industrial processes ii industrial processes ii inden 3313 lecture 7 – welding, welding design,...

Industrial Processes II

INDUSTRIAL PROCESSES IIINDUSTRIAL PROCESSES II

INDEN 3313INDEN 3313

Lecture 7 – Welding,Lecture 7 – Welding,

Welding Design, Welding Design,

Brazing and SolderingBrazing and Soldering


OVERVIEWOVERVIEW

• Directions to LabDirections to Lab

• Remaining Welding ProcessesRemaining Welding Processes

• Welding DesignWelding Design

• Brazing and SolderingBrazing and Soldering


QUESTIONSQUESTIONSTO START ??TO START ??


UPCOMING WELDING UPCOMING WELDING LABSLABS

• Three Lab SequenceThree Lab Sequence– Introduction and

•Oxyfuel•Arc Welding•MIG (SMAW) Welding

• LocationLocation– Bio-Systems and Agricultural

Engineering Laboratories– SE Corner of Hall of Fame and

Cleveland• Park Across from Colvin Center



• Three Lab SequenceThree Lab Sequence– Oxyfuel -> Arc Welding ->MIG (SMAW)– 12:00 Lab

Group A Gas ->Arc ->Stick

Billy

Group B Arc ->Stick->Gas

Sally

Group C Stick->Gas->Arc

Charley



• Three Lab SequenceThree Lab Sequence– Oxyfuel -> Arc Welding ->MIG (SMAW)– 3:00 Lab

Group A Gas ->Arc ->Stick

Billy

Group B Arc ->Stick->Gas

Sally

Group C Stick->Gas->Arc

Charley



• Location Location --Corner of Cleveland and Hall of Fame--Corner of Cleveland and Hall of Fame

Colvin Center

OSU TrackColvin Parking

AG Labs

Cle

vela

nd



WELDING LABEntry Door

N

HALL OF FAME

CL

EV

EL

AN

D


COLD WELDINGCOLD WELDING• Basic Process DescriptionBasic Process Description

– Use of Pressure to Cause Coalescence• Clean Mating Surfaces• Press Together and Plastically Deform, as in

Rolling, Cladding• If Dissimilar Metals, Inter-metallic

Compounds Form - Act as (Weak) Adhesive

• ParametersParameters– Pressure Used– Cleanliness of Surfaces– Similarity of Metals


COLD WELDINGCOLD WELDING

• Sources/Causes of DefectsSources/Causes of Defects– Inclusions, Delamination– Inadequate Ductility of Base

Material(s)

• ““Cures” For DefectsCures” For Defects– Adequate, Uniform Pressures– Surface Preparation


COLD WELDINGCOLD WELDING

Kalpakjian, Figure 28.1, p. 886


ULTRASONIC WELDINGULTRASONIC WELDING

• Basic Process DescriptionBasic Process Description– Mechanically Induced Vibrations Used

to Breakup Oxides and Provide Energy for Coalescence

• ParametersParameters– Vibration Frequency and Amplitude

– Temperature Induced (.33 - .50 Tmelt)

• DefectsDefects– Inclusions, Incomplete Fusion


ULTRASONIC WELDINGULTRASONIC WELDING

Kalpakjian, Figure 28.2a&b, p. 887


FRICTION WELDINGFRICTION WELDING• Basic Process DescriptionBasic Process Description

– Production of Heat By “Rubbing” the Surfaces to be Mated Against One Another and Holding the Heated Surfaces Against One Another Until Coalescence Occurs.

• ParametersParameters– Force Applied/Means (Linear or

Rotational)– Rotational Speed

• Sources/Causes of DefectsSources/Causes of Defects– Preparation of Surface (Oxides)– Misalignment


FRICTION WELDINGFRICTION WELDING

Kalpakjian, Figure 28.3, p. 888


EXPLOSION WELDINGEXPLOSION WELDING

• Basic Process DescriptionBasic Process Description– Use of Pressure (Wave) Produced by

the Detonation of an Explosive and the Use of this Pressure to Cause Coalescence. Oxides Broken and Expelled from Weld by Pressure Wave.

