896 J|R ; T= 33k
L 398E30C

Hm = mcoT+ mL = Hs
bolx$ caT+L
Areax depth x270o896x 630-+39 gxi000
0S 0:0S X deph x
deph=384 mm

Ot Ln a seot uSeding oF 2,mm thickDess

.

having iw shes J= (0, 000 A, ts02see

t=
Heot oecipiaed to base metau is (0,90ut
Heat Reqwred to mett is 20 J |mm3.
R= 2000 S.
Hect decspta
nuggetHs=IRE= 4000 Jowe wear
to Sum.
HeaHo

Hd=
|= Hs - Hm
l000
 428

oipes o/0Mm,0sicde d a &1 Dmm

OTuo oee
by Flash. butt
nade dig one foint Pow
43 sppy. Atintexke
technlque ust bemur o meach
mm of meteu wil
y2· S
P'pe which has o resistance
r me ts6ysmflms
Heat Regwreo
Time taren tD melt s
6A=4x(01o09)x2
32967 mm3
IRT = 64y* o.6 x.329-67161
v2

:
32?.6)x/6 1.
30xt
y2-4.
t=|0. See.

tt SoLID STATE WELDIN9.

) ExpLossiUe usedia: Fo High thi ckness
HTNT

detbntor Rubber
spacing
FLyee plate.
I0- 20°

Back forCe. TNT

Dynamites
A mmonium
Targer pLare.
L low vei.

stand offdistance

Thicyenn t Flye plate

 wjthot HAz Weding is done in Soil sw 41
Not adding FWe mate So No FUx uscd." ,

Hear: les than mneitia Point Cx plosi0we

by
Lage size plae is usededeol PLastic
Impa Force fs a . o n plate so deFomat
iS takes place
inerease Corrosion Resistonce process, Caug Ciat
To
timitoionis that ExpLOSioN.takespLgce grd
Gauied: 0 awy fLom popwaion
DeFenmaien 1s moreyiD so? matejali oshet oné 3ha
For the weding of the obtec Sr face to
Su face in mass prod his technigue can
be Used.
TwO ops which re to be uTelde oñe
siU be ixed (tarer plare) othee is movable|
tgoe pLate. expLoting Lou Uel. explos)ve
mateça oboue he Euer plare ExploSs
enegy uoill.eReleased. ft wi! be transfe
to the Fyee pLate through+the RUpber
Spaan°fye plate will bc appy more
|mpact force on the tanget plare. Due to
Plastic deforrnaon thece se poss jblites f
roint can be formed b|w t O SfFaces.
Similaue oR pisimilo meau can be goint
uyet plate is mai ntau Some distance nth
aun the momentum.
Hhe tager pae to
hith
1 y e PLae is prouided some inination
horizotau to prouide diro for weding
t Appicotion
to )ngeose
obge t to
Cledd} ng of the obge n coTove
9 70ollfDisinilo matia ike, ALt Titoi Um
n 9tee o H
 436

ULasonic wetding: f= 20-6OKHZ

t<-2 mm(Foils)

clamp

TranducoT

Anvil

Heat jenuaioh is "dueto Uitrasonie vbrahon:

twD contac yo-So. of m.temp: is reqches
then. bond -Pormaion takes place ar.contact
Sur face. HAZ is not apeats heg
tHAZ 0s not becz HA z produce hen ma
is :heated pto -m.temp
t Fox Joining tts less
e thicKness Foi)s
Ehis technique cgn be used.
High frequen cy pouer SuPpy wil be
ioen to the tranducut rt wi produce
high Frequeny ultrosontc ibraHen. jhis
wl be tranSFee to the, urork piece throgh
clamp. At the contat oP the tuso Susfaca
due to Rubbing aeion: heat wll be geneabet.
AEtoe getig sufficent amount of hear se
30-40 . of n: temp by Ppyin staic
Load eternalyTint can be produeed
Accuracy w be moe.
#|AppLËcation:
Fobrcation of dibde & Tolede yndvotiea
in eletnnie
1)l Fabricarion of Ks te
 43
HOtlow cyirdee
3 FR[CT ION WELDING:
N’U0oo-6O00pn
P >so-yUomPa.
t Po StrenghoF base
meta
tt one end Fxed aohe
iSROated and also
rmove Iineuy.
tt ausO done in Lathe.
t musFbe axiS-Symmerwc!
LPYess.

