diapositivas procesos union part 2

7/25/2019 Diapositivas Procesos Union Part 2

1/24

Chapter:Manufacturing processes by joining


2/24

ARC WELDING: consumable electrode

1. Introduction

2. Oxifuel gaswelding

3. Arc welding.a) Non

consumableelectrode.

GTAW

PAW AHW

b) Consumable

electrode. SMAW

SAW

GMAW FCAW

EGW

ESWc) Electrodes

d) Gases

e) Others: EBW

Shielded-Metal Arc Welding - SMAW

Manual welding 50% of the processes

f) Quality and

defectsg) Weldability

h) Design

4. Resistancewelding

RSW RSEW

HFRW

5. Economy

6. Brazing(soldadurafuerte)

7. Soldering(soldadurablanda)

8. Adhesive

bonding

DC or AC 50-300A10kW

ADVANTAGES AND LIMITATIONS:1. Useful in inaccessible places.2. Portability, flexibility, simple.3. Manual process difficult to automate.

APPLICATIONS:- Plate welding between 3-19 mm thickness.

- For deeper welding


3/24


1. Introduction




GTAW

PAW AHW

b) Consumable

electrode. SMAW

SAW

GMAW FCAW

EGW

ESWc) Electrodes

d) Gases

e) Others: EBW

Submerged Arc Welding - SAW

f) Quality and


h) Design


RSW RSEW

HFRW

5. Economy



8. Adhesive

bonding

Flux: lime, silica, oxide of magnesium, fluoride of calcium and other compounds

Avoids sparks and splashes.Avoids dangerous ultraviolet radiation and smoke typical of SMAW.Thermal insulation -> deep penetration of heat.

DC or AC 300-2000A

ADVANTAGES AND LIMITATIONS:1. Automated process (5m/min) -> 4-10 filler material/h than SMAW2. Ferrous and Non-Ferrous materials.

3. Excellent quality and good mechanical properties.

4. Plane position welding with backup.

APPLICATIONS:- Railways.- Ship plates (thick)

- Pressure vessels.


4/24


1. Introduction




GTAW

PAW AHW

b) Consumable

electrode. SMAW

SAW

GMAW FCAW

EGW

ESWc) Electrodes

d) Gases

e) Others: EBW

Gas metal Arc Welding - GMAW MIG or semiautomatic

f) Quality and


h) Design


RSW RSEW

HFRW

5. Economy



8. Adhesive

bonding


5/24


1. Introduction




GTAW

PAW AHW

b) Consumable

electrode. SMAW

SAW

GMAW FCAW

EGW

ESWc) Electrodes

d) Gases

e) Others: EBW

Gas metal Arc Welding - GMAW

f) Quality and


h) Design


RSW RSEW

HFRW

5. Economy



8. Adhesive

bonding

Stable Arc no splash Ar DC with very high curr High diameter electro Very Thick plates

Splashes CO2 High currents Thick plates

Splashes bad quality CO2 Low currents low energy Low diameter electrodes Thin plates


6/24


1. Introduction




GTAW

PAW AHW

b) Consumable

electrode. SMAW

SAW

GMAW FCAW

EGW

ESWc) Electrodes

d) Gases

e) Others: EBW


Power source:DC Tension constant

f) Quality and


h) Design


RSW RSEW

HFRW

5. Economy



8. Adhesive

bonding

Auto-regulation


7/24


1. Introduction




GTAW

PAW AHW

b) Consumable

electrode. SMAW

SAW

GMAW FCAW

EGW

ESWc) Electrodes

d) Gases

e) Others: EBW


f) Quality and


h) Design


RSW RSEW

HFRW

5. Economy



8. Adhesive

bonding

A Pulsed Arc. A1 !ime bac" current# A$ !ime pic" current.

B Selector of !ension.

C Post-burning time. Pre%ents the &ire from touching the part.

D: Wire 'eed speed.

E: General s&itch.F !ype of cycle

$t Start-Stop

(t Gas start) Wire feed and current start ) Wire and current stop ) Gas Stop

Spot &elding

H: Slo& &ire mo%ement setup time

I : *rater filling *urrent and tension reduction.J: Amperimeter and %oltmeter.

K: Positi%e pole + L ,egati%e pole.


8/24


1. Introduction




GTAW

PAW AHW

b) Consumable

electrode. SMAW

SAW

GMAW FCAW

EGW

ESWc) Electrodes

d) Gases

e) Others: EBW


GMAW parameters

Tensin / energy in the arc 0 1/ energy in the &ire.

Wire feed:as higher the &ire feed higher the current intensity.

Welding speed:function of filler rate and penetration grade. relacionada con

la tasa de depsito y penetracin.

f) Quality and


h) Design


RSW RSEW

HFRW

5. Economy



8. Adhesive

bonding

ADVANTAGES AND LIMITATIONS:1. Ferrous and Non-Ferrous materials.2. Simple process and easy qualification for welders in all positions.3. Flexible, rapid and economical. Double productivity than SMAW.4. Easy to automate with robots and flexible cells.

