Fabrication processes involve joining multiple elements to form a single part. There are several classification schemes for fabrication methods, including mechanical joining (bolts, screws, rivets), adhesive bonding, and welding. Welding is a key fabrication method that produces coalescence through heating and application of pressure or filler material. There are many types of welding processes classified by heat source (flame, arc) or state of the weld metal (fusion, solid-state). Common welding joints include butt, corner, lap, tee, and edge joints.
Fabrication processes involve joining multiple elements to form a single part. There are several classification schemes for fabrication methods, including mechanical joining (bolts, screws, rivets), adhesive bonding, and welding. Welding is a key fabrication method that produces coalescence through heating and application of pressure or filler material. There are many types of welding processes classified by heat source (flame, arc) or state of the weld metal (fusion, solid-state). Common welding joints include butt, corner, lap, tee, and edge joints.
Fabrication processes involve joining multiple elements to form a single part. There are several classification schemes for fabrication methods, including mechanical joining (bolts, screws, rivets), adhesive bonding, and welding. Welding is a key fabrication method that produces coalescence through heating and application of pressure or filler material. There are many types of welding processes classified by heat source (flame, arc) or state of the weld metal (fusion, solid-state). Common welding joints include butt, corner, lap, tee, and edge joints.
Fabrication processes involve joining multiple elements to form a single part. There are several classification schemes for fabrication methods, including mechanical joining (bolts, screws, rivets), adhesive bonding, and welding. Welding is a key fabrication method that produces coalescence through heating and application of pressure or filler material. There are many types of welding processes classified by heat source (flame, arc) or state of the weld metal (fusion, solid-state). Common welding joints include butt, corner, lap, tee, and edge joints.
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Fabrication Processes
Introduction:
Joining two or more elements to make a single part
is termed as a fabrication process. Large no. of industrial components are made by fabrication processes. Ex:- Aircraft & ship bodies, bridges, building trusses, machine frames, sheet metal parts etc.
It is also known as secondary manufacturing
process.
Most economical method.
Classification of fabrication methods
• Mechanical joining by means of bolts,
screws & rivets. • Adhesive bonding by employing synthetic glues such as epoxy resins • Welding , brazing & soldering Various factors affect during selection of fabrication method • Type of assembly : permanent, semi permanent & temporary • Materials being joined : steels, cast irons, similar or dissimilar metals • Economy achieved • Types of service required : such as assembly subjected to heavy loading, impact loading, high temp. etc. Welding (Fabrication method) Welding is a materials joining process which produces coalescence of materials by heating them to suitable temperatures with or without the application of pressure or by the application of pressure alone, and with or without the use of filler material.
Welding is used for making permanent joints.
It is used in the manufacture of automobile bodies,
aircraft frames, railway wagons, machine frames, structural works, tanks, furniture, boilers, general repair work and ship building. Classification of welding process There are various ways of classifying the welding processes. for example, they may be classified on the basis of state of the weld metal during welding , source of heat (flames , arc) etc.
In general all welding processes are
classified as follows. Classification of welding process ….. Welding processes are classified into two major groups:
1.Fusion welding: In this process, base metal is melted by
means of heat. Often, in fusion welding operations, a filler metal is added to the molten pool to facilitate the process and provide bulk and strength to the joint. Commonly used fusion welding processes are: arc welding, resistance welding, oxy- fuel welding, electron beam welding and laser beam welding.
2. Solid-state welding: In this process, joining of parts takes
place by application of pressure alone or a combination of heat and pressure. No filler metal is used. Commonly used solid- state welding processes are: diffusion welding, friction welding, ultrasonic welding. Classification of welding process Classification of welding process 2. Arc welding: 1. Gas welding: I. Shielded metal arc welding Oxy-acetylene II. Submerged arc welding welding III. Gas tungsten arc welding Oxy-hydrogen welding IV. Gas metal arc welding Air acetylene welding V. Carbon arc welding VI. Plasma arc welding VII.Atomic Hydrogen welding Conti……. 3. Resistance welding: 4. Other welding and I. Resistance spot welding related processes : II.Resistance seam Thermit welding welding Electro slag welding III.Projection welding Electron beam welding IV.Percussion welding Laser beam welding V.Flash welding Forge welding VI.Upset welding Friction welding Diffusion welding Explosion welding Brazing Braze welding soldering Types of welding joints 1. Butt joint: In Butt welded type, the parts lie in the same plane and are joined at their edges.
