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UNIT 2 JOINING PROCESS

UNIT 2 JOINING PROCESS. MANUFACTURING TECHNOLOGY-I. PREPARED BY D.BHARATHIRAJA AP/ MECH. TAGORE INSTITUTE OF ENGINEERING AND TECHNOLOGY. Introduction. The process of joining two dissimilar/similar metal by the application heat is known as welding. Application :

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UNIT 2 JOINING PROCESS

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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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