Notes-MDB4213-Jan 2018 - Solid State Welding Processes PDF

Advance Manufacturing Technology MDB 4213
Advance Manufacturing Technology

(MDB 4213)
A.P. Dr. Shahrul Kamaruddin | Extension: 7169 | Room 17.03.31
ASSESSMENT
• Course Work 50%

Quizzes: 5%
Individual Assignments: 5%
Group Project: 10%
Test 1 & 2: 30%
Final Examination : 50%
• Total : 100%
A.P. Dr. Shahrul Kamaruddin Jan 2018 Page 1

Advance Manufacturing Technology (MDB 4213)

Course Outcomes:
At the end of the course, the students should be able to:
1
Identify the technology in advanced machining
processes.
2
Identify the technology in advanced joining and welding
processes.
3 Develop the knowledge in design and fabrication of

Students will be assessed using Bloom’s Taxonomy: additive manufacturing/layer manufacturing.
1. Cognitive/Knowledge
2. Affective/Attitude
3. Psychomotor/Skill
4
Identify the principle of production system and layout for
manufacturing

Advance Manufacturing Technology (Lesson Plan)
1 2-3 4-6 7-9 10 - 12
Advanced Machining Advanced Joining and Rapid tools and Computer Integrated
Introduction Processes Welding Processes Prototyping Manufacturing System
• Advanced Joining • Introduction Cellular manufacturing
o Fundamental of
• Types of machining • Adhesive • Subtractive processes FMS
advance
• Chemical bonding • Additive processes JIT
manufacturing
• Electrochemical • Mechanical • RP System Lean Manufacturing
• Laser / electron beam Joining • Rapid Tooling AI
• Water / abrasive jet • Advanced Welding • Rapid Manufacturing
• Electrical discharge Machining • Friction welding
(EDM) • Friction stir welding
• EDM Wire Cut
• EDM Die Sinker

SOLID STATE WELDING PROCESSES
• Cold welding
• Roll welding
• Ultrasonic welding
• Friction welding
• Diffusion welding
• Explosion welding

COLD WELDING (CW)

SSW process done by applying high pressure between
clean contacting surfaces at room temperature
• Cleaning usually done by degreasing and wire brushing
immediately before joining
• No heat is applied, but deformation raises work
temperature
• At least one of the metals, preferably both, must be
very ductile
• Soft aluminum and copper suited to CW
• Applications: making electrical connections

ROLL WELDING (ROW)
SSW process in which pressure sufficient to cause
coalescence is applied by means of rolls, either
with or without external heat
• Variation of either forge welding or cold
welding, depending on whether heating of work
parts is done prior to process
• If no external heat, called cold roll welding
• If heat is supplied, hot roll welding

ROLL BONDING PROCESS
• Pressure is applied to the
work pieces through dies or
rolls
• Preferably both work pieces
should be ductile
• The work pieces should
cleaned thoroughly
• Can not join dissimilar metals
Fig: The roll bonding or cladding

process

ROLL WELDING APPLICATIONS
• Cladding stainless steel to mild or low alloy steel for
corrosion resistance
• Bimetallic strips for measuring temperature
• "Sandwich" coins for U.S mint

ULTRASONIC WELDING (USW)
Two components are held together, and
oscillatory shear stresses of ultrasonic
frequency are applied to interface to cause
coalescence
• Oscillatory motion breaks down any surface
films to allow intimate contact and strong
metallurgical bonding between surfaces
• Temperatures are well below Tm
• No filler metals, fluxes, or shielding gases
• Generally limited to lap joints on soft materials

•(a) General setup for a lap joint; and (b) close‐up of weld area

USW APPLICATIONS
• Wire terminations and splicing in electrical
and electronics industry
• Eliminates need for soldering
• Assembly of aluminum sheet metal panels
• Welding of tubes to sheets in solar panels
• Assembly of small parts in automotive
industry

FRICTION WELDING
• It is solid state joining process.
• Mechanical friction between a
moving work piece and a
stationary component.
• Lateral force (upset) is applied
to plastically displace and fuse
the materials

TYPES OF FRICTION WELDING
SPIN WELDING
• A rotating chuck along with
flywheel.
• After reaching to required speed
motor is removed form flywheel.

LINEAR FRICTION WELDING
• Oscillating Chuck is used.
• Use for non‐round shapes as
compare to Spin welding.
• Material should be of high shear
strength.

• FRICTION STIR WELDING
• A cylindrical shouldered
tool, with a profiled probe
(nib or pin) is used.
• Friction is between tool
shoulder, nib and work
metal.

