01 - Joining Technologies - Introduction and Geometries For Welding Final PDF

Joining Technologies
-
Welding and soldering processes
Prof. Dr.-Ing. 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
Agenda
 Introduction
 Welding processes and welding equipment
 Materials and their weldability
 Testing of welds
 Soldering processes
History of welding processes
 3200 b.c.: soldering of jewelry  Nr. of welding processes
 1500 b.c.: forge welding ● 1800: 2
 1782: Discovery of the arc ● 1900: 5

● 1950: 20
 1892: Acetylen welding
● Today: >40
 1930: Arc welding
Indexing
Production technologies
Change material
Master forming Forming Cutting Joining Coating
property
Joining by
welding
Joining by
soldering
….
Definition: DIN EN 14610: Joining by welding
 Metal welding
● Continuous inner joining of metals
by use of heat and/or pressure
Metal welding
 Welding with pressure
● Welding by use of outer force and
due plastic deformation of the
joining area
Welding with pressure Fusion welding
 Fusion welding
● Welding without force by melting of
the joint area
Classification of welding processes
1. Solid
2. Fluid
3. Gas
4. Electric discharge
5. Radiation
6. Motion of mass
7. Electric current
8. other
 Classification of the welding processes by energy carrier

● DIN EN 14610 6
 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
 Classification of the welding processes by welding purpose

● DIN 1910-100 7
 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]
 Fusion welding
● welding involving localized melting without the application of external force in which
the fusion surface(s) has (have) to be melted; filler metal may or may not be added
[EN 14610:2004]
 Classification of the welding processes by physical process

● DIN EN 14610 8
Examples
Welding with pressure Fusion welding
Process Energy carrier Process Energy carrier
Arc stud welding Electric discharge Laser beam welding Radiation
Friction welding Motion of mass Arc welding Electric discharge
Flash butt welding Electric current Gas shielded Electric discharge
Forge welding Electric current welding
Magnetic pulse Motion of mass Resistance fusion Electric discharge

welding welding
Explosion welding Motion of mass Submerged arc Electric discharge

welding
Spot welding Electric current
Plasma welding Electric discharge
Autogeneous gas
welding 9
Examples Burner/ component
Additional feed Specimen handling
WIG-Welding guide
Manual welding manually manually manually
Semi-automatic welding manually mechanically manually
Mechanized welding mechanically mechanically manually
Automatic welding mechanically mechanically mechanically
 Classification of the welding processes by mechanization
10
Classification of soldering processes
 Soldering
● Joining process with melted solder,
which possesses a melting
temperature below the ones of the
soldering base materials to be joined. Due to
wetting of the surfaces with the
solder a joint is formed
 soldering
● Temperatures below 450 °C
soldering Brazing
 brazing
● Temperatures above 450 °C
 High temperature brazing (GER)

● Temperature above 900 °C 11
Classification
soldering brazing
 Soldering by a solid  Brazing by a liquid
 Soldering by a liquid  Flame brazing
 Soldering by a gas  Brazing by arc
 Soldering by infrared radiation  Brazing by a beam
 Soldering by electric current  Brazing by electric current
 Soldering in an oven
12
Examples
Fusion welding
By Electric
By solid By liquid by gas By radiation By current
discharge
Friction stir Gas fusion Laser beam Electron beam

Flow welding Metal arc welding Electrode welding
welding welding welding welding
Submerged arc Solid State laser

Acetylen-Oxygen In vacuum
welding welding
Gas shielded
Propan-Oxygen Gas laser welding In athmosphere
welding
Hydrogen-Oxygen
13
Gas shielded welding
MAG
Metal gas
Electro gas
shielded
welding
welding
MIG
Gas shielded
welding
Plasma
Tungsten gas welding
shielded
welding Thungsten
inert gas
welding
14
Resistance welding
Resistance
welding
Butt seam High frequenz