|T=FexY Torque
t IF lena is mose theD P T X 2AN
**

Uso Possible LPosUL 60

Toining oF the obrecr end to end which

Tequires
be. used
more stvength this tech nique can
Two obTeet which re to.be
usill pixed ad othee is welded onc
e
moamnet. By makig the hauig RotaUl
Objet contat of the tw0
Uilf be(nihauydueto-
enecaed. Rbbing acHon hear
APter eting
ftetnp. by stoPping the Rotaion exteenoy
re-coystellisab
for Can be opplied to produce the foiot:
Similau and simav matei al aan be sejda
#APPLLCATION:
J.pril bit andshenk
I1|Axle ang hub
I1) Pipes and, Ualves-
 L 32
Date: 12|08||6
Sudden force is appliec
ORGE WELDI NG. ?
strengh. usilt' be depend
bn ..Sktu Of. wOT kee:
meeal oxide form
Surface:
Gccuau iS less
In Forging. opeohion we
expect moregtrengh.
Crane hook is made
made by forge Tela"
we can noF produce by cashn. bca
the grain orientaion (s in diFfeet dls
Sherah
willbe
IncreastA
in the
dir2 ot
CTae Lengh wit neeqses
and-Secion greg
decreageg
At time of hammonA ta°n is ojented in
a Sp d i t . d0 Streng increases
tt is Sniuc to back smithy forging opoca!
inside
-0bjeet will be heated by prouieing
the forge aboUe the Re-crygtalisa'on temp.
By proUde. on the Anvil» exBena hammering
Förce ean be appyed monually to defoed
the obfet ino requred Shgpe s)|e.
Ator this tuo eds of the obpet ean
be Toin by appyina hammoUng Force.
ACeracy & streng oF Tont depend on
SKiU. leue of op a r
dhee 9 a possibliHeo of onIde formatton
 45
To 'ovcome this Bwx can be added

Generay used in oaricwture oppicatn

Eon gining oF the object
t DIFFUSION WELDING ?
adualy-forceappyed plahe
Proche

Ah
2

’ANVIL
To oppy external force Uoids il bc Reduced.
DOe to diFfsion of% UU1ds in bottuSrace
Single phase i be produced) aGB.
Slosly presS and heat is increases gradualy
So Uoids usili be: nullify..and single pane prodyc
Similar and -similut meta can be prodyee
DiFfusion is a Red prrocess.
It can be c a i e Out in Uäccume (Innetns)

H By Keepina the
they will be in tuoobrectOn the anvil
external press. Inimate.contat by applyi
Press ond Hear ui be Simwtaneous app
a Slous Rare w.t time. Due to
rddual
|appicaHon oP extonal preSs and heat qraun
Un u be dFFused at g
contoct oF wD So Fafes
Ana by educing the Uoids
|Surfaces they wi be bjus the tuo
strength. diPuscd aràhigh
Accuvaya dnd streng
It.is of the Toint is uey h
tme talkin
 434

aminimize oxtde Form aion and to

DYeqse the S Face kinish.+his proess
o bec e d ouundec Uceum Cono
PPicarion,
Jotningof Simi la and disimilae
mateiau ike mtau to
Fabricaion o.
of eompsite LominaBese
chaoeNSHc

Dieg!-In MIG welding power Source

givenby VE= 36-t
by
re lengh chaaerisHc ae giuen
Va = 27+2Li. gind changes n
POs of Source e rc jeng t is char
Fom 22mm to y mm.
So: Va= 27+2 La

3S v a La =4mm.

Va= VE
31= 36 Lt Lt=.Sx60 360

----t (x60 6OV

)

P= 31X 36D 6ox3s

=7300 - 2/SD
7200 w
chamge in poS
Oces: [n Ac Arc welding techoique powee
wh
Sorsce is i n e a c h a q r sHe
Vo =80 V Es 000 A, ArC length ehacop
anre aiUn bs va 18+2SLa n e
opimum yo ttge
 47
Yt Và zi(8+ 2:s la
..

V=i Vó - I t
Lo
80
toor
(8o- ve)i.
8
.lsoD2sVt

VE (ooD- /2-sVe)
= 18 VE (io-/2sve)
&s VE=0
Tno method To use Va=I8+2-SLà
Tö
Vt= a.
80- ExgO = |8+2:S La

le= 77S.3):2SLa

((8+2slo)(S- 31.25La)
*
dP ’ (Lo='88 mm
Va =18+IS*88=
Two Stee bars edchoF. lo mm dia re
co-an
ticHon welded end to en t a axia press
oP 200 mPa ar a Rotatonau Speec of 400orpm
the torque is assmed ats 34th
Of Radias t Rotaing bar detemine poocje
Kguirement ding tHe foro er'
F= 8S3:8 N:

