industrial processes ii industrial processes ii inden 3313 lecture 6 – case study fusion welding...
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Industrial Processes II
INDUSTRIAL PROCESSES IIINDUSTRIAL PROCESSES II
INDEN 3313INDEN 3313
Lecture 6 – Case StudyLecture 6 – Case Study
Fusion Welding -- Oxyfuel and Fusion Welding -- Oxyfuel and Electric (Arc) Welding Electric (Arc) Welding
ProcessesProcesses
Industrial Processes II
OVERVIEWOVERVIEW
• Case Study Case Study – Overview and Phases
• Fusion WeldingFusion Welding– Oxyfuel
– Arc
– Resistance
Industrial Processes II
QUESTIONSQUESTIONSTO START ??TO START ??
Industrial Processes II
CASE STUDYCASE STUDY• Goal to Study the Design and Goal to Study the Design and
Manufacture of ToolingManufacture of Tooling– Phase I (15%)
• Identify Possible Parts for Case Study• Each Student to Identify Three (3) Parts for
Case Study– One part => Cast– One Part => Machined– One Part => Other Than Cast/Machined that
will require tooling for its Production (Forging Dies, Stamping/Bending Dies, …)
• Form/Format on Web– Part (Name, Function, Sketch)
• Due Next Thursday– Hard Copy and Electronic Submission (e-mail)
Industrial Processes II
CASE STUDYCASE STUDY– Phase II (15%) – Part Processing Concepts
• Following Part Submission (Phase I) Instructor will select/modify Parts and Assign
• A processing sequence will be designed for the part and the tooling requirement(s) for its production via this sequence will be determined.
• Each student will execute this phase for one part concept.
• Due 2/22/00• Format on Web
Industrial Processes II
CASE STUDYCASE STUDY– Phase III (70%)
• Each Student will detail the design and manufacture (parameters, costs, …) of an assigned piece of tooling. For part concepts requiring more than one piece of tooling, one student will be assigned each piece and one report will be developed for each part.– 10% -- Schedule for Project (Due 3/8/00) and
Progress/Adherence to Schedule (Due 3/29/00)– 20% -- Completed Draft (Due 4/12) Evaluation
of Technical Data and Report Format/Content Completeness (Format on Web IEM Tech. Writing)
– 40% -- Final Draft with all Technical Corrections and Presentation of Results to Class. (Slides Due 4/26, Final Report Due 4/28)
• Schedule may be modified to accommodate ENGL 3323
Industrial Processes II
FUSION WELDING METHODSFUSION WELDING METHODS
• Fusion => Use of Heat to MeltFusion => Use of Heat to Melt• Types (Source of Heat)Types (Source of Heat)
– Chemical Reaction (Combustion)• OxyFuel• Thermit
– Electric Arc• Consumable Electrode• Non-Consumable Electrode
Industrial Processes II
FUSION WELDING METHODSFUSION WELDING METHODS
• Types(cont.)Types(cont.)– Beam
• Electron Beam• Laser
– Electrical Resistance• Note: Text Classifies as Solid State Process
-- Nugget is Molten, But Contained
Industrial Processes II
OXYFUEL WELDINGOXYFUEL WELDING• Basic Process DescriptionBasic Process Description
– Use the Heat Produced by the Combustion of Acetylene and Oxygen to Cause Coalescence
• ParametersParameters– Rate of Combustion
•Affects Heat, Not Temperature•Size of (Nozzle) Tip
– Maintenance of Non-Corrosive Shield
– Operator Skill, Preparation of Parts
Industrial Processes II
OXYFUEL WELDINGOXYFUEL WELDING• ReactionsReactions
– 1. C2H2 + O2 -> 2 CO + H2 + Heat
– 2. 4 CO + 2 H +3 O2 -> 4 CO2 +2 H2O + Heat
• Discussion of FlameDiscussion of Flame
– Reducing Neutral Oxidizing
5500o F 2300o F
C2H2
O2
Industrial Processes II
OXYFUEL WELDINGOXYFUEL WELDING• Common DefectsCommon Defects
– Hydrogen Embrittlement– Corrosion (Neutral/Reducing Flame)– Spatter– Inadequate Penetration– Incomplete Fusion
• AdvantagesAdvantages– Low Cost, Skill Requirements– Portability
Industrial Processes II
THERMIT WELDINGTHERMIT WELDING• Basic Process DescriptionBasic Process Description
