Metallurgy Casting and Welding

TL234634 – 3 Credits

Welding Technology
Yusuf Pradesar, Ph.D.
 PLO & CLO
PROGRAM LEARNING OUTCOME
The ability to solve materials engineering and metallurgical problems using in-depth knowledge and
PLO-04
comprehension of science, technology, and mathematics
The ability to design complex and integrated components, systems and processes related to materials and
PLO-05
metallurgical engineering applications
The ability to inquire current state of the art of materials and metallurgical engineering and technology,
PLO-07
including their advanced applications

COURSE LEARNING OUTCOME

CLO-03 Students are able to understand the basic principle, classification in welding and characteristic of welding
CLO-04 Students are able to apply electric welding: SMAW, GTAW, GMAW, SAW
CLO-05 Students are able to apply gas welding: OAW, Cutting
CLO-06 Students are able to apply welding thermal cycle: CCT Diagram, Alloy CCT Diagram
CLO-07 Students are able to analyze welding microstructure: Base Metal, HAZ and Weld Metal
CLO-08 Students are able to specify welding process: Carbon Steel, Stainless Steel, Aluminum and Cast Iron
 What is welding?
“A process in which materials of the same fundamental type or class are brought together and caused to join (and
become one) through the formation of primary (and, occasionally, secondary) chemical bonds under the combined
action of heat and pressure.”

Messler, 1993

“To join (metals) by applying heat, sometimes with pressure and sometimes with an intermediate or filler metal having
a high melting point.”
The American Heritage Dictionary

Welding is an operation in which continuity is obtained between parts for assembly, by various means.
ISO standard R 857 (1958)

“e duobus unum,” which means “from two they become one.”

The Welding Institute

 Types of Metal Joints
Joining processes and equipment
1. Mechanical Joining
• Rivets The weld joint, quality and testing
Safety and environmental
considerations
• Bolts
• Bending Welding Adhesive bonding Mechanical fastening

• etc Fusion Brazing and soldering Solid state

2. Chemical Bonding
Chemical Electrical Electrical Chemical Mechanical
• Adhesive Bonding
3. Welding “Welding is an operation in which continuity is obtained
• Liquid Welding
between parts for assembly, by various means.”
• Press Welding
ISO standard R 857 (1958)
• Desoldering
 Development of Welding as
A Joining Process
1836 Acetylene gas discovered Electroslag welding
Plasma arc system using a 1962 Electrogas welding introduce
1909 gas vortex stabilized arc introduced
The principle of resistance 1950
1956 invented “One knob” (Synergic
welding discovered by joule First spray transfer patent for
Control) introduced for
First all steel automobile gas welding
Earliest carbon arc welding 1912 1964 GMAW
1881 body welded by RSW
machine invented Constricted plasma arc
1953 “Hot wire” welding process
Flux cored wires used for invented
First patent on resistance 1920 introduced for GMAW
1885 hard facing
welding machine Self shielded FCAW
1954 Plasma arc hot-wire cladding
First patent for flux-cored introduced 1969
1889 introduced
First act welding with bare wire
– Constricted arc (plasma arc)
wire 1955 Transistor-controlled
1890 Solid extruded coating for introduced
1926 1970 inventor welding power
Aluminothermic reaction SMAW electrodes introduced introduced
1895 1956 Friction welding invented
discovered Development of arc welding Solid-state electrodes used
LeChatelier credited with using He as a shielding gas 1957 First use of CO2 with GMAW in control
1900 discovered the oxygen 1980
Atomic hydrogen welding First laser beam produced Vapor phase reflow soldering
acetylene flame 1930
development using a ruby crystal introduced
First oxyacetylene torches 1960
1900 Submerged arc welding Pulsed power GMAW Inverter technology
made 1935 1990
developed introduced dominates power supplies
1907 Gas Tungsten arc welding
1941 First public disclosure of Friction stir welding
- Coated electrodes developed developed 1961 1991
EBW introduced
1910
 The Nature of an Ideal Weld:
Achieving Continuity
• If two perfectly flat surfaces of aggregates of
atoms are brought together to the equilibrium
spacing for the atomic species involved, bond
pairs form and the two pieces are welded together
perfectly.
• In reality, two materials never have perfectly
smooth, planar surfaces, so perfect matching up
of all atoms across an interface at equilibrium
spacing never occurs. Thus, a perfect joint or ideal
weld can never be formed simply by bringing the
two material aggregates together.
 Advantages and Disadvantages of
Welding as a Joining Process
Advantages Disadvantages
Joints of exceptional structural integrity and efficiency, Impossible to disassemble joints without destroying
will not accidently loosen or disassemble detail parts
Wide variety of process embodiments Heat of welding degrades base properties
Unbalanced heat input leads to distortion or residual
Applicable to many materials within a class
stresses
Manual or automated operation Requires considerable operator skill
Can be portable for indoor or outdoor use Can be expensive (e.g., thick sections)
Capital equipment can be expensive (e.g., electron-
Leak-tight joints with continuous weld
beam guns and vacuum chambers)
Cost is usually reasonable
Type of Joints

