Plasma arc and friction welding
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The document discusses two welding techniques: plasma arc welding and friction welding. Plasma arc welding uses a non-consumable tungsten electrode and very high temperatures, between 8,000 to 25,000°C, to weld materials. It can weld ferrous and non-ferrous metals up to 6mm thick using a DC power source of 70V and currents from 50 to 350 amps. Friction welding involves mechanically inducing sliding motion between two rubbing surfaces below their melting points, but at temperatures high enough to create plastic flow and welding. It is used to weld materials like aluminum and alloys, brass, and steel at rotational speeds of 1,500 to 3,800 rpm and contact pressures of
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Welding iv
The welding procedure specification provides direction for welding production joints using the shielded metal arc welding (SMAW) process. It specifies welding double-V groove joints in ASTM SA 516 Grade 70 steel from 4.76 to 50 mm thick using 2.5, 3.15, or 4.0 mm diameter E7018 electrodes. Welding is done in all positions with a preheat of 150°C minimum for thicknesses over 19mm. The procedure qualifies for full penetration groove and fillet welds.
stick welding is a manual arc welding process that uses a consumabl...
Shielded metal arc welding (SMAW),
Also known as Manual Metal Arc (MMA) welding
Informally as stick welding
Variable transformer pr
Shorting of more than one turn through Carbon Brush.( Voltage per turn affect). In windings with thinner wires that have high resistance perturn - this heating is lower in comparison to large heating on thicker wires. In Dimmers of 2 Amps, -this heating is very low in comparison to 200 A coil
Plasma Arc Machining (Modern Manufacturing Process)
Plasma arc machining (PAM) uses a plasma torch to cut metals. It was initially developed to cut difficult metals like stainless steel and aluminum. Recent improvements allow it to cut mild steel with improved cut quality compared to earlier plasma cutting. The plasma is generated by heating gas with an electric arc until it ionizes, producing free electrons and ions that conduct electricity. PAM works by melting metal with the high temperature plasma jet and blowing away the molten metal. Key parameters that affect PAM performance include the plasma torch design, the physical setup configuration, and the operating environment.
experimental investigation of gas metal arc welding (gmaw) on 2.25
This document summarizes an experimental investigation of gas metal arc welding (GMAW) on 2.25 CR-1MO steel. It describes the GMAW process and equipment used, including a 400-amp ESAB welding machine. The document discusses the properties of 2.25 CR-1MO steel, including its tensile strength, hardness, and strength. It also details the experimental procedure, which involves butt welding steel plates with 1.6mm electrode wire at high heat input settings to study weld properties like microstructure and hardness.
Plasma arc machining 5 unit
Plasma arc machining uses a high-temperature plasma stream to cut metals. It melts and vaporizes metal using the concentrated heat of an electrical arc formed through an ionized gas jet. This allows it to cut materials like stainless steel and aluminum that are difficult to cut with oxyfuel. It provides rapid cutting speeds, can cut a wide range of materials and thicknesses, and is more economical than oxyfuel for many applications.
Plasma arc machining 5 unit
Plasma arc machining uses a high-temperature plasma stream to cut metals. It melts and vaporizes metal using the concentrated heat of an electrical arc formed through an ionized gas jet. This allows it to cut materials like stainless steel that are difficult to cut with oxyfuel. It provides rapid cutting speeds, can cut a wide range of materials and thicknesses, and is more economical than oxyfuel for many applications.
Sem2
The document investigates the fundamentals of tool electrode wear in dry electrical discharge machining (DEDM). Spectroscopic analysis of DEDM plasma shows that single discharges with a copper tool electrode and aluminum workpiece have characteristics of hot anode vacuum arcs. The anode is active while the cathode is passive, resulting in relatively large workpiece erosion but very small tool wear. Inverting electrode polarity substantially changes the plasma characteristics and makes both electrodes active, increasing tool wear.
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stick welding is a manual arc welding process that uses a consumabl...
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Plasma Arc Machining (Modern Manufacturing Process)
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experimental investigation of gas metal arc welding (gmaw) on 2.25
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Milling machine
Milling is a machining process where a rotary cutter removes material from a workpiece via multiple cutting edges. Milling machines have various specifications including table size, spindle speeds, taper, and weight. Advantages are faster material removal and ability to mount multiple cutters, while disadvantages include high cost and investment in cutters. Common milling machines include horizontal, vertical, universal, and special types based on the column, table, or planer design. Workholding and cutterholding devices are used along with indexing heads for dividing and gear cutting operations.
