6/1/2009

Welding

Jim Johnson
Zach Kirsch
Ross McKenzie

Topics to be Covered

Welding Topics:
„ MIG

„ TIG

„ Stick

„ Diffusion

„ Friction

„ Explosion

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MIG Welding

„ Metal Inert Gas (MIG)

or Gas Metal Arc
Welding (GMAW)
„ DC or AC (rare)
Electric Arc
„ Consumable electrode
„ Shielding Gas

MIG - History
„ Developed in 1940’s to
weld aluminum,
aluminum
magnesium, and other
non--ferrous alloys
non
„ Use in steel was originally
limited by cost of Inert gas
– It the early 1950’s carbon
dioxide was used as shielding
gas for steel greatly reducing
the cost
„ Further developments
through the 1960’s
increased the versatility of
the process
– Today GMAW is the most
commonly used industrial
welding process

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MIG - Equipment
„ (1) Welding Torch
– Controls
C t l arc, gas, wire
i feed
f d
„ (2) Workpiece
„ (3) Power Supply
-Typically constant voltage DC
„ (4) Wire Feed Mechanism
„ (5) Electrode
– Usually similar material as
workpiece
– Contains small amounts of
deoxidizing metals (Si, Mg, Al)
„ (6) Shielding Gas
– Typically argon-
argon-CO2 mix

MIG - Process
„ Arc creates weld p
pool to bond
material
– DC Constant Voltage with
positively charged electrode –
reverse polarity requires special
electrode
„ Shielding gas protects the
weld pool from atmospheric
gas effects
g
– Porosity and embrittlement
„ Technique
– Simple: electrode is fed
automatically
– Torch is guided along weld area
keeping a constant tip to
workpiece distance

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MIG – Capabilities
„ Inexpensive machines ($500)
„ R
Required
i d skill
kill level
l l is
i relatively
l ti l
low
„ Can weld many ferrous and non non--
ferrous materials
– Different results and requirements
must be expected (shielding gas,
technique, electrode, etc)
„ Power of machine will determine
what it can weld
– More power – thicker material
„ GMAW can be automated more
easily than other methods

MIG - Industries
„ Automotive
– Almost exclusive
„ Pressure Vessels
„ Heavy rail and
construction equipment

„ At Home
– Easy and inexpensive
„ Automobile/Agricultural
repair

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TIG - Welding

„ T
Tungsten
t IInertt G
Gas
(TIG) or Gas Tungsten
Arc Welding (GTAW)
„ AC or DC Electric Arc
„ Non--consumable
Non
tungsten electrode
l d
„ Shielding Gas
„ Hand fed filler

TIG - History
„ Early 1900’s
1900 s welding
non--ferrous materials
non
was difficult
– Reacted with air making
welds weak and porous
„ Process was improved
in the 1930’s and
1940’s
1940 s
– Gas shielding increased
weld quality
– AC machines allowed for
high quality welds on
aluminum and
magnesium

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TIG - Equipment
„ Welding Torch
– Di t shielding
Directs hi ldi gas and
d holds
h ld
electrode
„ Power Supply
– AC typically used for aluminum and
magnesium
– DC with a negatively charged
electrode is typically used for steels
„ Electrode
– Made from tungsten or tungsten
alloys
– ISO standards for each alloy
„ Filler Rod
„ Shielding Gas
– Argon is most common
– Helium is sometimes used when
welding aluminum and copper

TIG - Process
„ Arc creates weld pool to bond
material
– AC or DC used depending on
base material
„ Shielding gas protects the weld
pool from atmospheric gas
effects
– Porosity and impurities
„ Technique
– Requires
q two hands
– Torch is moved forward as filler
rod is dipped into the weld pool
– Filler rod must remain inside
the gas shield at all times
– Considered one of the most
difficult welding methods – low
melt alloys increase difficulty

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TIG – Capabilities
„ Produces welds with very similar material
properties of the base metal
„ GTAW can produce high quality welds on
materials such as aluminum, magnesium,
titanium, copper, nickel, steel.
„ Dissimilar materials – copper and stainless
at Zak
„ Requires a skilled welder – considered to be
one of the more difficult types of welding
„ Automation is possible, but not as common
as GMAW due to the increase complexities

TIG - Industries
„ Aircraft
„ Spacecraft
„ Bicycles

„ Crack repair
– Aluminum wheels and
engine blocks

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Shielded Metal Arc Welding

(Stick Welding)
„ Common welding
technique
„ Stick is synonymous
with coated electrode

http://atpwelding.com/welding.jpg

Basic Principles
„ Arc created between
metal and electrode
„ Metal is melted and
coalesces to form weld

http://www.twi.co.uk/j32k/protected/band_3/jk2.html

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Coating
„ Different coatings for
different applications
„ Cellulosic, Rutile, and
Limestone are common
„ Coatings ease process
through slag creation,
and help to strengthen
weld

http://www.twi.co.uk/j32k/twiimages/jk82f1.jpg

Advantages/Disadvantages

Advantages: Disadvantages:
„ Simple „ Limited shielding
„ Portable „ Limited Deposition rates
„ Versatile „ Usually done by hand
„ Inexpensive „ Highly trained labor
equipment
q p required
q

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Diffusion Welding
„ Also known by:
diffusion bonding, solid
state bonding
„ Can be used to join
metals and ceramics
that otherwise can’t be
joined

http://www.turktoz.gazi.edu.tr/en_makale_files/image037.jpg

Diffusion Welding
“Diffusion
Diffusion Welding is a solid
solid--state welding process
that produces a weld by the application of
pressure at elevated temperature with no
macroscopic deformation or relative motion of the
work pieces.”

