Welding processes-Brazing & Soldering
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This document discusses different welding and joining processes. It begins by defining welding as a process that joins materials through heating and sometimes the use of filler material. It then discusses different types of welding processes, including plastic/pressure welding and fusion/non-pressure welding. The document further classifies welding into several categories such as arc, gas, resistance, thermit, solid state, and newer welding processes. It also discusses related processes like cutting and brazing. Finally, it provides details on brazing and soldering, defining them as lower temperature joining processes compared to welding and discussing their applications and advantages/disadvantages.
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Casting
Casting is a manufacturing process in which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify.
Design Consideration For Casting
The document discusses design considerations for castings. It notes that casting involves pouring molten material into a mold to create complex shapes. Successful casting requires controlling variables like the material, casting method, cooling rate, and gases. The document outlines design considerations like designing parts for easy casting, selecting suitable materials and processes, locating parting lines and gates, and including features like sprues and risers. It also discusses designing parts to avoid defects from things like shrinkage, stress concentrations, and uneven cooling. The document concludes by mentioning some common casting defects and factors in the economics of casting like costs of molds, materials, and production rates.
Bloom, billet, slab, plate
Bloom, billet, slab, plate, sheet, strip are terms used in metalworking and manufacturing. Blooms undergo first breakdown of ingots through hot working and have a large cross sectional area. Billets are further reduced through hot rolling. Slabs are hot rolled ingots with a specific cross sectional area and width. Plates are thick products over 6mm, while sheets are thinner but wide, and strips are thin and narrow. Blooms, billets, and slabs are considered semi-finished products.
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Sheet metal working
This document discusses sheet metal forming processes. Sheet metal forming takes a flat sheet of metal and uses mechanical forces to alter its shape. There are two main categories of sheet metal operations on a press: shearing/cutting operations and forming operations. Shearing operations like punching, blanking, and notching stress the metal beyond its strength limit. Forming operations like bending, drawing, spinning, and flanging mechanically deform the metal into the desired shape without breaking it. An example given is the process used to form aluminum cans.
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Manufacturing Technology 1 - Welding Operating principle, basic equipment, merits and applications of: Fusion welding processes : Gas welding - Types – Flame characteristics; Manual metal arc welding – Gas Tungsten arc welding - Gas metal arc welding – Submerged arc welding – Electro slag welding; Operating principle and applications of : Resistance welding - Plasma arc welding – Thermit welding – Electron beam welding – Friction welding and Friction Stir Welding; Brazing and soldering; Weld defects: types, causes and cure.
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This document is a series of lecture slides about sheet metal working and bending processes. It discusses topics like mechanics of sheet metal bending, bend allowance, numerical problems calculating blank size and bending force, springback and methods to eliminate it, including overbending and stretch forming. It also covers drawing as a sheet metal forming operation used to make cup-shaped or complex curved parts by pushing metal into a die cavity with a punch.
Forging
Forging processes involve shaping metals by applying compressive forces. There are four main types: hammer/drop forging uses gravity impacts, press forging uses hydraulic or mechanical presses, and open-die and closed-die forging differ in whether dies fully contain the metal. Forging increases strength by working the metal and altering its microstructure. Proper die and process design are needed to control metal flow, fill dies completely, and minimize flash and defects. Die materials must withstand thermal and mechanical stresses, while coatings can extend die life.
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Resistance welding is a process that uses heat generated by an electric current passing through contacting workpieces to weld them together. Spot welding is commonly used in the automotive industry to join vehicle body parts. The main types of resistance welding are spot welding, seam welding, flash welding, projection welding, and upset welding.
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There are two main categories of welding processes - fusion welding and solid state welding. Fusion welding involves melting the base metals using heat, sometimes with added filler metal. Common fusion processes are arc welding, resistance welding, and oxyfuel gas welding. Solid state welding joins metals without melting using pressure, heat, or both. Examples are forge welding and friction welding. The document then provides detailed descriptions and comparisons of various fusion welding techniques such as shielded metal arc welding, gas tungsten arc welding, plasma arc welding, and resistance spot welding.
