09 - Joining Technologies - Preparation Fo Rexamination Final PDF

Joining Technologies
-
preparation for examination
Univ.-Prof. Dr.-Ing. Prof. h.c. Stefan Böhm

Fachgebiet Trennende und Fügende Fertigungsverfahren (tff)
Universität Kassel
Kurt-Wolters-Str. 3
34125 Kassel
Tel.: +49 561-804-3141
Fax: +49 561-804-2045
s.boehm@uni-kassel.de
http://www.tff-kassel.de 1
1. Introduction and weld geometries
 Define welding with pressure
Welding with pressure

welding in which sufficient external force is applied
to cause a greater or lesser degree of plastic
deformation of both the faying surfaces, generally
without the addition of filler metal [EN 14610:2004]
Welding and soldering processes
 Classify the welding process by its purpose
Joining by welding
• Creation of a non-detachable joint between two or
more specimen by welding
Build-up welding
• Creation of a metal deposit on a specimen by
welding
 What is the difference between soldering and brazing
soldering
Temperatures below 450 °C
brazing
Temperatures above 450 °C
 Name the shown joint preparation (picture added)
6
 Mark the throat thickness in a given fillet weld
 What is the force distributaion for weld seam mostly advantegeous in
comparision to e.g. adhesive bonds?
 What defines the joint geometry
The joint geometry is defined by:

Orientation of the specimen at joint
Seam preparation
 Name the marked terminologie for the given joint (picture added)
10
 Which welding position is shown in the picture given (picture added)
Vertical down PG
11
 Draw a butt full penetration, close square weld seam and its preparation
12
 Name four surface irregularities for weld seams
 Surface Irregularities
 Uneven weld ripples

 Excessive reinforcement
 Concave fillet, convex fillet weld
 Uneven-leg fillet weld
 Undercut
 Overlap
 Herringbone, Pock mark, mouse footmark
 Underfill 13
 Which weld defects have long influcene on the weld strenght
If similar defects appear, the defects near to or on

the surface have a much higher impact on the
strength properties of the seam as the inner ones
14
2. Welding processes
 For what is aluminothermic welding mainly used?
 aluminothermic welding is mainly

used for:
● Railway welding
● Welding big cast steel parts
15
 What is the maximum temperature in a gas welding flame with acetylene
16
 Why is acetylene the most common gas for gas welding
Flame
Burning velocity power
8,5
330
methane methane
17
 What ist the task of rectifiers (add other component) in a current source?
 AC rectifier
● Smoothes all parts of the current
● Build by several diodes
18
 Name the marked components of a blow pipe (picture added)
injector Oxygen valve

Oxygen
Mixing jet Pressure jet handle connection
Mixing tube
Union nut
connector
Welding nozzle Burning gas
Burning gas connection
Blowpipe insert valve
19
 Draw the current voltage curve of a constant voltage current source
 Constant voltage characteristic

Welding Voltage [V] ● Soft descending characteristic
Constant voltage characteristic ● To keep voltage constant
● High current changes
 Used for:
● MSG, electro slag, submerged arc
Welding current [A] welding (thin wires)
20
 Name three different arc appearances?
 Short arc
● Thin plates, joint penetration
groove welds for thick plates
 Transitional electric arc
● Unpredictable, rarely used – only
for PA and PB at medium sized
plates
 Spray arc and long arc
● High melting volume for medium
and thick sized plates for filler
beads and final pass
21
 What is the application purpose of the short arc
 Short arc
● Thin plates, joint penetration
groove welds for thick plates
 Transitional electric arc
● Unpredictable, rarely used – only
for PA and PB at medium sized
plates
 Spray arc and long arc
● High melting volume for medium
and thick sized plates for filler
beads and final pass
22
 Name three types of electrode cover
symbol type
Acid coated
Basic coated
Cellulostic type coated
Rutil coated
Rutil acid coated
Rutil basic coated
Rutil cellulostic type coated
Thick Rutil coated
23
 Why temperature drops needs to be avoided for basic coated covered
electrodes ?
Basic coated
• High amount of earth alkali carbonates
• Sensitive to humidity
• Adsorbed energy in welds is higher
• Crack susceptibility is lower
 Hydrogen inside of the cover reduces the weldability a lot (cold cracks)
 If temperature drops, the humidify increases a lot, hence temperature drops
needs to be avoided
24
 What are the tasks of the cover of an electrode?
 Improvement of the conductibility of the arc column
● Easier ignition
● Improved welding properties
 Formation of slag, which

● Influence the droplet size
● Protect the melted metal
● The formation of the bead
● Enhanced the cooling time
 Formation of shielding gas

