MICRO WELDING
Supervisor And HOD Of ME Department
Dr. Alok Khatri
Presented by
Mr. Sagar Tak
19MTPE06
TABLE OF CONTENTS
1. INTRODUCTION
2. THE PROCESS OF MICRO WELDING
3. DIFFERENT TYPES OF MICRO
WELDING
3.1. MICRO LASER WELDING
3.2. TIG MICRO WELDING
3.3. FLASH MICRO-WELDING
3.4. RESISTANCE MICRO-WELDING
4. CURVE NORMALISING STRENGTH VS JOINT GAP
5. ADVANTAGES
6. DISADVANTAGES
7. APPLICATIONS
8. CONCLUSION
INTRODUCTION
Micro welding is a precision type of welding that is typically
designed to join together delicate minute components. It is the
process of welding together ferrous and nonferrous metal parts of
the minute thickness of less than 0.5 mm with the cross-section of
up to 10 sq. mm, and it produces welding beads of .065.
The Process of Micro Welding
Those who are not adept in micro-welding can only imagine how
micro-welding is wrought because the process is done on the
micro level. A micro welder, for example, must operate on
minute wires with .005 mm in diameter. Yet, despite the
minuteness of these wires, the joining of these micro wires is
precisely done via the use of highly-specialized technologies and
equipment. Moreover, since the process is performed on a
miniature scale, micro-welding is often wrought under a
microscope.
Under the microscope, the depositing of welded metal via the
use of minimal heat in a tightly controlled environment can be
carefully and meticulously done. Since micro welding
necessitates the use of a microscope, it also requires miniature
tools and equipment to correctly carry out the placement of
filler metal and hardware elements. Additionally, it requires
adeptness in the use of miniature tools and equipment which
only an expert micro-welder can usually perform with utmost
precision. Furthermore, with masterful precision, the micro
welder can apply the exact amount of heat energy on the
targeted area without affecting the adjacent surroundings.
Different Types of Micro Welding
Micro Welding is usually done via the use of
different methods such as those of electric,
pressure-contact, electrostatic, ultrasonic,
cold, electron-beam, Thermocompression, or
laser methods. The following, however, are the
four generally-known types of micro welding:
1. Micro Laser Welding
The first type of micro-welding is the micro laser welding. This
type of welding utilizes a solid-state fractional laser to perform
micro welding. Usable applications or apps are incorporated in this
type of micro welding to ensure and to allow for s completely
automated procedure for this type of micro welding. With utmost
precision, this type of micro welding produces the very best
quality of welded joints.
The use of fractional laser for micro welding allows for deep
inside welds. Compared with the Electron Beam Welding, this
type of micro-welding can be operated with no pressure
requirement, since laser, as a form of light, can be operated
through the air without necessitating a vacuum chamber. Lastly,
Micro Laser Welding is so precise that it produces no
contamination, saved for the use of the shielding gas when
operating on highly reactive materials.
Laser welding is a relatively new process to the tool repair
industry. Laser welding uses a complex and precision laser
source, a high powered microscope, and a motion control system.
The pin point accuracy of laser welding allows for maximum
control of weld placement. Very small welds can be achieved
.008" in diameter without any residual heat effecting
near by tolerances.
2. TIG Micro Welding
TIG Micro Welding necessitates the use of minute TIG welding
equipment like that of the Gas Tungsten Arc. This tool—
although a bit smaller than a pen—can operate with utmost
precision. Micro TIG provides the micro-welder with greater
control for weld placement, and it also produces fewer residual
stress. It likewise allows for greater structural integrity. With the
use of the Micro TIG, one can restore damaged components and
weld together minute parts even if these parts contain high alloy
density.
If you are requiring a resolution for larger, more complex
shape build-ups, micro-tig welding is the solution. Micro-tig
welding is performed with a very low amperage welder, a high
powered microscope, and surgeon-skilled hands. This form of
tool repair takes years of experience to master, and is a core
competency at MICRO-WELD TECHNOLOGIES.
3. Flash Micro-welding
The Flash Micro-welding type is designed for cost-efficiency and
high production. It is utilized for large-diameter steel-rod processing.
This type of micro welding consistently produces high-quality welds
using heavy upset pressures that are delivered by a motor-driven cam
assembly. As a reduced version of butt welding equipment, this type
of micro-welding is utilized for welding together, band saw ends and
hot junction of various thermocouple wires. However, this reduced
version is designed to operate on a micro level. Moreover, this type of
micro-welding is engineered to manufacture decorative chains of
regular or precious metals and can operate automatically to form
fantastic links.
4. Resistance Micro-welding
Micro resistance welding is a very common assembly method in
sensor manufacture and peripheral wire attachment.
There are many sensor products and designs that have existed for years
in much the same state and that employ one or more resistance welded
joints.
It is surprisingly common place to find mature product still being
made with old weld heads and old capacitor discharge or AC welders,
often with little knowledge or documentation about the real process in
place.
Micro resistance welding is not just used to make joints. As with
soldering ,the process can be used to consolidate flexible stranded
wires into a solid block in order to remove stray strands and to provide
a solid base for the next assembly stage.
Curve Between Normalising Strength V/S
Joint Gap
I. ADVANTAGE:-
A cost effective tooling repair process.
Minimal sink and distortion.
The ability to weld in very tight and deep areas, up to 4".
Optimizing large, complex build ups of various shapes and
sizes.
A portable welding solution for larger tools.
Process heat sensitive parts, such as electronic and medical
inserts.
Master welds with zero sink and zero distortion.
Weld non- ferrous and special alloy materials, such as
mold max, brass, and more.
Weld very hard, powered metals without realizing any cracks.
Weld without any preheating.
DISADVANTAGES
• The initial cost is high. The equipment used in micro
welding machining has a high cost.
• High maintenance cost.
• Due to the rapid rate of cooling, cracks may be produced in
some metals.
• High skilled labor is required to operate Micro welding
machine.
• The energy conversion efficiency is very low. It is usually
below 10 %.
