INTRODUCTION TO MECHANICA ENGINEERING [Publish Date]

Module 3
Metal Joining Process

Introduction
Some products cannot be manufactured as a single piece. The desired shape and size of such products
can be obtained by joining two parts of same or different materials. These parts are manufactured
individually and are joined together to obtain the desired product. For example, air craft and ship
bodies, welded machine frames, furniture, computers, bridges and the transmission or electric towers
etc., are all fabricated by joining several different parts.

Based on the type of joint produced joining processes can be classified as

1. Temporary Joint.
2. Permanent Joint.

If a product is in use for a long time and there is wear and tear, the parts need to be dismantled for
maintenance, repair or replacement. A temporary joint can be easily dismantled separating the original
parts without any damage to them. In case it is a permanent joint, an attempt to separate the parts already
joined will result in the damage of the parts. In a permanent joint, the joint is made such that it has
properties similar to the base metal of the two parts. The joined parts become one piece. These parts
cannot be separated into their original shape, size and surface finish. Based on the process used for
making the joint, the joining processes can be further classified as
1. Soldering.
2. Brazing.
3. Welding.
4. Mechanical Fasteners like bolts, nuts, rivets, screws etc.
5. Adhesive bonding.

Mechanical fasteners are most widely used for temporary joints. Joints obtained by bolts and screws are
temporary in nature and can be dismantled easily whenever necessary. Rivets are semi-permanent
fastening devices and the joint can be separated only by destroying the rivet without affecting the parent
elements. Adhesive bonding has generally less strength than the mechanical fasteners. But adhesive
bonding is used to join odd shaped parts or thin sheets which may not lend themselves to mechanical
fastening. Brazing and soldering are considered to form permanent joints, but for repair or replacement
these joints can be dismantled by heating. Welding is one of the most extensively used fabrication
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 INTRODUCTION TO MECHANICA ENGINEERING [Publish Date]

method. The joint strength obtained in welding is being equal to or some times more than that of the
parent metal. Welding is not only used for making structures, but also for repair work such as the joining
of broken castings. The choice of a particular joining process depends on several factors such as
application, nature of loads or stresses, joint design, materials involved and size and shape of the
components.

Soldering
Soldering is a method of joining similar or dissimilar metals by the application of heat and using a filler
metal or alloy called solder, whose liquidus temperature is below 4500 C. The molten filler metal is made
to flow between the two closely placed adjacent surfaces by the capillary action.
Though soldering obtains a good joint between the two plates, the strength of the joint is limited by the
strength of the filler metal used. Soldering is used for obtaining a leak proof joint or a low resistance
electrical joint. The soldered joints are not suitable for high temperature applications because of the low
melting temperatures of the filler metals used.
The purpose of using the flux is to prevent the formation of oxides on the metal surface when the same
is heated. The fluxes are available in the form of powder, paste, liquid or in the form of core in the solder
metal. It is necessary that the flux should remain in the liquid form at the soldering temperature and be
reactive to be of proper use. The filler metals used are essentially alloys of lead and tin. The composition
of solder used for different purposes are as given below
Soft solder - lead 37% tin 63%
Medium solder - lead 50% tin 50%
Plumber’s solder - lead 70% tin 30%
Electrician’s solder - lead 58% tin 42%

Soldering is classified into soft soldering and hard soldering.

Soft soldering is used extensively in sheet metal work for joining parts that are not exposed to the action
of high temperatures and are not subjected to excessive loads and forces or vibrations. Soft soldering is
also employed for joining wires and small parts. The solder is mostly composed of lead and tin. In soft
soldering, Zinc chloride and ammonium chloride are the most common soldering fluxes used which are
quick acting and produce efficient joints. But because of their corrosive nature the joint should
thoroughly cleaned of the entire flux residue from the joint. These are to be used only for non-electrical
soldering work. Rosin and rosin plus alcohol based fluxes are least active type and are generally used
for electrical soldering work.

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Hard soldering employs solder which melts at higher temperatures (3500 C to 9000 C) is stronger than
used in soft soldering. Hard solder is an alloy of copper and zinc to which silver is added some times.
German silver, used as a hard solder for steel is an alloy of copper, zinc and nickel.