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The document discusses various metal forming processes including rolling, forging, and extrusion. It describes rolling as reducing thickness of metal between opposing rolls. The main types are flat rolling and shape rolling, with hot rolling being most common. Forging involves compressing metal between dies to shape it. The main types are cold forging, hot forging, drop forging, and press forging. Extrusion uses compression to force metal through a die opening to produce parts with uniform cross-sections like rods.
Sheet Metal Operations
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Welding is a process that joins materials by heating them to melt or soften them and allowing them to cool, forming a permanent bond. It is commonly used to join metal parts in manufacturing. Some key types of welding include arc welding, gas welding, resistance welding, and solid state welding. Welding is used in many industries such as automotive, aerospace, shipbuilding, and construction.
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This document discusses metal forming processes. It defines forming and shaping, and provides examples of each. Metal forming involves plastic deformation of material under large external forces to change its shape. The document classifies metal forming processes as cold working, hot working, or warm working based on the temperature of the material. It also discusses properties important for metal forming like ductility and strength. Rolling, forging, extrusion, drawing, and press working are provided as examples of metal forming processes.
Welding and types
Welding is a process that joins metals by heating them to melting point and allowing them to merge together. There are two main types: plastic welding applies pressure and fusion welding fully melts the materials. Oxy-fuel welding uses a heated gas flame, such as oxy-acetylene, to melt the metals. It is inexpensive but has a lower temperature than other methods. The equipment includes welding torches, cylinders of gas, regulators to control pressure, and filler rods. Precise flame adjustment is required to protect the metal and achieve the necessary temperature.
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Deep drawing is a metal forming process where a sheet metal blank is placed over a die opening and forced into the die cavity by a punch. It is commonly used to make cylindrical or box-shaped parts like pots, pans, and automotive fuel tanks. Metals used include alloys, aluminum, brass, cold rolled steel, and copper. Lubrication is applied to reduce forces and increase formability.
welding
Fusion welding involves melting materials together using heat from sources like gas flames or electric arcs. It allows for joining of metal parts. Solid-state welding uses pressure, and sometimes heat, but no melting, to join metals. Welding is used in many industries like manufacturing, construction, and automotive as it allows for joining of metal parts that would otherwise be difficult or impossible to form as a single piece.
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Welding is a process that joins materials by heating them to melt or soften them and allowing them to cool, forming a permanent bond. It is commonly used in manufacturing to join metal parts like in automobiles, ships, and machinery. There are several types of welding including arc welding, gas welding, resistance welding, and solid state welding. Arc welding, one of the most common methods, uses an electric arc to heat and fuse metals while gas welding uses a flame from oxygen and fuel gases to do so. Welding has many applications and advantages but also limitations like safety hazards from high heat and difficulty detecting defects.
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This document is a series of lecture slides about sheet metal working and bending processes. It discusses topics like mechanics of sheet metal bending, bend allowance, numerical problems calculating blank size and bending force, springback and methods to eliminate it, including overbending and stretch forming. It also covers drawing as a sheet metal forming operation used to make cup-shaped or complex curved parts by pushing metal into a die cavity with a punch.
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Forging processes involve shaping metals by applying compressive forces. There are four main types: hammer/drop forging uses gravity impacts, press forging uses hydraulic or mechanical presses, and open-die and closed-die forging differ in whether dies fully contain the metal. Forging increases strength by working the metal and altering its microstructure. Proper die and process design are needed to control metal flow, fill dies completely, and minimize flash and defects. Die materials must withstand thermal and mechanical stresses, while coatings can extend die life.
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There are two main categories of welding processes - fusion welding and solid state welding. Fusion welding involves melting the base metals using heat, sometimes with added filler metal. Common fusion processes are arc welding, resistance welding, and oxyfuel gas welding. Solid state welding joins metals without melting using pressure, heat, or both. Examples are forge welding and friction welding. The document then provides detailed descriptions and comparisons of various fusion welding techniques such as shielded metal arc welding, gas tungsten arc welding, plasma arc welding, and resistance spot welding.
