MATERIAL

JOINING

CVS Murthy, Sc’F’

P.Mastanaiah, Sc’C’
 WELDING
Joining of two materials to produce the weld

Weld:

A localized coalescence of metals or non-metals which is produced

either by heating the materials to a suitable temperature with or without the
application of the pressure Or by the application of pressure alone and with
or without the use of filler metal
ROLE OF WELDING IN AEROSPACE APPLICATIONS
 ECONOMY AND DESIGN FLEXIBILITY

 OPERATING FLEXIBILITY

 MECHANISATION

 PROCESS ALTERNATIVES

 JOINING OF DISSIMILAR MATERIALS

DIFFERENT WELDING PROCESSES

SMAW DIFFUSION
BONDING
GTAW ULTRASONIC
GMAW FRICTION
RESISTANCE
ELECTRON BEAM
LASER BEAM
Type of Electrode
Consumable Electrodes
SMAW
SAW
FCAW
GMAW
ESW

Non Consumable Electrodes

GTAW
PAW
Features of fusion welded joint
Weld Fusion
Base Interface zone Heat Affected Zone
Metal

• Fusion zone - a mixture of filler metal and base metal melted

together homogeneously due to convection as in casting.
Epitaxial grain growth
• Weld interface – a narrow boundary immediately solidified
after melting.
• Heat Affected Zone (HAZ) – below melting but substantial
microstructural change in the base material.
• Unaffected base metal zone
JOINT DESIGN
JOINT DESIGN
WELD POSITIONS
WELDING FACILITIES
AT
DRDL
 WELDING APPLICATIONS IN DRDL

PROPELLENT TANK
ROCKET MOTAOR CASING
THRUST FRAME
AIR FRAME COMPONENTS
AIR BOTTLE
AIR INTAKE ASSEMBLY
INTER STAGE ASSEMBLY
 COMMON MATERIALS USED AT DRDL

 STAINLESS STEELS

 ALUMINIUM ALLOYS

 HIGH STRENGTH STEELS

 TITANIUM ALLOYS

 NICKEL BASED SUPER ALLOYS

 PRECIPITATION HARDENED STEELS

 STAINLESS STEELS

SS 304
SS 304L
SS 316
SS 316L
SS 321
SS 430

PROCESS: TIG WELDING

PROBLEMS: Cr- Carbide Precpitation and weld decay

 ALUMINIUM ALLOYS

NON- HEATTREATABLE HEAT TREATABLE

( Si, Fe, Mn, Mg) ( Cu, Mg, Zn, Si )

PRESENT AS DISPERSED PHASES SOLID SOLUTION IN

SOLID SOLUTION STRENGTHENING ALUMINIUM
 ALUMINIUM ALLOYS

AA 6061 H20

AA2014 H15

AA2219
AA 5083 NS6

AA5086 NS8

PROCESS : TIG
PROPELLENT TANK
 PROBLEMS IN
ALUMINIUM WELDING
 Oxidelayer formation
 Hydrogen Solubility

 Thermal Characteristics
 coefficient of thermal expansion 2 times
that of steel
 shrinkage 6% by volume during
solidification
 WELDABILITY

A weldable material is one that can be fused with out the formation of
deleterious Phases or constituents either in weld or in HAZ, has sufficient
ductility both in weld and HAZ from the melting temperature to room
temperature to resist cracking and has suitable strength and fracture
resistance either in the as welded condition or on completion of poet weld
thermal processing

A weldable material should also be amenable to repair welding procedure

without inherent tendencies towards the formation of new defects or
Significant reduction in properties
 WELDABILITY OF
ALUMINIUM ALLOYS
Non-heat treatable alloys:
 When welded these alloys may
lose the effects of work hardening
resulting in softening of HAZ.
Heat treatable alloys:
 Fusion welding redistributes the
hardening constituents in the HAZ
which locally reduces material
strength.
METALLURGICAL EFFECTS OF WELDING ALUMINIUM ALLOYS

BASE METAL - PROCESS , HEAT INPUT

WELDMENT - RATE OF SOLIDIFICATION

- HEAT INPUT
COMPOSITION Al-Mg
- PROCESS
- THICKNESS

NON- HEATREATABLE ALLOYS

- WELD METAL
- ANNEALED
- UNAFFECTED

AS WELDED PROPERTIES

FW UTS ANNEALED PS %E

1100 1100 9 8 4 30
3003 1100 11 10 5 24
5086 5356 28 25 12 18
 FILLER ALLOY SELECTION
Factors considered in selection of
filler alloy

 Weld crack sensitivity

 Tensile and shear strength of the weld
 Corrosion resistance
 Ductility
 Response to heat treatment
 Color match after anodizing
HEAT TREATABLE ALUMINIUM ALLOY WELD MACRO STRUCTURE

Unaffected
base metal

Weld metal

Fusion Zone
Solid Solution Zone
Partially annealed
and overaged zone
 Titanium & Its alloys

 HIGH STRENGTH TO WEIGHT RATIO

 EXCELLENT CORROSION RESISTANCE

CREEP STRENGTH & FATIGUE STRENGTH

FRACTURE TOUGHNESS

DUCTILITY

 AEROSPACE INDUSTRIES – 50-60%

 CHEMICAL & ELECTRO CHEMICAL INDUSTRIES

 FERTILIZER & FOOD INDUSTRY

 PAPER & PULP INDUSTRY

 PRECAUTIONS FOR GAS SHIELDED PROCESS

 100 % SHIELDING OF THE WELD & HEAT AFFECTED ZONE

INVOLVING PRIMARY & SECONDARY & BACKING
SHIELDING.

