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Resistance Welding
Principle
Both heat and pressure are used.
Heat is generated by the electrical resistance of the
work pieces and the interface between them.
Pressure is supplied externally and is varied
throughout the weld cycle.
Due to pressure, a lower temperature needed than
oxy-fuel or arc welding.
Contd…
Very rapid and economical.
Contd…
Overall resistance very low.
1. Very rapid.
2. Fully automation possible.
3. Conserve material; no filler metal, shielding gases, or
flux is required.
4. Skilled operators are not required.
5.Dissimilar metals can be easily joined.
6. High reliability and High reproducibility.
Limitations
3. Projection welding
4. Upset welding
5. Flash welding
6. Percussion welding
Resistance spot welding
Contd…
Electric Resistance Welding
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Fig. Resistance seam welding
Projection welding
Contd…
Dimples are embossed on work pieces at the weld
locations and then placed between large-area
electrodes, and pressure and current applied like
spot welding.
Current flows through the dimples and heats them
and pressure causes the dimples to flatten and form
a weld.
Fig. Principle of
projection welding,
(a) prior to application
of current and pressure
(b) and after formation
of welds
Contd…
Projections are press-formed in any shape.
name.
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This is the process used for making electric resistance-
welded (ERW) pipes starting from a metal plate of
suitable thickness.
The plate is first formed into the shape of the pipe with
the help of the three roll set as shown in Fig. above. The
ends of the plate would then be forming the butt joint.
The two rotating copper disc electrodes are made to
contact the two ends of the plate through which the
current is passed. The ends get heated and then forge-
welded under the pressure of the rolls.
The ends of the pieces to be upset welded must be
perfectly parallel. Any high spots if present on the ends
would get melted first before the two ends are
completely joined.
Flash Welding
Contd…
Two pieces are brought together and the power
supply is switched on. Momentarily the two pieces
are separated to create the arc to melt the ends of
the two pieces. Then again the pieces are brought
together and the power switched off while the two
ends are fused under force. Most of the metal
melted would flash out through the joint and forms
like a fin around the joint.
Faster than upset welding.
Percussion Welding
Contd…
Other Welding
Technique
Thermit Welding
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A 65-mm deep layer of molten slag, protect and
supply of filler.
Contd…
Applications: Shipbuilding, machine manufacture,
Large HAZ.
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Electron Beam Welding
in excess of 10kW/cm2
Contd…
Very thin HAZ and little thermal distortion.
used.
Deep penetration.
No vacuum needed.
Contd…
Total Heat input is very low, often in the range 0.1 to
10 J.
Contd…
Forge Welding
Blacksmith do this.
used by industry.
Friction Welding
Contd…
Very efficient.
Wide variety of metals or combinations of metals
can be joined such as aluminium to steel.
Grain size is refined
Strength is same as base metal.
Only round bars or tubes of the same size, or
connecting bars or tubes to flat surfaces can join.
One of the components must be ductile.
Friction welding is a solid state welding.
A low contact pressure may be applied initially to
permit cleaning of the surfaces by a burnishing
action.
Contd…
Fig- friction welding process
Ultrasonic Welding (USW)
Contd…
• Restricted to the lap joint
• Weld thin materials-sheet, foil, and wire--or the
attaching thin sheets to heavier structural members.
• Maximum thickness 2.5 mm for aluminum and 1.0
mm for harder metals.
• Number of metals and dissimilar metal combinations
and non metals can be joined such as aluminum to
ceramics or glass.
• Equipment is simple and reliable.
• Less surface preparation and less energy is needed.
Contd…
Applications
Joining the dissimilar metals in bimetallics
Titanium on steel
Contd…
Important factors are,
Critical velocity
Critical angle
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Typically the detonation velocity should not exceed
120% of the sonic velocity in the metal.
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High velocity explosives, 4572-7620 m/s.
TNT
RDX
PETN
Composition B
Composition C4
Datasheet
Primacord
Medium velocity explosives, 1524-4572 m/s
Ammonium nitrate
Ammonium perchlorate
Amatol
Nitroguonidine
Dynamites
diluted PETN
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Advantages,
Can bond many dissimilar, normally unweldable
metals
The lack of heating preserves metal treatment
The process is compact, portable, and easy to contain
Inexpensive
No need for surface preparation
Contd…
Disadvantages,
The metals must have high enough impact
resistance, and ductility (at least 5%)
The cladding plate cannot be too large.
Noise and blast can require worker protection,
vacuum chambers, buried in sand/water.
Contd…
Typical applications:
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Diffusion Welding
4. Less defects.
Contd…
Brazing metals are typically alloys such as,
Brazing brass (60% Cu, 40%Zn)
Manganese bronze
Nickel silver
Copper silicon
Silver alloys (with/without phosphorous)
Copper phosphorous
Contd…
Extremely clean surface needed.
Contd…
A popular composition is 75% borax and 25% boric
acid.
copper.
Contd…
Done with an oxyacetylene torch.
Contd…
Effective soldering generally involves six important
steps:
(1) Design of an acceptable solder joint,
(2) Selection of the correct solder for the job,
(3) Selection of the proper type of flux,
(4) Cleaning the surfaces to be joined,
(5) Application of flux, solder, and sufficient heat to
allow the molten solder to fill the joint by capillary
action and solidify, and
(6) Removal of the flux residue, if necessary.
Solder Metals
Contd…
Solder Flux
galvanized iron
use
Silver solders uses for higher-temperature service,
Electrical and Electronic purpose.
Difficulties with Grey Cast Iron