This document discusses various joining processes including welding, brazing, soldering and adhesive bonding. It covers the principles, equipment and techniques for gas welding, arc welding, resistance welding, special welding processes like TIG, MIG, plasma arc welding and friction welding. The document also discusses brazing and soldering methods, filler materials and fluxes used.
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MANUFACTURING PROCESS-I
1. 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.
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.
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)
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.
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.