lesson 1 introduction to welding technology - aalto · pdf filelesson 1 introduction to...

1

Lesson 1

Introduction to Welding Technology

February 2015

Department of Engineering

Design and Production

* ContactsAddress: P.O. Box 14200, FI-00076 Aalto, FinlandVisiting address: Puumiehenkuja 3, [email protected] ; Skype: fsweldone

Professor Pedro Vilaça *

Materials Joining and NDT

1Engineering Materials


Department of Engineering Design

and Production

Summary

Definition of welding

Introduction and scope of welding technology

Historical milestones of welding technology and allied techniques

Introduction to fusion welding processes

Introduction to brasing/soldering processes

Introduction to solid state welding processes with focus on friction

based technology and applications

Samples of advanced welding solutions

Joining mechanisms governing welding technology

Fundamental nomenclature

Introduction to weldability concept

Contents

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At the end of the seminar the student should be able to

1. To identify the multiphysical character of welding technology

2. To distinguish between fusion, brasing and solid state welding

3. To identify main historical milestones of welding technology

4. To identify main fusion welding processes

5. To identify main solid state welding processes

6. To classify the main joining mechanisms in welding technology

7. To describe the weldability concept

Learning Outcomes




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Please answer 2 of the following 3:

a) Give 10 samples of welding processes and for each one identify its

nature in terms of i) fusion; ii) solid state or iii) brasing.

b) Establish the main joining mechanisms governing fusion, solid state

and brasing welding technology.

c) Considering the weldability concept which are the main features

characterizing a welding application?

Questions for Lesson 1

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What is…?

(def.) welding - A joining process that produces coalescence

of materials by…

• Applying energy: heating them to the welding temperature,

with/without the application of pressure or by the application

of pressure alone

• With/without the use of filler metal

• With/without the use of shielding gas




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What is…?

Mechanical

Energy

Heat Energy

Liquid joining interface

”Third-body” region

Cold

pressure

Fusion of a nugget in

close die pressured zone

Fusion with no pressure

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What is…?

and

Business

and

Artmeet

Technology

Where

Science

Physical / Chemical

Power Sources

Fluid Mechanics

Thermodynamics

Computational

Modeling

Product Development

Production Management

Quality Systems

Automation

and Robotization

Electrical Equipment

Electronic Control

Material

Science

Manual

Skills

Innovation

Structural

Mechanics

Creativity




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Welding TechnologyThe Scope

Welding is not..

Fundamental

Science

…Welding is not

Practical

Application

Science Application

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Welding TechnologyThe Scope… Among other joining technologies

Welding

Adhesive

TechnologyMechanical

Joints(e.g.: epoxy; polyurethane...) Threaded

Technologies for

Joining of

Materials

Clinching

Riveting




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Introduction to WeldingHybrid Concepts… Are Becoming Frequent Solutions

adhesive

spot welding

nut

adhesive

Stud weld

Threaded

studadhesive

rivet

e.g.: weld bonding

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Introduction to WeldingRelated Technology… Thermal Spraying Techniques

Thermal spraying can provide thick coatings [20m .. to several mm],

over a large area at high deposition rate as compared to other coating processes

such as: electroplating, physical and chemical vapor deposition

(def.) Coating processes in which melted /heated materials are sprayed onto a surface

Plasma spraying (PSP) Arc spraying (ASP) Flame spraying (FLSP)

Patm

Vacuum




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Introduction to WeldingRelated Technology… Cutting Techniques

Mechanical cutting Thermal cutting Water jet cutting

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Introduction to WeldingRelated Technology… NDT Techniques




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Solid State WeldingClassification

Welding Process

Classification

Brazing and Soldering No fusion of base material components which are

joined by inserting melted filler metal in the overlap joint configuration

Fusion Welding Includes partial fusion of Base Material,

with /without application of pressure, with/without filler metal added to weld pool

Solid State Welding Joining is obtained by solid state joining mechanisms In some processes, superficial melting layer is

produced to then be expelled during forging Flash around weld zone is usual

Note: There are (many) others possible classifications

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Forg

ing

Solid State Welding…Prior to all Fusion Welding Techniques




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Forg

ing

Solid State WeldingFrom the Origins into the Most Developed Modern Solutions

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Fusion Welding

Electric Arc Based Welding

Overview of Techniques




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Forg

ing

Electric Arc

SMAW

SAW

GTAW

PlasmaPAW

GMAW

EBW Laser

Coal electrode 1881

1904

1930

1940

1950

1950

19701958

FCAW

Sinergic

CMT

Electro-gas

Electro-slag …Thermite

CO2

Nd-YAG

Diodes

Fiber

Excimers

…

Vacuum

Patm

Disc

Micro

Conventional

Keyhole

Oxifuel

1920

1903

Bare electrode 1888 1970

1959

19611980

1990

Welding

Thermal Treat.