• ParametersParameters– Pressure Reached– Detonation/Speed of Pressure Wave

• Rate Dependant Deformation Process



• Sources/Causes of DefectsSources/Causes of Defects– Inclusions– Tearing, Cracks



Amstead, Figure 8.30, p. 190


DIFFUSION WELDINGDIFFUSION WELDING

• Basic Process DescriptionBasic Process Description– Uses Heat and Pressure to Promote

Diffusion of Atoms Across Interface. Diffusion of One Crystalline Structure into Another (Can be Dissimilar Metals)

• ParametersParameters– Temperature– Pressure– Surface Preparation– Material Compatibility


WELDING DESIGN REVIEWWELDING DESIGN REVIEW• Design Considerations Design Considerations [[Boltz, pgs. 53-35 to 55]Boltz, pgs. 53-35 to 55]

– Analysis of Current Design• Define Previous Design Requirements• Analysis of Previous Failures/Problems

– Over/Under Design ?

– Determination of Load Conditions• Type and Magnitude of Forces, Safety Limits• Determine Desired “Fail Safe” Mode(s)

– Determine Major Design Factors• Satisfy Strength. Stiffness, Safety Requirements• Add Stiffness By Use of Bosses, • If Bending, Use Deep, Symmetrical Sections• Appearance Only where Critical (On Print)


WELDING DESIGN REVIEWWELDING DESIGN REVIEW• Design Considerations Design Considerations [[Boltz, pgs. 53-35 to 55]Boltz, pgs. 53-35 to 55]

– Determine Major Design Factors (Cont.)• Minimize Weight, Material Used• Used Closed (Tubular) Sections to Provide

Torsion Resistance• Use Non-Premium Material Grades where

Possible• Use Standard Sections, Plates, and Bar

– Use ‘Scrap’ for Stiffeners, etc.– Allow for Edge Preparation

• Provide all Necessary Maintenance Access• Compare Process Capability and Tolerance• Use Subassemblies to Distribute Tasks (Line)


WELDING DESIGN REVIEWWELDING DESIGN REVIEW• Design Considerations Design Considerations [[Boltz, pgs. 53-35 Boltz, pgs. 53-35

to 55]to 55]

– Joint/Bead Design Factors• Select Joint Needing Least Material

– If Thick, Use Double Grooves– Minimize Root Opening and Included Angle– Minimize Leg Size

• Select One Pass Joint/Process Combination• Balance Joint Preparation and Welding Time• Provide Welder Access to Joint• Continuous vs. Intermittent Weld Bead

– Lower Strength -- Intermittent– Automated -- Continuous– Distortion -- Intermittent

• Size Weld Based on Thinner Member


WELDING DESIGN REVIEWWELDING DESIGN REVIEW• Design Considerations Design Considerations [[Boltz, pgs. 53-35 Boltz, pgs. 53-35

to 55]to 55]

– Welding Operations• Use Properly Designed Fixtures (Strength,

Allow for Distortion, Rotate for Positioning)• Use “Two-Up” Design for Higher Production• Weld Thinner Sections First to Facilitate

Straightening• Use Backup Bars as Needed (Grooves)• Use Properly Sized Equipment• Weld One Side, If Possible• Weld Flat, Downhand when Possible• Use Recommended Electrodes, Polarity,

Speed, Voltage, Current


WELDING DESIGN REVIEWWELDING DESIGN REVIEW• Proper Gaps (Bridging or Burn Proper Gaps (Bridging or Burn

Through)Through)

Too Small Proper Gap Too Large

[Bolz, Figure 53.37, p 53-46)


WELDING DESIGN REVIEWWELDING DESIGN REVIEW• Backup PlatesBackup Plates

[Bolz, Figure 53.38, p 53-46)


WELDING DESIGN REVIEWWELDING DESIGN REVIEW

• Design Considerations Design Considerations [[Boltz, pgs. 53-35 Boltz, pgs. 53-35 to 55]to 55]

– Distortion Control• Use High Heat Flux, Deposition Rate

Processes• Use Least Weld Material Possible• Use Fewest Passes Possible• Weld Alternate Ends Inward or Backstep• Weld Joints with Greatest Contraction First


WELDING DESIGN REVIEWWELDING DESIGN REVIEW• Distortion ControlDistortion Control

[Bolz, Figure 53.41 a,b , p 53-49)