-American Welding Society description

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Basic Principles
„ Two materials are
heated and pressed
upon one another
„ Pressure causes heated
atoms to diffuse into
surface, creating a
bond upon
recrystalization
„ D=D0e-(Q/KT) Messler 1999

Equipment
„ A press is needed,
needed
which can create
pressure in a variety of
ways
„ Heat needs to be
generated as well
„ Fixturing system
required

http://frisch-gmbh.de/images/sinteranlage.jpg

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Advantages/Disadvantages

Advantages Disadvantages
„ “Perfect” weld possible „ Only perpendicular
„ Special material surfaces
properties „ Specially designed
„ Even weld properties components
throughout material „ Requires inert
„ Close tolerances atmosphere
„ Expensive materials „ Expensive

Friction Welding
(FW)
„ Solid state welding
process
„ Generates heat through
friction between moving
surfaces
„ Heat in combination
with lateral force called
“upset” fuses two
materials together
„ First Patent for the
development of FW was
applied for in 1891

http://www.fortunecity.com/village/lind/247/weld_book/fig10-79.gif

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Types of Friction Welding

„ Spin Welding (inertia,
(inertia rotational
rotational, inertial friction)
„ Linear Friction Welding (LFW)
„ Friction Stir Welding
„ Friction Surfacing

Spin Welding
„ Involves the rotation of one
surface relative to another
while applying pressure along
the axis of rotation
„ Work pieces are held by
chucks in spin welding
machines
„ Flywheel is used to store the
energy
gy produced
p byy the motor
„ Requires circular joining points

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Linear Friction Welding

„ Lateral motion of surfaces
rather than rotational
„ Most surface can be joined

Image: http://www.twi.co.uk/j32k/twiimages/spswksep99f9.gif

Image: http://www.eurotradeglobal.com/content/1124976586.jpg

Friction Stir Welding

„ A cylindrical probe rotates and
constant speed d and
d fed
f d at a
constant rate across the joint of two
components
„ Parts must be rigidly clamped
together to prevent them from being
forced apart from welding process

Image: http://www.boeing.com/news/frontiers/archive/2004/september/
photos/sept_i_tt.jpg

Image: http://www.hitachi-cable.co.jp/ICSFiles/afieldfile/2005/12/26/1_1.gif

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Friction Surfacing
„ Coatingg of material applied
pp
to surface of another
material
„ Rod composed of coating
material is rotated under
pressure across the surface
of a separate material
„ Closely resembles a hot
forging
g g process
p so
problems associated with
more traditional welding
process are avoided

Image: http://www.frictec.co.uk/frictec-whatisfr.html

Advantages/Disadvantages
„ Fast jjoining
g times „ Uneconomical for short
„ Small heat affected zones production runs due to high
„ Joined with little preparation of equipment costs
surfaces „ Excludes delicate and intricate
„ Believed that “flash” carries part
away dirt and debris from
surfaces
„ Welding of dissimilar metals
Aerospace - Aluminum and Steel
Nuclear - Copper and Steel

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Explosion Welding
(EXW)

„ Solid state welding

g process
p
„ Plates are bonded through
pressure created from a
controlled detonation of
explosive charge
„ Originates from WWI when it
was discovered that pieces of
shrapnel were welded to armor
plating
p g on tanks
„ Later development occurred in
the decades following WWII
„ Primarily used to clad
inexpensive structural material
with corrosion resistant
material
Image: http://www.metalwebnews.com/howto/explosive-welding/fig1.gif

Welding Process

Image:http://content.edgar-online.com/edgar_conv_img/2007/03/08/0001104659-07-017391_G57151FCI001.JPG

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Advantages/Disadvantages
„ Large surfaces may be welded
„ Produces a high quality bond
„ Low cost
„ Simple
„ Brittle materials cannot be
processed
„ Only simple shapes
- Plates and Cylinders

„ Little surface preparation „ Thickness of flyer plate is

required limited
„ Dissimilar metals can be „ There are many safety
welded concerns when storing and
detonating explosives

Common Bi-
Bi-Metals
Produced
„ Copper
pp to Steel
„ Nickel to steel
„ Aluminum to steel
„ Tungsten to steel
„ Titanium to steel
„ Copper to aluminum
„ Other

SS/Al Ring

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Commercially Available Combinations

Chart: http://www.aps.anl.gov/Facility/Technical_Publications/lsnotes/ls237/Images/ls237_t2.gif

Videos
„ http://video.google.com/videoplay?docid=-
http://video.google.com/videoplay?docid=
p // g g / p y -
7051110735654059178&q=friction+stir+welding&total=8&sta
rt=0&num=10&so=0&type=search&plindex=0&hl=en
„ http://video.google.com/videoplay?docid=8072096915190997
688&q=friction+welding&total=25&start=0&num=10&so=0&t
ype=search&plindex=2&hl=en

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