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Wel

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94 views4 pages

Wel

Uploaded by

Shaikhan Nadzemi
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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1. What is ferrous alloys?

Ferrous alloys are iron based alloys that has extensive use in wide range of industries
because of its flexibility to meet strength, toughness, and impact of diverse industrial
applications. This flexibility depends on the heat treatment procedures, which modifies
the final micro-structure

2. How ferrous alloys are classified? *

Metal Alloys - Divided into two basic categories

Ferrous Alloys is further subdivided into steel and cast iron. And further into many categories as
mentioned i

 Low carbon steel -:

- Not responsive to heat treatment

- Low strength

- very good ductility and toughness

 High Strength Low Alloy -:

- Total alloy concentration till 10 %

- Stronger than plain alloy

- Better resistance to corrosion than plain steel

 Medium Carbon Steel - :

- Can be heat treated

- Tempered martensite microstructure used

- Stronger than plain iron

 Stainless Steel -:

- Highly resistance to corrosion

 High Carbon Steel -:

- Used in Hardening and tempered condition

- Hardest, Strongest but least ductile of carbon steel


3. Define weldability
 the capacity of a metal to be welded under the fabrication conditions imposed into a
specific, suitably designed structure and to perform satisfactorily in the intended
service.
 to unite or fuse (as pieces of metal) by hammering, compressing, or the like,
especially after rendering soft or pasty by heat, and sometimes with the addition of
fusible material like or unlike the pieces to be united

4. Define thermal expansion *


 is the increase in volume of a material as its temperature is increased, usually
expressed as a fractional change in dimensions per unit temperature change.When a
material is a solid, thermal expansion is described in terms of change in length,
height, or thickness. 

5. Define thermal conduction


  transfer of heat between two objects in contact thermal conduction.

6. How thermal expansion and thermal conduction influence the welding process of stainless
steel and aluminium? *

 Yield Strength – Higher strengths material have higher yield strengths. 


As the yield strength goes up so does distortion susceptibility.  This is
because after the stretching and contracting caused by the thermal
cycle induced by welding, the material is stressed to approximately its
yield strength.  The higher the yield strength, the higher the residual
stress that will act to distort the material.
 Modulus of Elasticity – this is a measure of the stiffness of a material, or
its ability to expand and contract without plastic deformation.   The
higher the modulus of elasticity the more resistant to distortion a
material is.
 Coefficient of Thermal Expansion – this is a measure of how much a
material expands during heating and contracts during cooling.  The
higher the coefficient of thermal expansion the more a material is going
to expand and contract for a given temperature change.  Therefore, the
higher the coefficient of thermal expansion, the higher the distortion
susceptibility.
 Thermal Conductivity – this is a measure of how easy heat can flow a
material.  If a material has a high thermal conductivity, such as
aluminium, it dissipates heat very quickly.  Therefore, we tend to get
cold starts when MiG welding aluminium.  Materials with low thermal
conductivity, like stainless steels, don’t dissipate heat as rapidly.  In
terms of distortion, a low thermal conductivity will increase the
chances of it.  This is due to the increased shrinkage effect brought on
by the steep temperature gradient. So higher thermal conductivity is
better in preventing distortion.
7. How stainless steels can be lost it stainless properties? *

8. What are the limitations of welding the stainless steels?


 Stainless steel retains heat very efficiently, which makes welding it a bit more difficult
especially for the novice welder. When faced with excessive welding heat, stainless steel can
warp from the high temperatures and even distort during the cooling process
 Metal is hard, rigid and stiff.
 Stainless steel can sometimes include nickel,
 The main problem when welding this ferritic stainless steel is poor HAZ toughness.
Excessive grain coarsening can lead to cracking in highly restrained joints and thick
section material.

9. How selection of welding methods stainless steel welding is done? *

10. Define the meaning and function of each of aluminium series available in the market

 1xxx Series
The 1xxx series alloys are comprised of aluminium 99 percent or higher purity. This series
has excellent corrosion resistance, excellent workability, as well as high thermal and
electrical conductivity. Therefore, the 1xxx series is commonly used for transmission, or
power grid, lines that connect the national grids across the United States. Common alloy
designations in this series are 1350, for electrical applications, and 1100, for food packaging
trays.
 2xxx Series
In the 2xxx series, copper is used as the principle alloying element and can be strengthened
significantly through solution heat-treating. These alloys possess a good combination of high
strength and toughness, but do not have the levels of atmospheric corrosion resistance as
many other aluminium alloys. Therefore, these alloys are usually painted or clad for such
exposures. They’re generally clad with a high-purity alloy or a 6xxx series alloy to greatly
resist corrosion. Alloy 2024 perhaps the most widely known aircraft alloy.
 6xxx Series
The 6xxx series are versatile, heat treatable, highly formable, weldable and have moderately
high strength coupled with excellent corrosion resistance. Alloys in this series contain silicon
and magnesium in order to form magnesium silicide within the alloy. Extrusion products
from the 6xxx series are the first choice for architectural and structural applications. Alloy
6061 is the most widely used alloy in this series and is often used in truck and marine
frames. Additionally, the iPhone 6 extrusion was made from 6xxx series alloy.
 7xxx Series
Zinc is the primary alloying agent for this series, and when magnesium is added in a smaller
amount, the result is a heat-treatable, very high strength alloy. Other elements such as
copper and chromium may also be added in small quantities. The most known alloys are
7050 and 7075, which are widely used in the aircraft industry. Apple®’s aluminium Watch,
released in 2015, was made from a custom 7xxx series alloy.
 3xxx Series
Manganese is the major alloying element in this series, often with smaller amounts of
magnesium added. However, only a limited percentage of manganese can be effectively
added to aluminium. 3003 is a popular alloy for general purpose because it has moderate
strength and good workability and may be used in applications such as heat exchangers and
cooking utensils. Alloy 3004 and its modifications are used in the bodies of aluminium
beverage cans.
 4xxx Series
4xxx series alloys are combined with silicon, which can be added in sufficient quantities to
lower the melting point of aluminium, without producing brittleness. Because of this, the
4xxx series produces excellent welding wire and brazing alloys where a lower melting point
is required. Alloy 4043 is one of the most widely used filler alloys for welding 6xxx series
alloys for structural and automotive applications.
 5xxx Series
Magnesium is the primary alloying agent in the 5xxx series and is one of the most effective
and widely used alloying elements for aluminium. Alloys in this series possess moderate to
high strength characteristics, as well as good weldability and resistance to corrosion in the
marine environment. Because of this, aluminium-magnesium alloys are widely used in
building and construction, storage tanks, pressure vessels and marine applications.
Examples of common alloy applications include: 5052 in electronics, 5083 in marine
applications, anodized 5005 sheets for architectural applications and 5182 makes the
aluminium beverage can lid. The U.S. military’s Bradley Fighting Vehicle is made with 5083
and the 7xxx series aluminium.

11. What are the limitations of aluminium welding?


 Sensitive to heat-aluminium is not good conductor of heat, so when welding, a break
could occur if precision and care are not taking through the entire process.it happen
if the applying voltage is not applied to the right spot.
 Conductor of heat and electricity-now for all this is seen as good thing for most of
the application of application used for it.it also disadvantage to others, putting
certain restrictions on what and how it can be used.

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