Manufacturing Technology-I

JOINING PROCESS

MANUAL METAL ARC WELDING

Shielded metal arc welding (SMAW), also
known as manual metal arc welding (MMA or
MMAW), flux shielded arc welding or
informally as stick welding, is a manual arc
welding process that uses a consumable
electrode covered with a flux to lay the weld.

Advantages
Versatility - readily applied to a variety of applications and a
wide choice of electrodes
Relative simplicity and portability of equipment
Low cost
Adaptable to confined spaces and remote locations
Suitable for out-of-position welding
Disadvantages
Not as productive as continuous wire processes
Likely to be more costly to deposit a given quantity of metal
Frequent stop/starts to change electrode
Relatively high metal wastage (electrode stubs)
Current limits are lower than for continuous or automatic
processes (reduces deposition rate)

GAS TUNGSTEN ARC WELDING

Gas tungsten arc welding (GTAW), also known as
tungsten inert gas (TIG) welding, is an arc welding process
that uses a non-consumable tungsten electrode to produce
the weld.
The normal gas for TIG welding is argon (Ar). Helium (He)
can be added to increase penetration and fluidity of the weld
pool. Argon or argon/helium mixtures can be used for welding
of all grades.
GTAW is most commonly used to weld thin sections of
stainless steel and non-ferrous metals such as aluminum,
magnesium, and copper alloys.

GAS METAL ARC WELDING

Gas metal arc welding (GMAW), sometimes
referred to by its subtypes metal inert
gas (MIG) welding or metal active gas (MAG)
welding, is a welding process in which an
electric arc forms between a consumable wire
electrode and the work piece metal(s), which
heats the work piece metal(s), causing them to
melt and join.

SUBMERGED ARC WELDING

Submerged-arc welding (SAW) involves the
formation of an arc between a continuously
fed electrode and the work piece. A blanket of
powdered flux, which generates a protective
gas shield and a slag (and may also be used to
add alloying elements to the weld pool),
protects the weld zone. A shielding gas is not
required.

Advantages
Lends itself to the production of consistently high quality welds
with minimum operator skills.
Minimum of welding fume and of arc visibility (radiation).
Well suited to welding thick sections.
Suitable for welding carbon, low alloy and alloy steels.
Relatively high metal deposition rates
Disadvantages
Flat or horizontal position welding only
Care required to preserve correct electrode alignment, as
electrode
Tip and weld pool are underneath solid flux cover

Electro slag welding

Electroslag welding (ESW) is a highly
productive, single pass welding process for
thick (greater than 25 mm up to about 300
mm) materials in a vertical or close to vertical
position.
(ESW)
is
similar
to
electrogaswelding, but the main difference is
the arc starts in a different location.

Advantages

Joint preparation is often much simpler than for other welding processes.
Much thicker steels can be welded in single pass and more economically.
Thicknesses up to 450 mm in plain and alloy steels can be welded without
difficulty.
Electroslag welding gives extremely high deposition rates.
Residual stresses and distortion produced are low.
Flux consumption as compared to that in submerged arc welding is very
low.
During the electro slag process, since no arc exists, no spattering or intense
arc flashing occurs.
Disadvantages
Submerged arc welding is more economical than Electroslag welding for
joints below 60 mm.
In Electroslag welding, there is some tendency toward hot cracking and
notch sensitivity in the heat affected zone.

Electric resistance welding

Electricresistance
welding(ERW)
refers to a group ofweldingprocess
such as spot and seamwelding that
produce
coalescence
of
faying
surfaces
where
heat
to
form
theweldis generated by the electrical
resistanceof material combined with
the time and the force used to hold
the materials together during welding.

Resistance Welding Benefits

High speed welding
Easily automated
Suitable for high rate production
Economical
Resistance Welding Limitations
Initial equipment costs
Lower tensile and fatigue strengths
Lap joints add weight and material

Applications

Automotive / auto suppliers

Electrical / electronics
Aerospace / air plane
Train carriage / rail
Radiator / container
Domestic hardware
Medical instruments
Nuclear equipment
Food and drink

Other metal processing industries.

