MECH2402: Manufacturing

Lecture 5a: Resistance and Solid State Welding, Adhesives and Fasteners
DeGarmo Chapter 32 & 34
Prof. Tim Sercombe Room: 2.12 Phone: 6488 3124 email:: tim.sercombe@uwa.edu.au
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Introduction
Resistance welding uses heating caused by the resistivity of a metal to electron flow to melt the metal Solid State Welding creates joints without melting the workpiece and without filler metal.

Theory of Resistance Welding

Heat AND pressure used to create the joint Electrode provide both the current and pressure Use of pressure means joining can occur at lower temps that arc welding melting of workpiece may not even occur.

FIGURE 32-1 The basic resistance welding circuit.

Heating
Heat comes from passing large current through work piece for short times H = I2Rt
Where H = total heat in Joules I = current in amps R = electrical resistance in ohms t = length of time during which the current is

flowing

Resistance made up of 3 parts

1. 2. 3.

Want max resistance at the point of the weld and therefore want 1 and 2 to be as low as possible.
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Resistive Welding Temperature Distribution

FIGURE 32-2 The desired temperature distribution across the electrodes and workpieces during resistance welding.

Pressure for Resistive Welding

Controlling magnitude and timing of pressure is very important
Too little gives high resistance and surface burning Too high and material in the welded area may become deformed

Pressure essentially forges the material together

FIGURE 32-3 A typical current and pressure cycle for resistance welding. This cycle includes forging and postheating operations.

Current for Resistive Welding

Current is major factor in determining temperature As temp increases, bulk resistance increases and contact resistance decreases as contact area is improved Best conditions for welding are the initial conditions, so high currents and short times used. Overall voltage tends to be low (<10V), but currents can be very high (up to 100,000 amps)

FIGURE 32-3 A typical current and pressure cycle for resistance welding. This cycle includes forging and postheating operations.

Schematic of Resistive Welding

FIGURE 32-4 The arrangement of the electrodes and workpieces in resistance spot welding.

Resistance Welding Processes

Spot welding
The simplest and most widely used of the processes A car body contains 2000-5000 spot welds A good quality weld consists of a nugget of coalesced metals between the surfaces and little or no surface indentation.

FIGURE 32-4 The arrangement of the electrodes and workpieces in resistance spot welding.

FIGURE 32-5 A spot-weld nugget between two sheets of 1.3-mm (0.05-in.) aluminum alloy. The nugget is not symmetrical because the radius of the upper electrode is greater than that of the lower electrode. (Courtesy Lockheed Martin Corporation, Bethesda, MD.)

Spot Welding Application

Resistance Seam Welding

Performed by two different processes
1. Overlapping spot welds used to produce gas/liquid tight seals (eg fuel tanks)

FIGURE 32-8 Seam welds made with overlapping spots of varied spacing. (Courtesy Taylor-Winfield Corporation, Brookfield, OH.)

Schematic of Seam Welding

FIGURE 32-9 Schematic representation of the seam-welding process. those

Resistance Seam Welding

2. Resistance butt welding:
High frequency (AC) current used which keeps current located at the surface Pressure is then used when correct temp is attained Used in the manufacture of tubes and pipes

FIGURE 32-10 Using high- Squeeze roll frequency AC current to produce a resistance seam weld in buttwelded tubing. Arrows from the contacts indicate the path of the high-frequency current

Projection Welding (PW)

Overcomes the 2 main limitations of spot welding
Need to frequently maintain electrode Can only do one spot at a time

PW uses embossed dimples on the workpiece to isolate contact.

Single large electrode used to provide current and pressure

FIGURE 32-11 Principle of projection welding (a) prior to application of current and pressure and (b) after formation of the welds.

Advantages and Limitations of Resistance Welding

Advantages

Disadvantages

Process Summary for RW

Solid-State Welding Processes

Does not involve any melting of the work pieces.

Forge Welding:
Use of pressure to (metallurgically) bond two parts together Always done hot.

Cold Welding:
Uses room temperature plastic deformation to create the joint High localised pressures create 30-50 % cold work and pressure cold welds fresh surfaces Limited to small parts of soft ductile metals.

FIGURE 32-12 Small parts joined by cold welding. (Courtesy of Koldweld Corporation, Willoughby, OH.)

Roll Welding or Roll Bonding

Two or more sheets of metals joined by passing them simultaneously through a rolling mill. Can be done hot or cold

Method to produce clad steel (eg Al skin with steel core)

Friction Welding
Uses heat generated by relative motion of the work pieces

FIGURE 32-14 Sequence for making a friction weld. (a) Components with square surfaces are inserted into a machine where one part is rotated and the other is held stationary. (b) The components are pushed together with a low axial pressure to clean and prepare the surfaces. (c) The pressure is increased, causing an increase in temperature, softening, and possibly some melting. (d) Rotation is stopped and the pressure is increased rapidly, creating a forged joint with external flash.