Sequence of operations:
The following operations are required to be performed sequentially for making soldered joints.
1. Shaping and fitting of metal parts together: The two parts to be joined are shaped to fit closely
so that the space between them is extremely small and filled completely with solder by capillary
action. If a large gap is present, capillary action will not take place and the joint will not be
strong.
2. Cleaning of surfaces: In order to obtain a sound joint, the surfaces to be soldered are cleaned to
remove dirt grease or any other foreign material.
3. Application of flux: The flux is applied when the parts are ready for joining.
4. Application of heat and solder: The parts are held in a vice or with special work holding devices
so that parts do not move while soldering.

Advantages:
 Simple and economical process.
 Relatively low temperature process, there is no metallurgical damage to base metal.
 The soft soldered joints can easily be dismantled by simple heating.

Disadvantage:
 The strength of joint relatively low.
 Flux must be thoroughly cleaned off after soldering, as it is often corrosive.

WELDING
Welding is a process of metallurgically joining two pieces of metals by the application of heat with or
without the application of pressure and addition of filler metal. The joint formed is a permanent joint.
Modern methods of welding may be classified under two broad headings.
a. Plastic welding process
b. Fusion welding process

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In plastic welding process the pieces of metal to be joined are heated to a plastic state and then forced
together by external pressure. This procedure is used in forge welding, resistance welding, spot welding
in which pressure is required.
In the fusion welding, the material at the joint is heated to a molten state and allowed to solidify. This
includes gas welding arc welding and Thermit welding.
The surfaces of the metal which are to be joined by any of the welding processes must be sufficiently
clean to permit clean metallic surfaces to come in to contact. In some operations, materials known as
fluxes are applied to the parts being welded to dissolve the oxides or to prevent the formation of oxides.
Fluxes are different for different metals. For ferrous materials borax, sodium carbonate etc, have been
found to give excellent results.

Types of Joints:
The welding joints are classified as Butt, Lap, Tee, Corner joints and edge joints. The choice of the type
of joint is governed by the kind of metal to be welded, its thickness and technique of welding. Fig. 3.1
shows the different types of joints used in welding.

Fig. 3.1. Different Types of Joints

Arc Welding:
Arc welding is a method of joining metals with heat produced by an electrical arc. In this process the
heat necessary to melt the edges of the metal to be joined is obtained from an electric are struck between
the electrode (filler rod) and the work, producing a temperature of 40000C, in the welding zone. The heat
of the arc melts the base metal or edges of the parts fusing them together. Filler metal, usually added
melts and mixes with molten base metal to form the weld metal. The weld metal cools and solidifies to
form the weld. In most cases, the composition of the filler material, known as welding rod, needed to
provide extra metal to the weld, is same as that of the material being welded.

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A typical arc welding setup is shown in Fig. 3.2.

1. An arc welding circuit consists of a power
supply to furnish electric power.
2. An electrode to conduct the electricity to the
arc.
3. Cables which connect the power supply to the
electrode and workpiece to complete the
welding circuit.
4. The arc itself provides the heat for welding.
5. The workpiece to weld is kept on a metallic table. Fig. 3.2. Arc Welding Setup

The arc must be shielded because; as it hardens the molten metal combines with oxygen and nitrogen to
form impurities that weaken the weld. Shielding can be obtained by adding a paste, powder or fibrous
flux to the arc. The electrodes are usually coated with a flux. This coating forms a gaseous cloud that
shields the molten metal from the atmosphere. The coating also forms a protective slag. The slag floats
on the molten pool and hardens as the weld cools. This keeps impurities out of the weld. The process is
shown in Fig. 3.3.

Fig 3.3. Arc Welding Process

Advantages:
1. As a manual process it is applicable to an infinite variety of work and can be executed in any
position.
2. There is less buckling and warping of the work.
3. It produces strong sound and ductile welds.
4. Satisfactory welds can be produced in heavy as well as in light sections.
5. Low cost process.
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6. Excellent joint properties can be obtained in mild, low alloy and stainless steels, nickel and
copper-base alloys.
7. Low accuracy in setting up required.

