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BRAZE WELD
MECH. SOLDERING
Classification
• Joining processes can classified in different ways:
– Fusion or plastic state
• Fusion: Gas, arc
• Plastic: Friction and resistance welding
– Source of heat generation
• Gas, arc, laser, electron, friction, ultrasonic
– Composition of welds
• Heterogeneous: a filler material different from the parent
material is used. i.e. soldering and brazing
• Autogeneous: no filler (TIG with filler and resistance
welding)
• Homogeneous: filler is same as the parent i.e. arc, gas,
and thermit welding
CLASSIFICATION of JOINING PROCESSES
➢ Unlike the Manufacturing Processes Employed to Produce a Single
Component, the Joining Processes are Used to Assemble Different
Members to Yield the Desired Complex Configuration.
➢ Joining of Different Elements can be Either Temporary or Permanent
in Nature. The Mechanism of Bonding may be either Mechanical
Bonding or Atomic Bonding.
➢ Another Criterion Used for Classifying the Joining Processes is Based
on the Composition of the Joint.
❖ Autogeneous: No Filler Material is Added During Joining.
i.e. All Types of Solid Phase Welding and Resistance Welding
❖ Homogeneous: Filler Material Used to Provide the Joint is the
Same as the Parent Material.
i.e. Arc, Gas, and Thermit Welding
❖ Heterogeneous: A Filler Material Different from the Parent
Material is Used.
i.e. Soldering and Brazing
MI-102: Manufacturing Techniques I. I. T. ROORKEE
Metallurgical Bonding
• Fusion welding: (welding melting of
plates being welded)
– Gas welding, arc welding
processes
– Resistance welding processes
• Solid state
– Ultrasonic welding (usw)
– Friction welding
– Diffusion bonding
FUSION WELDING
LIQUID AND SOLID STATE WELDING
BRAZING
[4.2.1] Various Conventional Joining or Fabrication Processes
Bond Sub Sub-sub Categories, Examples, Remarks
Type Category
Mechanical Temporary Threaded Fasteners: Screws, Nuts, Bolts
Bonding ➢ Allow Easy Dissembling for Repair, Replace, and
Adjustment
➢ Convenient for Human Assembly Workers but
Difficult for Robots and Automated System
Permanent Riveting and Crimping:
or Press/Shrink Fit: Pulley or Gear on Shaft
Semi- ➢ Interference Fit Between Mating Parts
permanent
Snap Fit: C-Rings, Snap Rings, Retainers
➢ Temporary Interference of Mating Parts
Sewing, Stitching, Stapling: To Assemble Soft
Thin Materials
➢ For Fabrics, Cloth, Leather, Thin Flexible Plastics
Slot Weld
MI-102: Manufacturing Techniques I. I. T. ROORKEE
Common Weld Terminologies
• Base plate
• Weld bead
• Backing plate
• Puddle
• Bead geometry
• Penetration
• Tack weld
• Weld toe
• Weld root
• Weld face
• Weld pass
• Crater
Welded Joint Terminology
MI-102: Manufacturing Techniques I. I. T. ROORKEE
➢ Backing: It is the Material Support Provided at the Root Side of a
Weld to Aid in the Control Of Penetration.
➢ Base Material: The Material to be Joined or Cut is Termed as the
Base Material.
➢ Bead or Weld Bead: Bead is the Material Added during a Single
Pass of Welding. The Bead Appears as a Separate Material From
the Base Material.
➢ Crater: In Arc Welding, a Crater is the Depression in the Weld
Material Pool at the Point Where the Arc Strikes the Base Material.
➢ Deposition Rate: The Rate at which the Weld Material is
Deposited Per Unit Time, is the Deposition Rate and is Normally
Expressed as Kg Per Hour.
➢ Fillet Weld: The Metal Fused into the Corner of a Joint Made of
Two Pieces Placed at Approximately 90° to Each Other is Termed
Fillet Weld.
➢ Penetration: It is the Depth Up to Which the Weld Combines with
the Base Material as Measured from the Top Surface of the Joint.
