advance welding & brazing technology

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ADVANCE 26-05-2017 1 TECHNOLOGY SHARATH C M 1MS16MSE14 Manufacturing Science & Engineering

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ADVANCE

26-05-2017 1

TECHNOLOGY

SHARATH C M1MS16MSE14Manufacturing Science & Engineering

Generic view on Manufacturing Processes

Manufacturing Processes

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Shaping Processes

Surface Processing Operation

Particulate Processing

Material Removal

Deformation Processes

Solidification Processes

Processing Operation

Assembly Operation

Property Enhancing Processes

Coating & deposition Pro.

Cleaning & surface Treat..

Heat Treatment

Adhesive bonding

Mechanical Testing

Permanent Joining Processes

Permanent Fastening

Threaded fasteners

Brazing & Soldering

Welding

WELDING

◦ Welding is a materials joining process which producescoalescence of materials by heating them to suitabletemperatures with or without the application of pressure orby the application of pressure alone, and with or without theuse of filler material.

◦ Welding is used for making permanent joints.

◦ It is used in the manufacture of automobile bodies, aircraftframes, railway wagons, machine frames, structural works,tanks, furniture, boilers, general repair work and shipbuilding.

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TYPES

Plastic Welding or Pressure Welding

The piece of metal to be joined are heated to aplastic state and forced together by external pressure

Ex: Resistance welding

Fusion Welding or Non-Pressure Welding

The material at the joint is heated to a molten stateand allowed to solidify

Ex: Gas welding, Arc welding

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Classification of welding processes:

(i). Arc welding

Carbon arc

Metal arc

Metal inert gas

Tungsten inert gas

Plasma arc

Submerged arc

Electro-slag

(ii). Gas Welding

Oxy-acetylene

Air-acetylene

Oxy-hydrogen

(iv)Thermite Welding

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(iii). Resistance WeldingButtSpotSeamProjectionPercussion

(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

Equipments:

A welding generator (D.C.) or Transformer (A.C.)

Two cables- one for work and one for electrode

Electrode holder

Electrode

Protective shield

Gloves

Wire brush

Chipping hammer

Goggles

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Weld defects

Geometric

•Misalignment

•Concavity or Convexity

•Excessive Reinforcement

•Improper Reinforcement

•Burn-through

•Backing left on

•Incomplete Penetration

•Surface Irregularities

Other

•Arc Strikes

•Slag Inclusions

•Tungsten Inclusions

•Oxide Films

•Spatter

•Arc Craters

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•Lack of Fusion

•Shrinkage

•Overlap

•Undercut

Brazing

It is a low temperature joining process. It is performed attemperatures above 427ºC and it generally affords strengthscomparable to those of the metal which it joins.

It is low temperature in that it is done below the meltingpoint of the base metal. It is achieved by diffusion without fusion(melting) of the base.

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Brazing can be classified as

Torch brazing

Dip brazing

Furnace brazing

Induction brazing

BRAZING

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Brazing methods

(a) Torch and filler rods

(b) Ring of filler metal

at entrance of Gap

(c) Foil of filler metal

between flat part

surfaces

VARIOUS BRAZING JOINTS

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(a) Conventional butt

(b) Scarf joint

(c) Stepped joint

(d) Increased crossest

ion

(a)Conventional Lap

(b) Cylindrical part

(c) Sandwiched part

(d) Use of sleeve

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Brazing

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Brazing

Advantages & Disadvantages

Advantages

Dissimilar metals which can not be welded can be joined by brazing

Very thin metals can be joined

Metals with different thickness can be joined easily

In brazing thermal stresses are not produced in the work piece. Hence there is no distortion

Using this process, carbides tips are brazed on the steel tool holders

Disadvantages

Brazed joints have lesser strength compared to welding

Joint preparation cost is more

Can be used for thin sheet metal sections

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Recent Trend of Welding Technology Development and Applications

by OI Kenji et.Al.

Status of Technology Development in Automotive Field.

Status of Technical Development in Plate and Steel Pipe Fields.

Current Status of Basic Technology Development.

Trends in Welding Automation Technologies in Actual Fabrication.

o Unmanned Robot Welding System.

o Narrow Gap Welding of Heavy Plates.

o Field Girth Welding of Gas Pipelines.

o Rail Welding Technologies.

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Status of Technology Development in Automotive Field.

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Status of Technology Development in Automotive Field.

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Status of Technology Development in Automotive Field.

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Status of Technology Development in Automotive Field.

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Status of Technical Development in Plate and Steel Pipe Fields.

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Status of Technical Development in Plate and Steel Pipe Fields.

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Current Status of Basic Technology Development.

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Current Status of Basic Technology Development.

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Trends in Welding Automation Technologies in Actual Fabrication.

Unmanned Robot Welding System:

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Trends in Welding Automation Technologies in Actual Fabrication.

Narrow Gap Welding of Heavy Plates:

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Trends in Welding Automation Technologies in Actual Fabrication.

Field Girth Welding of Gas Pipeline:

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Trends in Welding Automation Technologies in Actual Fabrication.

Rail Welding Technologies:

ADVANCE BRAZING

INDUCTION BRAZING TORCH BRAZING: Manual Oxyacetylene Brazing

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Thanking All

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