industrial processes ii industrial processes ii inden 3313 lecture 6 – case study fusion welding...

Industrial Processes II

INDUSTRIAL PROCESSES IIINDUSTRIAL PROCESSES II

INDEN 3313INDEN 3313

Lecture 6 – Case StudyLecture 6 – Case Study

Fusion Welding -- Oxyfuel and Fusion Welding -- Oxyfuel and Electric (Arc) Welding Electric (Arc) Welding

ProcessesProcesses


OVERVIEWOVERVIEW

• Case Study Case Study – Overview and Phases

• Fusion WeldingFusion Welding– Oxyfuel

– Arc

– Resistance


QUESTIONSQUESTIONSTO START ??TO START ??


CASE STUDYCASE STUDY• Goal to Study the Design and Goal to Study the Design and

Manufacture of ToolingManufacture of Tooling– Phase I (15%)

• Identify Possible Parts for Case Study• Each Student to Identify Three (3) Parts for

Case Study– One part => Cast– One Part => Machined– One Part => Other Than Cast/Machined that

will require tooling for its Production (Forging Dies, Stamping/Bending Dies, …)

• Form/Format on Web– Part (Name, Function, Sketch)

• Due Next Thursday– Hard Copy and Electronic Submission (e-mail)


CASE STUDYCASE STUDY– Phase II (15%) – Part Processing Concepts

• Following Part Submission (Phase I) Instructor will select/modify Parts and Assign

• A processing sequence will be designed for the part and the tooling requirement(s) for its production via this sequence will be determined.

• Each student will execute this phase for one part concept.

• Due 2/22/00• Format on Web


CASE STUDYCASE STUDY– Phase III (70%)

• Each Student will detail the design and manufacture (parameters, costs, …) of an assigned piece of tooling. For part concepts requiring more than one piece of tooling, one student will be assigned each piece and one report will be developed for each part.– 10% -- Schedule for Project (Due 3/8/00) and

Progress/Adherence to Schedule (Due 3/29/00)– 20% -- Completed Draft (Due 4/12) Evaluation

of Technical Data and Report Format/Content Completeness (Format on Web IEM Tech. Writing)

– 40% -- Final Draft with all Technical Corrections and Presentation of Results to Class. (Slides Due 4/26, Final Report Due 4/28)

• Schedule may be modified to accommodate ENGL 3323


FUSION WELDING METHODSFUSION WELDING METHODS

• Fusion => Use of Heat to MeltFusion => Use of Heat to Melt• Types (Source of Heat)Types (Source of Heat)

– Chemical Reaction (Combustion)• OxyFuel• Thermit

– Electric Arc• Consumable Electrode• Non-Consumable Electrode


FUSION WELDING METHODSFUSION WELDING METHODS

• Types(cont.)Types(cont.)– Beam

• Electron Beam• Laser

– Electrical Resistance• Note: Text Classifies as Solid State Process

-- Nugget is Molten, But Contained


OXYFUEL WELDINGOXYFUEL WELDING• Basic Process DescriptionBasic Process Description

– Use the Heat Produced by the Combustion of Acetylene and Oxygen to Cause Coalescence

• ParametersParameters– Rate of Combustion

•Affects Heat, Not Temperature•Size of (Nozzle) Tip

– Maintenance of Non-Corrosive Shield

– Operator Skill, Preparation of Parts


OXYFUEL WELDINGOXYFUEL WELDING• ReactionsReactions

– 1. C2H2 + O2 -> 2 CO + H2 + Heat

– 2. 4 CO + 2 H +3 O2 -> 4 CO2 +2 H2O + Heat

• Discussion of FlameDiscussion of Flame

– Reducing Neutral Oxidizing

5500o F 2300o F

C2H2

O2


OXYFUEL WELDINGOXYFUEL WELDING• Common DefectsCommon Defects

– Hydrogen Embrittlement– Corrosion (Neutral/Reducing Flame)– Spatter– Inadequate Penetration– Incomplete Fusion

• AdvantagesAdvantages– Low Cost, Skill Requirements– Portability


THERMIT WELDINGTHERMIT WELDING• Basic Process DescriptionBasic Process Description

