JOINING AND ASSEMBLY PROCESSES:

WELDING

JOINING AND ASSEMBLY PROCESS

A. Joining - general term for welding, brazing, soldering and adhesive bonding

- form a permanent joint between the parts

B. Assembly

- mechanical method of fastening parts together

FUNDAMENTALS OF WELDING
WELDING
Materials joining process in which two or more parts are joined with a suitable application of heat and pressure Most commonly associated with metal parts, but also used in joining plastics

processes discussed would focus on metals

FUNDAMENTALS OF WELDING
ADVANTAGES
It provides a permanent joint The welded joint can be stronger than the parent materials It is usually the most economical way of joining components Not restricted in a factory environment, can be done in the field

DISADVANTAGES
Most welding operations are done manually and are expensive (in terms of labor) Welding processes are inherently dangerous It does not allow for convenient disassembly Welded joint can suffer from certain quality defects

TYPES OF WELDING PROCESSES

A. Fusion Welding 1. Arc welding (AW) 2. Resistance welding (RW) 3. Oxyfuel gas welding (OFW) 4. Other types of fusion welding B. Solid-State Welding 1. 2. 3. 4. 5. Diffusion welding (DFW) Friction welding (FRW) Friction stir welding (FSW) Ultrasonic welding (USW) Explosion welding (EXW)

A. FUSION WELDING
- These are the processes in which use heat to melt the base metals
- Filler metal (added to the molten pool to facilitate the process and provide bulk and strength to the welded joint)

- These processes are commonly used:

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ARC WELDING
Fig. 1. Schematic illustration of the shielded metal-arc welding process. About 50% of all large-scale industrial welding operations use this process.

Figure 2 Schematic illustration of the shielded metal-arc welding operations (also known as stick welding, because the electrode is in the shape of a stick).

RESISTANCE WELDING

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Figure 3 (a) Sequence in resistance spot welding. (b) Crosssection of a spot weld, showing the weld nugget and the indentation of the electrode on the sheet surfaces. This is one of the most commonly used process in sheet metal fabrication and in automotive-body assembly.

OXYFUEL GAS WELDING

OXYACETYLENE WELDING

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Figure 4. (a) General view of and (b) cross-section of a torch used in oxyacetylene welding. The acetylene valve is opened first; the gas is lit with a spark lighter or a pilot light; then the oxygen valve is opened and the flame adjusted. (c) Basic equipment used in oxyfuel-gas welding. To ensure correct connections, all threads on acetylene fittings are lefthanded, whereas those for oxygen are right-handed. Oxygen regulators are usually painted green, acetylene regulators red.

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OTHER TYPES

Fig. 5 (A) Laser welding of a gear (B) Electroslag Welding equipment

B. SOLID-STATE WELDING

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- It refers to the joining process in which applications of pressure alone or a combination of heat and pressure results two metals to merge - No filler metal is utilized

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DIFFUSION WELDING

Figure 6. The sequence of operations in the fabrication of various structures by diffusion bonding and then superplastic forming of (originally) flat sheets. Sources: (a) After D. Stephen and S.J.Swadling. (b) and (c) Rockwell International Corp.

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FRICTION WELDING
A

Fig. 7. (A) Sequence of operations in the friction welding process: (1) Left-hand component is rotated at high speed. (2) Right-hand component is brought into contact under an axial force. (3) Axial force is increased; flash begins to form. (4) Left-hand component stops rotating; weld is completed. The flash can subsequently be removed by machining or grinding. (B) Shape of fusion zone in friction welding, as a function of the force applied and the rotational speed.

FRICTION-STIR WELDING

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Fig. 8. The principle of the friction stir welding process. Aluminum-alloy plates up to 75 mm (3 in.) thick have been welded by this process. Source: TWI, Cambridge, U.K.

ULTRASONIC WELDING
(a) (b)

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(a) Components of an ultrasonic welding machine for lap welds. The lateral vibrations of the tool tip cause plastic deformation and bonding at the interface of the workpieces. (b) Ultrasonic seam welding using a roller. (c) An ultrasonically welded part.

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EXPLOSION WELDING
(a) (b)

(c)

(d)

Fig. 10 Schematic illustration of the explosion welding process: (a) constant interface clearance gap and (b) angular interface clearance gap. (c) and (d) Crosssections of explosion-welded joints. (c) titanium (top piece) on low-carbon steel (bottom). (d) Incoloy 800 (an ironnickel- based alloy) on lowcarbon steel. Source: Courtesy of E. I. Du Pont de Nemours & Co.

THE WELD JOINT: TYPES OF JOINTS

WELD JOINT
- The junction of two edges or surface parts that have been joined by welding

Types of Joints

THE WELD JOINT: WELD TYPES

THE WELD JOINT: WELD TYPES

THE WELD JOINT: WELD TYPES

A. Fillet weld B. Groove weld C. Plug or Slot weld D. Spot weld E. Seam weld F. Flange weld

G. Surfacing weld

WELD DEFECTS: INCOMPLETE FUSION

Figure 11. Low-quality weld beads, the result of incomplete fusion. Source: American Welding Society.

WELD DEFECTS: DISCONTINUITIES

Figure 12. Schematic illustration of various discontinuities in fusion welds. Source: American Welding Society.

WELD DEFECTS: CRACKS

Figure 13 Types of cracks (in welded joints) caused by thermal stresses that develop during solidification and contraction of the weld bead and the surrounding structure. (a) Crater cracks. (b) Various types of cracks in butt and T joints.

INSPECTION & TESTING METHODS

Figure 14 Two types of specimens for tensionshear testing of welded joints.

Figure 15 (a) Wrap-around bend test method. (b) Three-point bending of welded specimens

INSPECTION & TESTING METHODS

Figure 16 (a)Tension shear test for spot welds. (b) Crosstension test. (c) Twist test. (d) Peel test

Thank you for listening!

REFERENCES
Groover, M. (2011) Principles of Modern Manufacturing. John Wiley & Sons (Asia) Pte. Ltd. Kalpakjian & Schmid. (2001) Manufacturing Engineering and Technology. Prentice-Hall (n.a.) [PDF document] Joining processes. Available from http://www.ielm.ust.hk/dfaculty/ajay/courses/ieem215/ lecs/8_joining.pdf (n.a) [PDF document] The Weld Joints and Weld Types. Available from http://www.gw.com/pdf/sampchap/9781590708668_ch06.pdf