5. Low temperatures.

APPLICATIONS:- Plates up to 6 mm.

n%erse po ar y pre rerre e er arc s a y6 goo

penetration6 little splashes5. ,o A* used.

!as flo": lo& flo& means bad protection and o7idation# e7cessi%e flo&

means turbulences and corrosion.


9/24


1. Introduction




GTAW

PAW AHW

b) Consumable

electrode. SMAW

SAW

GMAW FCAW

EGW

ESWc) Electrodes

d) Gases

e) Others: EBW

'undent *ore Arc Welding - '*AW

f) Quality and


h) Design


RSW RSEW

HFRW

5. Economy



8. Adhesive

bonding

ADVANTAGES AND LIMITATIONS:The same as GMAW and:

1. Better stability of arc.2. Better productivity3. Better mechanical properties.4. Flexible wire -> continuous feed with regard to SMAW.

5. Can produce all kind of alloys.

5. Low temperatures.


10/24


1. Introduction




GTAW

PAW AHW

b) Consumable

electrode. SMAW

SAW

GMAW FCAW

EGW

ESWc) Electrodes

d) Gases

e) Others: EBW

4lectro-Gas Welding - 4GW

DCEP Constant Tension (30-50 V) 100-800 A

f) Quality and


h) Design


RSW RSEW

HFRW

5. Economy



8. Adhesive

bonding

ADVANTAGES AND LIMITATIONS:1. Low skill requirements.2. Plate thickness 12-75 mm

3. Ferrous and Non-Ferrous alloys.4. High Deposition Rate 20 times faster than

manual weldingOver 2.5 m long vertical seam in 50 min. by a

single operator. (50 mm/min)5. Welds in single pass, no inter-pass cleaning.6. High quality weld with minimum distortion.

7. Both gas shielded or flux cored wire are available.

8. Cost of equipment and transportation.

APPLICATIONS:- Ship welding- Structural welding


11/24


1. Introduction




GTAW

PAW AHW

b) Consumable

electrode. SMAW

SAW

GMAW FCAW

EGW

ESWc) Electrodes

d) Gases

e) Others: EBW

4lectro-Slag Welding - 4SWSimilar to EGW, except:

- Arc starts at different position(between electrode andbottom of part).

- The arc is not continuous andit acts the electrical resistanceof slag (not a electrical arcrocess .

f) Quality and


h) Design


RSW RSEW

HFRW

5. Economy



8. Adhesive

bonding

ADVANTAGES AND LIMITATIONS: same as EGW but1. Plate thickness 25-900 mm2. High Deposition Rate 10 times faster than manual welding

(12-25 mm/min)

APPLICATIONS:- Ship welding- Structural welding- Railway welding- Large tanks..


12/24

ARC WELDING: ELECTRODES

1. Introduction




GTAW

PAW AHW

b) Consumable

electrode. SMAW

SAW

GMAW FCAW

EGW

ESWc) Electrodes

d) Gases

e) Others: EBW

? Strength of deposited

metal Current (DC or AC). Type of coating.

Parameters: Diameter Length Intensity Core material

f) Quality and


h) Design


RSW RSEW

HFRW

5. Economy



8. Adhesive

bonding


13/24

ARC WELDING: ELECTRODES: Covering

1. Introduction




GTAW

PAW AHW

b) Consumable

electrode. SMAW

SAW

GMAW FCAW

EGW

ESWc) Electrodes

d) Gases

e) Others: EBW

Coveringpo&ders of o7ides6 carbonates6 fluorides6 metallic

alloys6 cellulose together &ith silicate agglutinants.

'unctions Electrical

- Arc strike: dissociable and ionisable substances

carbonates, silicates, oxides of Fe, Ti favour the arc strike.

- Arc stability: to maintain the state of ionization in the plasma column

*lay materials that includes

f) Quality and


h) Design


RSW RSEW

HFRW

5. Economy



8. Adhesive

bonding

, , .

Metallurgical:

- Provides alloy elements to improvemechanical ro erties.

Physical:- Protective gas generation:

CO2 H2O CO H2

- Controls the speed of electrode melting

- Fundent (fux): the slag protects the liquid metal from oxygen, nitrogen, inclusions

- Helps to transfer the melted drops towards the joining.

- Controls the cooling and tempering


14/24

ARC WELDING: ELECTRODES: Covering

1. Introduction




GTAW

PAW AHW

b) Consumable

electrode. SMAW

SAW

GMAW FCAW

EGW

ESWc) Electrodes

d) Gases

e) Others: EBW

*o%ering types Rutile (TiO2): dense and viscous slag.- Welding in all positions. Easy to use.

- Poor strength Hydrogen fragility

Basic (calcic carbonate and calcic fluoride (fundent)):

dense slag which ascends easy- Low hydrogen content Fix Mn, Cr, Ni, Mo in the bead.