Resistance spot Mash seam Projection Flash and butt Induction
Seam welding welding of thin resistance
welding welding welding welding welding
plates pressure welding
15
Overview pressure welding processes
Energy carrier: Heated tool
solid welding
Energy carrier:
Liquid
Energy carrier: Gas pressure

gas welding
Energy carrier:
Cold pressure
electric
welding
discharge
Welding with
Shock welding
pressure
Energy carrier:
Ultrasonic
movement of
welding
mass
Friction
welding
Forge welding
Energie
Resistance
carrier: electric
spot welding
discharge
16
Overview soldering processes DIN ISO 857-2:2005
Soldering by
solid
Soldering by
liquid
Soldering by
gas
soldering
Soldering by
infra red light
Soldering by
electric
discharge
Furnace
Soldering and soldering
brazing
Brazing by
liquid
Flame brazing
brazing Arc brazing
Brazing by
radiation
Brazing by
electric
discharge
17
Basic Terminologies for welds
18
Joint
 the junction of workpieces or the edges of workpieces that are to be joined or

have been joined
Joint geometries
Butt joint
Lap joint
Parallel joint
T-Joint
Cruciform joint
Joint geometries
Angle joint
Corner joint
Multiple joint
Cross joint
Joint
Corner joint B, K
T-joint C, E, H
Angle joint A, D
Lap joint G, J
Butt joint I
Cruciform joint F
Force distribution in a weld seam
 Nearly uniform
 No overlap needed
 Base material thickness is normally
sufficient to have a strong
connection between the parts
 Which is not the case for:
● Soldering
● Adhesive bonding
● etc.
23
Types of joint preparation and joint geometry
Types of joint geometries
 The joint geometry is defined by:

● Orientation of the specimen at joint
● Seam preparation
 Traditionally differentiation of weld seams

● Front seams
● Butt welds
● Fillet welds
● Other welds
Terminology for butt weld joint preparation
27
28
29
Terminology for T-joint preparation (butt)
30
Terminology for T-joint preparation
31
Terminology of welds with raised edges (front seam)
32
Terminology of projection weld forms
33
Terminology of lap weld configurations made with
pressure
34
Terminology of lap weld configurations made with
pressure
35
Welds - Geometric definitions
throat thickness definitions
 design throat thickness
● the throat thickness specified by the designer
 actual throat thickness

● for fillet welds, the value of the height of the largest isosceles triangle that can be
inscribed in the section of the finalized weld. For butt welds, the minimum distance
from the surface of the part to the bottom of the penetration [ISO 2553]
 effective throat thickness
● the dimension that is responsible for carrying the load, which is dependent on the
shape and penetration of the weld
 leg length
● side of the largest isosceles triangle that can be inscribed in the section
Fusion welds
38
Fusion welds
39
Typical examples of butt welds
40
41
42
43
Definition of throath thicknesses at fillet welds
 Because of the different shapes of fillet welds, it is necessary to distinguish

between various kinds of throat thicknesses
44
Weld composition of fillet welds
flat seam bead weld concave weld
Throat thickness
Throat thickness is limited, e.g.:
 The weld composition is dependent from the welding position. It is

differentiated between flat seam, bead weld and concave weld
Definition of throath thicknesses at fillet welds
46
Typical examples of fillet welds with different shapes
47
48
49
Multi run fusion welds
 Seam Processing
● Results from the appearance and seam tracking
● Welds are build by runs of welds in multiple layers
– Differentiation of weld runs
– Root run
– Filling runs
– Capping runs
– First run on the second side
Typical examples of multi-run fusion welds
51
52
53
54
55
Welding by pressure, terminology
56
Typical examples of welds made using pressure
57
58
59
60
61
62
63
64
Weld geometry
 Results from the functional design of the parts at the joint, which is necessary
for a sound weld
 Dependent on:
● Material
● Material thickness
● Loads
● Type of welding (e.g. arc, pressure, ..)
● Welding process (e.g. mechanized)
Weld geometry
 Dependent on the purpose and strength requirements at weld construction a

