Module 3 - 1

Laser Beam
Welding
(LBW)

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 2

LBW - 1 of 2
Laser
Light Amplification by Stimulated
Emission of Radiation
A fusion welding process
Heat from concentrated light source
Keyhole welding
Light beam very small x-section

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 3

LBW - 2 of 2
Light can be transmitted by fiber
optics or mirrors
Non-contact process
Shielding gas often required

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 4

Cross Section of LB Weld

Weld

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 5

LBW Advantages - 1 of 2
Low heat input
Less grain growth and distortion
High D/W ratios of 10:1 attainable
Relatively thick single pass welds - (up to
1.25 )
Welds thin metals or small diameter wires
Closely spaced components, small welds

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 Module 3 - 6

LBW Advantages - 2 of 2
Welds wide variety of materials
Beams readily focused and aligned
Not influenced by magnetic fields
Welds metals of dissimilar physical
properties
No vacuum or X-ray shielding required
Beams transmitted to many work stations

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 7

LBW Limitations
Joints must be accurately positioned
Surfaces must be forced together
Alloy reflectivity and thermal
conductivity
Plasma control device often required
Cost

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 8

LBW Discontinuities

Porosity
Embrittlement

Am e r i c a n We l d i n g S o c i e t y
Electron Beam Welding Module 3 - 9

(EBW)

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 10

EBW
Originally required high vacuum
Can now operate in low, or no,
vacuum
A fusion joining process
Heat applied from stream of high-
energy electrons from gun

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 Module 3 - 11

EB
Schematic

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 12

Electron
Beam
Welding
Fixture

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 13

EB Weld

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 14

EBW Advantages
Similar to LBW
Deeper penetration capability
High purity, especially for vacuum
environment
High welding speeds
Ability to change weld shape

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 15

EB Limitations
Similar to LBW
Vacuum chamber may be required
Vacuum chamber size can limit
assembly size
X-Rays generated
Cost

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 Module 3 - 16

EBW Discontinuities
Cracking
Root voids
Porosity

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 Module 3 - 17

Resistance
Welding - 1 of
3

Am e r i c a n We l d i n g S o c i e t y
Resistance Welding - 2 of Module 3 - 18

Am e r i c a n We l d i n g S o c i e t y
 Resistance Welding - 3 of Module 3 - 19

3
Heat obtained from resistance of
workpieces as current flows
through them
Electrodes are usually copper
3 types - RSW, PW, RSEW

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 20

RSW Advantages
Very fast welding times - < 1 sec /
spot
Semiautomatic or automatic
Good for thin materials
No flux required

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 21

RSW Limitations
Inspection of welds may be difficult
Primarily a shop process
Electrodes must be clean
Metal surfaces must be clean

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 Module 3 - 22

RSW Discontinuities
Non-fusion areas
Cracks
Misalignment of RSEW electrodes

Am e r i c a n We l d i n g S o c i e t y
 Welding Applications & Module 3 - 23

Personnel
Manual Welder
Semiautomatic
Mechanized Welding Operator
(machine)
Automatic

See A3.0-94 for AWS definitions.

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 24

Brazing

Am e r i c a n We l d i n g S o c i e t y
 Brazing vs Welding vs Module 3 - 25

Soldering
Base metal not melted in brazing or
soldering
Brazing filler metals melt above 840 0 F
(4500 C)
Soldering filler metals melt below 840 0
F
Strong joints possible with all
processes if designed properly

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 Module 3 - 26

Brazing Aspects
Large surface area
Very small clearance
Clean surfaces
Flux often used
Capillary action

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 Module 3 - 27

Braze Joint Configurations

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 Module 3 - 28

Brazing Filler Metals

Wire
Strip
Foil
Paste
Preforms

Am e r i c a n We l d i n g S o c i e t y
 AWS Brazing Filler Module 3 - 29

Metals
Designation Primary Element
BAlSi Aluminum-Silicon
BCuP Copper-Phosphorus
BAg Silver
BAu Gold
BCu Copper
RBCuZn Copper-Zinc
BMg Magnesium
BNi Nickel

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Brazing Methods
Named after heating method
Torch- Oxygen-Acetylene
Furnace
Induction
Resistance
Dip-water or oil
Infrared

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Brazing Advantages
Strong joints
Joins dissimilar metals
Joins metals to nonmetals
Joins unweldable metals
Less heat, less distortion

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 Module 3 - 32

Brazing Limitations
Cleanliness requirements
Joint design requirements
Difficult to inspect

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 33

Brazing Discontinuities
Voids, unbonded areas
Base metal erosion
Corrosion by flux
Trapped flux

Am e r i c a n We l d i n g S o c i e t y