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1. Overview
PART VII JOINING &
• Welding – A joining process of two materials that
ASSEMBLY PROCESSES coalesced at their contacting (faying) surfaces by the
application of pressure and/or heat.
FUNDAMENTALS OF WELDING – Weldment – The assemblage
Joining - welding, brazing, soldering, and adhesive bonding – Sometime a filler material to facilitate coalescence.
to form a permanent joint between parts • Advantage: portable, permanent, stronger than the
Assembly - mechanical methods (usually) of fastening parts together parent materials with a filler metal, the most
Some of these methods allow for easy disassembly. economical method to join in terms of material usage
and fabrication costs .
1. Overview of Welding Technology • Disadvantage: Expensive manual Labor, high
2. The Weld Joints energy and dangerous, does not allow disassemble
3. Physics of Welding and defects
4. Features of a Fusion Welded Joint
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UBMZ HAZ
• A typical fusion weld joint consists of fusion zone, weld
interface, heat affected zone and unaffected base metal
zone.
WELDING PROCESSES
• Fusion zone: a mixture of filler metal and base metal
melted together homogeneously due to convection as in Fusion welding – Heat & melting
casting. Epitaxial grain growth (casting) Arc Welding
• Weld interface – a narrow boundary immediately Resistance Welding
solidified after melting. Oxyfuel Welding
• Heat Affected Zone (HAZ) – below melting but Other Fusion Welding
substantial microstructural change even though the Solid-state welding – Heat and pressure, but
same chemical composition as base metal (heat no melting & no filler
treating) – usually degradation in mechanical properties Weld Quality
• Unaffected base metal zone (UBMZ) – high residual Weldability
stress Design Consideration
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6. Weld Quality
• Residual Stress and Distortion
– Welding fixtures, Heat sink,Tack welding, control weld condition, Preheating,
Stress-relief heat treatment, Proper design
• Welding Defects
– Cracks, Cavities, Solid Inclusions, Incomplete Fusion
– Imperfect shape, Miscellaneous Defects such as arc strike and excessive spatter.
• Visual Inspection – Most widely used welding inspection,
– dimensional, warpage, crack
• Limitations:
– Only surface defects are detectable
– Internal defects cannot be discovered
– Welding inspector must also determine if additional tests are warranted
• Nondestructive
– dye- and fluorescent-penetrant - detecting small defects open to surface
– Magnetic particle testing - iron filings sprinkled on surface reveal subsurface
defects by distorting magnetic field
– Ultrasonic - high frequency sound waves directed through specimen, so
discontinuities detected by losses in sound transmission
– Radiograph - x-rays or gamma radiation to provide photographic film record of any
internal flaws
• Destructive – mechanical & metallurgical tests
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8. Design Considerations
• Design for welding
• Minimum parts
• Arc Welding BRAZING SOLDERING AND
– Good fit-up of parts
– Access room for welding ADHESIVE BONDING
– Flat welding is advised
• Spot welding
– Low carbon steel up to 3.2mm
1. Brazing
– For large components: reinforcing part or flanges 2. Soldering
– Access room for welding
– Overlap is required 3. Adhesive Bonding
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Introduction 1. Brazing
• Brazing and soldering – A filler metal is • If properly designed and performed, solidified joint will
melted and distributed by capillary action but be stronger than filler metal.
no melting of parent metals occurs. • Why?
• Brazing & soldering instead of fusion welding – Small part clearances used in brazing
– Metallurgical bonding that occurs between base and filler
– Join the metals with poor weldability. metals
– Join dissimilar metals. – Geometric constrictions imposed on joint by base parts
– No heat damage on the surfaces. • Applications
– Automotive (e.g., joining tubes and pipes)
– Geometry requirement is more relaxed than – Electrical equipment (e.g., joining wires and cables)
welding. – Cutting tools (e.g., brazing cemented carbide inserts to shanks)
– No high strength requirement – Jewelry-making
– Chemical process industry, plumbing and heating contractors
• Adhesive Bonding – similar to brazing and join metal pipes and tubes by brazing
soldering but adhesives instead of filler – Repair and maintenance work
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