Fundamentals of Manufacturing Processes

Joining of Metals: Fundamentals I

DHEERENDRA KUMAR DWIVEDI

MECHANICAL & INDUSTRIAL ENGINEERING DEPARTMENT

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 Joining
Mechanical:nuts&bolts,clamps,&rivets
Adhesive:epoxyresins,fevicol,quickfix,M
seal
Welding:welding,brazing,soldering
Eachdiffer:loadcarryingcapacity,reliability,
compatibility,servicesuitability
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 Joining
A positive (addition) process used for
assembling different members to get
FUSION WELD
desired the configuration.

ADHESIVE JOINING SPOT WELD

GAS WELDING

BRAZE WELD
MECH. JOINTS SOLDERING
 ChoiceofJoint
Typeofjoint:temporary,permanent
Requirementofservice:temperature,corrosion,
reliability
Metallurgicalcompatibility
Natureofloading:static,dynamic
Metalsystemstobejoined
Economy

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WeldingVsotherManufacturingProcess
Localizedheating Residualstress
Differentialheating Partialmelting
andcooling Uniqueweldthermalcycle
conditions Chemical,mechanicalandmetallurgical
heterogeneity
Relaibility
Dimensionalaccuracyandfinish
DBTT,Creep,HAZ softening/hardening
Postweldingtreatment

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 Selectionofjoiningprocess
Metal:thickness,meltingpoint,thermal
expansion
Availabilityofconsumables
Criticalityofapplication
Serviceconditions
Precisionrequired
Economy

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 Advantagesofwelding
Permanent joint
Joint strength as good as base metal
Economical method of joining
Anywhere
 Disadvantagesofwelding
Needs expertise
High Labor cost
Problematic if dissembling.
Hazardous fumes and vapors
Poor reliability
 Weldingprocessvs.Sectors
Resistance welding: Automobile
Thermite welding: Rail joints in railways
Tungsten inert gas welding: Aerospace and nuclear
reactors
Submerged arc welding: Heavy engineering, ship work
Gas metal arc welding: Pressure vessel
Shielded metal arc welding: general purpose and repair
 Typesofweld
Grooveweld
Filletweld
Beadweld
Plugweld
Slotweld

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 Typesofjoints
Buttjoint
Lapjoint
Teejoint
Cornerjoint
Edgejoint

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 Weldingposition
Flat
Horizontal
Vertical
Overhead