● From organic substances
● From carbonates (e.g. CaCo3)
 Deoxidize and probably alloy up 25
 What properties posses a basic covered electrode?
 Basic coated
● High amount of earth alkali
carbonates
● Sensitive to humidity
● Adsorbed energy in welds is higher
● Crack susceptibility is lower
26
 Name the components of an arc welding process (picture added)
27
 Name 6 Components of an MSG equipment
MSG Equipment:
• Power source
• Wire feeder
• Shielding gas
• Burner
• Arc length regulation
• Adjustment of the power source
28
 Name to shielding gases and their reaction behaviour. What does inert mean?
Relative Boiling point

Chemical Density Reaction
gas density at 0,101 Mpa
sign Kg/m³ behaviour
to air °C
Carbon dioxide oxidizing

oxygen oxidizing
nitrogen Sluggish in reaction
hydrogen reducing
29
 What is the difference between solid wire and flux cored electrode?
 Solid wire electrode  Flux cored electrode

● Unalloyed, low alloyed and ● Rutil, basic and acid fill or
microalloyed steels
● Metal powder fill (for alloying)
● Stainless steels
● All alloys
● Heat resistant steels
30
 at which intensity does heat conduction welding starts for laser beam welding?
Hardening Heat-conduction welding Deep welding
Laser beam
Metal vapor
melt
melt
3 dimensional 3 dimensional 3 dim.
Solid state Solid and liquid Solid, liquid and

state gaseous state
Remelting
Hardening Drilling cutting
alloying
normalizing deep welding 31
Heat-conduction welding
tempering alloying
 Name the components of the pictured pressure welding process (picture
added)
32
 Define shock welding
Shock welding
welding with pressure in which the workpieces
are welded by the application of a striking force.
The heat generated by the sudden collision
contributes to the welding
33
 Where the highest heating in resistance spot welding does takes place?
specimen specimen
electrode electrode
pressure pressure
Electric heating
R1<R2>R3
Needed contact resistance conditions
Current heating is highest at highest resistance
34
3. Materials and their welding behaviour
 What is refining and what is its purpose
Reduce the carbon, silicium, magnesium and

phosphor content in the melt
Cleaning of the melt
35
 What are the tasks of displacements in the recrystallization process?
 Nucleation of new grains and their

growth at higher temperatures
 Displacements are nucleation
points
 For recrystallation a critical degree
of deformation is needed
36
 What are the influencing factors on recrystallization?
Influenced by:
Degree of deformation
Temperature
time
37
 What is the difference between theoretical and practical cooling?
 Theoretical heating and cooling  Practical heating and cooling
● super cooling of the melt due to a
delay of the crystallization
processes
● Size and speed are dependent
from number of nuclei and speed of
grain growth
temperature temperature
Super cooling
38
time time
 What are the basic parts of metal alloys (phases)?
 At least two chemical elements, at

least one of them is a metal
(components of the alloy)
 Alloys consist of three basic parts
(phases)
● Pure elements
● Solid solutions
● Intermetallic compounds
 Phase by its own is homogeneous

 Mixed phases can be seen after
etching 39
 Draw a fully solutable two phase system from the following given cooling
curves.
temperature temperature
constantan
compounding
40
 Draw stationary iron carbonate diagram for steel until 2,06 % carbonite
41
 Order the grain structures by ascending cooling rate: Martensite, Iamellar
perlite, grained perlite
42
 What is the name of the cooling rate, at which martensite appears first?
At lower critical cooling rate martensite appears at

the first time in the microstructure
43
 Draw a typical cct diagram with the different microscopie structures
44
 Show the t8/5 time from the given cct diagram and for the marked curve.
(picture added)
45
 Why bainite microstructure does not appear in a welding process?
By isothem heat treatment fully bainite

microstructure can be formed, which is not possible
with continious cooling
46
 Draw the upper and lower critical cooling rate in the ttt diagram
47
 What is the difference between conventional ttt and welding ttt?
The differ from conventional TTT-diagrams by:

Higher austenite formation temperature
Higher cooling rates
Strictly they only apply for the HAZ, not for the
weld
48
 What is the impact of C, Cr, Ni to the fusion welding ability?
properties Alloying elements
Tensile strength
For normal
hardness
conditions
Yield point
elongation
Impact toughness
Cold forming
Deep drawing capability
forge ability
Pressure welding ability
Fusion welding ability
Slightly increasing properties Slightly decreasing properties

