1 / 14

Joining Processes: Welding, Brazing, Soldering Brazing and Soldering: Melting of filler rod only

Joining Processes: Welding, Brazing, Soldering Brazing and Soldering: Melting of filler rod only Brazing: higher temperature, ~brass filler, strong Soldering: lower temp, ~tin-lead filler, weak Welding: Melting of filler rod and base metals

fadey
Download Presentation

Joining Processes: Welding, Brazing, Soldering Brazing and Soldering: Melting of filler rod only

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. Joining Processes: Welding, Brazing, Soldering • Brazing and Soldering: Melting of filler rod only • Brazing: higher temperature, ~brass filler, strong • Soldering: lower temp, ~tin-lead filler, weak • Welding: Melting of filler rod and base metals • Both: Join inexpensive parts to form complex product sales.nordex-online.com

  2. Types of Joints Kalpakjian

  3. Brazing • Steel base metal + Brass filler rod is common • Lower temp than welding: retains heat treatment (if present), minimizes grain growth. • Strong but slow (careful preparation, cleanup) • Furnace brazing is easily automated en.wikipedia.org Kalpakjian www.kirkframeworks.com

  4. Shielded Metal Arc Welding (SMAW): “Stick welding” • Older, simple technology • The electrode is also the filler rod • Only for steel • Strong welds if done properly (but often not) • Very high heat input: good for thick parts, bad for grain growth and distortion Kalpakjian

  5. Gas Metal Arc Welding (GMAW): “MIG” (Metal-Inert-Gas) • ~Complex mechanism but simple to perform and easy to automate • The electrode is also the filler rod, fed continuously from a spool. It melts in the arc. • For steel or aluminum • Low skill level can achieve good weld • Medium heat input: distortion and grain growth are significant Kalpakjian

  6. Gas Metal Arc Welding (GMAW): “MIG” (Metal-Inert-Gas) A fair/typical quality MIG weld (still hot!) www.scenta.co.uk www.mig-welding.co.uk www.difflock.com

  7. Gas Tungsten Arc Welding (GTAW): “TIG” (Tungsten-Inert-Gas) • The electrode is tungsten (not consumed) • The filler rod is separate and fed manually • High skill level required to achieve good weld • Difficult to automate • Low heat input and small weld bead: distortion and grain growth are minimized Kalpakjian

  8. Gas Tungsten Arc Welding (GTAW): “TIG” (Tungsten-Inert-Gas) • Typical good quality TIG welds www.steelmancycles.com www.kosman.net

  9. Resistance Spot Welding (RSW): “Spot Welding” • No filler rod: electrical current is passed through metal under pressure • Low skill level required • Easy to automate • Low heat input and no weld bead: distortion and grain growth are minimized Kalpakjian

  10. Distortion from Welding Processes • Non-uniform shrinkage of weld bead • Difficult to maintain alignments • Solution: Rigid fixtures, pre-compensate for warping, loose tolerances Kalpakjian

  11. Weld bead profile: Convex or Concave? • Solidification of molten bead leads to shrinkage • Shrinkage of a concave bead leads to tension on surface  tends to crack • Shrinkage of a convex bead leads to compression on surface  does not crack • Generally, slightly convex beads are preferred. Lincoln Electric

  12. Welding Flaws Kalpakjian

  13. Welding Flaws: Incomplete Penetration (not enough heat input) www.mig-welding.co.uk www.ndt-ed.org/EducationResources

  14. References Kalpakjian: http://www.nd.edu/~manufact/index3.htm

More Related