➢ Toe of Weld: It is the Junction Between the Weld Face and Base
Material.
➢ Torch: In Gas Welding, the Torch Mixes the Fuel and Oxygen and
Controls its Delivery to Get the Desired Flame.
➢ Weld Face: It is the Exposed Surface of the Weld
➢ Weld Material: The Material that is Solidified in the Joint is Called
Weld Material. It may be only Base Material or a Mixture of Base
Material and Filler Material.
➢ Weld Pass: A Single Movement of the Welding Torch or
Electrode Along the Length of the Joint which Results in a Bead, is a
Weld Pass.
MI-102: Manufacturing Techniques I. I. T. ROORKEE
[4.5] GAS WELDING PROCESS
➢ Gas Welding, also Called as Oxy-Fuel Gas Welding (OFW), Derives
the Heat from the Combustion of a Fuel Gas such as Acetylene in
Combination with Oxygen.
➢ This Process is a Fusion Welding Process wherein the Joint is
Completely Melted to Obtain the Fusion. The Heat Produced by the
Combustion of Gas is Sufficient to Melt Any Metal.
➢ Fuel Gas Generally Used is Acetylene Because of the High
Temperature Generated in the Flame. This Process is Called Oxy-
Acetylene Welding (OAW).
Welding techniques
➢ Arc welding uses of the heat of the electric arc for fusion of
plates for welding.
➢ Physic of arc: a) starting arc and stabilizing the same
➢Connect power supply to anode and cathode
➢Close the circuit by touching electrode together
➢Short circuiting: thermo ionic emission followed by
electro magnetic field emission on separation
➢Increased conductivity of gap facilitates to establishing
the arc
➢Ionization of gases is arc gap due to electron collision
➢Thus continuous flow of electron i.e. arc
MI-102: Manufacturing Techniques I. I. T. ROORKEE
Physics of arc
• Cope with heat and electron losses
• Collisions of electrons with anode
results in large amount of heat
generation (6000 °C).
• In case of DC, about 2/3rd of the
total arc heat is liberated at the
anode.
• Balance 1/3rd heat is generated at
cathode
• In case of AC, polarity reverse in
each which results equal distribution
of heat both sides.
Electrode, Arc and Arc-Shielding in SMAW process
Effect of arc gap
• Increase in gap increases the resistance for flow
of current and so potential difference.
Because of the versatility of the process and the simplicity of its equipment and
operation, shielded metal arc welding is one of the world's most popular welding
processes. It dominates other welding processes in the maintenance and repair industry,
and though flux-cored arc welding is growing in popularity, SMAW continues to be used
extensively in the construction of steel structures and in industrial fabrication. The
process is used primarily to weld iron and steels (including stainless steel) but
aluminium, nickel and copper alloys can also be welded with this method
Manual Metal Arc Welding (MMAW)
Gas tungsten arc welding (GTAW)
Gas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG)
welding, is an arc welding process that uses a non-consumable tungsten
electrode to produce the weld. The weld area is protected from atmospheric
contamination by an inert shielding gas (argon or helium), and a filler metal is
normally used, though some welds, known as autogenous welds, do not require
it. A constant-current welding power supply produces energy which is
conducted across the arc through a column of highly ionized gas and metal
vapors known as a plasma.
GTAW is most commonly used to weld thin sections of stainless steel and non-
ferrous metals such as aluminum, magnesium, and copper alloys. The process
grants the operator greater control over the weld than competing processes
such as shielded metal arc welding and gas metal arc welding, allowing for
stronger, higher quality welds. However, GTAW is comparatively more complex
and difficult to master, and furthermore, it is significantly slower than most other
welding techniques. A related process, plasma arc welding, uses a slightly
different welding torch to create a more focused welding arc and as a result is
often automated.
Gas tungsten arc welding (GTAW)
Gas metal arc welding (GMAW)
➢ After Establishing the Correct Arc Length, the Welder should Move
the Electrode Along the Length of the Joint Maintaining the
Arc. Intense Heat Generated Under the Arc Starts Melting the Metal,
with the Metal at the Centre of the Arc being at the Highest
Temperature.
