Professional Documents
Culture Documents
Titolo presentazione
1. Introduction to metal welding
sottotitolo 2. Oxy-gas welding
metal welding 3. Electric arc welding
Milano, XX mese 20XX
technologies 4. Resistance welding
Mounting processes:
permanent processes
o welding
o mechanical fixing
o bonding
non permanent processes
A welding can be
Fusion welding
Fusion and solidification of two faces with or
without filler metal (gas or arc fusion).
Brazing
Chemical or electrical fusion
of filler material only
WELDING
AUTOGENOUS
ETEROGENOUS
Light
Gas
Oxyacetylene
Brazing
Strong
Covered
electrodes
Submerged
arc
Arc
Braze-welding
TIG
MIG
-
MAG
Roll
Resistance
Spot
FricGon
Solid
state
USW
Laser
Plasma
Other
EBW
Thermit
Butt" Tee"
Lap"
Corner"
Cruciform"
Influencing parameters:
welding process
joint type
welding position
base metal nature
base metal thickness
Advantages:
II faces 3 - 4 mm X < 20 mm
K
<
20
mm
U*2
>
40
mm
Y
<
12
mm
Y*2
>
40
mm
20
-
40
U
mm
V
+
<
15
mm
sustain
a) faces preparations
b) front side welding execution
c) groove execution at back side
d) back side resumption
Toe" Throat"
Weld face" thickness"
Toe"
Root"
Leg length"
The
capacity
of
a
material
to
be
welded
under
the
imposed
fabricaIon
condiIons
into
a
specic,
suitably
designed
structure
and
to
perform
saGsfactorily
in
intended
service.
(ANSI
/
AWS
A3.0)
Build
Metallurgic
factors
factors
Metal/alloy
Welding
temperature
[C]
Steel
1300
-
1400
Aluminium
660
Brass
-
Bronze
900
Cast
iron
1200
Copper
1080
Tin
230
Temperature
CriGcal
temperature
Time
Heat
up
Maintain
at
high
T
Cool
down
Thermal cycle determines:
point position
Temperature
weld procedure
(thermal specific provision,
introduced heat / length unit)
Time
initial temperature
Welding
type
Rd
Fuse
zone
diluGon
raGo:
Rd
=
(Vbm_fuse
*
100)
/
Vtot_fuse
zone
Brazing
0%
External
to
internal
solidicaGon
Welding
100%
DendriGc
structure
without
FM
Number
and
dimension
of
grains
depend
on
thermal
cycle
TIG
20%
-
40%
(cooling
velocity)
Submerged
arc
10%
-
65%
New
passes
re-melt
the
previous
and
improve
joint
toughness
MIG
-
MAG
5%
-
40%
Hardened structures that reduce the local plastic deformation and cause
cracks
Discontinuity:
metallurgical inhomogeneity between HAZ and BM
metallic discontinuities (crack, inclusions, waste)
Undercut
Cold lap
Incomplete penetration
Slag inclusion
Gas characteristics:
o high flame T
o high thermal content
o low flame reactivity with BM and FM
o flame stability and tuning ease
Oxy-gas
weldability
Steels
- mild %C < 0.4 good
- semi-hard 0.4 < %C < 0.6 difficult
- hard %C > 0.6 BM pre heating
Cast iron BM pre heating
Copper excellent
Aluminium oxides, Cu and Zn alloys are not weldable
Brass, Bronze difficult
Fuel Flame T
C 2H 2
Flame T = 3200 C
maximum heat generated per unit time
minimum oxygen consumption
reducing combustion gases (CO and H )
Flame type:
neutral (steel, cast iron, Cu, Al)
carburating C2H2 excess (generates
carbides: surface hardening), T for
brazing
oxidising O2 excess (bronze and brass)
Equipment
oxygen feeder
acetylene feeder
connection and tuning devices
torch
supports and tools on the welding station
Torch
mixes the gases Thickness (mm) Power (l/h)
tunes the flame
guides the flame to get a localised 0.3 - 1 25 - 100
heat transfer 1-2 100 - 200
2-4 200 - 400
Torch power 4-6 400 - 600
Measured in lacetylene/h
6-9 600 - 900
9 - 12 900 - 1200
A head
B tip
C-D gas flow tuning valves
E oxygen pipe connection
F acetylene pipe connection
G handle
Advanced
Manufacturing
Processes
Oxyacetilenic welding - torch
More dangerous
Fixed ejection
Use
no FM for low thickness
FM similar to BM
faces cleaning before welding
Characteristics
no reactive alloys
suitable for low carbon steels
The arc is triggered by touching the base metal with the tip of the electrode and
immediately by pulling back it at a distance of few millimeters
Direct current
I is constant in time
constant travel direction
pole + and pole -
Alternate current
I is variable in time
variable travel direction
Applying a sufficient V:
cathode (-) electrons anode (+)
During their motion they hit the atoms in the air and they
ionize them. Therefore positive ions (+) and electrons (-)
are generated
Direct
polarity
The positive ions (+) move to the cathode (-), where (piece
=
anode
(+))
they neutralize their charge, generating a huge quantity
of heat, that is necessary for the heat emission of new
electrons
The electrons (-) hit the anode (+) producing the heat
required for the metal fusion
Inverse
polarity
The phenomenon is able to self-sustain, but between
(piece
=
cathode
(-))
the electrodes there must be a sufficient V
MagneGc
eld
Arc is deflected
Coating:
gaseous part envelops the arc and
the melt pool
liquid part floats above the melt
pool and solidify (slag)
Covered electrodes
Core (metal wire that is similar to the MB)
current conductor
gives filler metal
Coating (mixture of particular substances)
Gaseous part:
protects the melt pool from oxidation
enhances arc stability producing ionized gases (essential in a.c.)