Plasma arc welding

Plasma arc welding (PAW) is an arc welding
process
similar
to
gas
tungsten arc
welding (GTAW). The electric arc is formed
between an electrode (which is usually but not
always made of sintered tungsten) and the
work piece.

P Protected electrode, offers long times before electrode maintenance

(usually one 8 Hr Shift)
L Low amperage welding capability (as low as 0.05 amp)
A Arc consistency and gentle arc starting produce consistent welds, time
after time
S Stable arc in arc starting and low amperage welding
M Minimal high frequency noise issues, HF only in pilot arc start, not for
each weld
A Arc energy density reaches 3 times that of GTAW. Higher weld speeds
possible

W Weld times as short as 5 m.secs (.005 sec)

E Energy density reduces heat affected zone, improves weld quality
L Length of arc benefit due to arc shape and even heat distribution
D Diameter of arc chosen via nozzle orifice

Thermit welding
Exothermic welding,
also
known
as
exothermic bonding, thermit welding (TW),
and thermit welding, is a welding that employs
molten metal to permanently join the
conductors. The process employs an
exothermic reaction of a thermit composition
to heat the metal, and requires no external
source of heat or current.

Advantages:
This process is used for welding of damaged wobblers and
large broken crankshafts
To restore the broken teeth on gears
Disadvantages:
It is not possible for low melting points
High skill operators are required
Reduces the risks to operate
Low deposition rate
High level of fume
Application:
Mainly this technique is used in the repair works of rails in
railways.

Electron beam welding

Electron beam welding (EBW)
is
a
fusion welding process in which a beam of
high-velocity electrons is applied to two
materials to be joined. The work pieces melt
and flow together as the kinetic energy of the
electrons is transformed into heat upon impact.

Applications:
Bi-metal saw blades
Transmission assemblies
Aerospace components
Narrow/Deep-High depth-to-width ratio eliminates
multiple-pass welds. Penetration from .001 to 2.
Low Heat-Minimizes shrinkage and distortion and
allows welds in close proximity to heat sensitive
components.
Strength-Welds up to 95% of the strength of the base
material.

Friction welding
Friction Welding is a solid-state joint
process that produces coalescence of materials
under compressive force contact of work
pieces rotating or moving relative to one
another to produce heat and to plastically
displace material from the faying surfaces.

Advantages:
Easily joins dissimilar metals
The full surface of the cross section is made up of both metals,
Friction welds are higher strength
Friction welds often cost less
Friction welds minimize the Heat Affected Zone
Friction welding minimizes the need to clean furnace
residues
The ability of a designer to optimize material choices by using
friction welding cannot be overstated.

Friction-stir welding
Friction-stir welding (FSW) is a solid-state
joining process (the metal is not melted) that
uses a third body tool to join two facing
surfaces. Heat is generated between the tool
and material which leads to a very soft region
near the FSW tool.

Applications
FSW offers manufacturers many benefits over
conventional welding methods including lower levels
of defects, improved aesthetics in the appearance of
the weld and lower set-up and operational costs after
the initial investment.
Apples Next Generation iMac
The Ford GT
Chinas High Speed Railway Carriages
Nasas Orion Spacecraft
The Super Liner Ogasawara

Soldering and Brazing

Soldering is a process in which two or more items
(usually metal) are joined together by melting and
putting a filler metal (solder) into the joint, the filler
metal having a lower melting point than the adjoining
metal.
Solder is basically metal wire with a "low" melting
point, a mix of tin and lead.

 Brazing is a metal-joining process in which

two or more metal items are joined together by
melting and flowing a filler metal into the
joint, the filler metal having a lower melting
point than the adjoining metal.

Welding Defects
Common weld defects include:
Lack of fusion.
Lack of penetration or excess penetration.
Porosity.
Inclusions.
Cracking.
Undercut.
Lamellar tearing.

Thank You