[go: up one dir, main page]
Scribd
Upload
79 views10 pages

Engineering Materials

This document provides an overview of welding as a process for joining metals. It discusses the main types of welding including fusion welding and solid-phase welding. Fusion welding involves melting the metals together with or without a filler material. Some common fusion welding techniques described are oxyacetylene welding, metallic arc welding, atomic hydrogen welding, and laser welding. Solid-phase welding joins metals through pressure or pressure and heat without melting. Spot welding, seam welding, and friction welding are examples of solid-phase welding processes. The document also discusses effects of welding on the structure and properties of materials like inclusions, porosity, and cracking in the weld deposit as well as microstructural changes in the heat-affected zone of the

Uploaded by

R-jayVenturillo
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
79 views10 pages

Engineering Materials

This document provides an overview of welding as a process for joining metals. It discusses the main types of welding including fusion welding and solid-phase welding. Fusion welding involves melting the metals together with or without a filler material. Some common fusion welding techniques described are oxyacetylene welding, metallic arc welding, atomic hydrogen welding, and laser welding. Solid-phase welding joins metals through pressure or pressure and heat without melting. Spot welding, seam welding, and friction welding are examples of solid-phase welding processes. The document also discusses effects of welding on the structure and properties of materials like inclusions, porosity, and cracking in the weld deposit as well as microstructural changes in the heat-affected zone of the

Uploaded by

R-jayVenturillo
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
You are on page 1/ 10

ENGINEERING MATERIALS

CHAPTER 18
Welding



Submitted To:
Engr. Ron Chuck Gabayan

Prepared by Group 12:
Mark Anthony Velano
R-jay Venturillo
Edward Venturillo

Introduction:
Welding is an operation of joining metals and alloys. Thus differences
between the weld metal and the pieces being joined are structural rather
than compositional.

There are many types of joining materials and the alloys which they are :

1. Soft soldering






2. Brazing







3. Welding



There are two types of welding :

1. Fusion welding processes
2. Solid phase welding processes




1. Fusion welding
In fusion welding any additional material added to the joint has a similar
composition and strength to the metals being joined. . Figure 1 shows the
principle of fusion welding, where not only the filler metal but also the edges
of the components being joined are melted. The molten metals fuse together
and, when solid, form a homogeneous joint whose strength is equal to the metals
being joined.

Figure 1. Fusion welding: (a) before - a single 'V' butt requires extra metal; (b) after - the edges of
the 'V' are ,melted and fused together with the molten filler metal.

There are several way to fusion weld such as :
a) Oxyacetylene welding
In this process the heat source is a mixture of oxygen and acetylene burning
to produce a flame whose temperature can reach 3250 :C. and this is above the
melting point of most metals. Figure 2 shows a typical set of welding equipment.
The welding gases form a highly flammable and even explosive mixture, so this
equipment must only be used by a suitably qualified person or a trainee under
the direct instruction of such a person.






Figure 2 Oxyacetylene welding equipment

b) Metallic arc welding
This is a fusion-welding process where the heat energy required to melt the edges of
the components being joined and also the filler rod is supplied by an electric arc. The
arc is the name given to the prolonged spark struck between two electrodes. In this
process the filler rod forms one electrode and the work forms the other electrode. The
filler rod/electrode is coated with a flux which melts and shields the joint from
atmospheric oxygen at the very high temperatures involved. (Average arc temperature
is about 6000 :C.) The flux also stabilises the arc and prevents the rod from short
circuiting against the sides of the when welding thick metal.



Figure 3 Comparison of (a) oxyacetylene welding and (b) manual metallic arc welding.

c. Atomic hydrogen welding (AHW)
This is an arc welding process that uses an arc between two metal tungsten
electrodes in a shielding atmosphere of hydrogen.




d. Laser welding
This is the process of joining metals or non-metals at high speed with a very
low heat input. Lasers can weld in air, in vacuum, in controlled atmospheres
and in pressurized chambers. It is easily automated and is highly reliable.

Laser welding
2. Solid phase welding
-In this method the material which are welded does not fuse, it uses an out
pressure to weld so it is not using any external material in the welding
process..
-A welding method in which the weld is consummated by pressure or by heat
and pressure without fusion.

There are several ways to weld in the solid-phase welding such as:
a.Spot welding - Ideal for joining light sheet metal. The electrodes are made from
copper. Pressure is applied to the electrodes and an electric current is passed
through the circuit. The high resistance between the joint faces causes rapid heating
and fusing of a small globule of metal from both faces.






Spot Welding


b. Seam welding
In this process, the rollers allow the workpiece to move through the welder
continously. A stream of electrical pulses pass through the rollers and welds the
joint.





Workpiece
s
Non-rotating vise
Motor
Chuc
k
Spindle
Hydraulic cylinder
Brak
e

c. Friction Welding
It is a solid state joining process that produces coalescence by the heat developed
between two surfaces by mechanically induced surface motion.





Friction Welding

In the figure above, one part is held stationary while the other part is rotated. When
the parts are hot enough the rotation is stopped and the parts forged together.

Effects of welding on the structure and properties of materials:
1.The weld-metal deposit
a. Non-metallic inclusions
The formation of oxide and nitride inclusions due to atmospheric contamination is
reduced by the blanket of burnt gases (products of combustion) in the case of gas
welding, and by the use of a flux when electric arc welding.
b. Gas porosity
The chief cause of gas porosity is the presence of hydrogen in the weld metal or
the formation of steam from the reaction of hydrogen with any oxide present
in the molten parent metal. In addition, hydrogen is present in the welding flame
when gas welding and in the flux coatings of electrodes when arc welding.

c. Weld-metal cracking
Welded joints that are prepared under restraint are liable to intercrystalline
cracking in the weld deposit due to contractional strains set up during the cooling
of the metal. Such cracking, usually known as 'hot cracking', is largely related to
the grain size and the presence of grain boundary impurities.

2. The heat-affected zone
The heat-affected zone of the parent metal is difficult to define. It will
depend upon such factors as:
The temperature of the weld pool.
The time taken to complete the weld.
The thermal conductivity of the parent metal.
The specific heat of the parent metal and the dimensions of the parent metal.
The method of welding used.

You might also like