Increasing properties Decreasing properties
Highly increasing properties Highly decreasing properties
49
Empty fields: no influence or not clear
 Draw an i-Butt weld with the heat affected zone, name the different zones in
the weld seam and allocate them in the iron carbonate diagram
Impact of weld heat on the base material in the heat
affected zone (HEZ)
Weld bead
Incomplete melt
Over heating
normalizing
Incomplete recrystallization
recrystallization
Heat annealing
affected zone
zone 50
 Why preheating for weld seams is used?
Due to rapid cooling carbon rich alloys tend to

produce problems
in the red area a hard alloy can occur
Due to hardness and shrinking forces hot
cracks can occure
Solution: reduce temperature gradient by pre heating
51
 Calculate the carbon equivalent for the given steel.
52
 What is the transition heat thickness? Define it with the given diagram:
Transition thickness
Equalization of both equitation give the transition Three dimensional

sheet thickness for 2D heat flow to 3D heat flow
Three dimensional
Two dimensional
Two dimensional
Heat input
53
 In which part of a weld do solidification cracks, in which part liquiditation
cracks occur?
liquidation cracks
Thermal Weld
distortion deposid • Grain boundaries with low
Fusion line melting point can melt
and disperse on the
Solidification surface of grains
direction
Heat
affected
zone
Sodification cracks:
Model for the formation of solidification cracks • Tensile stress and low melting eutectic phases at
Grain boundaries
Black lines represent low melting phases the dendrite boundariesmelting cause a material
Model for liquidation crack formation in the base
segregation 54
material
 What are the impact factors on hot crack formation?
• Separation in
• Common metallurgical factors
• Metallurgical influences at welding high alloy
steel and austenitic steel
• Technological factors
55
4. Testing of weld seams
 What is the difference between destructive and non destructive testing
Measures for quality assurance in welding processes
Destructive testing Non destructive testing

+ Destruction free testing
+ 100% control possible
+ Process control + In process control
+ Experienced data + Direct correction of the process possible
+ high potential for cost reduction
− Unit costs (test waste) − Less experienced data and results from
− Destruction of the weld specimen series production process
− Time-consuming test for complex parts − Test system costs are high
− No direct access to the joining process − Physically complex processes
possible − Partly: bad automation
− Party: long testing times 56
 Explain the non proportional elongation in a tensile test
tension
Non proportional
elongation elongation
Breaking elongation
57
 Which parameters can be observed in a tensile test?
Yield + tensile Strength. Ultimate strain
58
 What kind of body is used for the brinell hardness test?
Hardened steel ball
59
 Why the RockweIl hardness test can be used for harder materials than the
brinell hardness test?
Advantages over Brinell:

Very hard body, hence very hard materials can
be tested
Small indentations enable the test of small
specimen, e.g. thin sheets
Higher accuracy due to clearness of display of
the diameters
60
 Calculate the Vickers hardness from the given picture of the indentatiori and
name the value in full length. Given Parameters: Load = 30 kgf; time =15 s
61
 What can be indentified with an technological fracture test?
 Used to determine the mechnical-technological properties of

welded components
 Enables the test of the deformability of weld joints
 Process
● Specimen mounted on rolls
● Mandrel pushes specimen
● Result: Angle of deformation until the first crack appears

62
 Name the general used methods for non destructive testing
Thermic processes
Processes with mechanical vibration
Processes with penetration radiation
63
 Name three thermic non destructive testing methods
Impulse-Video-
Thermography
Reflextion
impulse
Thermografphy
Induction
thermography
Eddy current
thermography
Lock-In-
Thermography
US-Burst-Phase
Thermography
Imageing
vibrometriy
Strass analysis
64
 When non destructive testing is used?
Non destructive testing is normally used:
• In safety related parts and components (aviation industrie)

• For expensive processes/ semi finished parts
• If welding is in the beginning of a long process chain
• For high quality requirements
65
 Which radiation is used by thermography?
Infrared
66
 Which principal is used for ultrasonic testing
• Probe is sending ultrasonic waves

• Probe is switched to reception to detect failures
• Run time of sound waves is proportional to the
distance in cm
• Calibration of cm possible, enables exact
measurement results
67
 What is the difference of the reflection and the transmission process for
ultrasonic testing
One or two sides
68
 How x-ray radiation is produced? What is the side effect?
1 – Kathode
2 – Glühwendel
3 – RichtungszylinderCathode
4 – Vakuumgefäß
5 – Führungszylinder Vacuum body
6 – Anode
Anode
7 – Wolframtarget Tugsten target
8 – Fenster window
99 % heat, 1 % x-ray radiation

69
 How is 3D X-Ray inspection is called? "
3D CT
70
5. Soldering processes
 What are the influencing factors of the soldering process?
temperature Brazing fit
Soldering
process
wetting flux
71
 Which physical principals are used for soldering
Solid specimen surfaces Liquid solder •diffusion

•alloying
•cooling
72
 What are the surface conditions, so that no wetting takes place?
q = 180°
No wetting
EO >> E A
EA : adhesion energy
73
 What is the purpose of flux
• Dissolution of the adsorption layer (gas, water)

