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Welding is a process that joins metal materials by heating them to form a permanent bond. There are several common welding processes, including oxy-acetylene welding which uses a flame, metal-arc welding which uses an electric arc, and resistance spot welding which uses electric current to form spots that join sheet metal. Each process has advantages and disadvantages depending on the application and type of materials being welded. Proper welding requires consideration of variables like material thickness, position, and heat treatment to achieve high quality, strong joints.

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76 views20 pages

Sudare e PDF

Welding is a process that joins metal materials by heating them to form a permanent bond. There are several common welding processes, including oxy-acetylene welding which uses a flame, metal-arc welding which uses an electric arc, and resistance spot welding which uses electric current to form spots that join sheet metal. Each process has advantages and disadvantages depending on the application and type of materials being welded. Proper welding requires consideration of variables like material thickness, position, and heat treatment to achieve high quality, strong joints.

Uploaded by

Fornade Andrei
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© © All Rights Reserved
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METALS WELDING

Method of permanent joining of two metal bodies by establishing


bonds between atoms of the two bodies under certain conditions of
temperature and pressure.
Welding process = practically execution of a welds taking into
account the thickness of the part, its position and the nature of the
metal to weld.
Welding procedures used in modern technology allowed to produce
different sized products - from the giant - to the miniature

Advantage
- material economy (compared to riveting - overlapping tables);
- joint tightness is achieved;
- without holes for rivets increases the resistance assembly;
- may be obtained more flexible construction (to castings);
- less labor consuming;
-can get mixed construction consisting of several parts each of other
material, obtained by different technological process;
- accessible and simple devices (to weld usual materials).
Disadvantages:
- can not run large manufacturing series;
- often required heat treatment after welding;
- welding technological processes of high productivity requires
expensive equipment.

The physical principle of the welding


To create a connection between the objects it is necessary that the
atoms arranged on the surface of one of the bodies to react with
the atoms of the other body.
This condition can be achieved by two basic solutions:
1. warming the surfaces to be joint in adjacent position
through warming it will increases the plasticity of the metal
and the amplitude of thermal oscillations of atoms
(increases the number of holidays);
2. Exerting a pressure between them.

By heating

- increases the free energy of the atoms;


- the inter-atomic bonds will be weaker.
Carry out a molten metal bath its solidification will be the seam.

Through pressure - between the parts to be joined plastic


deformation will cause the material flow along the surfaces in contact.
If the pressure is high enough, it alone can achieve cold welding producing structures with large grains worse mechanical
properties.
Mechanism of binding forces between the parts to weld depends on
the aggregate state where they are:
- both liquids: the joint begin into the molten bath with the interaction
of the molten material and continuous with crystallization process;
- both solid - the clamping forces of the different parts are obtained by
putting the parts in adjacent position - the atoms near the surfaces in
contact (distance between atoms of the two parts must be within the
crystal lattice parameters) - oxide layer block the molecular cohesion.

The structure of welded joints


Welding = is the result of the welding operation;
Seam or weld joint = the area in which the inter-atomic cohesive
forces act effectively. Seams obtained by melting have its own
structure and chemical composition.
Filler = metal or alloy - wires, rods or pellets, which participate at
the formation of seam; its chemical composition has to be close to
the base material.
Welding with filler material into the seam will be included base
material too. The resulting bath shall enter into chemical reactions
with elements in the environment:
- O2 - gives rise to oxides;
- H2 - encourages cracks;
- N2 - form hard nitrides - reduce the plasticity of the seam);
- with various alloying elements (Si, Mn, W, Cr).

The structure of welded joints

MB1,2 - base material 1, 2 = elements of metals or alloy that are


assembled;
CS

- seam - dendrite structure which is typical for cast metal;

ZIT1,2 - the heat-affected zone narrow zone between the choke and
the base metal = mixture of molten metal and the base metal
superheat formed by diffusion of the constituents.
Its depth depends on the thermal regime used. Depending on
the cooling rate there are obtained quenching structures, which
increase the hardness of the steel.
As the difference between the chemical composition of the weld
metal and the base one is higher, as this area is more visible.

Depending on the type of energy used to heat the material:


Welding heat source chemical - is achieved when the thermal energy
is provided by chemical reactions (gas welding).
Electric welding - when heat energy is obtained by converting
electricity through resistance, electric arc, induction etc.

WELDING PROCESEES:
1. Oxyacetylene Flames Used in Welding
2. Metal-arc welding
3. Submerged-arc welding
4. Resistance spot and seam welding

1. Oxyacetylene Flames Used in Welding

Three basic types of oxyacetylene flames used in oxy fuel - gas welding and
cutting operations: (a) neutral flame; (b) oxidizing flame; (c) carburizing, or
reducing, flame. The gas mixture in (a) is basically equal volumes of oxygen and
acetylene.

(a) General view and (b)


cross-section of a torch
used in oxyacetylene
welding. The acetylene
valve is opened first; the
gas is lit with a spark
lighter or a pilot light; then
the oxygen valve is
opened and
the flame adjusted.
(c) Basic equipment used
in oxyfuel-gas welding. To
ensure correct
connections, all threads on
acetylene fittings are lefthanded, whereas those for
oxygen are right-handed.
Oxygen
regulators are usually
painted green, acetylene
regulators red.

(a) Flame cutting of steel plate with an oxyacetylene torch, and a crosssection of the torch nozzle.
(b) Cross-section of a flame-cut plate showing drag lines.

2. Metal-arc welding
Schematic illustration of the
shielded metal-arc welding
process. About 50% of all
large-scale industrial welding
operations use this process.

Schematic illustration of the


shielded metal-arc welding
operations (also known as stick
welding, because the electrode is
in the shape of a stick).

3. Submerged-arc welding

Schematic illustration of the submerged-arc welding process and


equipment. The unfused flux is recovered and reused.

4. Plasma-arc welding
- plasma = mixture of electrons, ions and neutral particles - in constant
motion - similar to the gaseous state of aggregation
- open arc temperature may reach 6000 - 8000 0 C

Two types of plasma-arc welding processes:


(a) transferred, (b) non-transferred.
Deep and narrow welds can be made by this process at high welding speeds.

Comparison of the size of weld beads in (a) electron-beam or laser-beam


welding to that in (b) conventional (tungsten-arc) welding.
Source: American Welding Society, Welding Handbook (8th ed.)

Laser welding of
razor blades.

5. Resistance spot welding

(a) Sequence in resistance spot welding.


(b) Cross-section of a spot weld, showing the weld nugget and the indentation of the
electrode on the sheet surfaces. This is one of the most commonly used process in
sheetmetal fabrication and in automotive-body assembly.

Resistance
Seam
Welding

(a) Seamwelding process in which rotating rolls act as electrodes.


(b) Overlapping spots in a seam weld.
(c) Roll spot welds.
(d) Resistance-welded gasoline tank.

Spot Welding
Example

(a)

(b)

(a) and (b) Spotwelded cookware and muffler.


(c) An automated spotwelding machine with a programmable robot; the welding tip
can move in three principal directions. Sheets as large as 2.2 m X 0.55 m can be
accommodated in this machine.
Source: Courtesy of Taylor-Winfield Corporation.

(c)

Robots equipped with spot-welding guns and operated by computer


controls, in a mass-production line for automotive bodies.
Source: Courtesy of Cincinnati Milacron, Inc.

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