Schematic for Friction Welding

FIGURE 32-15 Schematic diagram of the equipment used for friction welding. (Courtesy of Materials Engineering.)

FIGURE 32-17 Some typical friction-welded parts. (Top) Impeller made by joining a chromemoly steel shaft to a nickel steel casting. (Center) Stud plate with two mild steel studs joined to a square plate. (Bottom) Tube component where a turned segment is joined to medium-carbon steel tubing. (Courtesy of Newcor Bay City, Division of Newcor, Inc., Royal Oak, MI.)

Adhesive Bonding
Ideal Adhesive:
Bonds to any material Needs no surface preparation Cures rapidly Maintains high bond strength under all conditions Doesnt exist!

Adhesives widely used

Wood (eg ply wood), packaging, furnature, electronics, books, medical applications

Use on a wide range of materials

Metals, ceramics, glass, plastic, rubber, wood

Adhesive Bonding
Non metallic material (the adhesive) is used to fill the gap and create the joint between two surfaces. Can be thermosplastic or thermoset resin, artificial elastomers.... Applied as drops, beads, pellets, tapes of coating in the form of liquid, paste, gel or solid

Curing can be induced by heat, radiation, lights, moister, activators/catalysts, or combinations.

Can be used as structural/lead bearing, light duty holding/fixing or sealing applications.
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Structural Adhesives
Chosen for their ability to transmit load (bond must be able to be stresses to a high percentage of its max load for extended times. eg
Epoxies: most common. Strong and versatile Cyanoacrylates (eg superglue). Extremely rapid curing Anaerobics: thermosetting acrylics that harden in the absence of oxygen Acrylics: adhesive applied to one side and curing agent (primer) the other. Smelly Urethanes: cure quickly to handling stage (few minutes, but longer (24h) to full cure Silicones: cure for the moisture in the air. Low strength, but excellent flexibility.

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Consumption of Adhesives by End-Use

FIGURE 34-2 Distribution of adhesives and sealants by enduse areas. (Reprinted with permission from The Rauch Guide to the US Adhesives & Sealants Industry, Fifth Edition, 2006, Grey House Publishing, Millerton, N

Advantages/Disadvantages of Adhesives

Stresses in Adhesive Joints

Which are the weakest ones?

FIGURE 34-3 Types of stresses in adhesive-bonded joints.

Adhesive Joint Design

FIGURE 34-4 Possible designs of adhesive-bonded joints and a rating of their performance in service.

Failure Modes

Which is the best one?

FIGURE 34-6 Failure modes of adhesive joints. (a) Adhesive failure, (b) cohesive failure within the adhesive, and (c) cohesive failure within the substrate

Advantages and Disadvantages

Advantages

Disadvantages

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Mechanical Fastening
Wide range of techniques including

Mechanical Fasteners
Joint acquires strength via
Mechanical interlocking
Sheet metal seams, snap fits etc

Surface interference as a result of the clamping force

Nuts and bolts, rivets etc

Effectiveness of fastener depends on

Material of the fastener (eg strength of the bolt) Fastener design (including area of load bearing head) Hole preparation Installation procedure.

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Types of Integral Fasteners

Most commonly used in sheet metal products
Edge an edge seam is used to join the top of a drink can to the body and a protrusion is flattened to attach the opening tab.

FIGURE 34-7 Several types of integral fasteners: (a) lanced tab to fasten wires or cables to sheet or plate; (b) and (c) assembly through folded tabs and slots for different types of loading; (d) use of a flattened embossed protrusion; (e) single-lock seam.

Discrete Fasteners
Separate pieces whose function is to join the primary components.
Huge variety available and it can be difficult to select the correct one Easy to install and (usually) remove

FIGURE 34-8 Various types of discrete fasteners, including a nail, screw, nut and bolt, two-side access supported rivet, one-side access blind rivet, quick-release fastener, and snap-fit.

Shrink and Press fits

Shrinks/Expansion fits:
Heat or cold is use to change the temperature of the components (eg heat the hole, cool the shaft) At room temp, a strong interference fit is established.

Press fit
Similar to shrink fits, but mechanical force is used instead of temperature differential.

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Advantages and Disadvantages

Advantages

Disadvantages

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Summary
Spot welding uses an electric current to heat the work piece and pressure to form the joint. Excellent method for joining sheet metal

Solid state welding uses plastic deformation to produce the bond.

Adhesives can be used in a wide range of applications Mechanical fasteners are one of the more popular joining methods.
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