Liquid part:
traps the BM
purifies the melt pool from harmful substances (sulfur and phosphorus)
thanks to calcium carbonate or magnesium
alloying elements improve the bead mechanical and technological features
covers the melt pool with a slag, protects from oxidation slows down cooling
Covered electrodes
The coating composition influences the results of the welding operation.
Covered electrodes
Cellulosic: based on organic materials:
good mechanical and technological joint properties, easily removable slag
low penetration
high fume generation
Yes carbon steels, stainless steels, cast iron, copper, nickel and its alloys
No low melting alloys (based on tin (Sn), lead (Pb) and zinc (Zn))
reactive metals with oxygen (titanium (Ti), aluminium (Al) and
zirconium (Zr))
Characteristics
Electrode has to be substituted (operation interruption)
Slag has to be removed after every pass
Simple and portable equipment
Higher speed and lower cost respect the oxyacetylene welding
Welding of parts with different thickness
Uncompetitive respect other arc processes
Head junction of tubes for liquid transport
Minimum thickness 1 mm
Wire: 2 8 mm
Advantages
semi-automatic or fully automatic operation
execution of long welds
cleaner weld joint cleaner, uniform and with controlled composition through the
granular flow
welding speed higher compared to a covered electrode process
plant shutdown time decrease for the electrodes replacement respect welding
with covered electrodes
high penetration and high hourly deposition (number of passes decrease)
minimal piece deformations
very high welding currents (the electrical resistance decreases in the arc area
due to the presence of the melt flow that becomes electrically conductive)
Limitations
flow preserved from contamination which could cause porosity in the weld joint
metal base completely devoid of flakes, rust, grease and other contaminants
dross elimination before making any following passes
welding position: flat or corner
Possibility
to
deposit
very
large
weld
joint
GeneraGon
in
a
single
pass
of
greater
distorGons
Yes carbon steel, stainless steel, low and intermediate alloy steel,
nickel and nickel alloys
No light alloys, steels for tools, cast iron
Applications
longitudinal weld of pipe, also wide-ranging
welds on large thick panels (up to 60 mm)
naval and railway carpentry
In electric welding the weld pool and the arc are exposed to air oxidation.
The protective action of the coating is often not sufficient.
Inert gases: they do not combine with other elements of the weld pool and
exclude air from contact with the area to be welded (Ar, He)
Characteristics
Suitable for stainless steels, copper, brass, light alloys (aluminium and
magnesium), very reactive materials (titanium and zirconium) and alloys resistant
to high temperatures
High gas cost
Absence of slag and melted material projection
Easy execution in any position
Excellent quality with the exception of low-melting materials (tin, lead and zinc)
Low feed rate
Suitable for thin sheets, not very competitive for medium and large thicknesses
Weld joints does not require additional finishing
Precise control of energy introduced into the joint
Components
A torch or gun
B tungsten electrode
C FM
D BM
E ground terminal
F water inlet
G water outlet
H generator
I electric cables
L flowmeter
M pressure gauge
N gas cylinder
O economizer
P gas pipe
assistance gas
MIG: Ar, He (inert)
MAG: CO2 (active)
electrode: continuous fuse wire
arc between wire and BM
semiautomatic or automatic devices
DC reverse polarity: favourable to the wire fusion
Characteristics
MIG MAG
Expensive gas Lower quality than TIG and MIG
Welding with any type of metal Less expensive
Only gentle or low alloy steel of
large thickness
Components
A electrode wire
B motor and wire feeding device
C reel trimmer
D generator
E electric cables
F water circulation pipe
G gas pipe
H gas cylinder
I heater (for CO2 only)
L manometer
M flowmeter
N control and adjustment unit
O economizer
Spray-arc mode
Arc V > 25 V, small droplets do not disturb the arc
Thick parts, high penetration and high FM deposition rate
Flat welding
Very stable
Pulsed-arc mode
Achievable only with special machines that can control arc V to heat the
electrode (low V) and to transfer FM (high V)
Thin parts and big electrodes
No FM needed
Q = k Rtot I2 t
Rtot = r1 + r2 + r3 + r4 + r5 + r6
Retention under compression: to avoid pick up cavities when the solidifying metal
contracts
Voltage transformer
5000 to 20000 A
for short times
Electrode characteristics
High thermal and electric conductivity (low r)
Low contact r with BM, to avoid surface fusion
Low electron affinity with BM
Composition and shape
Raw electrolytic copper, copper-zirconium, copper-cadmium-zirconium
Truncated-cone tip to convey current and compression stress to BM
Maintenance
Periodic tip cleaning
Substitution in case of abrasions or local burning
E = electrodes
P = parts to be welded
T = transformer
B = sustaining base
Characteristics
Achievable features
Metal sheet joining, even made of different metals and thickness
Suitable for steel treated with corrosion-resistant coatings
Suitable for joint thickness up to 15 mm
Use
Easy and cheap to be automated for high production rates (automotive)
Easy to use also for not specialised workmen
Needs
No FM needed, no powders, no protective atmosphere or finishing
Surface cleaning recommended
Advantages
sealed joints
suitable for almost all metals and alloys (no copper)
Drawbacks
sheets must not vary in thickness
Similar to resistance spot wending, but on one metal sheet is made a relief
(for thin sheets 0.25 - 3.5 mm)