JOINING PROCESSES AND EQUIPMENT
Introduction:
1. It is common for manufactured products to contain
components that are actually joined assemblies of two or more
smaller pieces, because of the ease of manufacture, handling
of smaller and simpler parts, etc.
2. A wide variety of consolidation/joining processes have been
developed to facilitate the joining or assembly, which include :
a) Welding, brazing and soldering
b) Use of fasteners, such as bolts, screws and rivets.
c) Adhesive bonding ( Its use has grown with new
developments in polymeric materials and the need for low
temperature joining of composite materials.
d) Lesser known techniques include shrink fits, slots and
tabs, and a wide variety of other mechanical methods.
JOINING PROCESSES : WELDING
We will begin our study of consolidation processes with
the joining techniques known by the generic term of
welding.
Welding is the permanent joining of two materials,
usually metals, by coalescence.
COALESCENCE: Means joining of two metals to
become one whole.
COALESCENCE
1. COALESCENCE is brought together by a combination of :-
a) Temperature
b) Pressure
c) Metallurgical Conditions
2. The combination of these variables can range from:
a) High temperature with NO pressure, to
b) High pressure with NO increase in temperature
3. Since welding can be accomplished under a wide variety of
conditions, a number of different processes have been
developed.
TYPES OF WELDING
1. Fusion Welding or Non-Pressure Welding
The material at the joint is heated to a molten state
and allowed to solidify
(Example: Gas welding, Arc welding)
2. Plastic Welding or Pressure Welding
The piece of metal to be joined are heated to a
plastic state and forced together by external pressure
(Example: Resistance welding )
COALESCENCE
1. COALESCENCE between two metals requires sufficient proximity
and activity between the atoms of the pieces being joined to
cause the formation of common crystals.
2. The ideal metallurgical bond, for which there would be no
noticeable or detectable joint would require:
a) Perfectly smooth, flat or matching surfaces
b) Clean surfaces free from oxides, absorbed gases, grease, and
other contaminants.
c) Metals with no internal impurities
d) Two metals that are both single crystals with identical crystal
structure and orientation.
3. Above conditions are virtually impossible to achieve in normal
production. Various joining methods have been designed to
overcome the various deficiencies.
EFFECT OF HIGH HEAT IN FUSION WELDING
1. In fusion welding, where molten material is produced and high
temperatures, accelerate the reaction between the metal and
its surroundings, contaminants are often removed from the
pool of the molten metal by the use of the fluxing agents.
2. The structure of the metal may be significantly altered.
3. Even in the absence of melting, heating and cooling of the
welding process can effect the metal structure and quality of
both the weld and the material.
4. The production of a high quality weld, therefore requires:
a) A source of satisfactory heat and/ or pressure
b) A means of protecting or cleaning the metals to be joined
c) Caution to avoid or compensate for, harmful metallurgical
effects.
CLASSIFICATION OF WELDING PROCESSES:
(iv) Solid State Welding (SSW)
(i). Arc welding (AW) • Friction welding (FRW)
• Shielded metal arc welding (SMAW)
• Ultrasonic welding (USW)
• Gas metal arc welding (GMAW)
• Forge welding (FOW)
• Gas Tungsten arc welding (GTAW)
• Explosion welding (EXW)
• Plasma arc welding (PAW)
• • Roll welding (ROW)
Submerged arc welding (SAW)
(ii). Oxyfuel-Gas Welding (OFW) (v) Newer Welding
• Oxy-acetylene • Electron-beam welding
• Pressure gas welding (similar to (EBW)
Resistance welding) • Laser welding (LRW)
(iii). Resistance Welding (RW) (vi) Related Process
• Resistance spot welding (RSW) • Oxy-acetylene cutting
• Resistance seam welding (RSW) • Arc cutting
• Projection welding (PW) • Hard facing
• Percussion welding (PW) • Brazing
• Soldering
SOURCES OF ENERGY FOR FUSION WELDING
• CHEMICAL REACTIONS
– Burning gases
– Gas welding
• HEAT FROM ELECTRICITY
– Arc
– Arc welding systems
– Resistance welding
• LIGHT
- Laser
