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Manufacturing Processes
Rahul Panat
RESEARCH TOPICS
Thank you for submitting the topics
Very interesting areas
Presentations will be done by the end of April and
May
EXAM ON FRIDAY
Same format as Exam #1
Topics covered until last week ; Emphasize will be on questions after the exam #1, but there
may be some questions from before the exam #1 as stated before in the class
Three sets of questions
Set-1: Multiple choice
Set-2: Short answers
Set-3: Numerical problems
Please study the text and class material (posted on Angel) with particular attention to
Review questions in the class
Problems discussed in the class
HWs
One A4 sheet (both sides) with your notes allowed for exam 2. You can bring the older
sheet from exam 1 as well
OUTLINE
(Last Lecture)
Joining and assembly
Joining processes
Welding
Fusion
(This Lecture)
Solid state
Mechanical fastening
SOLID-STATE WELDING
Joining without fusion, ie., no liquid (molten)
phase in the joint
Coalescence results from application of pressure
alone or a combination of heat and pressure
If heat is used, temperature is below melting point of
metals being welded
No filler metal is added in solid state welding
Ultrasonic welding
Friction welding
Resistance welding
Explosion welding
Diffusion bonding
Movie
ULTRASONIC WELDING
In USW, the faying faces are
subjected to a static normal
force + oscillating shear stress
The shear stress is applied by
the tip of a transducer, freq =
10-75 kHz
Movie
https://www.youtube.com/watch?v=6-iuT_o8f00
https://www.youtube.com/watch?v=fazeH4PHvpk
Movie
(1) Rotating part, no contact; (2) parts brought into contact to generate friction
heat; (3) rotation stopped and axial pressure applied; and (4) weld created
Cross section of
butt joint of two
steel tubes joined
by friction welding
(courtesy George
E. Kane
Manufacturing
Technology
Laboratory, Lehigh
University)
Applications:
Limitations:
Advantages
Disadvantages
Spot (primary)
Seam
Projection
Flash
Upset
Animation
Applications:
Gasoline tanks
Automobile mufflers
Advantages:
Disadvantages:
EXPLOSION WELDING
Flyer (cladding)
Welded interface
Target (substrate).
Explosion. 5 Explosive powder.
Plasma jet.
Movie
Temperatures 0.5 Tm
BRAZING
SOLDERING
SUMMARY
Welding