– Use of Heat Produced by Thermite Reaction to Superheat Fe and Use Superheated Fe to Effect Weld

• ReactionsReactions– 1. 3 Fe3O4 + 8 Al -> 9 Fe + 4 Al203 + Heat

– 2. 3 FeO + 2 Al -> 3 Fe + Al203 + Heat

– 3. Fe203 + 2 Al -> 2 Fe + Al203 + Heat

• Iron for Weld, Aluminum Oxide Slag Iron for Weld, Aluminum Oxide Slag (Protects Weld as It Cools)(Protects Weld as It Cools)


THERMIT WELDINGTHERMIT WELDING• Sources/Causes of DefectsSources/Causes of Defects

– Inclusions– Large Grooves Required (Superheat of

Base)

• AdvantagesAdvantages– Large Amounts of Filler Metal Available

Quickly


THERMIT WELDINGTHERMIT WELDING

[Amstead et al, Figure 8.26, p. 186]


CONSUMABLE ELECTRIC ARC CONSUMABLE ELECTRIC ARC WELDINGWELDING

• Basic Process DescriptionBasic Process Description– Creation of an Electrical Potential and

Exceeding the Initiation Voltage to Produce an Electrical Arc, the Heat of Which (~55,000o F) Effects the Weld; the Electrode is Melted by the Arc and Supplies Filler Metal to the Weld

• ParametersParameters– Distance from Electrode to Work

Determines Initiation Voltage, Temperature, Current/Frequency Determines Heat Flux



• Two TypesTwo Types– Consumable Electrode– Non-consumable Electrode

• AdvantagesAdvantages– Automated– High Temperature– High Heat Flux– Shielding from Corrosion



• Provision of Non-Corrosive Provision of Non-Corrosive EnvironmentEnvironment– Shielded Metal Arc Welding (SMAW)

• Flux Coated Stick Electrode

– Submerged Arc Welding (SAW)• Flux Supplied by Separate Delivery System

– Gas Metal Arc Welding (GMAW)• Inert Gas Supplied - Local Inert Atmosphere

Around Weld

– Flux Cored Arc Welding (FCAW)• Flux Embedded in ‘Hollow’ Electrode (Wire)



• Provision of Non-Corrosive Provision of Non-Corrosive EnvironmentEnvironment– Electro-Gas Welding (EGW)

• Inert Gas Supplied

– Electroslag Welding (ESW)• Slag Used to Shield • Technically, Arc is Extinguished - Resistance

Used To Heat


SHIELDED METAL ARC SHIELDED METAL ARC WELDINGWELDING

[Kalpakjian, Figure 27.4, p. 862]


SUBMERGED METAL ARC SUBMERGED METAL ARC WELDINGWELDING



GAS METAL ARC WELDINGGAS METAL ARC WELDING



FLUX CORED ARC FLUX CORED ARC WELDINGWELDING



ELECTRO-GAS WELDINGELECTRO-GAS WELDING



ELECTROSLAG WELDINGELECTROSLAG WELDING



NON-CONSUMABLE ELECTRIC NON-CONSUMABLE ELECTRIC ARC WELDINGARC WELDING

• Basic Process DescriptionBasic Process Description– Creation of an Electrical Potential and

Exceeding the Initiation Voltage to Produce an Electrical Arc, the Heat of Which (~55,000o F) Effects the Weld; the Electrode is Not Melted by the Arc and a Separate Rod (Optional) Supplies Filler Metal to the Weld

• ParametersParameters– Distance from Electrode to Work

Determines Initiation Voltage, Temperature, Current/Frequency Determines Heat Flux


NON-CONSUMABLE ELECTRIC NON-CONSUMABLE ELECTRIC ARC WELDINGARC WELDING

• Gas Tungsten- Arc WeldingGas Tungsten- Arc Welding– Gas Shielding

• Atomic Hydrogen WeldingAtomic Hydrogen Welding– Uses Hydrogen as Shielding

• Plasma Arc WeldingPlasma Arc Welding– Plasma (60,000o F)– Shielding Gas Used


Gas Tungsten- Arc Gas Tungsten- Arc WeldingWelding

• [Kalpakjian, Figure 27.13, p. 872]