DIRECT DRIVE FRICTION WELDING PROCESS

Friction Welding (Inertia Welding)
• One part rotated, one stationary
• Stationary part forced against rotating
part
• Friction converts kinetic energy to
thermal energy
• Metal at interface melts and is joined
• When sufficiently hot, rotation is
stopped & axial force increased

INERTIA WELDING PROCESS

ADVANTAGES OF FRICTION
• Simplicity of operation and simple equipment.
• Less time requirement.
• Low Surface impurities and oxide films.
• Compare to resistance butt welding produces improved welds at higher speed and lower
cost, less electric current is required.
• Heat affected zone is small as compare to conventional flash welding.
• Less shortening of the component, as compared to that in flash or butt welding.
• There is no flux, gas, filler metal or slag present to cause imperfections in welds.

DISADVANTAGES OF FRICTION
• Process is restricted to flat and angular butt welds.
• Use only for joining small parts.
• In case of tube welding process becomes complicated.
• In case of high carbon steels it is difficult to remove flash.
• It require heavy rigid machine due to high Thrust pressure.

MATERIALS USED IN FRICTION WELDING PROCESS:
Variety of metals can be joined by this process as well as it gives variety of metals
combination which cannot join by conventional process.
• Aluminum • Aluminum Alloys
• Brass • Steel Alloys
• Cast iron • Magnesium
• Ceramic • Magnesium Alloys
• Copper • Tungsten
• Lead • Vanadium
• Bronze

APPLICATIONS:
• Automobile: Bimetallic engine valve, universal joint yoke, gear hub etc.
• Aerospace: Turbine blade joining, seamless joining etc.
• Consumer: Hand tools, sports equipment
• Industrial: Spindles, tapers, tools
• Military
• Medical: Stainless steel joining of containers
• Marine: Shipping Industry
• Mining/Drilling: Twist drill etc.
• Hydraulic equipments

APPLICATIONS:

RESISTANCE WELDING (RW)
• A group of fusion welding processes that use a
combination of heat and pressure to accomplish
coalescence
• Heat generated by electrical resistance to current flow
at junction to be welded
• The resistance of metal to the localized flow of current
produces heat
• Process variables
• Current
• Time
Resistance welding, showing
• Force
components in spot welding, the
main process in the RW group
RESISTANCE SPOT WELDING (RSW)
Resistance welding process in which fusion of faying surfaces of a lap joint
is achieved at one location by opposing electrodes
• Used to join sheet metal parts
• Widely used in mass production of automobiles, metal furniture,
appliances, and other sheet metal products
• Typical car body has ~ 10,000 spot welds
• Annual production of automobiles in the world is measured in tens of millions
of units

• Resistance Welding is a pressure welding technique using high current and low
voltage
• The current passing through the two overlapping work pieces causes local heating and
temperature of the metallic pieces raises to the fusion point due to resistance offered
by the work pieces to flow of current
• Subsequent application of pressure results in permanent joining of the work pieces by
the formation of weld without the use of filler material
• Work pieces are placed between two rods or wheels(rolls), which serve as conductor
for producing welds
• AC electric current is supplied through copper electrodes or rolls connected to the
secondary coil of a welding transformer.
It is used for welding thin sheets of similar metallic materials

The following metals may be welded by Resistance Welding:
•Low carbon steels ‐ the widest application of Resistance
Welding
•Aluminum alloys
•Medium carbon steels, high carbon steels and Alloy steels
(may be welded, but the weld is brittle)

APPLICATIONS:
Resistance Welding (RW) is used for joining vehicle body parts, fuel tanks, domestic
radiators, pipes of gas oil and water pipelines, wire ends, turbine blades, railway tracks.
TYPES OF RESISTANCE WELDING ARE:
• Resistance spot welding
• Resistance seam welding
• Resistance butt welding 1.Upset welding
2.Flash welding
•Resistance projection welding

RESISTANCE SPOT WELDING (RSW)‐ PROCESS
• The contact resistance between the two pieces of
sheet metal to be joined is much higher than the
bulk resistance of the copper electrodes or of the
sheet metal itself.
• Highest resistive heating occurs between the two
pieces of sheet metal.
• As current continues to flow, melting occurs and a
weld nugget is formed between the two sheets.
• On termination of the welding current, the weld
cools rapidly under the influence of the chilled
electrodes. This causes the nugget to resolidify,
joining the two sheets of metal.
• Resistance spot welding is used extensively because
it is a simple, inexpensive, versatile, and forgiving a) Spot welding cycle
process. It has been shown to be adaptable to
some degree of feedback control. (b) Plot of force and current
Cycle: (1) parts inserted between electrodes, (2) electrodes
close, (3) current on, (4) current off, (5) electrodes opened

