Lecture - 10

Introduction to Metal Joining

Introduction to metal joining

During the Bronze age, metals were used for domestic tools, weapons etc. but more complex shapes cannot be built in one piece. The first development of forge welding by the Syrians (1400 BC). Welding was then increasingly utilised in response to military requirements for example, riveting of suits of armour. A commercial scale for bolting, riveting, soldering and finally welding was introduced.

If the desired component cannot be made by means of simple fabrication processes such as casting, forging, rolling, extrusion, etc. ------ Welding is required Metal joining is indispensable to manufacturing industry because it is necessary in large constructions, components required for modern living.

Note: it is important to choose the suitable methods of metal joining for each application

Brazing/ Soldering Fusion Welding

Metal Joining Processes

Adhesive bonding

Friction Welding

Fasteners

Fusion welding
Gas welding Oxyacetylene welding Oxyhydrogen welding Arc welding Shielded metal arc welding (SMAW) Gas-tungsten arc welding (GTAW) Gas-metal arc welding (GMAW) Flux-core arc welding (FCAW) Plasma arc welding (PAW) Submerged arc welding (SAW) Electroslag welding (ESW) High energy beam welding Electron beam welding (EBW) Laser beam welding (LBW)

Resistance Welding Resistance spot welding Resistance seam welding Projection welding

Solid state welding

Forge welding Friction welding Ultrasonic welding Explosive welding Friction stir welding Unique Processes Electroslag welding Thermit welding Flash welding Induction welding

Welding heat sources

Electrical sources Arc welding Resistance welding Electroslag Heat intensity ~ 106-108 W/m2 Chemical sources Oxyfuel gas welding Thermit welding Heat intensity ~ 106-108 W/m2 High energy sources Laser beam welding Electron beam welding Heat intensity ~ 1010-1012 W/m2 Mechanical sources Friction (stir) welding Ultrasonic welding (15-75 KHz) Explosion welding (EXW) Heat intensity ~ 104-106 W/m2 Other sources Diffusion welding

Welding: Definition
The process of joining together two pieces of metal so that bonding accompanied by appreciable interatomic penetration takes place at their original boundary surfaces. The boundaries more or less disappear at the weld, and integrating crystals develop across them. Welding is carried out by the use of heat or pressure or both and with or without added metal.

Welding vs Casting
Weld must adhere to mould wall Heat is added continually to welds
High temperature gradient

Welds solidify much faster than castings In welds, the surface shape is constant There is strong mixing of weld pools

Definition of weldability
The capacity of a material to be welded under the imposed fabrication conditions into a specific, suitably designed structure & to perform satisfactorily in intended service.
(ANSI / AWS A3.0)

Factors affecting weldability

Weldability is often considered to be a material property, however the effect of other variables should not be ignored. Design of weldment Its service conditions Choice of welding process

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Material properties
Melting & vaporisation temperatures Electrical & thermal properties
Conductivity, expansion capacity, latent heat Susceptibility to wetting problems coefficient, thermal

Affinity of weld metal for O, N & H

porosity, embrittlement or

Presence of a surface film on base metal

Oxide, paint or metallic surface coating
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Service environment
Extreme environments
Corrosive Low temperature (brittle failure) High temperature (oxidation, creep, embrittlement) Others (wear, fatigue, nuclear)

The more extreme the environment

The more difficult it is to find suitable materials The more restricted the welding procedure becomes to avoid service failure

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Thank u