• Remove oxides, sulfides and other reaction
products
• Dissolving of specimen substrate molecules and
start of the intermetallic joint building
• Protection for oxidization
• Assistance of the wetting
74
 Which distance of solder gap is needed for braze welding?
75
 How do you can classify soldering processes?
soldering
brazing
(high temperature brazing)
Working
temperatur
Applied solder
Soldering Insert solder
Solder
and brazing
feeding Dip soldering
processes and brazing
Energy carrier for solid

heating gas
liquid
radiation
Electrical current 76
 Name the difference between soldering and brazing
77
 What is the difference between direct and indirect resistance soldering?
indirect direct
electrode
(carrier)
specimen specimen
(e.g. Hard metal) Solder, fluxl Formed
Current source
electrode tip
(coal)
Solder, flux
Electrode
Current source tip
specimen (coal, thungsten)
Copper electrode
(e.g. steel)
Second
electrode 78
(carrier)
 Compare the following brazing processes (gas brazing, laser beam brazing)
for their difference in machine cost, productivity and achievable quality
Gas Current
Energy source: Laser oven induction (Resistanc
flame
)
Machine costs
portability
Energy density
Soldering time
flexibility
Process
factors
handling
quality
Braze ability of large parts

Sheet part
Massive part
Profitability of small / big massive parts

Job shop
Mass
production
Profitability of small / big massive parts
Job shop
Mass
production
Very high high medium Low Very low
79
 What brazeability does depend on?
Joint materials
brazeability Solder materials
flux
80
 What you have to look for, when you design a brazing fit?
 Design of the brazing fit

● Normally parallel for a constant gap thickness
● Keep maximum and minimum width
● Brazing fit shall not grow in solder flux direction (avoid
capillary flow break)
● Maximum brazing fit length 15 mm (to have sufficient
capillary pressure)
● Tool marks in solder flow direction
81
 What is the main disadvantage of soldering
 Soldering has a low strength

 Pretreatment of specimen needs to be done with care
 Strength decrease at high temperatures
 Risk of corrosion at solder joints
 Flux inclusions
 Intensive post treatment of joint areas necessary
82
 What failures do you know for solder joints
• Huge soldering areas increases

defects, like pores, gas- and flux
inclusions, and unheated areas
83
 How the used area affects a solder connection?
More area more strength
84
 Why braze welding is normally the more expensive process?
• Higher temperature higher cost
85
 Why joint strength can be stronger than the solder strength?
Alloys are often higher strenght than solder
86
 Advantages of the solder process?
• Combination of different materials (especially

metals)
• Low heat input
• Low distortion at soldering and brazing
• Good electric conductivity
• Jointing of parts with different thicknesses
• Easily automatable
87
Thank you for your attention!
88

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Joining Technologies

Univ.-Prof. Dr.-Ing. Prof. h.c. Stefan Böhm

Welding with pressure

The joint geometry is defined by:

 Uneven weld ripples

If similar defects appear, the defects near to or on

 aluminothermic welding is mainly

injector Oxygen valve

 Constant voltage characteristic

Cellulostic type coated

Rutil acid coated

Rutil basic coated

Rutil cellulostic type coated

Thick Rutil coated

● Improved welding properties

 Formation of slag, which

● Protect the melted metal

● The formation of the bead

● Enhanced the cooling time

 Formation of shielding gas

 Deoxidize and probably alloy up 25

Relative Boiling point

Carbon dioxide oxidizing

 Solid wire electrode  Flux cored electrode

3 dimensional 3 dimensional 3 dim.

Solid state Solid and liquid Solid, liquid and

Reduce the carbon, silicium, magnesium and

 Nucleation of new grains and their

 At least two chemical elements, at

 Phase by its own is homogeneous

At lower critical cooling rate martensite appears at

By isothem heat treatment fully bainite

The differ from conventional TTT-diagrams by:

properties Alloying elements

Deep drawing capability

Pressure welding ability

Fusion welding ability

Slightly increasing properties Slightly decreasing properties

Due to rapid cooling carbon rich alloys tend to

Equalization of both equitation give the transition Three dimensional

Measures for quality assurance in welding processes

Destructive testing Non destructive testing

Yield + tensile Strength. Ultimate strain

Hardened steel ball

Advantages over Brinell:

 Used to determine the mechnical-technological properties of

● Result: Angle of deformation until the first crack appears

Processes with mechanical vibration

Processes with penetration radiation

Non destructive testing is normally used:

• In safety related parts and components (aviation industrie)

• Probe is sending ultrasonic waves

One or two sides

99 % heat, 1 % x-ray radiation

temperature Brazing fit

Solid specimen surfaces Liquid solder •diffusion

• Dissolution of the adsorption layer (gas, water)

Energy carrier for solid

Braze ability of large parts

Profitability of small / big massive parts

 Design of the brazing fit

 Soldering has a low strength

• Huge soldering areas increases