Typical car body has about 10,000 spot welds
RESISTANCE SEAM WELDING (RSEW)
• Adopting process of continuous joining of
overlapping sheets by passing them between
two rotating electrode wheels. Heat generated
by the electric current flowing through the
contact area and pressure provided by the
wheels are sufficient to produce a leak‐tight
weld.
• Seam Welding is high speed and clean process,
which is used when continuous tight weld is
required (fuel tanks, drums, domestic
radiators,gasoline tanks, automobile muffler ).

RESISTANCE PROJECTION WELDING (RPW)
• A resistance welding process in which
coalescence occurs at one or more
small contact points on the parts
• Contact points determined by design of
parts to be joined
• May consist of projections,
embossments, or localized intersections
(1) Start of operation, contact between parts is
of parts at projections;
(2) (2) when current is applied, weld nuggets
similar to spot welding are formed at the
projections

OTHER RESISTANCE PROJECTION WELDING
OPERATIONS
(a) Welding of fastener on sheet metal (b) cross‐wire welding

RESISTANCE BUTT WELDING
It is of two types:
1. Upset welding
2. Flash welding

• Upset Welding is used to join the pieces end to end
• The process is best suited to rods , pipes and many other parts of uniform
cross section.
• In upset butt welding , the parts are clamped and brought in solid contact
and current is applied so that the heat is generated through the contact
areas of the parts.
• When the temperature of the interface reaches to plastic state, the current
is switched off and the two parts are pressed together firmly. This results
in lateral flow of the surfaces oxide layers. This action of pressing together
is called upsetting.
• Butt welding is used for welding small parts. The process is highly
productive and clean.

Upset Butt Welding

Flash Welding (FW)
• Flash welding is similar to upset welding except that the heat is obtained by
means of an arc than the simple resistance heating.
• The two parts are brought together and the power supply is switched on.
• As the parts are moved closer , flashing or arcing raises the temperature of the
parts to a welding temperature.
• Now power is switched off and two parts are rapidly pressed (forced) together
causing a small upset. This squeezes out liquid metal and oxides, formed on the
joint surfaces and the two parts are welded together.
• Thick pipes, ends of band saws, frames, aircraft landing gears are produced by
Flash Welding.

FLASH BUTT WELDING

STUD WELDING


ADVANTAGES AND DRAWBACKS OF RESISTANCE
WELDING
ADVANTAGES:
• No filler metal required
• High production rates possible
• Lends itself to mechanization and automation
• Lower operator skill level than for arc welding
• Good repeatability and reliability
DISADVANTAGES:
• High initial equipment cost
• Limited to lap joints for most RW processes

EXPLOSION WELDING (EXW)

• SSW process in which rapid coalescence of two metallic surfaces is caused by
the energy of a detonated explosive
• No filler metal used
• No external heat applied
• No diffusion occurs ‐ time is too short
• Bonding is metallurgical, combined with mechanical interlocking that results
from a rippled or wavy interface between the metals

EXPLOSIVE WELDING
Commonly used to bond two dissimilar metals, e.g., to clad one metal on top of a base
metal over large areas
(1) Setup in parallel configuration (2) during detonation of the explosive charge

ADVANTAGES
• No heat‐affected zone (HAZ)
• Only minor melting
• Material melting temperatures and coefficients of thermal
expansion differences do not affect the final product
• The shock front compresses and heats the explosive material
which exceeds the sonic velocity of undetonated explosives

COMMON INDUSTRIES THAT USE EXPLOSION WELDING
• Chemical Processing
• Petroleum Refining
• Hydrometallurgy
• Aluminum Smelting
• Shipbuilding
• Electrochemical
• Oil & Gas
• Power Generation
• Cryogenic Processing
• Pulp & Paper
• Air conditioning & Chillers
• Metal Production
APPLICATIONS
• Can weld large areas of metal
• Can weld inside and outside surfaces of pipes
• Transition joints can be made
3 ” Diameter AI/SS Ring Copper/Stainless 12” UHV Assembly

DEFINITION OF DIFFUSION WELDING
• A solid‐state welding process that produces
coalescence of the faying surfaces by the Work pieces
Force
application of pressure at elevated
temperature.
A
• The process does not involve macroscopic
B
deformation, or relative motion of the work
pieces.
• A solid filler metal may or may not be
inserted between the faying surfaces. Schematic representation of
diffusion welding using
electrical resistance for heating

DIFFUSION WELDING WORKING PRINCIPLES
• 1st stage asperities come 1st stage deformation
and interfacial boundary
into contact.
• deformation forming formation
interfacial boundary.
• 2nd stage
• Grain boundary migration
and pore elimination.
• 3rd stage 2nd stage grain 3rd stage volume
boundary migration diffusion pore
• Volume diffusion and pore and pore elimination elimination
elimination.

