MECHANICS OF MACHINE PRESENTATION NAME

APPLICATION OF GEARS

WELDING
Welding is a process in which two or more similar or different parts are joined together with the help of heat or pressure is known as welding. The joint formed is known as welded joint.

TYPES OF WELDING

THERMITE WELDING
Thermite welding is an exothermic welding process that uses thermite to melt metal, which is poured between two workpieces to form a welded joint.
HISTORY A welding developed by Hans Goldschmidt a German chemist.

REACTION
The aluminium reduces the oxide of another metal, most commonly iron oxide, because aluminium is highly reactive. The maximum reachable temperature is 3090 0C. The products are aluminium oxide, free elemental iron, and a large amount of heat. The reaction is used for thermite welding, often used to join rail tracks.

Fe2O3 + 2Al 2Fe + Al2O3

TEMPERATURE VARIATION
The reaction of the Thermite-welding powder mixture is started at about 1200 0C using a special ignition powder. The maximum reachable temperature is 3090 0C that has to be reduced quickly to about 2480 0C by the addition of non reacting pellets of ferroalloy.

SLAG
At 2500 0C the aluminum would vaporize. The aluminum slag (Al2O3), that has to remain liquid to float and separate from the metal, would solidify at 2040 0C (3700 0F) and less.

LABLED DIAGRAM

ADVANTAGES
Heat required for welding is obtained from the chemical reaction of the thermit mixture. Hence, no costly power supply is required The process is best suitable, particularly in remote locations where sophisticated welding equipments and power supply cannot be arranged

DISADVANTAGES
Process is applicable only to ferrous metal parts Process consumes more time The weld quality of chemically pure thermite is low

APPLICATION
Thermite welding is mainly used in repair and welding of large forgings and castings, pipes, mill housings and heavy rail sections. Applications are used to repair heavy sections

Often used to join rail tracks

Field welding of track

ELECTRON BEAM WELDING

Electron Beam Welding (EBW) is a fusion joining process that produces a weld by impinging a beam of high energy electrons to heat the weld joint. (EBW) is done in vacuum.

PROCESS
An EBW gun functions similarly to a TV picture tube. The major difference is that a TV picture tube continuously scans the surface of a luminescent screen using a low intensity electron beam to produce a picture. An EBW gun uses a high intensity electron beam to target a weld joint. The weld joint converts the electron beam to the heat input required to make a fusion weld.

EQUIPMENTS
Electron gun, generating the electron beam Working chamber, mostly evacuated to "low" or "high" vacuum Work-piece manipulator (positioning mechanism) Supply and control/monitoring electronics

FUNCTION
The electron generated in a vacuum welding purity and high welds. beam is always high Although, high will provide maximum depth to width ratio

LABLED DIAGRAM

DEFECTS
Undercutting Porosity Cracking Underfill Lack of fusion Shrinkage voids Missed joints

ADVANTAGES
Single pass welding of thick joints Hermetic seals of components retaining a vacuum Low distortion Low contamination in vacuum Weld zone is narrow Heat affected zone is narrow Dissimilar metal welds of some metals Uses no filler metal

DISADVANTAGES
High equipment cost Work chamber size constraints Time delay when welding in vacuum High weld preparation costs X-rays produced during welding Rapid solidification rates can cause cracking in some materials

APPLICATION
Aerospace: Rotors, Vanes, Blades, Nozzles, Cases etc Power Generation: Gas & Steam Turbines, Blades, Vanes, Buckets, Nozzles etc Defense: Missile, Engine & Turbine Components, Transmission Gears etc Electronics: Semiconductor Fab Equipment, Sensors, Cooling Plates etc

APPLICATION
Medical: Medical Instruments, Orthopedic Implants, Surgical Tools etc Oil/Gas/Petrochemical: Compressors, Impellers, Drill Repair, Drill Head Assemblies, Subsea Valves, Downhole Gauges, Sensors, Valves etc
Automotive: Speed Gears, Torque Converters, Shaft Assemblies, Differential Gears, Fuel Injectors, Planet Carriers, Turbocharger Impellers

SOLID STATE WELDING

Solid State Welding is a welding process, in which two work pieces are joined under a pressure providing an intimate contact between them and at a temperature essentially below the melting point of the parent material.