P= (234 Kw
 Hld.
magrehc
ANODE ooRo
(Tungsren) LElecode
thod ca 1)
2166
Beam Electron )
(EBW)NeLDING:
ÉCHNIQUE; WELDING
-ENERGY. DIENT RA
e632" nml2.69 0 c 2
64:03 12 Hm
=
masS-
000 1RT Hs
mm3 Iys6 d>xh= VDx
7:3S =
tgyonsi 0F=6SE So
as200.
NS Resisfance tack eon
ake Caucayate 8m. Iy38. 1:
tyda) lam
of Regiredto
mu Hear
q)cm mateia
's thiaknes,;
density
oF
shee of toSher
Îs onthe albiec "...
aion mgxn oSec: for. oooA b, oF
ielding, welded Spot
thickness mm 'rs of sheers Two Cus:4
bd to Gre
436
 437
SO,000 - 2,0000o
2,09000 kml sec e· of h4
the eechon
(2x/08 m|sec)
1920 kv
b : depth:touidh Raio
to1, ’ 30:1
produce due to Rgdlent n g
Enexa uill be electon beom
eH qt Requwred is produce by
uP.anid:
and high conc is focusèd on. wP
wedina: happens:
Anode is c i e d anulat anode.
dcceleated fom
Dueto high P-D. elechon is produCe fs more
RtCatho dto anode. 4 So. kÉ
Say, veyx2 h igh (bez jel· of lecHon is more z1)
aeneated4
Due tO more k¬ more Hect is
penhaion i maxm and wld begd is min m
HAZ'0S: veyX2 lowU, So uni For mJoinF Îsepossb
ithout any change in icrostrucre.
Uhen We do in m +hen arm aur CauSe To
efiethe jetron beom caued sca teed.
due to Caojed o in Vaccum
No ox ide is form
Dueito Uaccum Requured cost oF process is
mãre. 2) Sie |imnitahon. (can nt able to do
max mSize ofwP)
lead;.coating s Prouided to absob Rodira
EBN produce more dccurte wdn
tElectons wiu be emitted fom the cathod
nigh enecgy level. They ill be dreced
toüsods anode. Durin +he pTOCeSS due to
more poteniu diFFence electtons can be
|acceleated tousads +he anode dura hiah
Speec· Electrons comning fom ifrenldirh
fom he anode il| be convee as a Sin
rOg of elechron beam gnd it si br focus
On the up a a
a0e Pont .
 438

+his hear Concentration on. wp.

yey high:
Beph op pen ehation. and selding speed
Bt be max! ..
Jld bead uidth and HAZ Ts less
To minimize Scateung op elechonsum
th1s
condA
be cmie) ourUndee Jocc
Hhy oxidisingm efa) Can beegstty we
IE is expen slue Pocess.
APPLicahon :
) Joining. oP Ttanium, Barium, stain less
Steel (supUL awoye), Tungsten &Columbium
in: eTospace,
Space Craft, qeospacei Neclea pow
PLant and missiles
tH LASER BEAM WELDING - (LBW)
Refect . L)co2 Lasex
chamb A Na: YAG:
’Nedtymium
(oo. q84. 4 | ’|0:
XeNon
Lamp ’ optical Focusina.
(ense.
Ehbcgy genecated ill be minmless than) EBW
moboctronate ano eoheeent ay eofnes om
ReflecHng Chambor be,Reducco
So eost w)
No any Uaccum Reqwre
Bhole is pNesent caled key holes marria.
DiFfAcw to weld highy Reecte
YAG: i8.
Gar ne.
|yAL
Lytum
 y39

auom con be pumped into high energy lev

the.form t
Jhey oill Rel ease +he en e y in
photons. From the ReFlechng chambe mono
Fchromatc and còherent lighr xays wil! be
comming arthey a be direche touAs
the o|P Uslna opicau Focusig le sise
Heat conel on ojp is vexy hiah.
Depth o pentaion & wslding speed is
|Vey high
* Wel bead idth and HAZ Is minm
HAPPicaion.
Joining oF Al, tonium and Supr-woys
|n aeOSPqce onc eectron ic Indusies.
!

t SOLID| LIQUID STATE WELDING

* 8RAZING| SoLDER0NG
Base merau is SoUd and leUmatesia is
..

tthout apply +he press and sithour appiican

OF heaing the base mera
Fwe matea) is Fled by capillay qcion
but not by nauity force. rcopiary
qct
Fuec mate au hauing loo mpt
Leqid meral hauing ho more temp
MF mose temp the pnete basSe mro.
PP bls tuo |P is mare impt whiçh decide
iergth oF wldin Sttength.

