Cold welding is a solid state welding process that joins metals through plastic deformation without melting, using only pressure. It can join similar and dissimilar metals. Roll bonding is another solid state welding process that produces a weld by passing two metal sheets through a rolling mill under high pressure and temperature. Both processes rely on forming new metal surfaces (nascent surfaces) through plastic deformation to achieve bonding between the materials at a molecular level. Pressure gas welding uses gas flames to heat and join metal surfaces while also applying pressure. It was an early welding process commonly used before electric welding methods.
Cold welding is a solid state welding process that joins metals through plastic deformation without melting, using only pressure. It can join similar and dissimilar metals. Roll bonding is another solid state welding process that produces a weld by passing two metal sheets through a rolling mill under high pressure and temperature. Both processes rely on forming new metal surfaces (nascent surfaces) through plastic deformation to achieve bonding between the materials at a molecular level. Pressure gas welding uses gas flames to heat and join metal surfaces while also applying pressure. It was an early welding process commonly used before electric welding methods.
Cold welding is a solid state welding process that joins metals through plastic deformation without melting, using only pressure. It can join similar and dissimilar metals. Roll bonding is another solid state welding process that produces a weld by passing two metal sheets through a rolling mill under high pressure and temperature. Both processes rely on forming new metal surfaces (nascent surfaces) through plastic deformation to achieve bonding between the materials at a molecular level. Pressure gas welding uses gas flames to heat and join metal surfaces while also applying pressure. It was an early welding process commonly used before electric welding methods.
Cold welding is a solid state welding process that joins metals through plastic deformation without melting, using only pressure. It can join similar and dissimilar metals. Roll bonding is another solid state welding process that produces a weld by passing two metal sheets through a rolling mill under high pressure and temperature. Both processes rely on forming new metal surfaces (nascent surfaces) through plastic deformation to achieve bonding between the materials at a molecular level. Pressure gas welding uses gas flames to heat and join metal surfaces while also applying pressure. It was an early welding process commonly used before electric welding methods.
Cold welding adalah proses solid state dimana tekanan digunakan pada temperatur kamar untuk menggabungkan logam melalui
Die
deformasi pada lasan
Sambungan butt dan lap dapat di cold welded
Flash
A: Lap both sides indented
B: Lap One side indented C: Edge both side indented D: Butt in Tube
E: Draw Weld F: Wire Lap (before and after) G: Mash Cap Joint AWS Welding Handbook H: Butt (before and after)
Characteristics of Cold Welding
Salah satu logam yang akan dilas harus ductile tanpa mengalami workhardening yang berlebihan. Tidak ada pemberian panas. Dapat menyambng dissimilar metals Preparasi permukaan sangat penting
Cold Welding Process Description
Dies
Komponen yang akan dilas harus
dibersihkan dulu. A short section of the part is sheared. The parts are clamped in a die with some initial extension. A forging force is applied to complete welding.
Workpiece
Workpiece
Before welding
After welding
Applications of Cold Welding
Cold welded butt joints are used in the manufacturing of aluminum, copper, gold, silver, and platinum wire. Most commonly, successive reels of wire are joined for continuous drawing to a smaller diameter. Aluminum alloys used in cold welding include: 1100, 2319, 3003, all 5000 series, 6061 and 6201.
Equipment
Cold Welding Equipment
A manually operated cold welding machine (courtesy AWS handbook).
States of Upset During Butt
Single Upset Cold Weld in Cold Welding Type 1100 Aluminum Wire Courtesy AWS handbook
Stages in Multiple Upset Cold Welding
AWS Welding Handbook
AWS Welding Handbook
Multiple Upset Cold Weld
AWS Welding Handbook
Can Effect Joint Efficiency
Transverse Flow Lines in a
Cold Welded Butt Joint Courtesy AWS handbook
AWS Welding Handbook
Other Cold Welding
Applications
Application
Cold Welding in the Manufacture
of Industrial Packaging Cold Welded Electrical Component
Saijo, K et al, method and Apparatus for Cold Rolling Clad
Sheet, US Patent 4,896,813 Jan 30, 1990
Clean Surface To Rolling Mill
PRESSURE GAS WELDING
Heat Can Help
Electrical
Flame Contact Solid State Welding
Chemical
Mechanical
Pressure & Deformation
Pressure Gas Weld
Pressure Gas Welding
Proses las dengan oxy-fuel gas menghasilkan penggabungan secara simultan pada seluruh area permukaan melalui pemanasan menggunakan gas flames. Gas flame diperoleh dari pembakaran bhn bakar gas dengan oksigen dan pemberian tekanan dan deformasi tanpa menggunakan filler metal
Pressure Gas Welding Processes
Open joint pressure welding. Closed joint pressure welding.
