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Ship Structures
Types of Welding
Fusion Welding
Homogeneous
Gas Welding
Electroslag
High Energy Beam
Electric Arc
Pressure Welding
Heterogeneous
Brazing
Friction Welding
Soldering
MIG
TIG
Shielded Metal Arc Stick
Weldability of a Metal
Metallurgical Capacity
Parent metal will join with the weld metal without
formation of deleterious constituents or alloys
Mechanical Soundness
Joint will be free from discontinuities, gas porosity,
shrinkage, slag, or cracks
Serviceability
Weld is able to perform under varying conditions
or service (e.g., extreme temperatures, corrosive
environments, fatigue, high pressures, etc.)
Oxyacetylene gas
Electric Arc
Plasma Arc
Laser
Welding Processes
Consumable electrode
Flux coated rod
Flux produces protective gas around weld pool
Slag keeps oxygen off weld bead during cooling
Welding Processes
SMAW - DC Polarity
Straight Polarity
Reverse Polarity
()
(+)
Shallow penetration
(thin metal)
(+)
()
Deeper weld penetration
Welding Processes
Welding Processes
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Welding Processes
Weld Fluxes
Typical fluxes
SiO2, TiO2, FeO, MgO, Al2O3
Produces a gaseous shield to prevent
contamination
Act as scavengers to reduce oxides
Add alloying elements to the weld
Influence shape of weld bead during
solidification
Inert Gases
Argon, helium, nitrogen, and carbon
dioxide
Form a protective envelope around the
weld area
Used in
MIG
TIG
Shield Metal Arc
Vacuum
Produce high-quality welds
Used in electron beam welding
Nuclear/special metal applications
Zr, Hf, Ti
Oxyacetylene Cutting/Welding
Shielded Metal Arc (Stick)
Metal Inert Gas (MIG)
Tungsten Inert Gas (TIG)
Oxyacetylene Welding
Flame formed by burning a mix of acetylene
(C2H2) and oxygen
TORCH TIP
2300 deg F
DRIVE WHEELS
POWER
SOURCE
SHIELDING GAS
BASE METAL
ARC COLUMN
PUDDLE
TUNGSTEN
ELECTRODE
(CATHODE)
++
SHIELDING GAS
BASE METAL
ARC COLUMN
PUDDLE
++
Welding Positions
INCREASING DIFFICULTY
FLAT
HORIZONTAL
VERTICAL
OVERHEAD
Weld Defects
Undercuts/Overlaps
Grain Growth
A wide T will exist between base metal and HAZ.
Preheating and cooling methods will affect the brittleness of
the metal in this region
Blowholes
Are cavities caused by gas entrapment during the
solidification of the weld puddle. Prevented by proper weld
technique (even temperature and speed)
Weld Defects
Inclusions
Impurities or foreign substances which are forced into the weld
puddle during the welding process. Has the same effect as a
crack. Prevented by proper technique/cleanliness.
Segregation
Condition where some regions of the metal are enriched with an
alloy ingredient and others arent. Can be prevented by proper
heat treatment and cooling.
Porosity
The formation of tiny pinholes generated by atmospheric
contamination. Prevented by keeping a protective shield over the
molten weld puddle.
Residual Stresses
Rapid heating and cooling results in thermal stresses
detrimental to joint strength.
Prevention
Edge Preparation/Alignment beveled edges and space
between components to allow movement
Control of heat input skip or intermittent weld technique
Preheating reduces expansion/contraction forces (alloys)
and removes moisture from the surface
Peening help metal stretch as it cools by hitting with a
hammer. Use with care since it may work harden the metal
Heat Treatment soak the metal at a high temperature to
relieve stresses
Jigs and Fixtures prevent distortion by holding metal fixed
Number of Passes the fewer the better.
Joint Design
BUTT JOINT
FILLET JOINT
STRAP JOINT
LAP JOINT
CORNER JOINT
Weld Geometry
Electrode
Material
L1-L2
L1-L2
1/2
1/2
1/2
Backing
Cold Welding
Pressure is applied to the
workpieces through dies or
rolls
Preferably both work pieces
should be ductile
The work pieces should
cleaned thoroughly
Fig: The roll bonding or cladding process
Ultrasonic Welding
Surfaces of the two
components are
subjected to a static
forces and oscillating
shearing force
Produces a strong,
solid-state bond
Versatile and reliable
for joining metals
Friction Welding
Developed in the 1940s
Parts are circular in shape
Can be used to join a wide variety of materials
Fig: Sequence of operation in the friction welding process 1)Left-hand component is rotated at high speed. 2)
Right-hand component is brought into contact under an axial force 3)Axial force is increased;the flash begins to
form 4) Left-hand component stops rotating;weld is completed.The flash can subsequently be removed by
machining or grinding
Friction Welding
Process can be fully automated
Can weld solid steel bars up to 250mm in outside diameter
Fig:Shape of friction zone in friction welding,as a function of the force applied and the rotational speed
Resistance Welding
Developed in the early 1900s
A process in which the heat required for welding is
produced by means of electrical resistance across the
two components
RW does not requiring the following:
Consumable electrodes
Shield gases
Flux
Fig : (a) Seam-Welding Process in which rotating rolls act as electrode (b)
Overlapping spots in a seam weld. (c) Roll spot weld (d) Resistance-welded gasoline tank
Flash Welding
Heat is generated from the arc as the ends as the two members
contacts
An axial force is applied at a controlled rate
Weld is formed in plastic deformation
Fig : (a)Flash-welding process for end-to end welding of solid rods or tubular parts
(b) & (c) Typical parts made by flash welding (d)Design Guidelines for flash welding
Stud Welding
Fig:The sequence of operation in stud welding,which is used for welding bars threaded rods and
various fasteners onto metal plates
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