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This document provides information on various welding processes and techniques. It begins by defining welding as joining metals through heat, pressure, or both. It then lists and describes common welding types including arc welding, oxyfuel gas welding, and resistance welding. The document focuses on explaining different arc welding processes such as shielded metal arc welding, submerged arc welding, flux-cored arc welding, gas metal arc welding, gas tungsten arc welding, plasma arc welding, and carbon arc welding. It also provides brief descriptions of oxyfuel gas welding and resistance welding.
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The document discusses various metal forming processes including rolling, forging, and extrusion. It describes rolling as reducing thickness of metal between opposing rolls. The main types are flat rolling and shape rolling, with hot rolling being most common. Forging involves compressing metal between dies to shape it. The main types are cold forging, hot forging, drop forging, and press forging. Extrusion uses compression to force metal through a die opening to produce parts with uniform cross-sections like rods.
Sheet Metal Operations
Sheet metal operations are cold-working processes that can manufacture low-cost metal parts in high volumes quickly. Sheet metal is metal between 0.006-0.25 inches thick that can be cut, bent, or stretched into various shapes. Common sheet metal operations include embossing to add raised or sunken designs using heat and pressure, coining to add similar impressions to both sides, spinning to shape metal over a rotating mandrel, stretch forming to simultaneously stretch and bend metal over a die, and nibbling which cuts contoured shapes using overlapping slits.
Friction stir welding (sfw)
One of the welding processes that used in Engineering field is friction stir welding.
Thanks for the colleagues who give this slides to publish.
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- Heat is generated in three zones during machining: the primary deformation zone, tool-chip interface, and tool-workpiece interface. Heat depends on factors like material properties and cutting parameters.
- High temperatures can damage tools and workpieces. Cutting fluids help reduce temperatures by conduction and convection of heat away from the cutting zone.
- Temperature is commonly measured using tool-workpiece thermocouples, which generate electrical signals related to temperature at the cutting interface.
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1. Welding is a metal joining process that involves applying heat, pressure, or both to joining materials. There are several types of welding processes including solid state welding, fusion welding, and pressure welding.
2. Solid state welding joins metals below their melting point using mechanical pressure and heat. Examples are cold welding, ultrasonic welding, friction welding, and friction stir welding.
3. Resistance welding generates heat for welding through electrical resistance across components. Common resistance welding methods are spot welding, seam welding, and projection welding.
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Welding is a process that joins materials by heating them to melt or soften them and allowing them to cool, forming a permanent bond. It is commonly used to join metal parts in manufacturing. Some key types of welding include arc welding, gas welding, resistance welding, and solid state welding. Welding is used in many industries such as automotive, aerospace, shipbuilding, and construction.
Forming process forging
The document discusses two main forging processes: open die forging and closed die forging. Open die forging uses simple flat dies and is used for large or low volume parts. Closed die forging uses carefully machined matching dies to produce parts to close tolerances. The process involves preforming billets, rough forging in blocking dies, finishing in final dies, and trimming flash. Closed die forging produces parts with good dimensions and properties but requires high die costs for small volumes.
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This document discusses metal forming processes. It defines forming and shaping, and provides examples of each. Metal forming involves plastic deformation of material under large external forces to change its shape. The document classifies metal forming processes as cold working, hot working, or warm working based on the temperature of the material. It also discusses properties important for metal forming like ductility and strength. Rolling, forging, extrusion, drawing, and press working are provided as examples of metal forming processes.
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Welding is a process that joins metals by heating them to melting point and allowing them to merge together. There are two main types: plastic welding applies pressure and fusion welding fully melts the materials. Oxy-fuel welding uses a heated gas flame, such as oxy-acetylene, to melt the metals. It is inexpensive but has a lower temperature than other methods. The equipment includes welding torches, cylinders of gas, regulators to control pressure, and filler rods. Precise flame adjustment is required to protect the metal and achieve the necessary temperature.
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welding
Fusion welding involves melting materials together using heat from sources like gas flames or electric arcs. It allows for joining of metal parts. Solid-state welding uses pressure, and sometimes heat, but no melting, to join metals. Welding is used in many industries like manufacturing, construction, and automotive as it allows for joining of metal parts that would otherwise be difficult or impossible to form as a single piece.
