welding lecture 1 welding introduction
TRANSCRIPT
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7/29/2019 Welding Lecture 1 Welding Introduction
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3/29/2013 Prof.Dr.Adel M. abdelmaboud 1
1-Welding Definition
Welding is a material joining process inwhich two or more parts arejoined together
at their contacting surfaces by a suitable
application ofheatand/orpressure. In some welding process a filler materialis
added to facilitate coalescence.
Welding is most commonly associatedwith metallic partsbut for plastics also it is
used.
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7/29/2019 Welding Lecture 1 Welding Introduction
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3/29/2013 Prof.Dr.Adel M. abdelmaboud 2
\ \..Resistance Welding\9-Weld Procedures UtubeWelding Videos - ARO Technologies - Projection Welding.flv
\ \..ARC WELDING\1-Arcwelding . MPG
\ \..Gas Welding\2 - oxy acetylene welding andbrazing.flv
\ \..Friction Welding\9-Weld Procedures Utube
Welding Videos - Inertia Friction Welding Demonstration -Manufacturing Technology_ Inc..flv
\ \..Resistance Welding\5-Seam
welding machine.flv\ \..Resistance Welding\2-Spot
welding 99.9% Aluminum with DeltaSpot.flv
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Welding
Advantage:1. Provides permanent joint.
2. The welded joint can be stronger than the parentmaterials .
3. The welding joint most economical method to join interms of material usage and fabrication costs.
Limitations:
1. Expensive in the terms of Labor costs (performedmanually).
2. Dangerous because they involve the use of highenergy.
3. Can suffer from certain quality defects that are difficultto detect.
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2-Welding History
Thermit Welding (1903)
Cellulosic Electrodes (1918)
Arc Stud Welding (1918)
Seam Welding of Tubes (1922) Mechanical Flash Welder for Joining Rails
(1924)
Extruded Coating for MMAW Electrodes (1926)
Submerged Arc Welding (1935)
Air Arc Gouging (1939)
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Welding history
Inert Gas Tungsten Arc (TIG) Welding (1941)
Iron Powder Electrodes with High Recovery (1944)
Inert Gas Metal Arc (MIG) Welding (1948)
Electro Slag Welding (1951)
Flux Cored Wire with CO 2 Shielding (1954)
Electron Beam Welding (1954)
Constricted Arc (Plasma) for Cutting (1955)
Friction Welding (1956)
Plasma Arc Welding (1957)
Electro Gas Welding (1957)
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Welding history
Short Circuit Transfer for Low Current, LowVoltage Welding with CO 2 Shielding (1957)
Vacuum Diffusion Welding (1959)
Explosive Welding (1960) Laser Beam Welding (1961)
High Power CO 2 Laser Beam Welding (1964)
All welded Liberty ' ships failure in 1942, gave abig jolt to application of welding. However, it haddrawn attention to fracture problem in weldedstructures
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3-Welding Applications
General Applications
Welding is vastly being used forconstruction of transporttankers for transporting oil, water, milk and fabrication ofwelded tubes andpipes, chains, LPG cylinders and otheritems. Steel furniture, gates, doors and door frames,body and other parts of white goods items such asrefrigerators, washing machines, microwave ovens andmany other items of general applications are fabricatedby welding.
Pressure Vessels
One of the first major use of welding was in the fabricationofpressure vessels. Welding made considerableincreases in the operating temperatures and pressurespossible as compared to riveted pressure vessels.
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Welding Applications
Building Structures
Aircraft and Spacecraft
Railways
Micro-Joining Electrical Industry:Nuclear Installations
Defense Industry
Electrical Industry:
Nuclear InstallationsDefense Industry
Micro-Joining
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4-Type of welding joints
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Type of welding joints
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5-Types of Welds
A :inside single fillet corner joint
B :out side single fillet corner joint
C: Double fillet lap joint
D: Double fillet tee jointDashed lines show the original part edges
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Types of groove welds
A: Square groove weld one side
B: Single bevel groove weld C: Single V groove weld
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Types of groove welds
D: Single U groove weld
E: Single J groove weld F: Double V groove weldDashed lines show the original part edges
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Types of Welds
A: Plug weld
B: Slot weld
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Types of Welds
A: Spot weld
B: Seam weld
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Types of Welds
A : Flange weld
B: Surface welding
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Joint Configuration
Butt Weld
1= Groove Face
2= Root Opening 3= Groove Angle
4= Root Face
5=Plate thickness
6=Bevel Angle 1 2
3
4
5
6
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Joint Configuration
Parts of a butt weld
Weld Face
Weld Root
Toe of Weld
both side
Face or Weld
Reinforcement
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Joint Configuration
Parts of a butt weld
Heat Affected
Zone (HAZ)
Weld Metal
Groove Faces
Cap
Root
Base
Metal
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6-Welding Classification (Types)
Types of Welding Processes
I-Liquid state welding processes (Fusion).