Principle of Operation
Pressure Gas Welding Principles of
Operation: Open Joint Method The faces to be joined are heated individually to the welding temperature. After heating, the two faces are brought into contact. Upsetting force is applied to complete welding.
Workpiece
Workpiece
Workpieces are heated separately
Upsetting pressure is applied
Final weld
Upsetting force
Principles of Operation
Pressure Gas Welding Principles of
Operation: Closed Joint Method Flame
Faces to be welded are butted together
under initial pressure. Metal at the joint is heated to welding temperature with a gas flame. Finally, the metal is upset sufficiently to Upsetting force produce a weld.
Heating torch
Workpiece
Workpiece Upsetting force
Before welding
After welding
AWS Welding Handbook
AWS Welding Handbook
AWS Welding Handbook
AWS Welding Handbook
AWS Welding Handbook
Pressure Gas Weld
Little Visible Centerline Good Mechanical Properties AWS Welding Handbook
Applications of Pressure Gas
Welding
Applications
Pressure gas welding has been
successfully applied to plain carbon, low carbon, and high alloy steels, and to several non-ferrous metals, including nickel-copper and copper-silicon alloys.
Forge Welding The Blacksmiths Art
Electrical
Solid State Welding
Chemical Radiation Mechanical
Pressure & Deformation
Forge Weld
Forge Welding Forge welding is a solid-state welding process that produces a weld by heating the work pieces to welding temperature and applying blows sufficient to cause permanent deformation at the faying surface. Forge welding was the earliest welding process and the only one in common use until the 19th century.
AWS Welding Handbook
Fluxes Often fluxes are needed to prevent oxide formation on the parts to be welded. Two commonly used fluxes for steels are silica sand and borax (sodium tetraborate).
ROLL BONDING
Nascent Surface
Interface
Defined as the new
surface formed during Nascent compressive plastic Surface Original deformation (upset). Can be free of oxides and contamination. Deformed Increased nascent surface Area increase under compressive area usually results in plastic deformation (upset) increased weld strength.
Roll Bonding A solid state welding process in which bonding is made between two sheets of metal by passing them through a rolling mill. Surface preparation is of utmost importance. Welding is promoted with increasing temperature, increasing pressure, increasing roll diameter, and decreasing rolling speed. 60 to 70% deformation is required for maximum weld strength.
Weld interface
a Nascent surface Rolling
Original weld interface
Plane Strain Roll Bonding
(Deformation in thickness and length only.) xa a
100% 1 100% % reduction in thickness x x
by y
100% 1 100% % nascent (new) surface b b
Plane Strain Roll Bonding
Assuming constant volume, xy = ab or a/x = y/b
1 a 100% 1 y 100% x b
% reduction in thickness is equal to % nascent
surface, assuming no change in width. For 100% nascent surface 100% reduction in thickness is needed.
Surface Deformation Bulk compressive deformation or upsetting is measured as the percentage reduction in sheet thickness. A threshold deformation exists below which no weld is made. Above this threshold the joint strength is close to that predicted by assuming the welded area is the nascent surface area. Increasing the temperature reduces the value of threshold deformation.
Predicted strength
Strength of welded joint.
Threshold deformation
Deformation%
Steel - Aluminum Cladding
Rolling a. Cold b. 600-750 F
Cleaning Post-Heating ~ 1000F
FeAl3, Fe2Al5 Steel Aluminum Steel Steel
(Brittle) Si > 0.25% in Steel Tends to Reduce Brittle IronAlumindes Thus Higher Post Roll Temperatures can be employed
