METAL JOINING

PROCESS

PREPAED BY:
VACHHANI PARTH K.

METAL JOINING
Even

the simplest object is an assembly

of components
Complex ones - greater number of
parts- subassemblies joined to perform
the function
METHODSWELDING,
BRAZING,
SOLDERING,
ADHESIVE BONDING,
MECHANICAL JOINING
Dr. N. RAMACHANDRAN, NITC

NITC

WHY JOINING?
IMPOSSIBLE

TO MAKE AS ONE PIECE

EASINESS AND ECONOMY IN
MANUFACTURE
EASY IN REPAIRS AND MAINTENANCE
FUNCTIONAL PROPERTIES DIFFERe.g.: Carbide tips of tools,corrosion
resistant parts, tungsten carbide tip of
pens, brake shoes to metal backing
etc
TRANSPORTING SITE/ CUSTOMER
Dr. N. RAMACHANDRAN, NITC

NITC

WELDING
CLASSIFICAION
AND DESCRIPTION

WELDING
Welding

is a process of joining similar metals

by the application of heat with or without
application of pressure and addition of filler
material. The result is a continuity of
homogenous material, of the composition and
characteristics of two parts which are being
joined together. And make a permanent joint .
It is used in the manufacture of automobile
bodies, aircraft frames, railway wagons,
machine frames, structural works, tanks,
furniture, boilers, general repair work and ship
building.

TYPES OF WELDING
Pressure Welding

The piece of metal to be joined are

heated to a Plastic state and forced together
by external pressure
(Ex) Resistance welding
Fusion Welding
The material at the joint is heated to a
molten state and allowed to solidify
(Ex) Gas welding, Arc welding

PRINCIPLE OF WELDING
An ideal joint between two pieces of metal or plastic can be made by
heating the workpieces to a suitable temperature. In other words, on
heating, the materials soften sufficiently so that the surfaces fuse
together. The bonding force holds the atoms, ions or molecules together
in a solid. This 'bonding on contact' is achieved only when:
the contaminated surface layers on the workpiece are removed,
recontamination
is
avoided,
and
the two surfaces are made smooth, flat and fit each other exactly.
In highly deformable materials, the above aims can be achieved by
rapidly forcing the two surfaces of the workpiece to come closer
together so that plastic deformation makes their shape conform to each
another; at the same time, the surface layers are broken up, allowing
the intimate contact needed to fuse the materials.
This was the principle of the first way known to weld metals; by
hammering the pieces together while they are in hot condition.

CLASSIFICATION OF WELDING
(i) Gas Welding

Oxy-acetylene
Air-acetylene
Oxy-hydrogen

(ii )Arc welding

Carbon arc
Metal arc
Metal inert gas
Tungsten inert gas
Plasma arc
Submerged arc
Electro-slag

(iii). Resistance Welding

Butt
Spot
Seam
Projection
Percussion

(iv)Thermit Welding
(v)Solid State Welding
Friction
Ultrasonic
Diffusion
Explosive

(vi)Newer Welding
Electron-beam
Laser

(vii)Related Process
Oxy-acetylene cutting
Arc cutting
Hard facing
Brazing
Soldering

GAS WELDING EQUIPMENT...

1.

Gas Cylinders
Pressure
Oxygen 125 kg/cm2 (Black-right hand)
Acetylene 16 kg/cm2 (Maroon-left hand)

2.

Regulators
Working pressure of oxygen 1 kg/cm2
Working pressure of acetylene 0.15 kg/cm2
Working pressure varies depends upon the thickness of
the
work pieces welded.

Pressure Gauges
4. Hoses
5. Welding torch
6. Check valve
7. Non return valve
3.

