AUTOMATIC WELDING SYSTEM

WELDING
 It is a fabrication or sculptural process that joins
materials, usually metals or thermo plastics, by
causing coalescence.
 This is often done by melting the work pieces and
adding a filler material to form a pool of molten
material (weld pool) that cools to become a strong
joint, with pressure sometimes used in conjunction
with heat, or by itself, to produce the weld.
OTHER PROCESS SIMILAR TO
WELDING
Soldering Brazing
ENERGY SOURCES FOR WELDING

 Gas flame
 Electric arc
 Laser
 Electron Beam
 Friction
 Ultrasound
DANGERS INVOLVED IN WELDING

 Burns
 Electric Shock
 Vision Damage
 Inhalation of poisonous gases and fumes
 Exposure to intense ultraviolet radiation
 AUTOMATIC WELDING SYSTEMS
POPULAR WELDING PROCESSES
 Arc Welding
 Gas Welding
 Laser and Energy Beam Welding
 Resistance Welding
o Spot Welding
o Shot Welding
o Seam Welding
 Solid State Welding
o Ultrasonic Welding
o Explosion Welding
 ARC WELDING
 Uses a welding power supply to create and maintain an electric
arc between and electrode and the base materials to melt metals
at the welding point.
 Power source: DC or AC
 The length of the arc is directly related to the voltage, and the
amount of heat input is related to the current.
 Electrodes: Consumable or non- consumable
 The welding region is sometimes protected by some type of inert
or semi- inert gas, known as a shielding gas, and filler material
is sometimes used as well.
 WELDING ELECTRODES
 Electrodes- are used to conduct current through a work
piece to fuse two pieces together.
 WELDING ELECTRODES
TYPES OF WELDING ELECTRODES:
 Consumable Electrode
- uses direct current and electrodes can be charged
by either be positive or negative.
Positively-charged Electrode:
-The base will be hotter, increasing weld penetration
and welding speed.
Negatively-charged Electrode:
-Results in more shallow welds.
 WELDING ELECTRODES
 Non- consumable Electrode
- can use either type of direct current, as well as alternating
current.
WITH DIRET CURRENT.
- It only creates the arc and does not provide filler material.
Positively-charged Electrode: causes shallow welds.
Negatively-charged Electrode: makes deeper welds.
WITH ALTERNATING CURRENT.
- Results in medium penetration welds.
 FORMS OF ARC WELDING
 Shielded Metal Arc Welding (SMAW)
 Gas Metal Arc Welding (GMAW)
 Flux- cored Arc Welding (FCAW)
 Gas Tungsten Arc Welding (GTAW)
o Plasma Arc Welding (PAW)
 Submerged Arc Welding (SAW)
 GAS WELDING
 It is one of the oldest and most versatile welding
processes, but in recent years it has become less popular
in industrial applications.
 Relatively inexpensive and simple equipment.
 Combustion of acetylene in oxygen to produce a welding
flame temperature of about 3100 °C.
 It is still widely used for welding pipes and tubes, as well
as repair work.
 LASER AND ENERGY BEAM
WELDING
Laser Beam Welding. Employs a highly focused laser beam.
Energy Beam Welding. Done in a vacuum.
These two processes are quite similar, differing most notably in their source of power.
CHARACTERISTICS:
 Extremely fast
 Easily automated
 Highly productive.
 Very high energy density
 Makes deep weld penetration possible
 Minimizes the size of the weld area.
DISADVANTAGES:
 Very high equipment costs
 Susceptibility to thermal cracking
 RESISTANCE WELDING

 Resistance welding involves the generation of heat by passing

current through the resistance caused by the contact between two
or more metal surfaces.
 Small pools of molten metal are formed at the weld area as high
current (1000–100,000 A) is passed through the metal.
 Efficient and cause little pollution, but their applications are
somewhat limited and the equipment cost can be high.
 RESISTANCE WELDING
 Spot welding
- Is a popular resistance welding method used to join overlapping metal
sheets of up to 3 mm thick. Two electrodes are simultaneously used to clamp the
metal sheets together and to pass current through the sheets.
 Shot Welding
- Can be used to spot weld stainless steel
 Seam Welding
- Relies on two electrodes to apply pressure and current to join metal
sheets.
- Uses wheel-shaped electrodes that roll along and often feed the work
piece, making it possible to make long continuous welds (like in beverage
cans).
 SOLID STATE WELDING
 The materials being joined are not melted.

TYPES:
Ultrasonic Welding Exothermic Welding
High frequency welding
Explosion Welding
Hot pressure welding
Friction Welding Induction welding
Electromagnetic Pulse welding Roll welding
Co-Extrusion
Cold Diffusion Bonding
 ULTRASONIC WELDING
 Used to connect thin sheets or wires made of metal or
thermoplastic by vibrating them at high frequency and under high
pressure.
 The equipment and methods involved are similar to that of
resistance welding, but instead of electric current, vibration
provides energy input.
 Ultrasonic welding is commonly used for making electrical
connections out of aluminum or copper, and it is also a very
common polymer welding process.
 EXPLOSION WELDING

 Involves the joining of materials by pushing them together under

extremely high pressure.
 The energy from the impact plasticizes the materials, forming a
weld, even though only a limited amount of heat is generated.
 The process is commonly used for welding dissimilar materials,
such as the welding of aluminum with steel in ship hulls or
compound plates.
 FACTORS AFFECTING THE QUALITY OF
WELDS
Factors influence the strength of welds and the material around them:

 Welding method
 Amount and concentration of energy input
 Weld ability of the base material, filler material, and flux material
 The design of the joint
 Interactions between all these factors.
Sequence of Operation in Making a Weld

Squeeze Interval
Weld Interval
Hold Interval
Release
Standby Interval
Sequence of Operation in Making a Weld
 Squeeze Interval
-Welding electrode comes forward and engage the metal
processing against the surface.
- Typical squeeze time is 1 second.
 Weld Interval
-Welding transformer is energized, current flows and creates
a weld. The welding current is turned on and off in short
bursts, called pulsations.
- Heat subinterval is a condition when the current is on.
- Cool subinterval is when the current is off.
- Typical duration is 2-10 seconds.
Sequence of Operation in Making a Weld
 Hold Interval
-Weld is interval is finished.
-Electrode pressure is maintained.
-Lasts about a second.
 Release
-Welding electrode is retracted.
 Standby Interval
-The time interval after release interval to the next
start sequence.