[Bolz, Figure 53.41 c-f , p 53-49)



[Bolz, Figure 53.41 g,h , p 53-49)



[Bolz, Figure 53.41 i,j , p 53-49)



[Bolz, Figure 53.41 k,l , p 53-49)


WELDING DESIGN REVIEWWELDING DESIGN REVIEW• Cost/Strength/Joint Design Cost/Strength/Joint Design

[Bolz, Figure 53.30, p 53-42)



[Bolz, Figure 53.33,

p. 53-43)



[Bolz, Table 35-1,

p 53-44)


SUMMARY OF WELDING SUMMARY OF WELDING PROCESSESPROCESSES

• Welding (Definitions)Welding (Definitions)– Metal Joining Process in Which Coalescence is

Obtained Using Heat and/or Pressure• Coalescence - (From The Random House Dictionary)

– 1. to grow together or into one body 2. to unite so as to form one mass, community, etc.; blend; fuse; join; 3. to cause to unite into one body. from the Latin “alere” meaning to grow.

– A Metallurgical Bonding Accomplished by the Attracting Forces Between Atoms

– Joining Two (or More) Pieces of Material by Applying Heat, Pressure, or Both, With or Without Filler Metal to Produce Localized Union Through Fusion or Recrystallization Across the Interface.


SUMMARY OF WELDING -- SUMMARY OF WELDING -- BASIC PROCESS REVIEWBASIC PROCESS REVIEW

• Part/Weld Function and Operating Part/Weld Function and Operating Environment is DefinedEnvironment is Defined

• Type of Joint Selected/AnalyzedType of Joint Selected/Analyzed• Component Parts ManufacturedComponent Parts Manufactured• Surfaces to Be Welded Are CleanedSurfaces to Be Welded Are Cleaned• Components Are Aligned and ClampedComponents Are Aligned and Clamped• Non-Corrosive/Protective Environment Non-Corrosive/Protective Environment

Formed Around Area to Be WeldedFormed Around Area to Be Welded


SUMMARY OF WELDING -- SUMMARY OF WELDING -- BASIC PROCESS REVIEW BASIC PROCESS REVIEW

• Heat and/or Pressure Applied to Heat and/or Pressure Applied to ComponentsComponents

• Portion of Components Melt/Coalesce Portion of Components Melt/Coalesce – Grain Structure Revised/Reformed

• (Optional) Add Molten (Filler) (Optional) Add Molten (Filler) MaterialMaterial

• Heat From Process Affects Non-Heat From Process Affects Non-Melted Portion of ComponentsMelted Portion of Components– Grain Structure Affected– Expansion, Warping– Out Gassing, Corrosion


SUMMARY OF WELDING -- SUMMARY OF WELDING -- BASIC PROCESS REVIEW BASIC PROCESS REVIEW

• Heat and/or Pressure RemovedHeat and/or Pressure Removed• Molten Material Begins to SolidifyMolten Material Begins to Solidify

– Coalescence/Grain Formation• Size, Shape, Strength Function of Cooling

Rate

– Dissolved Gases Evolve• Out Gassing,

– Shrinkage/Expansion of Weld Nugget Due to Change in State• Stresses, Shrinkage Voids

• Solidification Of Molten Material Solidification Of Molten Material CompleteComplete


INTRODUCTION TO JOINING INTRODUCTION TO JOINING PROCESSESPROCESSES

• Brazing, Soldering, and Adhesives DefinitionBrazing, Soldering, and Adhesives Definition– Processes in Which Filler Material(s) i.e., Adhesives,

are Introduced Between Two or More Faying Surfaces. The Filler Material Fills the Closely Fitting Space and Wets the Surfaces. The Resulting Physical Bonds Causes the Joining of the Two Faying Surfaces• Faying -- From The Random House Dictionary

– to fit, esp. closely together, as timbers in ship building. From Middle English, “feie” to put together.

• Why UseWhy Use– Join Dissimilar Materials– Lower Temperature and Lower Pressure Processes– Weaker Bonds (Compared to Welding)– Range of Bond Strength Can Be Produced


INTRODUCTION TO JOINING INTRODUCTION TO JOINING PROCESSESPROCESSES

• Brazing, Soldering, and Adhesives -- Key Concepts Brazing, Soldering, and Adhesives -- Key Concepts

– Introduction of One or More Layers of Material Between Two (Or More) Components to Be Joined.