Oxyacetylene Welding (OAW)

The oxyacetylene welding process uses a
combination of oxygen and acetylene gas to
provide a high temperature flame.
OAW is a manual process in which the
welder must personally control the the torch
movement and filler rod application
The term oxyfuel gas welding outfit refers to
all the equipment needed to weld.
Cylinders contain oxygen and acetylene gas
at extremely high pressure

Typical Oxyacetylene Welding Station

During the welding, heat from the flame is

concentrated on the joint edges until the metal
melts and starts to flow. When the molten
metal from both sides melts it starts to fuse,
when the metal cools down the two parts
become Permanently joined
Additional Filler
Metal is fed in by
hand into the
weld pool, at
regular intervals
where it becomes
molten and joins
with the parent
metal.

Typical startup procedures

Verify

that equipment visually appears

safe IE: Hose condition, visibility of gauges
Clean torch orifices with a tip cleaners
(a small wire gauge file set used to clean
slag and dirt form the torch tip)
Crack (or open) cylinder valves slightly
allowing pressure to enter the regulators
slowly
Opening the cylinder valve quickly will
Slam the regulator and will cause
failure.

Never

stand directly in the path of a regulator

when opening the cylinder
Check for leaks using by listening for Hissing
or by using a soapy Bubble solution
Adjust the regulators to the correct operating
pressure
Slightly open and close the Oxygen and
Acetylene valves at the torch head to purge any
atmosphere from the system.
Always use a flint and steel spark lighter to light
the oxygen acetylene flame.
Never use a butane lighter to light the flame

Types of Oxyacetylene
Welding:
Reducing
or Carburizing
Inner Cone
Excess acetylene (0.9:1)
(Alloy steels and
aluminium alloys)

Oxidizing
Excess oxygen (1.5:1)
(Brasses, Bronzes,
copper)
Neutral
Equal acetylene & oxygen
(low carbon steel, mild
steels).

Max. Temp.
Zone

Secondary Combustion
envelope

Acetylene
feather

Oxy-acetylene
flames

The Oxy-acetylene welding Flame

Carburising

Neutral

Oxidising

The Oxy-acetylene welding Flame

The oxy-acetylene flame has two distinct
zones.
The inner zone (Primary combustion Zone) is
the hottest part of the flame. The welding should
be performed so as the point of the inner zone
should be just above the joint edges.
Primary Combustion zone

C2H2 + O2

2CO + H2

The outer zone the secondary combustion

envelope performs two functions
Preheats the joint edges
Prevents oxidation by using some of the
surrounding oxygen from weld pool for
combustion and gives off carbon dioxide and water
vapour
CO + H2 + O2

CO2 + H2O

Secondary Combustion zone

Welding Techniques

Leftward welding is used on

steel for flanged edge
welds, for unbevelled plates
up to 5mm & cast iron and
non-ferrous metals.
Welding is started at the
right-hand end of the joint
and proceeds
towards the left.

Rightward
welding
is
recommended for steel plate
over 5.0mm
The weld is started at the
left-hand end and moves
towards the right with the
blowpipe flame preceding
the filler rod in the direction
of travel.

Advantage of Rightward Welding Over Leftward Welding

Consumption

of filler rod is less.

Welds are made faster.
Less chance for expansion or contraction.
Flame anneals the weld portion; therefore the
mechanical properties are superior.
Better control of weld as the molten pool can be
viewed clearly.
Less risk of excessive oxidation as the reducing
flame covers the weld.

Advantages &
Disadvantages
Advantages :
Disadvantages:
Limited power density
Simple
Very low welding speed
equipment
High total heat input per
Portable
unit length
Inexpensive
Large heat affected zone
Easy for
Severe distortion
maintenance and Not recommended for
repair
welding reactive metals
such as titanium and
zirconium.

OXY-HYDROGEN WELDING

The oxygen-hydrogen process were once used

extensively to weld low temperature metals like
aluminium, lead and magnesium, but it is not
popular today because more versatile and faster
welding process such as TIG (tungsten inert gas)
and MIG (metal inert gas) have replaced the
oxygen-hydrogen flame. The process is similar to
oxygen-acetylene system, with the only difference
being a special regulator used in metering the
hydrogen gas.