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MANUFACTURING PROCESSES
5.1 Introduction
Type of joining
Adhesives
Soldering & Brazing
Mechanical Fasteners
Welding
Type of adhesives
1)Natural adhesives
such as starch, dextrin (a gummy substance obtained from starch), soya
flour, and animal products.
Lowstress applications: cardboard cartons, furniture, bookbinding,
plywood
2)Inorganic adhesives
such as sodium silicate and magnesium oxychloride.
Low cost, low strength
3)Synthetic organic adhesives
which may be thermoplastics (used for nonstructural and some structural
bonding) or thermosetting polymers (used primarily for structural
bonding).
Classification of synthetic adhesives:
- Chemical reactive
- Pressure sensitive
- Hot melt
- Reactive hot melt
- Evaporative/diffusion
- Film and tape
- Delayed tack
- Electrically and thermal conductive
Surface preparation
Part surfaces must be extremely clean
Bond strength depends on degree of adhesion between adhesive
and adherend, and this depends on cleanliness of surface
For metals: solvent wiping often used for cleaning, and
abrading surface by sandblasting improves adhesion
For nonmetallic parts: surfaces are sometimes mechanically
abraded or chemically etched to increase roughness
Process capabilities
Can bond variety of similar and dissimilar metallic and non
metallic material and components of different sizes,shapes and
thicknesses
Can combine with mechanical joining method to improve strength
of bond
Adhesive joints are designed to withstand shear,compressive,and
tensile force but not peeling
Applications
Automotives(eg brake lining assemblies),aerospace (aircraft
bodies and control surfaces),appliances,building product
industries
Group
Adhesive
substance
Joined Material
Animal glues
Animal hides or
bones, fish
casein(from milk),
blood albumen
Vegetable glues
Natural resins
Inorganic cement
Elastomer materials
Gum Arabic
Sodium silicate
Foundry moulds
Portland cement,
plaster of Paris
Building industries
Natural
Rubber, sealing
rubber(latex/solvent) strips
Synthetic rubber
Footwear industries,
Group
Synthetic polymer
materials
Adhesive
substance
Joined Material
Polyvinyl acetate
and vinyl copolymers
Cellulose derivatives
(solvent release)
Acrylics
Acrylics,
polycarbonates
Anaerobic acrylics
Metals
Cyanoacrylates
Metals, rubbers,
polycarbonates, PVC,
polystyrene,
polyimide
Epoxy/amine
Metals, glass,
ceramics, reinforced
plastics, wood, wide
range of uses
Epoxy/polyimide
Advantages
Interfacial bond has sufficient strength for structural
applications but also for non structural purposes
Eliminate localized stress because load at interface is
distributed
External appearance is unaffected
Thin and fragile components can be bonded
Porous material and different material can be joined
No significant distortion because performed in room temp200C
Disadvantages
Limited service temperature
Bonding time can be long
Great care in surface preparation
Bonded joints are difficult to test non destructively
Reliability under hostile environment
condition(stress,degradation,radiation etc)
Brazing
What is brazing?
Joining process in which a filler metal is melted and distributed
by capillary action between faying surfaces of metal parts
being joined
No melting of base metals occurs ;Only the filler melts
Filler metal Tm greater than 450C (840F) but less than Tm of
base metal(s) to be joined
Procedure:
Filler (braze) metal wire is placed along periphery of
components to be joined-apply heat-filler melt-filling space by
capillary action
Filler metals
Significantly different from metals to be joined
Variety of shapes:wire,rod,ring,fillings
The selection of the type of filler metal and its composition are
important in order to avoid embrittlement of the joint by
(a) grain-boundary penetration of liquid metal,
(b) formation of brittle intermetallic compounds at the joint,
(c) galvanic corrosion in the joint.
Fluxes
Is essential to prevent oxidation and to remove oxide films from
workpiece surfaces.
Brazing fluxes generally are made of borax, boric acid, borates,
fluorides, and chlorides.
Wetting agents also may be added to improve both the wetting
characteristics of the molten filler metal and the capillary action.
It is essential that the surfaces to be brazed be clean and free
from rust, oil, and other contaminants in order to
(a) obtain proper wetting and spreading of the molten filler metal
in the joint
(b) develop maximum bond strength.
Brazing joints
(a) Conventional butt joint, and adaptations of the butt joint for brazing: (b)
scarf joint, (c) stepped butt joint, (d) increased crosssection of the part
at the joint.
(a) Conventional lap joint, and adaptations of the lap joint for brazing: (b)
cylindrical parts, (c) sandwiched parts, and (d) use of sleeve to convert
butt joint into lap joint.
Brazing method
Torch brazing
Furnace brazing
Induction brazing
Resistance brazing
Dip brazing
Infrared brazing
Diffusion brazing
High energy beam
Braze welding
Torch Brazing
Furnace Brazing
Furnace Brazing
Soldering
What is soldering?
Joining process in which a filler metal with Tm less than or equal to
450C (840F) is melted and distributed by capillary action between
faying surfaces of metal parts being joined
Important characteristics: low surface tension, high wetting
capability
Soldering techniques:
Same like brazing +reflow(paste) soldering + wave soldering
Wave soldering
Refers to a mechanized technique that allows multiple leadwires
to be soldered to a PCB as it passes over a wave of molten solder
Processing step : i) flux , ii) preheat, iii)pumping solder from
molten bath
Threaded fasteners
Discrete hardware components that have external or internal
threads for assembly of parts
Common : screws, bolts, and nuts
Screw - externally threaded fastener generally assembled into a
blind threaded hole
Bolt - externally threaded fastener inserted into through holes and
"screwed" into a nut on the opposite side
Nut - internally threaded fastener having standard threads that
match those on bolts of the same diameter, pitch, and thread form
Threaded fasteners
Screw
Has a raised twisted part on it called thread
Types of screws
cap screws (made of higher strength metals and to closer
tolerances)
set screws- Hardened and designed for assembly functions
such as fastening
collars, gears, and pulleys to shafts
Types of Rivets