APPLICATIONS OF DIFFUSION WELDING
• Application in titanium welding for aero‐space vehicles.
• Diffusion welding of nickel alloys include Inconel 600, wrought Udimet
700, and Rene 41.
• Dissimilar metal diffusion welding applications include Cu to Ti, Cu to
Al, and Cu to Cb‐1%Zr. Brittle intermetallic compound formation
must be controlled in these applications.

Superplastic Formed & Diffusion Bonded
Titanium Heat Exchanger
A.P. Dr. Shahrul Kamaruddin Jan 2018

Froes, FH, et al, “Non‐Aerospace Applications of Titanium” Feb 1998, TMS Page 50
ECONOMICS OF WELDING OPERATIONS
•Costs in welding and joining processes
depend on such factors as:
• Equipment Capacity
• Level of automation
• Labor skill required
• Weld quality
• Production Rate
• Preparation Required

WELDING AND JOINING COSTS
High‐ brazing and fasteners
They require hole‐making operations and fastener cost
Intermediate‐ arc welding, riveting, adhesive bonding
Low‐ resistance welding, seaming, and crimping
They are simple to perform and automate

EQUIPMENT COSTS FOR WELDING
• High‐ Electron‐Beam and Laser‐Beam Welding
• Intermediate‐ Spot, Submerged Arc, Gas Metal‐Arc, Gas Tungsten
Arc, Flux‐Cored Arc, Electro‐gas, Electro‐slag, Plasma Arc, and
Ultrasonic Welding
• Low‐ Shielded Metal‐Arc and Oxyfuel‐Gas Welding

LABOUR COSTS
•Labor Costs are usually higher in welding compared to other
metalworking operations due to operation skill, welding time and
preparation required.
•In robotic controlled welding the welding time is 80% of the overall
time; whereas in manual welding only 30% of the overall time is
spent welding.
• High to Intermediate‐ Oxyfuel‐Gas Welding and Shielded Metal‐Arc
Welding
• High to Low‐ Electron‐Beam and Laser‐Beam Welding and Flux‐
Cored Arc Welding
• Intermediate to Low‐ Submerged Arc Welding

SUCCESS FACTORS IN SSW
• Essential factors for a successful solid state weld are that the two faying
surfaces must be:
• Very clean
• In very close physical contact with each other to permit atomic
bonding

SSW ADVANTAGES OVER FW PROCESSES
• If no melting, then no heat affected zone, so metal around joint retains
original properties
• Many SSW processes produce welded joints that bond the entire contact
interface between two parts rather than at distinct spots or seams
• Some SSW processes can be used to bond dissimilar metals, without
concerns about relative melting points, thermal expansions, and other
problems that arise in FW

References
• me.emu.edu.tr/behzad/3SOLID%20STATE%20WELDING.pptx
• Kalpakjian, Schmid, Sekar, Manufacturing Engineering and Technology © 2014
• aml883.wdfiles.com/local‐‐files/misc‐mat/FrictionWelding.ppt
• www.energyenergy.ir/index.php/fa/.../532_e4ec3b36222696192ae0ea198d014980
• www.gatewaycoalition.org/files/Instructional.../2‐3%20Diffusion%20Welding.ppt
• www.impact‐
net.org/.../94C58000001B5.filename.Monday_Breakout_9_John_Hartne


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Advance Manufacturing Technology MDB 4213

Advance Manufacturing Technology

• Course Work 50%

A.P. Dr. Shahrul Kamaruddin Jan 2018 Page 1

Advance Manufacturing Technology (MDB 4213)

3 Develop the knowledge in design and fabrication of

A.P. Dr. Shahrul Kamaruddin Jan 2018 Page 2

Advance Manufacturing Technology (Lesson Plan)

1 2-3 4-6 7-9 10 - 12

A.P. Dr. Shahrul Kamaruddin Jan 2018 Page 3

A.P. Dr. Shahrul Kamaruddin Jan 2018 Page 4

COLD WELDING (CW)

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Fig: The roll bonding or cladding

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EXPLOSION WELDING (EXW)

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