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5. JOINING
Topics:
•
Objectives:
•
5.1 Introduction
• Welding is the process of joining two or more objects together. In general this is done by melting
the adjacent surfaces, or by melting a third material that acts as a ‘glue’
• Basically, an electric arc is used to heat base metals and a consumable filler rod.
• This is the most common form of welding and is used in about half of all applications.
• A power supply is used to create a high potential between an electrode (guided by the welder)
and a metal work piece. When moved close enough electrodes break down the air and start to
flow. The local current of the flow is so high that it heats metals up to 30000C or 54000F.
welding stick
electric arc
work piece
current flows
power in a loop through
supply the metal metal welding table
• Material is added during this welding process.This material can come from a consumable elec-
trode, or from a rod of material that is fed separately.
• The electrodes/rods are often coated. This coating serves a number of functions,
- it protects the welder from contact
- it deoxidizes and provides a gas shield
• Problems that arise in this form of welding is contamination of the metal with elements in the
atmosphere (O, H, N, etc.). There can also be problems with surfaces that are not clean. Solu-
tions to this include,
Gas shields - an inert gas is blown into the weld zone to drive away other atmospheric
gases.
Flux - a material that is added to clean the surface, this may also give off a gas to drive
away unwanted gases.
coating
filler material
coating
MIG (Metal Inert Gas) - A consumable electrode in a gas shield. In addition to simple
materials, this can handle aluminum, magnesium, titanium, stainless steel, copper,
etc. This torch is normally water or air cooled.
TIG (Tungsten Inert Gas) - A nonconsumable tungsten electrode is used with a filler rods
and a gas shield. This can handle aluminum, titanium, stainless steel, copper, etc.
This torch is normally water or air cooled.
SAW (Submerged Arc Welding) - A normal wire is used as a consumable electrode, and
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the flux is applied generously around the weld. The weld occurs within the flux,
and is protected from the air.
work
electrode and feed rod
rod is fed into work
• Basically, filler and base materials are heated to the point of melting by a burning a gas.
• These are suited to a few applications, but they produce by-products that can contaminate the
final weld.
• Typically the flame is adjusted to give a clean burn, and this is applied to the point of the weld.
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• A welding rod will be fed in separately to melt and join the weld line.
• Basically, soldering and brazing involve melting a filler material that will flow into a narrow gap
and solidify. It is distinct because the base materials should not be melted.
• Materials include,
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- Solder is often an alloy combination of two of tin, lead, silver, zinc, antimony or bis-
muth.
- Brazing metals are typically alloys such as,
brazing brass (60% Cu, 40%Zn)
manganese bronze
nickel silver
copper silicon
silver alloys (with/without phosphorous)
copper phosphorous
ABS 350
Acylics 350
PC 350
Polyamide 400
Polybutylene 350
Polyethylene high density 300
Polyethylene low density 270
Polypropylene 300
Polypropylene rubber 300
Polyurethane 300-350
PVC high density 300
PVC low density 400-500
• Plastics to be joined should be compatible. A common method is based on trial and error testing.
• To determine plastic types burning small samples with a low flame gives the following observa-
tions,
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Material Observations
• Joints may be weakened by incomplete fusion, oxidation or thermal degradation of the plastic.
• Sheet welding,
- heat and pressure are applied at an overlapped joint between thin sheets.
- rollers join the sheets (one roller is often motor driven and heated while the other just
applies pressure).
- typical variables are,
- roller temperatures
- feed rate
- pressure
-underheating leads to a loose seam.
- overheating leads to a hole formation.
- parametric setting is very sensitive.
- welds can be done on tables with a hand roller and a heat gun.
- advantages
- simple tools
- disadvantages
- hard to set parameters
- preparation of welded sheets.
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Single butt
Double butt
- if welded plastics to repair cracks, drill holes at the ends to stop crack propaga-
tion.
- Disadvantages,
- welding angles hard to set
• Tack welding,
- parts are put in position.
- the gun temperature is allowed to heat up (a tack welding nozzle is used).
- the gun is put at an angle of 30-40°F to the weld and held in place until melting begins.
- the gun is slowly drawn along the seam.
- since the tack weld is weak (used for positioning) subsequent welding is required.
• General welding,
- operation
1. the gun is held 90° to the weld and a rod is inserted.
2. once the rod starts to melt, the gun is turned to a 45° angle and moved steadily
along the weld.
3. The gun is moved in an elliptical path over the weld with an amplitude of about
1”.
4. The rod is forced into the groove with a pressure of about 3-6 lbs. This pressure
prevents air from entering the weld. An angle of 45° to 90° is used for the
rod.
5. When ending a weld, the heat is turned off, and after cooling the rod is twisted
off, or for continuous welds there should be an overlap of 1/2”.
6. If required a weld can be restarted by cutting the previous weld at an angle, and
starting from that point.
• Speed Welding
- the rod and gas are fed side by side.
- the rod is heated in the gun, and is “wiped” out as it leaves the gun.
- when starting pressure is applied to the rod and a sharpened tip is forced into the work.
- as the rod starts to melt, the gun is lowered to 45° and drawn along. The welding rod is
pulled in itself.
- moving the tip too fast will result in beading and too slow will result in charring.
- the weld is stopped by standing the gun at 90° to the surface and pulling the gun off. The
rod is then cut off.
causes friction, and then heat, often causing a solid bond in less than a second.
- frequencies above 20 KHz.
- the distance the vibration travels has a great deal to do with determining the classifica-
tion.
- very well suited to rigid thermo plastic parts.
- good designs make direct application of the vibrations possible.
Better
- a smaller contact area increases the energy concentration. As a result V-notches, tongues,
pins, and other special joints are commonly used.
Better
- if remote sealing is necessary, thicker walls should be incorporated into the part design
- epoxy molds can be used to reinforce weaker parts when doing this operation.
- advantages,
- fast
- clean
- no extra materials needed
- disadvantages,
- tool design required
- simple design rules not always available
- this is best used with high coefficient of friction, low viscosity plastics.
• Spin/Friction Welding,
- two parts are spun and the contact area builds up heat through friction and pressure. The
pressure forces a good bond between parts and drives out bobbles.
- flashing may occur with this method.
- advantages,
- produces a good weld
- air does not enter during welding
- inexpensive machines, such as drill presses may be used
- disadvantages,
- circular weld joints are required
5.7 Examples
5.8 Summary
5.10 Problems
3. List 20 parts you have seen that are welded. Indicate which welding process is the most appro-
priate for each.
4. What types of processes would be best suited for joining the following items? Indicate why.
a) two 12” dia. plastic pipes.
b) two 12” dia. steel pipes.
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5. What are the primary differences between welding soldering and gluing?