MI-102: Manufacturing Techniques I. I. T. ROORKEE
Details Edge Preparation of Butt Joint for Manual Metal Arc Welding
MI-102: Manufacturing Techniques I. I. T. ROORKEE
[4.6.7] ARC BLOW
➢ Predominant Problem Faced with the DC Arc Welding is the Arc
Blow, Deflection of the Arc by the Magnetic Fields Setup due
to the Flow of the Welding Current.
➢ Magnetic Flux Lines Move with the Electrode, when the Weld
Comes to the Edge of the Plate, or Taking a Turn, the Flux Lines
Move Out of the Base Material which is Not Possible. This Causes
High Magnetic Pull on the Arc which Results in a Backward Arc
Blow.
➢ Result of an Arc Blow is an Excessive Spatter (Throwing Out the
Tiny Droplets of Weld Metal Out of the Joint on to the Base Material
which Appear as Tiny Dots on the Base Material) and Incomplete
Fusion and Reduced Welding Speed.
➢ When a Large Slag is Produced, the Arc Blow Melts the Slag
Causing Still More Excessive Spatter.
➢ Problem of Arc Blow Gets Multiplied when Welding the Strongly
Magnetic Materials such as Nickel Alloys because of the Strong
Magnetic Fields Set Up by These Metals.
Current
The effect of the electron beam is dependent upon many conditions. The
most important factors in determining the effectiveness of EBW are:
➢ Physical properties of the material to be welded, especially the ease with
which the material is melted or turned to gas in low-pressure conditions.
➢ Electron beam welding can be so intense that loss of material due to
evaporation or boiling during the process must be taken into account when
welding. At lower values of surface power density (in the range of about 103
W/mm2) the loss of material by evaporation is negligible for most metals,
which is favorable for welding.
➢ In the upper region of the power density the material affected by the
beam may be evaporated totally in a very short time; while unsuitable for
welding, this is occasionally used in machining to remove material.
Beam formation
Cathode - the source of free electrons
Magnetic lens
Beam deflection system
Welded membranes
• Not all materials could be welded by electron beam in vacuum. This
technology can not be applied to materials with high vapour
pressure at the melting temperature, like zinc, cadmium,
magnesium and practically all non-metals.
• Another limitation of weldability may be the change of material
properties inflicted by the welding process, as e.g. the high speed
of cooling. As detailed discussion of this matter exceeds the scope
of this article, the reader is recommended to look for more
information to other literature.
Joining dissimilar materials
Joining two metal components by welding, i.e. by melting part of both in the
vicinity of the joint, in case of two materials with very different properties is often
not applicable because of unsuitable properties of their alloy, due to creation of
brittle inter-metallic compounds. This fact cannot be changed even by electron
beam heating in vacuum, but nevertheless it makes possible to realize joints
meeting high demands on mechanical compactness that are perfectly vacuum-
tight. The principal rule of the method is not to melt both parts, but only that one
with lower melting point, while the other remains in solid state. Advantage of the
electron beam is in the possibility to localize the heating to a proper point and to
control exactly the energy needed for the process. High vacuum atmosphere, no
doubt, substantially contributes positively to the success. General rule of the
construction of joints that should be made in the way mentioned above is that the
part with the lower melting point should be directly accessible for the beam.
Possible problems and limitations
• The material melted by the beam shrinks during cooling after solidification,
which may have unwanted consequences, like cracking, deformations and
changes of shape, depending on conditions.
• The butt weld of two plates will result in bending of the weldment due to
the fact that more material has been melted at the head than at the root of
the weld. This effect is of course not as substantial as by arc welding.
• Another potential danger is the emergence of cracks in the weld. If both
parts are rigid, the shrinkage of the weld produces high stress in the weld
which may lead to cracks if the material is brittle (even if only after
remelting by welding). Consequences of the weld contractions should
always be considered by the construction of the parts to be welded.