Types of welded joints

Welding positions Butt joint edge preparation methods

The Roles of
Temperature And Pressure
Obtaining continuity between two pieces made from metals or other whether

enabled by plastic deformation entirely in the solid state (without or with

recrystallization), by diffusion (entirely in the solid state or with assistance from the

presence of some liquid, even if transient), or by melting and then solidification

(relying on the presence of liquid and subsequent epitaxial growth), always requires

some combination of heat (or temperature) and pressure.

 Pressure in Welding (1)
• A growing number of welding processes depend on or are facilitated by the application of pressure
to bring the atoms of the material substrates to be joined close enough together to obtain continuity
and achieve bond formation across the interface.

• The effect of pressure in accomplishing welding is multifold.

▪ First, it increases the number and area of contacts between mating substrates through plastic
deformation of the highest asperities, bringing lower-height asperities into contact.

▪ Second, it enhances diffusion of atoms across the interface by increasing the temperature locally
as the result of the mechanical work done by the macroscopic deformation process or microscopic
friction (really, deformation) process and, to a lesser extent, through stress enhanced diffusion.
 Pressure in Welding (2)
• Non-pressure welding processes rely on heat only, with little or no pressure except to hold
the joint elements together. In fact, welding processes that do not require pressure are not
generally referred to as non-pressure welding, they are just called welding.
 Welding Zone
Where heating caused the temperature of the pure material to rise
above its melting point or the alloy to rise above its liquidus
temperature, complete melting or fusion occurred, producing a fusion
zone (FZ). Outside this region or zone, where the temperature of the
alloy was below the liquidus but above the solidus, a partially-melted
zone (PMZ) was produced. farther from the centerline of the heat
source and the resulting weld, the temperature was lower, but may
have been high enough to have caused some observable
microstructural changes due to solid-phase transformations. These
transformations may be due to allotropic phase changes,
recrystallization and/or grain growth (in cold-worked materials), or
aging, over-aging, or re-solutioning (or reversion) in precipitation
hardenable systems. When such observable microstructural changes
occur, the region is referred to as the heat-affected zone (HAZ).
 Welding Terms That Are Generally Used
Backing It is the material support provided at the root side of a weld Tack weld A small weld, generally used to temporarily hold the two
to aid in the control of penetration. pieces together during actual welding, is the tack weld.
Base metal The metal to be joined or cut is termed as the base metal. Toe of It is the junction between the weld face and the base metal.
weld
Bead or Bead is the metal added during a single pass of welding.
Torch In gas welding, the torch mixes the fuel and oxygen and
weld bead The bead appears as a separate material from the base
controls its delivery to get the desired flame.
metal.
Weld face It is the exposed surface of the weld.
Crater In arc welding, a crater is the depression in the weld metal
pool at the point where the arc strikesthe base metal plate. Weld The metal that is solidified in the joint is called weld metal. It
Deposition The rate at which the weld metal is deposited per unit time metal may be only base metal or a mixture of base metal and filler
rate is the deposition rate and is normally expressed as kg/h. metal.

Fillet weld The metal fused into the corner of a joint made of two Weld pass A single movement of the welding torch or electrode along the
pieces placed at approximately 90 degrees to each other is length of the joint which results in a bead is a weld pass.
termed fillet weld.
Penetration It is the depth up to which the weld metal combines with
the base metal as measured from the top surface of the
joint.
Puddle The portion of the weld joint that melted by the heat of
welding is called puddle.
Root It is the point at which the two pieces to be joined by
welding is nearest.
 Joining processes and equipment

Safety and environmental

The weld joint, quality and testing
considerations

Welding Adhesive bonding Mechanical fastening

Fusion Brazing and soldering Solid state

Chemical Electrical Electrical Chemical Mechanical

Fusion Welding vs Solid State Welding
Fusion welding: joining the two metals by applying heat up to melting temperatures
• The heat source to reach melting point obtained from chemical sources or electricity
sources (Oxyacetylene welding, arc welding)

Solid state welding: joining the two metals without reaching melting temperature,
although carried out at high temperatures
• The unification of the two metals occurs at solid state, caused by softening at the
end of the two metals, yields bonding
• The energy source can be obtained from combination of source of electrical and
mechanical
• Examples: soldering, friction welding