Disadvantages:
1. Basically a manual process requiring adequate operator skill for good results.
2. Electrodes require frequent changing.
3. Multi run welds necessary on thick plate-slag chipping necessary after each run.
4. The principal disadvantage has been the high heat of the metal arc which makes it unsuitable for
use on materials less than 1.55 mm thick.
5. High initial cost of welding equipment.

Difference between soldering and welding

Soldering Welding
Soldering using the filler Welding using the filler metal having the melting
metal having the melting point less than point nearly equal to the base metal, above 3500ºC
450ºC
Capillary action is also present in soldering No capillary action is present. Joint takes place due to
between fusion.
the base metal and filler metal.
Base metal does not melt. Base metal melts in welding
Filler metal is having the melting point less In welding filler metal is not
than the base metal. having the melting point less
than the base metal.
Filler metal is uniformly Filler metal melts and gets
distributed because of capillary action mixed with the base metal
Joints are weaker than Joints are stronger as
brazing compared to brazing, soldering
It uses the filler metal which It uses the filler metal mostly having the same
contains lead and tin. composition as that of base metal.
Zinc-Chloride Borax ash

Very less Less

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Very less Less

Tungsten inert gas (TIG) welding

Fig 3.4. TIG Welding Process

 In this operation, the work pieces to be joined are cleaned to remove dirt, grease and other oxides
chemically or mechanically to obtain a sound weld.
 The welding current and inert gas supply are turned ON.
 An arc is struck by touching the tip of the tungsten electrode with the work piece, and
instantaneously the electrode is separated from the work piece by a small distance of 1.5-3 mm
such that the arc still remains between the electrode and the work piece.
 The high intensity of the arc melts the work piece metal forming a small molten metal pool. filler
metal in the form of a rod is added manually to the front end of the weld pool.
 The deposited filler metal fills and bonds the joint to form a single piece of metal.
 The arc is extinguished by widening the gap between the workpiece and the electrode.
 The shielding gas is allowed to imping on the solidifying weld pool for a few seconds even after
the arc is extinguished.
 This will avoid atmospheric contamination of the solidifying metal thereby increasing the
strength of the joint.
 Fig. 3.4. represents the TIG welding process and components.
Advantages
 Suitable for the thin metals
 Clear visibility of the arc provides the operator to have a greater control over the weld
 Strong and high quality joints are obtained
 No flux is used. Hence, no slag formation. This results in clean weld joints.
Disadvantages
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 TIG is the most difficult process compared to all the other welding processes.
 Skilled operator is required
 Process is slower
 Not suitable for thick metals.

Metal inert gas (MIG) welding

Fig 3.5. MIG Welding Process

 In this operation, the workpieces to be joined are cleaned to remove dust, gease and other oxides,
chemically or mechanically to obtain a sound weld. The tip of the electrode is also cleaned with
a wire brush.
 The control switch provided in the welding torch is switched ON to initiate the electric power,
shielding gas and the wire (electrode) feed.

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 An arc is struck by touching the tip of the electrode with the work piece, and instantaneously the
electrode is separated from the work piece by a small distance of 1.5-3 mm such that the arc still
remains between the electrode and the work piece.
 The high intensity of the arc melts the work piece metal forming a small molten pool.
 At the same time, the tip of the electrode also melts and combines with the molten metal of the
work pieces there by filling the gap between the two work pieces.
 The deposited metal upon solidification bonds the joint to form a single piece of metal.
 Fig. 3.5 represents the MIG welding process and components.

Advantages
 MIG welding is fast and economical
 The electrode and inert gas are automatically fed. This reduces the burden on the operator, and
also helps him to concentrate on the arc.
 Weld deposition rate is high due to the continuous wire feed.
 No flux is used. Hence, no slag formation. This results in clean welds
 Thin and thick metals can be welded.
 Process can be automated.
Disadvantages
 Equipment is costlier
 Dross and porosity are the most prevalent quality problems in this process. However, extensive
edge preparation can be eliminate this defect.

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