2. Corner joint: The parts in a corner joint form a right angle and are joined at the center of the angle.
Butt Joint
Corner Joint Types of welding joints …. 3. Lap joint: Lap joint consists of two overlapping parts.
4. Tee-joint: Lap Joint
Tee welding joints are formed when two
members intersect at a 90° angle which makes the edges come together in the center of a plate or component. Tee Joints are considered a type of fillet weld, and can also be made when a pipe or tube is welded onto a base plate. Extra care is required to Tee Joint
ensure effective penetration into the roof of
the weld. Types of welding joints …. 5. Edge joint: Edge welding Joints are often applied to sheet metal parts that have flanging edges or are placed at a location where a weld must be made to attach to adjacent pieces. Being a groove type weld, Edge Joints, the pieces are set side by side and welded on the same edge.
Edge Joint Types of welding joints ….
Butt Joint Lap Joint
Corner Joint
Tee Joint
Edge Joint Types of welding joints …. Types of welds Mainly Four types.
Bead Weld
Groove Weld
Fillet weld
Plug or Slot weld Types of welds ……. Bead Weld: A weld bead is a weld deposit produced by a single pass. A weld bead may be either narrow or wide, depending on the amount of transverse oscillation (side-to-side movement) used by the welder. When there is a great deal of oscillation, the bead is wide; when there is little or no oscillation, the bead is narrow. Types of welds ……. Groove Weld A weld groove is defined as “A channel in the surface of a work piece or an opening between two joint members providing space to contain weld metal.”
Groove welds fill the space made between sections of
the work piece. Types of welds Fillet weld Process of joining two pieces together whether they be perpendicular or at an angle.
Commonly referred to as Tee joints or Lap joints.
The weld is triangular in shape and may have a
concave, flat or convex surface depending on the welder’s technique.
Fillet welds are used when connecting flanges to
pipes, welding cross sections of infrastructure. Types of welds ….. Fillet weld Types of welds ….. 4. Plug Or Slot weld A plug weld is used to fasten two pieces of metal together.
When joining the pieces, a hole is drilled into the top piece and it is laid over the bottom one.
A weld is then made by running a bead inside of the
drilled hole, thereby holding the two pieces together. Welding Positions Increasing Difficulty
FLAT
HORIZONTAL OVERHEAD
VERTICAL Weld joints edge preparation methods Welding Terms (Terminology) Backing: It is the material support provided at the root side of a weld to aid in the control of penetration. Base metal: The metal to be joined or cut is termed the base metal. Bead or weld bead: Bead is the metal added during a single pass of welding. The bead appears as a separate material from the base metal. Crater: In arc welding , a crater is the depression in the weld metal pool at the point where the arc strikes the base metal. Deposition rate: The rate at which the weld metal is deposited per unit time is the deposition rate is normally expressed as kg/h Welding Terms ….. Welding Terms ….. Fillet weld: The metal fused into the corner of a joint made by two pieces placed at approximately 90 0 to each other is termed fillet weld. Penetration: It is the depth up to which the weld metal combines with the base metal as measured from the top surface of the joint. Puddle: The portion of the weld joint that is melted by the heat of welding. Root: It is the point at which the two pieces to be joined by welding. Tack weld: A small weld , generally used to temporarily hold the two pieces together during actual welding . Welding Terms ….. Toe of weld: It is the junction between the weld face & base metal.
Weld face: It is the exposed surface of the weld.
Weld metal: The metal that is solidified in the joint is
called weld metal. It may be only a base metal or a mixture of base metal & filler metal.
Weld pass: A single movement of the welding torch or
electrode along the length of the joint which results in a bead is a weld pass. Thank You
