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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
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
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.