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Welding Techniques and Applications in Manufacturing

Learn about different welding processes like Gas Welding, Arc Welding, and Laser Beam Welding, along with applications in industries such as automotive, aerospace, and shipbuilding. Explore techniques, equipment, and safety measures.

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Welding Techniques and Applications in Manufacturing

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  1. UNIT 2 JOINING PROCESS MANUFACTURING TECHNOLOGY-I PREPARED BY D.BHARATHIRAJA AP/ MECH TAGORE INSTITUTE OF ENGINEERING AND TECHNOLOGY

  2. Introduction • The process of joining two dissimilar/similar metal by the application heat is known as welding. • Application : • Structural joints of bridges, pipelines • Aircraft frame works • Railway wagon • Automobile bodies • Ship building

  3. Five Types of Joints • (a)Butt joint, (b) corner joint, (c) lap joint, (d) tee joint, and (e) edge joint

  4. Classifications • Fusion Welding • Metal at the joint is heated to a molten state. • No pressure applied • Eg : Gas welding, Arc welding • Plastic Welding • Heated to plastic state. • Pressure is applied • Eg : Electric resistance welding, Forge welding

  5. Fusion welding • Gas welding • Manual metal arc welding • Gas tungsten arc welding • Gas metal arc welding • Submerged arc welding • Electro slag welding

  6. Gas welding • Oxy-acetylene welding • Oxy-hydrogen welding • Air- hydrogen welding

  7. Oxy-Acetylene welding:

  8. Gas Welding Equipment

  9. Gas cylinders • Pressure regulators • Pressure gauges • Hoses • Welding torch • Goggles • Welding Gloves • Spark lighter • Wire brush

  10. Flame Characteristics • Neutral flame:

  11. Carburising flame:

  12. Oxidising flame:

  13. Gas Welding Technique 1.Leftward or forward welding:

  14. 2.Rightward or backward welding:

  15. Manual Metal Arc welding

  16. Manual Metal Arc Welding Equipment

  17. Welding Generator(DC) or Transformer (AC) • Electrode • Electrode holder • Two cables one for work and other for electrode • Gloves • Protective shield • Apron • Wire brush • Chipping hammer • Safety goggles

  18. Gas Tungsten arc welding(GTAW)

  19. Gas Metal Arc Welding(GMAW)

  20. Submerged Arc Welding(SAW)

  21. Electro slag welding (ESW)

  22. Resistance welding

  23. Spot welding

  24. Butt welding • Upset butt welding • Flash butt welding

  25. Upset butt welding

  26. Flash butt welding

  27. Seam welding

  28. Percussion welding

  29. Jaw act as electrode • Electric current connected to work piece. • Two parts 1.6mm –sudden discharge of electric energy is released. • Used to weld pins,studs,bolts. • Used small areas 150 to 300mm²

  30. Projection welding

  31. Two metal arms act as electrodes. • One work piece projection on its surface. • A.C power supplied • Heat is produced at contact points • Work pieces pressed • Used upto 3mm thickness sheetmetal.

  32. Stud welding

  33. Trigger of the gun is pressed welding current flows between stud end and work surface. • Electric arc produced between stud and flat surface. • It melts the end of the stud. • Melted end is pressed. • Welding approximately 1 sec.

  34. Plasma Arc Welding

  35. High temperature plasma is passed through the orifice. • Supply electrical energy between nozzle & tungsten electrode. • It release high energy & heat. • Heat 10,000⁰C to 30,000⁰C. • Used to weld cast iron, Carbides.

  36. Thermit welding

  37. Using liquid thermit steel • Thermit is a mixture of aluminium and iron oxide ratio of 1:3 • Welding in plastic state & mechanical pressure is applied. • 2800⁰C

  38. Electron Beam Welding (EBM)

  39. Electron producing high temperature melding the workpiece to be welded. • Tungsten Filament is heated,it emit electrons • It passed through anode, Diaphragm • It focused by focus lens. • Electron beam strikes the workpiece.

  40. Laser Beam Welding (LBM)

  41. Light energy is converted into heat energy. • Light energy is produced from the laser source such as ruby rod in the form of monochromatic light. • Laser light focused by focusing lens.

  42. Friction Welding

  43. One part is rotated at high speed, other part is stationary. • The heat is produced between contact surfaces. • Heat is used to weld the components under pressure.

  44. Friction Stir Welding

  45. Rotating tool is fed along the joint line between two workpieces. • Generates heat • Mixing of the metal along the butt surfaces.

  46. Flame Cutting • Cutting steel • 1500⁰F • Finished parts not fine

  47. Brazing • Joining of two metal pieces by using a filler metal. • 450⁰C • Flux for brazing ferrous materials -Boric Acid,Chlorides • Flux for Copper based material - Silver • Purpose for flux is to remove the oxides present in the filler metal.

  48. Brazing Methods • Torch brazing • Furnace brazing • Induction brazing • Dip brazing • Resistance brazing • Laser and Electron beam brazing

  49. Soldering • Joining of two dissimilar metals by means of filler metal. • < 430⁰C • Low temp 300⁰C

  50. Soldering methods • Hard soldering • Soft soldering • Dip soldering • Wave soldering

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