weld geometry needs to be chosen which fits the constraints.
 Furthermore the weld geometry needs to be producible with the chosen
welding process
 The strength of a weld seam is dependent from the weld geometry
Examples of fusion welds made with different types
of joints and joint preparations
67
Examples
68
Examples
69
Examples
70
Examples
71
Examples
72
Examples
73
Examples
74
Examples
75
Examples
76
Examples
77
Examples
78
Examples
79
Technical drawing of welds
Welding positions
 The welding position can have an influence on the strength of an weld seam –
especially on the fatigue behavior, e.g. due to the hard to manufacture
overhead position. Therefore fatigue loaded designs should be mainly
manufactured in flat position (PA), or for pressure pipes in vertical up position
(PH)
81
Welding positions
 1: Flat position
 2, 8: horizontal vertical position
 3, 7: horizontal position
 4,6: horizontal overhead position
 5: overhead position
Welding positions
PF, PG-Position PH, PJ-Position
PJ
PG
PH
PF
83
Welding positions
definition label
Flat position
PA
Horizontal
vertical PB
position
Horizontal
overhead PD
position
Welding positions
definition label
Vertical up PF
Vertical down PG
horizontal PC
Welding positions
Definition label
overhead PE
PF
PF
Wels seam defects
Imperfections/ Defects
 Imperfections may result from:

● Insufficient edge preparation at the junction of the specimen (offset, wrong gap
size, wrong angle)
● Improper welding
● Characteristics of the welding process
● Characteristics of the material to be welded (e.g. chemical composition)
Imperfections/ Defects
 Avoidable imperfections are
defects if they have a intense
shape, e.g.:
● Excess weld metal
● Weld seam sag
● Weld seam sinkage
● Shingling and irregularities of the

weld seam
Important defects
Surface Irregularities Weld discontinuities
 Uneven weld ripples  Porosity (pit)
 Excessive reinforcement  Porosity (Blowhole)
 Concave fillet, convex fillet weld  Slag inclusions
 Uneven-leg fillet weld  Incomplete Fusion
 Untercut  Incomplete joint penetration
 Overlap  Excessive melt-through (Burn-trough)
 Herringbone, Pock mark, mouse footmark  Cold Crack (Root crack, Toe carack,
Underbead crack, Transverse crack)
 Unterfill
 Cold Crack (Lamellar Crack)
 Hot Crack (Crater Crack, Longitudinal
Crack, Pear shape crack, Sulfur Crack)
Surface Irregularities
91
92
93
94
Weld discontinuities
95
96
97
98
99
Weld defects
 Boarder values and for quality and
technical groups to evaluate
 If similar defects appear, the
defects near to or on the surface ● B sound quality
have a much higher impact on the ● C medium quality
strength properties of the seam as
● D bad quality
the inner ones
 Acceptance of weld defects

 Mainly the surface defects,
depends on the task and purpose
especially the ones with area
of the weld
defects have a high influence on
the strength, namely incomplete
penetration, slag inclusions and
cracks
Safety issues
112
Safety issues
 Intoxication by gas and smoke
 Accidents by electric current
 Breathing and cardiac arrest
 In case of an accident call as soon as possible a doctor.

 Reanimate until the doctor appears
Thank you for your attention
114

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Joining Technologies

Prof. Dr.-Ing. Stefan Böhm

 Welding processes and welding equipment

 Materials and their weldability

 1782: Discovery of the arc ● 1900: 5

 Classification of the welding processes by energy carrier

 Classification of the welding processes by welding purpose

 Welding with pressure

 Classification of the welding processes by physical process

Magnetic pulse Motion of mass Resistance fusion Electric discharge

Explosion welding Motion of mass Submerged arc Electric discharge

Manual welding manually manually manually

Semi-automatic welding manually mechanically manually

Mechanized welding mechanically mechanically manually

Automatic welding mechanically mechanically mechanically

 Classification of the welding processes by mechanization

 High temperature brazing (GER)

Friction stir Gas fusion Laser beam Electron beam

Submerged arc Solid State laser

Butt seam High frequenz

Energy carrier: Gas pressure

brazing Arc brazing

 the junction of workpieces or the edges of workpieces that are to be joined or

 The joint geometry is defined by:

 Traditionally differentiation of weld seams

 actual throat thickness

 Because of the different shapes of fillet welds, it is necessary to distinguish

flat seam bead weld concave weld

 The weld composition is dependent from the welding position. It is

 Dependent on the purpose and strength requirements at weld construction a

 Imperfections may result from:

● Weld seam sag

● Weld seam sinkage

● Shingling and irregularities of the

 Acceptance of weld defects

 Intoxication by gas and smoke

 Accidents by electric current

 Breathing and cardiac arrest

 In case of an accident call as soon as possible a doctor.

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