– Use of Heat Produced by Thermite Reaction to Superheat Fe and Use Superheated Fe to Effect Weld
• ReactionsReactions– 1. 3 Fe3O4 + 8 Al -> 9 Fe + 4 Al203 + Heat
– 2. 3 FeO + 2 Al -> 3 Fe + Al203 + Heat
– 3. Fe203 + 2 Al -> 2 Fe + Al203 + Heat
• Iron for Weld, Aluminum Oxide Slag Iron for Weld, Aluminum Oxide Slag (Protects Weld as It Cools)(Protects Weld as It Cools)
Industrial Processes II
THERMIT WELDINGTHERMIT WELDING• Sources/Causes of DefectsSources/Causes of Defects
– Inclusions– Large Grooves Required (Superheat of
Base)
• AdvantagesAdvantages– Large Amounts of Filler Metal Available
Quickly
Industrial Processes II
THERMIT WELDINGTHERMIT WELDING
[Amstead et al, Figure 8.26, p. 186]
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CONSUMABLE ELECTRIC ARC CONSUMABLE ELECTRIC ARC WELDINGWELDING
• Basic Process DescriptionBasic Process Description– Creation of an Electrical Potential and
Exceeding the Initiation Voltage to Produce an Electrical Arc, the Heat of Which (~55,000o F) Effects the Weld; the Electrode is Melted by the Arc and Supplies Filler Metal to the Weld
• ParametersParameters– Distance from Electrode to Work
Determines Initiation Voltage, Temperature, Current/Frequency Determines Heat Flux
Industrial Processes II
CONSUMABLE ELECTRIC ARC CONSUMABLE ELECTRIC ARC WELDINGWELDING
• Two TypesTwo Types– Consumable Electrode– Non-consumable Electrode
• AdvantagesAdvantages– Automated– High Temperature– High Heat Flux– Shielding from Corrosion
Industrial Processes II
CONSUMABLE ELECTRIC ARC CONSUMABLE ELECTRIC ARC WELDINGWELDING
• Provision of Non-Corrosive Provision of Non-Corrosive EnvironmentEnvironment– Shielded Metal Arc Welding (SMAW)
• Flux Coated Stick Electrode
– Submerged Arc Welding (SAW)• Flux Supplied by Separate Delivery System
– Gas Metal Arc Welding (GMAW)• Inert Gas Supplied - Local Inert Atmosphere
Around Weld
– Flux Cored Arc Welding (FCAW)• Flux Embedded in ‘Hollow’ Electrode (Wire)
Industrial Processes II
CONSUMABLE ELECTRIC ARC CONSUMABLE ELECTRIC ARC WELDINGWELDING
• Provision of Non-Corrosive Provision of Non-Corrosive EnvironmentEnvironment– Electro-Gas Welding (EGW)
• Inert Gas Supplied
– Electroslag Welding (ESW)• Slag Used to Shield • Technically, Arc is Extinguished - Resistance
Used To Heat
Industrial Processes II
SHIELDED METAL ARC SHIELDED METAL ARC WELDINGWELDING
[Kalpakjian, Figure 27.4, p. 862]
Industrial Processes II
SUBMERGED METAL ARC SUBMERGED METAL ARC WELDINGWELDING
[Kalpakjian, Figure 27.7, p. 864]
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GAS METAL ARC WELDINGGAS METAL ARC WELDING
[Kalpakjian, Figure 27.8, p. 865]
Industrial Processes II
FLUX CORED ARC FLUX CORED ARC WELDINGWELDING
[Kalpakjian, Figure 27.10, p. 867]
Industrial Processes II
ELECTRO-GAS WELDINGELECTRO-GAS WELDING
[Kalpakjian, Figure 27.11, p. 868]
Industrial Processes II
ELECTROSLAG WELDINGELECTROSLAG WELDING
[Kalpakjian, Figure 27.12, p. 869]
Industrial Processes II
NON-CONSUMABLE ELECTRIC NON-CONSUMABLE ELECTRIC ARC WELDINGARC WELDING
• Basic Process DescriptionBasic Process Description– Creation of an Electrical Potential and
Exceeding the Initiation Voltage to Produce an Electrical Arc, the Heat of Which (~55,000o F) Effects the Weld; the Electrode is Not Melted by the Arc and a Separate Rod (Optional) Supplies Filler Metal to the Weld
• ParametersParameters– Distance from Electrode to Work
Determines Initiation Voltage, Temperature, Current/Frequency Determines Heat Flux
Industrial Processes II
NON-CONSUMABLE ELECTRIC NON-CONSUMABLE ELECTRIC ARC WELDINGARC WELDING
• Gas Tungsten- Arc WeldingGas Tungsten- Arc Welding– Gas Shielding
• Atomic Hydrogen WeldingAtomic Hydrogen Welding– Uses Hydrogen as Shielding
• Plasma Arc WeldingPlasma Arc Welding– Plasma (60,000o F)– Shielding Gas Used