TYPES OF SOLID STATE WELDING

COLD PRESSURE WELDING ULTRA SONIC WELDING

COLD WELDING
Cold or contact welding is a solid state welding process in which joining takes place without fusion/heating at the interface of the two parts to be welded. Unlike in the fusionwelding processes, no liquid or molten phase is present in the joint.

PRINCIPLE
Cold welding is a method for joining non-ferrous metals and their alloys without using heat, fillers or fluxes. Round wire sections, dissimilar materials and materials of different sizes can all be welded with BWE's proven cold welding technology. A cold weld is generally stronger than the parent material and has the same electrical characteristics.

DIES IN COLD WELDING

The dies play an important role in the cold weld process. Firstly, they must grip the material firmly and, therefore, the inside of the cavity is either etched with an electric pencil or, when the die is to be used for welding large pieces of aluminium, grip marks are put in the cavity before the die is heat treated.

CHARACTERISTICS OF COLD WELDING

At least one of the metals must be ductile without excessive work-hardening Total absence of applied heating

Dissimilar metals can be joined

Surface preparation is important

COLD WELDING PROCESS DESCRIPTION

The parts to be welded are first cleaned. A short section of the part is sheared The parts are clamped in a die with some initial extension A forging force is applied to complete welding.

ADVANTAGES
Absence

of gas emission

No molten metal spatter

Absence of luminous radiation No noise

Absence of vibration

STAGES OF COLD WELDING

COLD WELDING EQUIPMENT

MANUALLY OPERATED COLD WELDING MACHINE

COLD WELDED PART DIAGRAM

APPLICATION
Cold welded butt joints are used in the manufacturing of aluminum, copper, gold, silver, and platinum wire Most commonly, successive reels of wire are joined for continuous drawing to a smaller diameter

Aluminum alloys used in cold welding

DISADVANTAGES
While speed is an advantage to assemblers, it can also be a limitation. The process is so fast that it does not lend itself to deep drawing of material since the material does not have time to stretch. The outer member to be welded must be accelerated at a speed greater than 300 meters per second, Says Plum. When a body moving that fast meets another, it will try to displace it. This is what causes the weld. The movable body meets an immovable body.

ULTRASONIC WELDING
Ultrasonic welding is an industrial technique whereby high-frequency ultrasonic acoustic vibrations are locally applied to work pieces being held together under pressure to create a solid-state weld.

Why to use US welding?

First - Ultrasonic assembly uses ultrasonic vibratory energy which is transmitted through the parts to melt and bond thermoplastic materials And joining thin sheet gauge metals and other lightweight materials Second - This technique is fast, efficient, noncontaminating and requires no consumables. Third - In ultrasonic welding, there are no connective bolts, nails, soldering materials, or adhesives necessary to bind the materials together.

PRINCIPLE
In ultrasonic welding, frictional heat produced by the ultrasonic waves and force is used for the joining process. Ultrasonic waves (15 to 60 kHz) are transferred to the material under pressure with a sonometer. Welding times are lower than 3 s. The welding can proceed with or without the application of external heat.

ADVANTAGES
Heat affected zone is minimized Very thin materials can be welded Surface deformation is minimum Welding of glass is also possible No defects due to gases, arc and filler metal Equipment is simple and moderate skill is enough Dissimilar materials can be joined

DISADVANTAGES
Restricted to join thin materials Competitively not economical Materials being welded may tend to weld to the tip and anvil

Application
Manufacturing of toys Joining of electrical and electronic components Welding aluminium wire and sheet Mobiles, sports shoes , laminations, cars etc Packing , medical industries, computers.

MANUFACTURING PROCESSES I PRESENTATION NAME

DIFFERENT TYPES OF WELDING

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