- Good mechanical and corrosion characteristics

- Dissolve impurities (FeS)

f) Quality anddefects

g) Weldability

h) Design


RSW RSEW

HFRW

5. Economy



8. Adhesive

bonding

Acid (FeS, FeMn, FeO, MnO): dissolve basic oxides as MnO

- Dense and abundant slag Smooth bead finish Easy to weld

- Rapid melting

- Medium strength Hydrogen fragility Slag in the bead

- Difficult to use Hygroscopic

Cellulosic(organic substances): very good gas envelope

- Oxidizing protection Better arc transference Good penetration due to H2heat and gas pressure Good quality in descending and pipe welding

- Welding splashes Smoke

Not used(only 2%)


15/24


16/24

ARC WELDING: GASES

1. Introduction




GTAW

PAW AHW

b) Consumable

electrode.

SMAW SAW

GMAW FCAW

EGW

ESWc) Electrodes

d) Gases

e) Others: EBW

UNE-EN ISO 14175

f) Quality and


h) Design


RSW RSEW

HFRW

5. Economy



8. Adhesive

bonding


17/24

ARC WELDING: GASES

1. Introduction




GTAW

PAW AHW

b) Consumable

electrode.

SMAW SAW

GMAW FCAW

EGW

ESWc) Electrodes

d) Gases

e) Others: EBW

UNE-EN ISO 14175

f) Quality and


h) Design


RSW RSEW

HFRW

5. Economy



8. Adhesive

bonding


18/24

ARC WELDING: GASES

1. Introduction




GTAW

PAW AHW

b) Consumable

electrode.

SMAW SAW

GMAW FCAW

EGW

ESWc) Electrodes

d) Gases

e) Others: EBW

UNE-EN ISO 14175

f) Quality and


h) Design


RSW RSEW

HFRW

5. Economy



8. Adhesive

bonding


19/24

ARC WELDING: GASES

1. Introduction




GTAW

PAW AHW

b) Consumable

electrode.

SMAW SAW

GMAW FCAW

EGW

ESWc) Electrodes

d) Gases

e) Others: EBW

Inert gases (Ar, He) Non-ferrous alloys (Al and Cu)

Low thermal conductivityHigh electrical conductivity

High thermal conductivityLow electrical conductivity

Helium only for thickness higher than 4 mm

f) Quality and


h) Design


RSW RSEW

HFRW

5. Economy



8. Adhesive

bonding

Less tension

meansbetter arc stability


20/24

ARC WELDING: GASES

1. Introduction




GTAW

PAW AHW

b) Consumable

electrode.

SMAW SAW

GMAW FCAW

EGW

ESWc) Electrodes

d) Gases

e) Others: EBW

Active gases (CO2, N2, H2, O2) Steels No alloyedLow AlloyedHigh AlloyedCarbon steels (> 0,2%C)

80% Ar-20% CO2

100% CO2 only when using flux or shielded wire with deoxidizing elements (Mn, Si) and C

Low alloyed steels

75% Ar-25% CO2

f) Quality and


h) Design


RSW RSEW

HFRW

5. Economy



8. Adhesive

bonding

Stainless steels (> 0,2%C)

98% Ar-2% CO22% O2

Active gas provides fluidity, required for penetration


21/24

ARC WELDING: GASES

1. Introduction




GTAW

PAW AHW

b) Consumable

electrode.

SMAW SAW

GMAW FCAW

EGW

ESWc) Electrodes

d) Gases

e) Others: EBW

GUA DE SELECCIN DE GASES (Fuente: La flor del rbigo)

f) Quality and


h) Design


RSW RSEW

HFRW

5. Economy



8. Adhesive

bonding


22/24

ARC WELDING: GASES

1. Introduction




GTAW

PAW AHW

b) Consumable

electrode.

SMAW SAW

GMAW FCAW

EGW

ESWc) Electrodes

d) Gases

e) Others: EBW

GUA DE SELECCIN DE GASES (Fuente: La flor del rbigo)

f) Quality and


h) Design


RSW RSEW

HFRW

5. Economy



8. Adhesive

bonding


23/24

ARC WELDING: GASES

1. Introduction




GTAW

PAW AHW

b) Consumable

electrode.

SMAW SAW

GMAW FCAW

EGW

ESWc) Electrodes

d) Gases

e) Others: EBW

2::/ Ar ) 1$/ *;$ Spray transference

29/ Ar) $9/ *;$5 Short-cort transference29/ Ar ) 9/ *;

$5 Pulsed transference

2*arbon and lo& alloy steels5

8nfluence of /*;$onarc transference

f) Quality and


h) Design


RSW RSEW

HFRW

5. Economy



8. Adhesive

bonding

8nfluence of gases on

penetration


24/24

ELECTRON BEAM WELDING (EBW) / LASER BEAN WELDING (LBW)

1. Introduction




GTAW

PAW AHW

b) Consumable

electrode.

SMAW SAW

GMAW FCAW

EGW

ESWc) Electrodes

d) Gases

e) Others: EBW

f) Quality and


h) Design


RSW RSEW

HFRW

5. Economy



8. Adhesive

bonding

EBW or LBW MGAW or GTAW

diapositivas procesos union part 2

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