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Design for casting and weldments design of casting
Design for casting and weldments
design of casting
Welding
Welding is a process that joins materials by causing fusion and filling the joint with a filler material. There are several advantages to welding including lighter structures, maximum strength in joints, easy alterations, pleasing appearance, and strength equal to the parent material. Spot welding uses two electrodes to locally fuse materials and is commonly used in automotive and aircraft industries to join sheet metal. MIG welding uses an inert gas shield to prevent contamination and is often used for carbon/alloy steels, stainless steel, aluminum and other metals due to its high welding speed and economy. Common welding defects include lack of penetration, undercut, slag inclusion, porosity, cracks, spatter, and distortion.
Welding & joining
1. The document discusses various welding and joining processes including fusion welding, pressure welding, brazing, and soldering. It describes the principles, temperatures involved, and common applications of each process.
2. Various welding heat sources are discussed along with their impacts on temperature distribution and weld properties. Main welding techniques covered include gas welding, arc welding methods like shielded metal arc welding and gas tungsten arc welding, and their characteristics.
3. Weld quality and non-destructive testing methods are summarized, focusing on defects like porosity and cracks that can be detected using techniques like radiography and liquid penetrant testing to evaluate weld integrity without damage.
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Welding processes-Brazing & Soldering
- 1. Welding Processes. Brazing and Soldering Prof. Yagnesh J Gambhava. Assistant Professor Automobile Engineering Department A.D.Patel Institute of Technology, Gujarat
- 2. Introduction to Welding – Welding is a materials joining process which produces coalescence (joint) of materials by heating them to suitable temperatures with or without the application of pressure or by the application of pressure alone, and with or without the use of filler material. – Welding is used for making permanent joints. – It is used in the manufacture of automobile bodies, aircraft frames, railway wagons, machine frames, structural works, tanks, furniture, boilers, general repair work and ship building.
- 3. TYPES Plastic Welding or Pressure Welding The piece of metal to be joined are heated to a plastic state and forced together by external pressure (Ex) Resistance welding Fusion Welding or Non-Pressure Welding The material at the joint is heated to a molten state and allowed to solidify (Ex) Gas welding, Arc welding
- 4. Classification of welding processes: (I). Arc welding Carbon arc Metal arc Metal inert gas Tungsten inert gas Plasma arc Submerged arc Electro-slag (ii). Gas Welding Oxy-acetylene Air-acetylene Oxy-hydrogen (iii). Resistance Welding Butt Spot Seam Projection Percussion (iv)Thermit Welding (v)Solid State Welding Friction Ultrasonic Diffusion Explosive (vi)Newer Welding Electron-beam Laser (vii)Related Process Oxy-acetylene cutting Arc cutting Hard facing Brazing Soldering
- 5. Brazing and Soldering Brazing A joining process in which filler metal is placed at or between the surfaces to be joined. The temperature is raised to melt the filler metal but not the work piece. Braze melts between 840-2400 degrees F The filler material is in thin layers compared to base metal The filler penetrates the gap by capillary attraction Can connect dissimilar metals Brazing can be classified as Torch brazing Dip brazing Furnace brazing Induction brazing
- 6. • A variety of alloys are used as filler metals for brazing depending on the intended use or application method. In general, braze alloys are made up of 3 or more metals to form an alloy with the desired properties. The filler metal for a particular application is chosen based on its ability to: wet the base metals, withstand the service conditions required, and melt at a lower temperature than the base metals or at a very specific temperature. Some of the more common types of filler metals used are: • Aluminum-silicon • Copper • Copper-phosphorus • Copper-zinc (brass) • Gold-silver • Nickel alloy • Silver
- 7. Brazing
- 9. Advantages & Disadvantages Advantages Dissimilar metals which cannot be welded can be joined by brazing Very thin metals can be joined Metals with different thickness can be joined easily In brazing thermal stresses are not produced in the work piece. Hence there is no distortion Using this process, carbides tips are brazed on the steel tool holders Disadvantages Brazed joints have lesser strength compared to welding Joint preparation cost is more Can be used for thin sheet metal sections
- 10. Soldering It is a low temperature joining process. It is performed at temperatures below 840ºF for joining. Soldering is used for, Sealing, as in automotive radiators or tin cans Electrical Connections Joining thermally sensitive components Joining dissimilar metals
- 12. Thank You