Fajar Yusya Ramadhan 1

Tugas-04 Welding

1. The principle of cold welding material which is two ends facing each other, clamped
using a clamp , the next pressure both ends so that the connection process may occur .
Style sizable required in this process so that it contacts the interface is good.
The main requirement for the material can be joined by this method are:

At least one metal that will have a resilient nature / very tough .
Do not undergo drastic strain hardening .
2. Threshold deformation is a very important parameter which the function is to determine
the maximum power that can be obtained from the cold welding process . Usability
threshold deformation is to mendpatkan minimum limit value that has ties to the material
deforms when cold .
Example calculation for Aluminum and The alloy material :
Initial thickness ( to ) = 10 mm
Final thickness ( tf ) = 5 mm
Then,
Deformasi=

105
x 100
10

Deformasi=50

3. Factors affecting the threshold deformation value is:

a. The crystal structure of materials
b. b . type of material
c. Pressure exerted on the material
d. surface preparation Here is the relationship between the threshold deformation by
pressure and surface preparation in the cold welding process : Pressure on
material deformation threshold and connection strength The better the
surface when prepared then , the threshold deformation

4. Explosion Welding is a solid state welding process in which the connection is produced
by high-speed collisions have on the workpiece from the explosion.

Fajar Yusya Ramadhan 2

Tugas-04 Welding

The working principle of explosion welding which uses three components: base metal,
prime metal, explosive. Details of the working principles of explosion welding are:
a. The three components are arranged, prime component placed on the middle layer and a
detonator at the top.
b. When the detonator detonated the prime component will pound base metal so that
plastic deformation occurs and the two plates are connected.

5. Working Principle of this welding is of the ultrasonic vibration obtained from the
transducer is transmitted to the tip of the sonotrode so that the two metals that you want
to connect will arise when the heat and subsequent rupture of the oxide layer with the
pressure of clamping will result in material connected.

Fajar Yusya Ramadhan 3

Tugas-04 Welding

In ultrasonic welding method is there is a relationship between the energy needed and
weldability, which can be seen from the formula below:

Where:
E = Electrical Energy, W.s (J)
K = Constant of welding systems
H = Vicker Hardness Number
T = thickness of the workpiece in contact with the sonotrode (mm)
From formula can be a relationship that the harder a material is the energy required would
be even greater.
Examples of the use of ultrasonic welding applications in the field like the image shown
below:

6. The working principle of this welding is :

a. Two workpiece is pressed and rotated so that both will arise due to friction heat .

b. Then used for the connection process

Fajar Yusya Ramadhan 4

Tugas-04 Welding

The stages can be explained from the image above:

a) The object is rotated

b) The object pressed into the stationary objects spinning

c) Occurs friction
d) Occurs Welding
Advantages
Disadvantages
Heating of friction occurs locally, so Usually for circular objects
that softening does not spread
Without any metal melting

For same kind and same geometry

Fast process

shape of metals
Preparation pf sampel affects the

Can weld 2 different materials

welding product
High cost

Example of friction welding:

Fajar Yusya Ramadhan 5

Tugas-04 Welding

7. Principle of Roll Bonding:

Keuntungan
Keterbatasan
To connect two different materials to Relatively
obtain metal with different applications
Can be applied at room temperature and

seldom

used

for

mass

production
Development of these methods are not

hot temperature
sufficiently comprehensive
Aplikasi field: For US quartes, to make the two outer layers of 75% Cu 25 % Ni in
the middle of pure Cu.

8. The principle of friction stir welding :

1 ) Pin rotating at a speed of 3000-4000 rpm is put on material
2 ) The material is heated due to friction
3 ) The material that has been heated to reach a temperature of plasticizer ( 800F to
aluminum )
4 ) Materials that have been terplastisasi draped back to pin

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Tugas-04 Welding

5 ) The material is cooled with formation of grains - grains finer dibandigkan with the
parent material .

Metal material that is generally applied to this method :

Magnesium
Copper
Aluminum and aluminum alloys
Lead , etc.
FSW advantages :
o Energy efficiency
o Simple and clean
o More powerful and cleaner when compared to fusion welds
o low distortion and shrinkage
o high ductility in the weld
o No porosity , lack of fusion, changes in the composition of the material
o Not required treatment after the process

9. The welding parameters for FSW :

Heating the material to a temperature of 800 F
The amount of minimum rpm : 3000-4000 rpm
Schematically welding area :

Fajar Yusya Ramadhan 7

Tugas-04 Welding

When using FSW is obtained in the form of structural weld area finer connection than on
its base metal . It is obtained due to the structure of sambugan produce finer grains than
its base metal .

10. Material from which , among others, AISI H13 , AISI H22 , etc.
The material must have a melting point higher than the workpiece . Preferably the stirrer
material must have a melting point of at least 100 Fahrenheit higher than the workpiece
or 200 F for aluminum . Furthermore, the stirrer material should also have a higher
strength than the workpiece . In addition the material must have good wear resistance ,
and good machinability . The type of surface treatment that can be done between heat
treatment such as hardening , tempering ( lowered into a 45-47 HRC hardness )
11. The difference of ultrasonic welding and spot welding:
Ultrasonic welding
The quality of the connection for the
transfer enerfi uniform and constant
residual heat released and limited to the
connection area

Spot resistance
There is smoke on the welding process

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Tugas-04 Welding

The required pressure is small and heat up

to the middle

heat does not get to the center

For the metal having high conductivity

( Cu , Al ) only requires a lower energy

In metals with high conductivity requires

high energy

Be able to connect different metal

( dissimilar ) even metal-plated ( plating /
coating)

There are sparks that could cause a fire or

explosion

Generally used for relatively small -sized

metal vulnerable

Electrical shock occurs

There is no melting area

Have melting area

When using the current density is too

high , it can cause molten metal was
thrown and the impact on the formation of
cavities , cracks and degrade the
mechanical properties of the weld results