Electron beam welding equipment
Any electron beam equipment
comprises:
1 - : electron gun, generating the
electron beam,
2 - : working chamber, mostly
evacuated to "low" or "high" vacuum,
3 - : work-piece manipulator
(positioning mechanism),
4 - : supply and control/monitoring
electronics.
Electron gun
In the electron gun, the free electrons
are gained by thermo-emission from a
hot metal strap (or wire), which are then
accelerated and formed into a narrow
After passing the anode opening the electrons move with constant speed in
a slightly divergent cone. For the technological applications the divergent
beam has to be focused, which is realized by the magnetic field of a coil, the
"magnetic focusing lens.
For the proper function of the electron gun, it is necessary that the beam is
perfectly adjusted with respect to the optical axes of the accelerating
electrical lens and the magnetic focusing lens. This can be done by applying
magnetic field of some specific radial direction and strength, perpendicular to
the optical axis before the focusing lens. This is usually realized by a simple
correction system consisting of two pairs of coils. By adjusting the currents in
these coils any required correcting field can be produced.
After passing the focusing lens the beam can be applied for welding directly
or after being deflected by the deflection system. This consists of two pairs
of coils, each pair for one of the X and Y directions. These can be used for
"static" or "dynamic" deflection. The static deflection is useful for exact
positioning of the beam by welding. The dynamic deflection is realized by
supplying the deflection coils by currents which can be controlled by the
computer. This opens new possibilities of electron beam applications, like
e.g. surface hardening or annealing, exact beam positioning, etc.
The fast deflection system can also be applied (if provided with appropriate
electronics) for imaging and engraving. In this case the equipment is
operated similarly as a scanning electron microscope, with the resolution of
about 0.1 mm (limited by the beam diameter). In a similar mode the fine
computer controlled beam can "write" or "draw" a picture on the metal
surface by melting a thin surface layer.
• Working chamber
Since the publication of the first electron beam welding machines at the end of
1950s, the application of electron beam welding spread rapidly into industry and
research in all highly developed countries. Up to nowadays uncountable number of
various types of electron beam equipment have been designed and realized. In
most of them the welding takes place in the working vacuum chamber in high or
low vacuum environment.
The vacuum working chamber may have any desired volume from a few liters up
to hundreds of cubic meters. They can be provided with electron guns supplying
electron beam with any required power up to 100 kW, or even more if needed. In
micro-electron beam devices the components in the tenths of a millimeter
dimension range can be precisely welded. In welders disposing with high enough
power electron beams, welds up to 300 mm deep can be realized.
There are also welding machines in which the electron beam is brought out of
vacuum into the atmosphere. With such equipment very large objects can be
welded without huge working chambers.
• Work-piece manipulators
The electron beam welding can never be "hand-manipulated", even if not realized
in vacuum, as there is always strong X-radiation. The relative motion of the beam
and the work-piece is most often rotation or linear travel of the work-piece. In some
cases the welding is realized by the beam being moved by the computer controlled
deflection system. The work-piece manipulators are mostly designed individually to
meet specific requirements of the welding equipment.
• Power supply and control/monitoring electronics
Any electron beam equipment must be provided with appropriate
supply of power for the beam generator. The accelerating voltage
may be chosen between 30 and 200 kV. Usually it is about 60 or
150 kV, depending on various conditions. With rising voltage the
technical problems and the price of the equipment are rising
rapidly, hence, whenever it is possible the lower voltage about 60
kV is to be chosen. The maximum power of the H.V. supply
depends on the maximum depth of weld required.
The high voltage equipment must also supply the low voltage above 5
V for the cathode heating, and negative voltage up to about 1000 V
for the control electrode.
The electron gun also needs low voltage supplies for the correction
system, the focusing lens, and the deflection system. The last one
may be very complex when it should provide the computer
controlled imaging, engraving and similar applications of the beam.
Complex electronics may also be needed for the control of the work-
piece manipulator.