Shaper machine
The document discusses the shaper machine, which is a reciprocating machine tool used to produce flat surfaces. It has a ram, tool head, and table. The tool head cuts on the forward stroke and returns idle on the back stroke. Flat surfaces can be made horizontally, vertically, or at angles based on the movement of the tool head and table. Shapers are classified based on ram travel direction and cutting stroke action. Other machine tools discussed include the planer, slotter, drilling machines, and broaching machines.
Lathe machine
The document provides information on the history and evolution of lathe machines. It describes early lathe models that were powered manually like the strap lathe, bow lathe, and pole lathe. It then discusses more advanced lathes that used mechanical power sources like the treadle lathe and lathes powered by a great wheel. The document also outlines the main components of a lathe like the headstock, spindle, tailstock, carriage, and tooling. It provides details on workholding devices, lathe operations, and different types of lathes used for various applications.
Stretch forming operations
Stretch forming is a manufacturing process where sheet metal is stretched and bent simultaneously over a die to form large contoured parts. It is performed on a stretch press, where the sheet metal is gripped along the edges by jaws attached to carriages that stretch the sheet against a contoured form die. Special forming processes include hydro forming, where hydraulic fluid acts as a flexible die; rubber pad forming, where sheet metal is pressed between a die and rubber block; and metal spinning, where force is applied to sheet metal wrapped over a rotating mandrel to take its shape.
Bending and drawing
The document discusses bending operations in sheet metal manufacturing. There are two main types of bending: V-bending and edge bending. V-bending is done with a V-shaped die for low production, while edge bending uses a pressure pad and more complex dies for high production. When metal is bent, the inside of the neutral plane is compressed and the outside is stretched. After bending, springback occurs as the bent part partially recovers toward its original shape due to residual elastic energy.
Sheet metal processes - shearing
This document discusses sheet metal processes and operations. Sheet metal is metal formed into thin, flat pieces that can be cut and bent into various shapes. Common materials for sheet metal include steel, aluminum, copper, and other metals. Key sheet metal operations covered include shearing, blanking/punching, bending, drawing, deep drawing, stamping, and others. Factors that influence these operations such as punch and die design, clearance, and lubrication are also addressed.
Extrusion
This document discusses the manufacturing process of extrusion. Extrusion is a compression forming process that forces metal to flow through a die opening to produce a desired cross-sectional shape. There are two main types of extrusion: direct extrusion where the ram forces the billet through the die, and indirect extrusion where the die is mounted to the ram. Extrusion can be performed hot or cold, and defects may occur such as center-bursting or piping due to excessive stresses during the process. Variations on extrusion include impact extrusion for discrete parts and hydrostatic extrusion which uses pressurized liquid to reduce friction.
Rolling
The document discusses various types of rolling mills used to roll metals, including two high, three high, two high reverse, four high, multi, universal, and planetary rolling mills. It describes the basic setup and functions of two high, three high, two high reverse, four high, and cluster rolling mills. Additionally, it mentions tandem, universal, and planetary rolling mills as well as shape rolling operations like ring and thread rolling. Finally, it lists some common defects in rolled metal parts.
Forging
This document discusses various manufacturing technologies related to forging. It describes forging as a metalworking process involving plastic deformation between dies to achieve a desired shape. Forging can be classified based on the process (open die or closed die) or equipment (drop, power hammer/press, hand, or machine forging). The document outlines the key characteristics and applications of these different forging methods. It also describes various forging tools and common forging operations like upsetting, drawing down, setting down, bending, punching, welding, and cutting.
Hot and cold working process, drawing tube, wire and spinning
The document discusses various bulk deformation processes used to shape metals, including hot working, cold working, drawing, and metal spinning. Hot working involves shaping metals above their recrystallization temperature using processes like rolling, forging, and extrusion. Cold working shapes metals below the recrystallization temperature through drawing, bending, and squeezing, increasing strength but decreasing ductility. Drawing is used to produce wires, rods, and tubes by pulling the metal through a die to reduce its size. Metal spinning forms axisymmetric parts by pressing a rotating workpiece against a mandrel using a tool.
Welding defects, soldering and brazing
The document discusses various welding defects that can occur. It divides defects into two categories: external defects, which include incorrect profile, cracks, crater, spatter, and edge melting; and internal defects such as blowholes, cracks, inclusions, and lack of fusion. Specific external defects described include overlap, undercut, excessive penetration, convexity, and concavity. Internal defects result from dissolved gases, inclusions of foreign materials, and incomplete fusion or penetration. The document also covers soldering and brazing processes.