II-Solid state welding processes.III-Solid / Liquid state bonding processes.
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I-Liquid state welding processes (Fusion)
Use heat to melt the base metals.
A fillermetal is added.
A fusion welding with no filleris referred to as autogenousweld.
There are two inherentproblems with fusion welding:
Effect of localized heating and rapid cooling on themicrostructure and properties of the parent metals.
Effect ofresidual stresses developed in the parent
metals due to restrained expansion or contraction.This effect the impact of fatigue life of weldment
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Liquid state welding processes (Fusion)
Examples
1. Arc Welding (AW).
2. Resistance welding (RW) .
3. Oxyfuel Welding (OFW) .4. Other Processes:
(Electron beam welding and Laser beam welding.)
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1-Arc Welding (AW)
Heating of the metals with electric arc
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2-Resistance welding (RW)
Using heat from electric resistance to the
flow of a current passing between the
faying surface of two parts held together
under pressure.
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3-Oxyfuel Welding (OFW)
Heating with a mixture oxygen and
acetylene (oxyfuel gas).
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II-Solid state welding processes.
In solid state welding the surfaces to be joinedare brought into close proximity by:
1. Heating the surfaces without causing meltingand applying normal pressure.
2. Providing relative motion between the twosurfaces and applying light normal pressure.
3. Applying high pressure without heating.
In these processes the materials remain in solid
state and welding is achieved through theapplication of heat and pressure, or highpressure only (No melting, No fillers ).
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Solid state welding processes
Examples
1. Friction welding (FW).
2. Diffusion welding (DFW).
3. Ultrasonic welding (USW ).
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1-Friction welding (FRW)
Coalescence is achieved by the heat of
friction between two surfaces.
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2-Diffusion welding (DFW)
Two surfaces are held together under pressure at an at
an elevated temperature and the parts coalesce by solid
state fusion.
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Diffusion welding (DFW) is a solid state
welding process by which two metals (which
may be dissimilar) can be bonded together.
Diffusion involves the migration ofatoms across
the joint, due to concentration gradients.
The two materials are pressed together at anelevated temperature usually between 50 and
70% of the melting point.
The pressure is used to relieve the void that may
occur due to the different surface topographies.
http://en.wikipedia.org/wiki/Weldinghttp://en.wikipedia.org/wiki/Metalhttp://en.wikipedia.org/wiki/Atomhttp://en.wikipedia.org/wiki/Melting_pointhttp://en.wikipedia.org/wiki/Melting_pointhttp://en.wikipedia.org/wiki/Atomhttp://en.wikipedia.org/wiki/Metalhttp://en.wikipedia.org/wiki/Welding -
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3-Ultrasonic welding (USW )
Moderate
pressure is
applied
between the
two parts withultrasonic
oscillating
motion
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Ultrasonic welding
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III-Solid / Liquid state bonding processes
In these processes, the braze metal, solder,
or an adhesive is applied to the joint in
liquid state while the materials to be
joined remains in a solid state, that is,they do not melt.
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7-Features of a fusion welded joint
Fusion zone
Weld
interface
Heat affected
zone (HAZ) Unaffected
base metal
(BM
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Regions of a Fusion Weld
Fusion zone (FZ)
Weld interface
Heat affected zone (HAZ) Unaffected base metal (BM)
BMHAZFZ
http://upload.wikimedia.org/wikipedia/commons/0/0d/Welded_butt_joint_x-section.pnghttp://upload.wikimedia.org/wikipedia/commons/0/0d/Welded_butt_joint_x-section.pnghttp://upload.wikimedia.org/wikipedia/commons/0/0d/Welded_butt_joint_x-section.pnghttp://upload.wikimedia.org/wikipedia/commons/0/0d/Welded_butt_joint_x-section.png -
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8-Welding Symbols
Examples: Single V Butt Weld
1/8
1/8 root
opening
1/875 deg
75 deg
75 deg. groove angle
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WELDING SYMBOL
Staggered intermittent fillet weld
3-10
3-10
Fillet weld side view
10
3
(3/8)
(3/8)
3/8
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WELDING SYMBOL
Single V Groove
Double V Groove
Single Bevel Groove
Double Bevel Groove