Laser Beam Welding (LBW)
Laser beam welding (LBW) is a welding
technique used to join multiple pieces of metal
through the use of a laser. The beam provides
a concentrated heat source, allowing for
narrow, deep welds and high welding rates.
The process is frequently used in high volume
applications, such as in the automotive
industry.
Operation
Like electron beam welding (EBW), laser beam welding has high power density
(on the order of 1 MW/cm2) resulting in small heat-affected zones and high
heating and cooling rates. The spot size of the laser can vary between 0.2
mm and 13 mm, though only smaller sizes are used for welding. The depth of
penetration is proportional to the amount of power supplied, but is also
dependent on the location of the focal point: penetration is maximized when
the focal point is slightly below the surface of the workpiece.
A continuous or pulsed laser beam may be used depending upon the
application. Millisecond-long pulses are used to weld thin materials such as
razor blades while continuous laser systems are employed for deep welds.
LBW is a versatile process, capable of welding carbon steels, HSLA steels,
stainless steel, aluminum, and titanium. Due to high cooling rates, cracking is
a concern when welding high-carbon steels. The weld quality is high, similar
to that of electron beam welding. The speed of welding is proportional to the
amount of power supplied but also depends on the type and thickness of the
workpieces. The high power capability of gas lasers make them especially
suitable for high volume applications. LBW is particularly dominant in the
automotive industry.
Some of the advantages of LBW in comparison to EBW
are as follows:
• the laser beam can be transmitted through air rather
than requiring a vacuum,
• the process is easily automated with robotic machinery,
• x-rays are not generated, and
• LBW results in higher quality welds.
A derivative of LBW, laser-hybrid welding, combines the
laser of LBW with an arc welding method such as gas
metal arc welding. This combination allows for greater
positioning flexibility, since GMAW supplies molten metal
to fill the joint, and due to the use of a laser, increases
the welding speed over what is normally possible with
GMAW. Weld quality tends to be higher as well, since
the potential for undercutting is reduced
Equipment
• The two types of lasers commonly used are solid-
state lasers and gas lasers (especially ruby lasers
and Nd:YAG lasers).
• The first type uses one of several solid media,
including synthetic ruby and chromium in aluminum
oxide, neodymium in glass (Nd:glass), and the
most common type, crystal composed of yttrium
aluminum garnet doped with neodymium (Nd:YAG).
• Gas lasers use mixtures of gases like helium,
nitrogen, and carbon dioxide (CO2 laser) as a
medium.
• Regardless of type, however, when the medium is
excited, it emits photons and forms the laser beam.
Solid state laser
Solid-state lasers operate at wavelengths on the order of 1
micrometer, much shorter than gas lasers, and as a result
require that operators wear special eyewear or use special
screens to prevent retina damage. Nd:YAG lasers can
operate in both pulsed and continuous mode, but the other
types are limited to pulsed mode. The original and still
popular solid-state design is a single crystal shaped as a
rod approximately 20 mm in diameter and 200 mm long,
and the ends are ground flat. This rod is surrounded by a
flash tube containing xenon or krypton. When flashed, a
pulse of light lasting about two milliseconds is emitted by
the laser. Disk shaped crystals are growing in popularity in
the industry, and flashlamps are giving way to diodes due
to their high efficiency. Typical power output for ruby lasers
is 10–20 W, while the Nd:YAG laser outputs between 0.04–
6,000 W. To deliver the laser beam to the weld area, fiber
optics are usually employed.
Gas laser
Gas lasers use high-voltage, low-current power sources
to supply the energy needed to excite the gas mixture
used as a lasing medium. These lasers can operate in
both continuous and pulsed mode, and the wavelength
of the laser beam is 10.6 μm. Fiber optic cable absorbs
and is destroyed by this wavelength, so a rigid lens and
mirror delivery system is used. Power outputs for gas
lasers can be much higher than solid-state lasers,
reaching 25 kW.
Fiber laser
In fiber lasers, the gain medium is the optical fiber itself.