PERFECT CLEANING OF THE BASE METAL & FILLER METAL

HIGH PURITY & DRY INERT GAS ( 99, 95 % MIN) ONLY

SHOULD BE USED

ADVISABLE TO USE OPTIMUM GAS FLOW RATES TO

AVOID TURBULENCE & ENTRAPMENT OF AIR.

SHORT ARC LENGTH

 GTAW WITH PRIMARY
OPEN TIG ARC / SECONDARY
WITH FLUX GLOVE BOX
& BACKING SHIELDING METHODS

TITANIUM WELDING

LASER WELDING

ELECTRON BEAM WELDING RESISTANCE

 TORCH TRAILING SHIELD FOR GAS SHIELDED
ARC WELDING OF TITANIUM ALLOYS
WELDING DIRECTION
metal inert gas Trailing shield
chamber inlet

POROUS METAL
torch DIFUSION
nozzle SCREEN

rimary shielding : Fusion zone by Torch nozzle

Hot solidified weld metal by Trailing s
 SECONDARY INERT GAS SHIELDING
INCORPORATED IN THE WELDING FIXTURE

Shield gas flow

througth torch nozzle shielding gas diffuser
Shielding hold down bars
F
gas port F

base
F F

shielding - gas port

Provides 3 way shielding – 2 at the sides

1 at root side
Backing shielding

Shielding provided in backing bars

Employed in Fillet & Corner welds

Backing gas in
Glove box welding

 100 % Shielding

 Inert gas is filled in the chambe

after evacuation 2 to 3 times.

 A positive pressure is always

maintained.

 Welding is done manually

automatically

 Avoids wastage of costly argon

gas
CONFIGURATION OF ELECTRON BEAM WELDING M/

THERMIONIC EMISSION

 WHEN CERTAIN MATERIALS LIKE TUNGSTEN/ TANTALUM

ARE HEATED TO 25000C , THEY EMIT ELECTRONS.
 SPECIAL CHARACTERISTICS OF
ELECTRON BEAM WELDING
 EXTREMELY HIGH POWER DENSITY OF 107 W/Cm2

 ENERGY TRANSFER NOT BY CONDUCTION ACROSS THE SURFACE

OF WORKPIECE BUT WORKS MORE EFFIECIENTLY WITHIN THE

WORK PIECE.

HIGH WELD SPEED RESULTS IN NARROW WELDS & HEAT

AFFECTED ZONE WITH LITTLE DISTORTION

 INERTIA FREE OSCILATION OF EB MAKES IT POSSIBLE TO JOIN

MATERIALS OTHERWISE CONSIDERED UNSUITABLE FOR WELDING.

 WELDING IS CARRIED OUT IN VACUUM , NO CONSUMABLES

REQUIRED , HIGHLY SUITABLE FOR REACTIVE METALS

 COMPUTER MONITORING & CONTROL OF THE ELECTRICAL &

MECHANICAL WELDING PARAMETERS

 WELDING PARAMETERS AND THUS THE QUALITY OF THE WELDS
 KEYHOLE FORMATION

THE BUTT JOINT MELTING OCCURS AT THE IMPINGEMENT

PRIOR TO WELDING OF THE ELECTRON BEAM

KEY HOLE FORMATION THE KEY HOLE AND ITS THE WELD SEAM FORMED
MOLTEN POOL HAVE ON SOLIDIFICATION
PENETRATED
THE WORK PIECE
 KINEMATICS OF ELECTRON BEAM WELD
MOVEMENT OF MATERIAL

DIRECTION OF WELD
KEY HOLE
MOLTEN ENVELOPE ELECTRON BEAM

FACE OF THE
BUTT JOINT

F4 F1

F5
F1 — VAPOUR PRESSURE F2 F5
F2 — SURFACE TENSION
FORCE
F3
F3 --- HYDROSTATIC PRESSURE F1 F4
F4 –- FRICTIONAL FORCE
F5 — WEIGHT OF MOLTEN
METAL SOLIDIFIED FUSION
ZONE
ELECTRON BEAM
TYPICAL HEAT INPUTS& COOLING RATES FOR
VARIOUS WELDING PROCESSES
PROCESS HEAT COOLING
INPUT(KJ/C) RATE
( 0C/Sec)
MANUAL 30 14
GTAW
PLASMA ARC 22 36
WELDING
AUTOMATIC 10 70
GTAW
EBW 2.8 535

LASER 1.6 >535

WELDING
POWER DENSITY OF HEAT SOURCES

WELDING HEAT POWER

SOURCE DENSITY
GAS FLAME (Watts/cm2
10 )
ARGON ARC 30
PLASMA ARC 10 3 - 104

ELECTRON BEAM 104 - 107

LASER BEAM 103 - 107