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Welding lab assignment 3

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14 views3 pages

Welding lab assignment 3

Uploaded by

Arooj Javaid
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Selected Material: Al 6063

Welding Technique: TIG welding


TIG welding, also known as gas tungsten arc welding (GTAW), is a type of welding that uses a
non-consumable tungsten electrode to join two pieces of metal. It is a popular choice for welding
metals that need precise control and accuracy.
PARAMETERS:
Tungsten electrode
filler metal for aluminum 6063:4043 aluminum filler wire.
Amperage: A range of 100 to 200 amps is common for welding aluminum 6063.

PROCESS:
 Clean the base metal - Aluminum 6063 should be cleaned thoroughly before welding to
remove any dirt, oils, or other contaminants. This can be done using aluminum cleaning
brush.
 Prepare the joint – In lap joint
 Begin welding - Start the weld by positioning the tungsten electrode close to the base metal,
Aluminum acts like a big heat sink and rapidly transfers heat away from the weld area,
which makes puddle control crucial to success. Hand and torch placement are key to puddle
control. Hold the torch by bracing it with the base of your hand flat against the table.
 Now keep light pressure on your hand and a firm grip of the welding torch and slide your
hand across the welding table in an even, steady motion Keep the torch in a steady, forward-
moving position with a slight backward tilt of 5 to 15 degrees.
 Filler metal deposition takes place ahead of the TIG torch as we push forward. The torch
and the filler rod should roughly be in a 90-degree configuration to each other.
 The filler metal should be deposited on the leading edge of the puddle. One hand is smooth
and steady as it slides, while the other hand dabs the filler metal.
 Keep a close distance from the tungsten to the work piece, typically equal to the diameter
of the tungsten up to about 1/4 inch. By pulling the tungsten too far away from the work
piece, the arc spreads out too wide and overheats the piece, causing loss of puddle control
 Steady hand and a consistent speed is necessary to maintain a stable arc and avoid
overheating or distortion of the base metal.
 Control the heat input - Aluminum 6063 is a heat-sensitive material, so it is important to
control the heat input during welding to avoid warping or melting of the base metal. Use a
low amperage and a short arc length to minimize the heat input and maintain control of the
weld.
 Perform post-weld cleaning - After welding, any oxide buildup or discoloration should be
removed using a dedicated aluminum cleaning brush.
Fig. TIG welding setup

INSPECTION TECHNIQUE:
ULTRASONIC TEST:
Ultrasonic Testing (UT) generally uses a high frequency sound energy to conduct
examinations and make measurements of given frequency. Ultrasonic inspection can be used
for flaw detection of weld defects. It can be used for evaluation, dimensional measurements,
material characterization, and more. A typical UT inspection system consists of several
functional units, such as the pulsar/receiver, transducer, and display devices. A pulsar/receiver
is an electronic device that can produce high voltage electrical pulse. Driven by the pulse, the
transducer generates high frequency ultrasonic energy. Most inspections are carried out in the
frequency range of 1 to 25MHz. Couplets are used to transmit the ultrasonic waves from the
transducer to the test piece; typical couplets are water, oil, glycerin and grease. The sound
energy is introduced and propagates through the materials in the form of waves and reflected
from the opposing surface. An internal defect such as crack or void interrupts the waves'
propagation and reflects back a portion of the ultrasonic wave. The amplitude other energy and
the time required for return indicate the presence and location of any flaws in the work-piece.
Fig: Ultrasonic testing

RADIOGRAPHIC TESTING:
Radiography is the testing method most commonly used to detect the precise location of defects
in a welded joint. In radiographic testing, the part to be inspected is placed between the radiation
source and a piece of radiation sensitive film. The radiation source can either be an X-ray machine
or a radioactive source (Ir-192, Co-60, or in rare cases Cs-137). The part will stop some of the
radiation where thicker and denser areas will stop more of the radiation. The radiation that passes
through the part will expose the film and forms a shadowgraph of the part. The film darkness
(density) h will vary with the amount of radiation reaching the film through the test object where
darker areas indicate more exposure (higher radiation intensity) and lighter areas indicate less
exposure (lower radiation intensity).

This variation in the image darkness can be used to determine thickness or composition of material
and would also reveal the presence of any flaws or discontinuities inside the material.

Fig: Radiographic testing

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