Industrial Processes II
Gas Tungsten- Arc Gas Tungsten- Arc WeldingWelding
• [Kalpakjian, Figure 27.13, p. 872]
Industrial Processes II
Plasma Arc WeldingPlasma Arc Welding
[Kalpakjian, Figure 27.15, p. 874]
Industrial Processes II
ELECTRON BEAM WELDINGELECTRON BEAM WELDING• Basic Process DescriptionBasic Process Description
– Use of Heat Produced by High Velocity Stream of Electrons to Effect Deep Penetration Welds
• AdvantagesAdvantages– High Penetration
• ShieldingShielding– Performed in a Vacuum
• DisadvantagesDisadvantages– Cost, X-Rays Produced
Industrial Processes II
LASER BEAM WELDINGLASER BEAM WELDING• Basic Process DescriptionBasic Process Description
– Use of Heat Produced by High Intensity Beam of Light to Effect Deep Penetration Welds
• AdvantagesAdvantages– High Penetration
• ShieldingShielding– Performed in a Vacuum
Industrial Processes II
SOLID STATE METHODSSOLID STATE METHODS
• Coalescence Through PressureCoalescence Through Pressure• TypesTypes
– Resistance Welding– Cold Welding– Ultrasonic Welding– Friction Welding– Explosion Welding– Diffusion Welding
Industrial Processes II
RESISTANCE WELDINGRESISTANCE WELDING• Basic Process DescriptionBasic Process Description
– The Heating of the Base Materials Through Electrical Resistance at Material Interfaces/Discontinuities to Produce Coalescence.
• SequenceSequence– Material Surfaces Cleaned and Aligned– Electrodes Used to Clamp Components in
Place– Current Passed Through Components
(Electrodes Water Cooled), Nugget Melted– Current Turned Off, Coalescence,
Unclamped
Industrial Processes II
RESISTANCE WELDINGRESISTANCE WELDING• ParametersParameters
– Voltage• Usually Low Voltage
– Current (Amperage)• Controls Heat Flux• Usually High Current
– Time of Current Passage• Heat = I2 * Ω * t
– Total Resistance• Power = I2 * Ω
– Clamping Time/Pressure– Area of Electrode/Workpiece Contact
Industrial Processes II
RESISTANCE WELDINGRESISTANCE WELDING• TypesTypes
– Spot– Projection– Seam
• Lap• Mash• Finish
– Butt– Flash– Percussion– Induction
Industrial Processes II
RESISTANCE WELDINGRESISTANCE WELDING• Spot - Temperature DistributionSpot - Temperature Distribution
Amstead, Figure 8.10, p. 168
Industrial Processes II
RESISTANCE WELDINGRESISTANCE WELDING• SpotSpot
Kalpakjian, Figure 28.6b, p. 892
Industrial Processes II
RESISTANCE WELDINGRESISTANCE WELDING• ProjectionProjection
Amstead, Figure 8.11, p. 169
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RESISTANCE WELDINGRESISTANCE WELDING• Seam -- Lap SeamSeam -- Lap Seam
Amstead, Figure 8.12, p. 170
Industrial Processes II
RESISTANCE WELDINGRESISTANCE WELDING• Seam -- Mash SeamSeam -- Mash Seam
Amstead, Figure 8.12, p. 170
Industrial Processes II
RESISTANCE WELDINGRESISTANCE WELDING• Seam -- Finish SeamSeam -- Finish Seam
Amstead, Figure 8.12, p. 170
Industrial Processes II
RESISTANCE WELDINGRESISTANCE WELDING• Butt -- PipeButt -- Pipe
Amstead, Figure 8.14a, p. 171
Industrial Processes II
RESISTANCE WELDINGRESISTANCE WELDING• Butt -- Bar StockButt -- Bar Stock
Amstead, Figure 8.14b, p. 171
Industrial Processes II
RESISTANCE WELDINGRESISTANCE WELDING• Flash (Also Considered Arc Welding)Flash (Also Considered Arc Welding)
Kalpakjian, Figure 28.15a, p. 892
Industrial Processes II
RESISTANCE WELDINGRESISTANCE WELDING• Stud --(Also Considered Arc Welding)Stud --(Also Considered Arc Welding)
Kalpakjian, Figure 28.16, p. 898
Industrial Processes II
RESISTANCE WELDINGRESISTANCE WELDING• PercussionPercussion
Modified from Kalpakjian, Figure 28.15, p. 897
Industrial Processes II
RESISTANCE WELDINGRESISTANCE WELDING• InductionInduction
Modified from Kalpakjian, Figure 4.26a,b, p. 147
Part to be Welded
Industrial Processes II
QUESTIONSQUESTIONSOR OR
CLARIFICATIONCLARIFICATIONS ???S ???
Reminder :Reminder :