Plasma Arc WeldingPlasma Arc Welding



ELECTRON BEAM WELDINGELECTRON BEAM WELDING• Basic Process DescriptionBasic Process Description

– Use of Heat Produced by High Velocity Stream of Electrons to Effect Deep Penetration Welds

• AdvantagesAdvantages– High Penetration

• ShieldingShielding– Performed in a Vacuum

• DisadvantagesDisadvantages– Cost, X-Rays Produced


LASER BEAM WELDINGLASER BEAM WELDING• Basic Process DescriptionBasic Process Description

– Use of Heat Produced by High Intensity Beam of Light to Effect Deep Penetration Welds

• AdvantagesAdvantages– High Penetration

• ShieldingShielding– Performed in a Vacuum


SOLID STATE METHODSSOLID STATE METHODS

• Coalescence Through PressureCoalescence Through Pressure• TypesTypes

– Resistance Welding– Cold Welding– Ultrasonic Welding– Friction Welding– Explosion Welding– Diffusion Welding


RESISTANCE WELDINGRESISTANCE WELDING• Basic Process DescriptionBasic Process Description

– The Heating of the Base Materials Through Electrical Resistance at Material Interfaces/Discontinuities to Produce Coalescence.

• SequenceSequence– Material Surfaces Cleaned and Aligned– Electrodes Used to Clamp Components in

Place– Current Passed Through Components

(Electrodes Water Cooled), Nugget Melted– Current Turned Off, Coalescence,

Unclamped


RESISTANCE WELDINGRESISTANCE WELDING• ParametersParameters

– Voltage• Usually Low Voltage

– Current (Amperage)• Controls Heat Flux• Usually High Current

– Time of Current Passage• Heat = I2 * Ω * t

– Total Resistance• Power = I2 * Ω

– Clamping Time/Pressure– Area of Electrode/Workpiece Contact


RESISTANCE WELDINGRESISTANCE WELDING• TypesTypes

– Spot– Projection– Seam

• Lap• Mash• Finish

– Butt– Flash– Percussion– Induction


RESISTANCE WELDINGRESISTANCE WELDING• Spot - Temperature DistributionSpot - Temperature Distribution

Amstead, Figure 8.10, p. 168


RESISTANCE WELDINGRESISTANCE WELDING• SpotSpot

Kalpakjian, Figure 28.6b, p. 892


RESISTANCE WELDINGRESISTANCE WELDING• ProjectionProjection



RESISTANCE WELDINGRESISTANCE WELDING• Seam -- Lap SeamSeam -- Lap Seam



RESISTANCE WELDINGRESISTANCE WELDING• Seam -- Mash SeamSeam -- Mash Seam



RESISTANCE WELDINGRESISTANCE WELDING• Seam -- Finish SeamSeam -- Finish Seam



RESISTANCE WELDINGRESISTANCE WELDING• Butt -- PipeButt -- Pipe

Amstead, Figure 8.14a, p. 171


RESISTANCE WELDINGRESISTANCE WELDING• Butt -- Bar StockButt -- Bar Stock

Amstead, Figure 8.14b, p. 171


RESISTANCE WELDINGRESISTANCE WELDING• Flash (Also Considered Arc Welding)Flash (Also Considered Arc Welding)

Kalpakjian, Figure 28.15a, p. 892


RESISTANCE WELDINGRESISTANCE WELDING• Stud --(Also Considered Arc Welding)Stud --(Also Considered Arc Welding)

Kalpakjian, Figure 28.16, p. 898


RESISTANCE WELDINGRESISTANCE WELDING• PercussionPercussion

Modified from Kalpakjian, Figure 28.15, p. 897


RESISTANCE WELDINGRESISTANCE WELDING• InductionInduction

Modified from Kalpakjian, Figure 4.26a,b, p. 147

Part to be Welded


QUESTIONSQUESTIONSOR OR

CLARIFICATIONCLARIFICATIONS ???S ???

Reminder :Reminder :

industrial processes ii industrial processes ii inden 3313 lecture 6 – case study fusion welding...

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case studyfusion welding

fe al203 heatiron

superheated fe

fe al203 heat3

case studyeach student

assigned piece of tooling

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