They are capable of power up to 50 kW and are
increasingly being used for robotic industrial welding.
Laser beam delivery
Modern laser beam welding machines can be grouped
into two types. In the traditional type, the laser output is
moved to follow the seam. This is usually achieved with
a robot. In many modern applications, remote laser
beam welding is used. In this method, the laser beam is
moved along the seam with the help of a laser scanner,
so that the robotic arm does not need to follow the seam
any more. The advantages of remote laser welding are
the higher speed and the higher precision of the welding
process.
Ultrasonic Welding (USW)
Ultrasonic welding is an industrial technique
whereby high-frequency ultrasonic acoustic
vibrations are locally applied to workpieces
being held together under pressure to create a
solid-state weld. It is commonly used for
plastics, and especially for joining dissimilar
materials. In ultrasonic welding, there are no
connective bolts, nails, soldering materials, or
adhesives necessary to bind the materials
together.
Process
For joining complex injection molded thermoplastic parts, ultrasonic
welding equipment can be easily customized to fit the exact specifications
of the parts being welded. The parts are sandwiched between a fixed
shaped nest (anvil) and a sonotrode (horn) connected to a transducer,
and a ~20 kHz low-amplitude acoustic vibration is emitted. (Note:
Common frequencies used in ultrasonic welding of thermoplastics are 15
kHz, 20 kHz, 30 kHz, 35 kHz, 40 kHz and 70 kHz). When welding
plastics, the interface of the two parts is specially designed to
concentrate the melting process. One of the materials usually has a
spiked energy director which contacts the second plastic part. The
ultrasonic energy melts the point contact between the parts, creating a
joint. This process is a good automated alternative to glue, screws or
snap-fit designs. It is typically used with small parts (e.g. cell phones,
consumer electronics, disposable medical tools, toys, etc.) but it can be
used on parts as large as a small automotive instrument cluster.
Ultrasonics can also be used to weld metals, but are typically limited to
small welds of thin, malleable metals, e.g. aluminum, copper, nickel.
Ultrasonics would not be used in welding the chassis of an automobile or
in welding pieces of a bicycle together, due to the power levels required.
Ultrasonic welding of thermoplastics causes local melting of the plastic
due to absorption of vibration energy. The vibrations are introduced
across the joint to be welded. In metals, Ultrasonic welding occurs due to
high-pressure dispersion of surface oxides and local motion of the
materials. Although there is heating, it is not enough to melt the base
materials. Vibrations are introduced along the joint being welded.
➢ CAUSES:
❖ Slag Inclusions are Compounds such as Oxides, Fluxes, and Electrode
Coating Materials that are Trapped in the Weld Zone.
❖ Cleaning the Weld Bead Surface before the Next Layer is Deposited
by Using a Hand or Power Wire Brush
Cold crack
Control of cracks
• Reduce tensile residual stresses
– Reduce volume of (shrinking) weld metal by modifying groove
design (e.g. from V to U groove)
– Balance the shrinkage stresses (use double V or U groove)
– Proper filler of low yield strength if acceptable
– Post weld stress relieving heat treatment
– Preheat of the base metal to avoid rapid cooling
• Control the composition and impurities of the weld metal
– Avoid hydrogen in weld
– Control the low melting point elements S, P, Pb within limits
– Add enough Mn to reduce effect of S (Mn/S>7)
[4.7.7] Surface Damage
➢ CAUSES:
❖ Spattering of Some of the Metal and its Deposition as Small
Droplets on Adjacent Surfaces during the Welding
❖ In Arc Welding, the Electrode may Inadvertently Contact the
Parts being Welded at Places Outside the Weld Zone (Arc
Strikes).
➢ CONSEQUENCES:
➢ These Surface Discontinuities may be Objectionable from the
Point of View of Appearance or Subsequent Use of the Welded
Part.
➢ Severe Surface Damage may Adversely Affect the Properties
of the Welded Structure, Particularly for Notch Sensitive Metals.
➢ REMEDIES:
❖ Follow the Proper Welding Procedures