Electron beam and thermit welding
The document discusses two welding processes: electron beam welding and thermit welding. Electron beam welding uses a concentrated beam of electrons to melt and fuse base metals in a vacuum chamber, allowing for high purity welds of dissimilar metals. However, it has high costs and downtime for pumping the vacuum chamber. Thermit welding uses an exothermic reaction between aluminum and a metal oxide to produce enough heat to melt metals for welding without external energy. The reaction separates into a superheated metal and aluminum oxide slag. Thermit welding is used to join shafts, railway tracks, and machinery frames.
Electric arc welding processes metal arc welding, tungsten inter gas
The document discusses various electric arc welding processes. It focuses on metal arc welding and gas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG) welding. Metal arc welding uses an electric arc between an electrode and base metal to weld pieces together. It can be done in various positions and with different materials but is slower than other processes. GTAW uses a tungsten electrode and inert shielding gas to weld reactive metals without contamination. It produces high quality welds but requires more complex equipment than other arc welding methods.
Metal Casting - Manufacturing Technology 1
The document discusses manufacturing technology and focuses on sand casting. It defines key terms like manufacturing, technology, and manufacturing technology. It then discusses the history and process of metal casting. The main focus is on sand casting, including its definition, the 6 step process, and types like green sand and dry sand. Pattern materials and allowances are explained. Finally, it touches on moulding sand constituents, properties, core making, and sand testing methods.
Oxy fuel gas welding
The document discusses oxy-fuel gas welding (OFW), specifically oxy-acetylene gas welding. It describes OFW as a group of welding processes that produces coalescence by heating materials with an oxy fuel gas flame. Four distinct OFW processes are listed: oxy-acetylene welding, oxy-hydrogen welding, air-acetylene welding, and pressure gas welding. The document then focuses on oxy-acetylene gas welding, explaining how oxygen and acetylene gases are produced and stored in cylinders, as well as the equipment used, including cylinders, regulators, hoses, welding torch, and safety devices.
Introduction to joining process, welding classification,terminology,positions
The document discusses various metal joining processes with a focus on welding. It defines welding as the process of joining two metal pieces in a permanent manner using heat, with or without pressure. Various types of welding processes are classified based on whether filler material is used, the type of filler material if used, and whether fusion, plastic deformation, or solid-state joining occurs. Key terms related to welding such as filler metals, fluxes, and welding positions are also defined. The document provides an overview of metal joining processes and fundamentals of welding.
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Hot and cold working process, drawing tube, wire and spinning
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- 1. MANUFACTURING TECHNOLOGY – I CRAFTED BY: RAMESH KUMAR A ASSISTANT PROFESSOR SONA COLLEGE OF TECHNOLOGY SALEM 07-02-2019 05:38 1
- 2. PLASMA ARC WELDING 07-02-2019 05:38 2
- 3. PLASMA ARC WELDING 07-02-2019 05:38 3
- 4. PLASMA ARC WELDING… Non-consumable tungsten electrode Transferred arc – workpiece in positive and electrode in negative Non-transferred arc – between electrode in negative and water- cooled constricting nozzle in positive Temperatures between 8000 to 25000°C depend upon plasma gas Such temperatures are attained by the constriction of the arc, by forcing the arc through a water cooled constricting nozzle at the bottom end of the inner gas cup Thereby reducing the arc diameter and consequently increasing current density, which results in increase in pressure, temperature and heat intensity of the arc Two inert gas – plasma and shield 07-02-2019 05:38 4
- 5. PLASMA ARC WELDING… DC power source – 70V Currents – 50 to 350 amps Voltage – 27 to 30V DCSP except Al Argon He or mixture of He and Ar Ferrous and non-ferrous metals Upto 6mm Radiators, exhaust manifolds, air ducting, metal mesh, fine wires, etc., 07-02-2019 05:38 5
- 6. PLASMA ARC WELDING… 07-02-2019 05:38 6
- 9. FRICTION WELDING… Mechanically induced sliding motion between the two rubbing surfaces Temperatures developed are below the melting point of the metals being welded but high enough to create plastic flow and inter-molecular welding Under pressure during welding Rotational speed – 1500 rpm (carbon steels) to 3800 rpm (aluminum) Contact pressure – 280 kg/cm2 (Al) to 525 kg/cm2 (steel) Welding time – 15s Materials – Al and alloys, brass, bronze, stainless steel, nickel alloys, carbon steels etc., Applications: Automobile industries Bimetallic shafts 07-02-2019 05:38 9