– The Introduced Material “Wets” the Surfaces of the Components and the Surface Tension of the Introduced Material is Used to Hold the Components Together.

– Changes in the Surface Tension of the Adhesive are Achieved Via Changes in State, Composition, and/or Area of Contact• Adhesive is Melted, Introduced, and Allowed to Cool,

Increasing Surface Tension.• Adhesive is Composed of Plural Components, Some of

Which May Evaporate or Chemically React • Application of Pressure “Spreads” the Adhesive and

Increases the Surface Contact, Increasing Surface Tension


BRAZING AND SOLDERINGBRAZING AND SOLDERING• Brazing/Soldering DefinitionBrazing/Soldering Definition

– Processes in Which Filler Material(s) i.e., Adhesives, are Introduced Between Two or More Faying Surfaces. The Filler Material Fills the Closely Fitting Space and Wets the Surfaces. The Resulting Physical Bonds Causes the Joining of the Two Faying Surfaces• Faying -- From The Random House Dictionary

– to fit, esp. closely together, as timbers in ship building. From Middle English, “feie” to put together.

• Why UseWhy Use– Join Dissimilar Materials– Lower Temperature and Lower Pressure

Processes– Weaker Bonds (Compared to Welding)– Range of Bond Strength Can Be Produced


BRAZING AND SOLDERINGBRAZING AND SOLDERING

• Brazing and Soldering-- Key Concepts Brazing and Soldering-- Key Concepts – Introduction of One or More Layers of Material

Between Two (Or More) Components to Be Joined.– The Introduced Material “Wets” the Surfaces of the

Components and the Surface Tension of the Introduced Material is Used to Hold the Components Together.

– Changes in the Surface Tension of the Adhesive are Achieved Via Changes in State, Composition, and/or Area of Contact• Adhesive is Melted, Introduced, and Allowed to Cool,

Increasing Surface Tension.• Adhesive is Composed of Plural Components, Some of

Which May Evaporate or Chemically React • Application of Pressure “Spreads” the Adhesive and

Increases the Surface Contact, Increasing Surface Tension


BRAZINGBRAZING• Basic Process DescriptionBasic Process Description

– Processes in Which Filler Material(s) with Melting Temperatures Greater than 840o F are Introduced Between Two or More Faying Surfaces. The Filler Material Fills the Closely Fitting Space and Wets the Surfaces, Often Aided by Fluxes. The Resulting Physical Bonds Causes the Joining of the Two Surfaces

• ParametersParameters– Brazing Material– Brazing Method


BRAZINGBRAZING• Brazing MethodsBrazing Methods

– Torch (Oxy-Fuel)• Uses Outer Flame to Retard Oxidation

– Furnace (Gas or Electric)• Maybe Vacuum or Inert Gas Filled

– Induction• Switching Magnetic Field Alignment

• DefectsDefects– Incomplete Wetting/Filling of Space– Inclusions


SOLDERINGSOLDERING• Basic Process DescriptionBasic Process Description

– Processes in Which Filler Material(s) with Melting Temperatures Less than 840o F are Introduced Between Two or More Faying Surfaces. The Filler Material Fills the Closely Fitting Space and Wets the Surfaces, Often Aided by Fluxes. The Resulting Physical Bonds Causes the Joining of the Two Surfaces

• TypesTypes– Torch - Oven– Wave


SOLDERING/BRAZINGSOLDERING/BRAZING

Kalpakjian, Figure 30.1a, p. 929


SOLDERING JOINTSSOLDERING JOINTS

Groover, Figure 30.7, p. 778


SOLDERING JOINTSSOLDERING JOINTS

Groover, Figure 30.8, p. 778


WAVE SOLDERINGWAVE SOLDERING

Groover, Figure 30.9 p. 780


QUESTIONSQUESTIONSOR OR

CLARIFICATIONCLARIFICATIONS ???S ???

Reminder :Reminder :

industrial processes ii industrial processes ii inden 3313 lecture 7 – welding, welding design,...

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