Lead Tin)
Solde vapourisaion temp 427°
 Baze weding tew) m-temp is
more than-Tin:
du to ailoyd
OWetiing> SBw >
Tw s Tgw > Tg >TS

soideing
Hngtemp-ofFeHomaoia /s lesS
T
Lhan.427°
FeUo mareiau is an aUoy. o lead &Tn
knoun as soldet
Hux mateiau is used as nO chhhorge
(znd) and amonia chtoide (NH4c)
Fille mateuau is ente Into the wp
by means ot caplay aion.
# APPLICATIONS:
I)) Electuc an Elechrntcs crtdesigh.
Fabricaion. .oP.pinhed
BRAZING:
Fille matei a mtempis gredter tan
427% ond le ss than the mitemp oF
bgse matejdl.
FllL mateæal is an, dloy
éu and AL eu and silve (AA). Ft`s
knoun as speito
Flux natevau is. used as borax.
Felle mateUay is enteced by eopilay
g ci on:
8Toenath ofthe toint iS more when
Compred to Soldeg
 H RPpltcations
Joining oP the obrects tó prDduce leak
proof Join: ke Rgditos bodies, pipes
Usec in watL SUPppy
tBRAZE WELDING -
Ei
Fillot metou is enter into the wp
wtP by
|means oF.aGihy focë
Filloc. metau-is an-clloy of cO gnd in
Knoun as bronze:
Strengthof the Joint is high.
tAPPicaion :
.
) Toininâ oF cutting tool tips made uup of
tngsten. cabide

HEAT FLOW CHARACTERISTICs: Y

L. 3D. FLOW
H= F , y,z)
point Sorce.
ex: Sppt

Fbk @mt
4

|2. 2-D FLOW :

H= F( )
Line source
: Butuweding:
8KOm t 9= |1near seld
b= weld beg# wich. Speed
K= therema corduciuiy QRte rtshea
 b

ve. iwill be opimem ncithee moe nor less

.

OLu3En a butt welrng process heat.inpur

iS given by 9= 8kemtt96). Tuo steel
PLares 4
re uelded sitha her inpu
2;s Kw. Hear transfee eff: oF8 . take
k=y3:6 J|mG and = l2xIGS m sec.
diff D ntemp = 14s0c Det. nax maxMusldig
Speed for the Tob shich ts shousn in
Fia:
tan 30=

’ b= 2 X 3 tan30
-3.46y m 3y 6vR¡

2.s xo*o8S = g* u36x 145°x 3x0 4y

2*105
V=66.mm |see
# WELDIN GDEFECT
Gas De fect:
a) porDsity
Due t absobing oF am ases fn thé liq:
meau duing Soidiicahon prsocess, gas
defect can be formne.
Remedy: Wx and
ProUide suficient armount o
Shildina gses
2. $Laa inclusions:
pue to mprope posiHoniy
oF welding toUrch &
Lack oF hear inPW Sloa can be haPped inde
he iaq . merau will fom sloi ineusjon.
 Remedy:- prouide SuFficdent amoUNt oFhedt
H
and protect +he iq- metau by pro Uding
shielding gos
i) Weld spattu
Dueto exceSs amounE of hea
in p and. rc blowi Lra. mea is spatte
Splashecl onEhe base mateia psodu
a ruh surface knoun as sdd Spatte
Remedy Poide SufHdent amount oF
inpur and Reduce rc blbu.
1 Lack oF Russion and penetaion:
Due to Lack OF heat inpwr IF the
Felet metau is not Fussed pro Pedy
base meta will form a with
defect.
HRemedy: Proide SuFfiient amount oFheat
inp and select Optimurm welding speed.
V) Weld Cracks
Due to non- niForm cooling intonal
stresses ill be develope in the
Jont. IF the stsesses will be more
Ehan-the Strenath oF mateioJ CTaks oil|bfom
IF Ehe Hyrogen gas is aPpe to the
ussion zone it il| be penetated into HAz
wil! For ma crack knon as Hydrogen enbite
tt Remedy >prAride pre heding and PoS heathg
stainless Deay
Wed deca ony in Steee
ncase of
Stanless Stee) due to FasRae SF
CooLna,chronmium uill be convLted into
Cocbiqe. In comiu
absence of chromiu m +heree. iS 4
possibies OF
corTosion oF He mateUaU, Dye to
fhiS decay can be Formed
Rmety prroUjde knoun as wed deast
uniform
I WELD BEAD, CHARAC TERISTLCS; -

Fusio HAZ' IcoOrse,

..ran

Base Fine

withour
any, defe

Columnrc Equaxk Srength oF

Hard nesS
graun:
Duchiliy
t IA ussion zone
Soidi Fy.
Fast Rate oF cooling Fene run (Hard )
wedabiliy:) m:pE 1 ’ wA
(wA e) 2)

i: I9 oF Cabon ->
v) oxide for mation
tendeny
(A)

mild Steed> c.I> eu> AL

Lbwedability
H So wel dabliky is max m iD mtld Stee) and
minn is aUuminium. due to Jow m pt.