24ME303 MANUFACTURING PROCESS UNIT - II.ppt

24ME303 MANUFACTURING PROCESS UNIT - II, METAL JOINING PROCESSES

1. METAL JOINING PROCESSES
Fusion welding processes – Types of Gas welding – Equipments used –
Flame characteristics – Filler and Flux materials - Arc welding equipments -
Electrodes – Coating and specifications – Principles of Resistance welding –
Spot/butt, seam welding – Percusion welding - Gas metal arc welding –
Flux cored – Submerged arc welding – Electro slag welding – TIG welding
– Principle and application of special welding processes - Plasma arc
welding – Thermit welding – Electron beam welding – Friction welding –
Diffusion welding – Weld defects – Brazing and soldering process –
Methods and process capabilities – Filler materials and fluxes – Types of
Adhesive bonding.

2. Fusion welding
The metal at the joint is heated to a molten state and then it is
allowed to solidify. E.g. – gas welding , Arc welding, Thermit
welding
The metal at the joint is heated to a plastic state and are pressed
together to make the joint. E.g. – Electric resistance welding,
Forge welding
Plastic welding

3. Types of gas welding
2.Air – Acetylene welding
Air taken from the atmosphere and compressed , mixed the acetylene to
the required proportion. Temperature is lower than oxy-acetylene
welding.
3. Oxy – Hydrogen welding
Oxygen and hydrogen gases are mixed with the required proportion. It
is used for low temperature welding metals like aluminium, lead.
1. Oxy – Acetylene welding
Hottest region - 3200°C
Acetylene pressure not more than
1.5atm
Oxygen pressure – HP -0.1 to 3.5 bar, LP –
0.5 to 3.5bar,Torch pressure upto
0.06bar.
CaC2+2H2O Ca(OH)2+C2H2+127.3
Kj/mol.
Metal 2mm to 50mm thick are welded.

4. Gas Welding Equipments
Oxygen- black (125-140kg/cm2)
Acetylene-maroon(16kg/cm2)

5. Flame Characteristics
1. Neutral Flame
Equal quantity of oxygen and acetylene.
Inner cone develops heat to melt the
metal.
Outer cone are
2. Carburising Flame More acetylene than oxygen.
Sharp Inner cone
White intermediate cone called feather
cone
Bluish Outer cone

6. Flame Characteristics
3. Oxidising Flame
More oxygen than acetylene.
Smaller Inner cone
Outer cone

7. Gas Welding Technique
1. Leftward or Forward Welding
2. Rightward or Backward
Welding

8. Arc Welding Equipment
Heat is developed by an electric arc

9. Filler rod – Gas Welding Equipment
To supply additional metal to make the joint. Metal rod as a parent metal.
D=t/2 + 1
Electrode – Arc Welding Equipment
1.Consumable electrodes
It used to produce arc between work and electrode but also
provides filler material during welding
i. Bare electrode ii.Lightly coated electrode(1-5%) iii. Heavily
coated electrode (1to 3mm & 15-30%)
2. Non- Consumable electrodes
Made of carbon, graphite which do not consume during welding
Arc length remains constant and stable.

10. Specification and choice of Electrodes

11. RESISTANCE WELDING

12. 1.0 SPOT WELDING
0.025mm to 1.25mm thickness metal sheats
RESISTANCE WELDING

13. 2.0 BUTT WELDING
1. Upset butt welding 2. Flash butt welding
RESISTANCE WELDING

14. 3.0 SEAM WELDING
RESISTANCE WELDING

15. 4.0 PERCUSSION WELDING
RESISTANCE WELDING

16. TUNGSTEN INERT GAS WELDING (TIG)
GAS TUNGSTEN ARC WELDING (GTAW)
Tungsten carbide melting point- 330°c
Less than 6.5mm metal thickness

17. GAS METAL ARC WELDING (GMAW)
MIG – METAL INERT GAS WELDING

18. FLUX CORE
When the flux is required continuously or where large quantity of flux has to be
supplied, on that time the flux is used in the form of wire wound on a rotating drum or
reel called as flux core.
1. Submerged Arc welding (SAW)

19. 2. Electro Slag welding (ESW)
FLUX CORE

20. SPECIAL WELDING
2. Thermit welding

21. SPECIAL WELDING
3. Electron Beam welding

22. SPECIAL WELDING
1.Plasma Arc welding (PAW)
a) Non Transferred type

23. Power is directly connected to the torch and
torch nozzle
Tungsten is connected to the negative pole of DC
supply and the nozzle to the positive pole.
The gas is issued from the nozzle orifice as a high
temperature, high velocity plasma jet, cylindrical
in shape and of very narrow diameter realizing
temperature up to 10000 C
The non transferred plasma arc possesses less
energy density as compared to transferred arc
plasma and used for ceramic or metal plating.

25. SPECIAL WELDING
4. Friction welding

27. BRAZING
Joining of two metal pieces by using a filler metal and the
liquid temperature is above 450 deg C.
Joining of two metal pieces by using a filler metal and the
liquid temperature is below 450 deg C.
SOLDERING

28. METHODS AND PROCESS CAPABILITES - BRAZING
 Torch brazing
Acetylene, natural gas and butane are combined with air or
oxygen.
 Furnace brazing
The heat is supplied by gas or electric heating coils.
 Induction brazing
Heated by placing within the field of high frequency induction
coil.
 Dip Brazing
Chemical dip - Filler metal placed in molten bath or flux.
Molten metal bath – The assembled parts are first prefluxed
and then immersed into molten bath.
 Resistance brazing
Rapid heating minimizes oxidation and the heat affected zone
is small
 Laser brazing and electron beam brazing
Laser beam and electron beam are used to join the metal.

29. METHODS AND PROCESS CAPABILITES - SOLDERING
 Hard Soldering
The filler metal is silver. Also called as Silver soldering.
 Soft Soldering
Soldering iron is copper rod.
 Dip Soldering
A large amount of solder is melted in a closed tank and
parts to be soldered are cleaned and properly dipped in a
flux bath.
 Wave soldering
Parts is not dipped into the solder tank but wave is
generated in the tank.

30. FILLER MATERIALS
FLUX MATERIALS
1.Chlorides 2. Borax and boric acid,
3. Borates, 4. Fluorides.

31. TYPES OF ADHESIVE BONDING