Brasing

Fusion Welding TechnologyHistorical Development

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Milestones of Electric Arc Welding (1/4)Shielded Metal Arc Welding




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Milestones of Electric Arc Welding (2/4)Submerged Arc Welding

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Milestones of Electric Arc Welding (3/4)Gas Tungsten Arc Welding




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Milestones of Electric Arc Welding (4/4)Gas Metal Arc Welding

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Variants of GMAWFlux Cored Arc Welding




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Fusion Welding

Laser Welding

Overview of Fundaments

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Light

Amplificatio

n

Stimulated

Emission

Radiation

Characteristics of a Laser Beam




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Wavelength of main active laser media

Ultraviolet

(0.1m – 0.4m)

Visible

(0.4m – 0.7m)

Infrared

(0.7m – 100m)

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Robotic Style Beam Delivery




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Continuous Wave Laser Welding Applications

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Fusion Welding

Electron Beam Welding

Overview of Fundaments




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Simplified Representation of a Triode

Electron Beam Gun Column

Generation

Acceleration

Focusing

Guidance

Working zone

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• Equipment: Level of Vacuum in Gun and Working Cameras

Variants:

High-Vacuum: 10-3

to 10-6

Torr

Fine-Vacuum: 25 to 10-3

Torr

Non-vacuum (1 atm 760 Torr)

High-vacuum chamber equipment for EBW




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• Equipment: Influence of Level of Vacuum in EBW quality.

High-Vacuum

Fine-Vacuum

Non-vacuum

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Fusion with Pressure Welding

Resistance Welding

Overview of Variants




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Fusion Welding ProcessesFusion but not only… Resistance Welding Variants

F

I

Spot Welding Projection Welding Seam Welding

Flash Welding

SResistência_Faiscamento/ResistanceWeld_Spot_Detail.avi

SResistência_Faiscamento/ResistanceWeld_Spot_Detail.avi

SResistência_Faiscamento/OTHER4_ResistanceWeld_Roletes.MPG

SResistência_Faiscamento/OTHER4_ResistanceWeld_Roletes.MPG

SResistência_Faiscamento/OTHER5_FaiscamentoWeld.MPG

SResistência_Faiscamento/OTHER5_FaiscamentoWeld.MPG

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Fusion Welding ProcessesFusion but not only… Resistance Welding Variants

Spot Welding




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Brasing and Soldering

Interfacial Joining of Solid

Base Materials by

Third-body Fusion Filler Material

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Classification of WeldingBrazing and Soldering




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Brazing and SolderingFundaments and Application Samples

Joining Mechanisms: Interfacial Diffusion (chemical) and/or Embedding (mechanical)

Physical Principles: capillary (wetting and spreading) + fluidity + viscosity +

vapor pressure + gravity + metallurgical interaction between Base Mat and Filler Mat

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Solid State Welding

and Processing Technology

Solid State Welding

Overview of Main Processes




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Overview of Solid State ProcessesHigh-Frequency Welding (1/2)

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Overview of Solid State ProcessesFlash Welding (1/1)




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Overview of Solid State ProcessesStud Welding (1/1)

Filmes/4_StudWeldingRobotizado.avi

Filmes/4_StudWeldingRobotizado.avi

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Overview of Solid State ProcessesCold Pressure Welding (1/2)




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Overview of Solid State ProcessesDiffusion Welding (2/2)

Filmes/4_zAcoustic bonding&Cold pressure.mpg

Filmes/4_zAcoustic bonding&Cold pressure.mpg

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Overview of Solid State ProcessesUltrasonic Welding (1/4)

Application to plastics




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Interfaces in Ultrasonic Welding

Overview of Solid State ProcessesUltrasonic Welding (2/4)

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Overview of Solid State ProcessesExplosion Welding (1/3)




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Solid State Welding


Friction Based Technology

“Third-Body” Region

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“Third-Body” Region

Based Technology




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Friction Based TechnologySample of Processes

Friction Welding

Internacional Patent

2/1956 (A.I.Chudikov)

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Overview of Solid State ProcessesFriction Welding (13/13)

Application samples: Automotive industry




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Friction Based TechnologySample of Processes

Friction Linear Welding

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Friction Stir Based TechnologyFriction Surfacing: Applications

Production of

Functionally Graded Materials (FGM)

FS for Built-Up




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Solid State Welding


Friction Stir Welding

Fundaments

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Overview of FSW FeaturesFundaments and Parameters

A breakthrough innovation in welding technology patented in Dec 1991

Courtesy of RIFTEC - Germany




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Friction Stir Welding ProcessFundaments – Example of Joints

SPIF of tailored blanks welded by FSW

Movies/FSW_IST_AA6082t5.wmv

Movies/FSW_IST_AA6082t5.wmv

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Materials Joining and NDTFSW @ Aalto University

ESAB LEGIOTM

FSW 5UT

Z-axis Control: Position + Speed + Force

Maximum Forces: Fz_max = 100kN (Fx_max = Fy_max = 40kN)

Maximum Welding Travel Speed: Vx_max = Vy_max = 4m/min

Maximum Spindle Power = 30kW ; Maximum Spindle Speed: max = 3000rpm

Work Envelope (x ; y ; z) : 2000mm x 400mm x 300mm

Special focus on the application to: Al, Cu, HSSteels, SSteels, and Ni based alloys




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Industrial Application of FSWAerospace Industry – Boeing Co.

New FSW for Space Launch System:

Vertical Assembly Center (VAC)

(NASA’s Michoud Assembly Facility New Orleans)

61 m Tall x 8.4 m Diameter cryogenic liquid hydrogen and liquid oxygen that will feed the vehicle’s RS-25 engine

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Industrial Application of FSWShipbuilding Industry – Steel (source: HILDA project)

FSW… Aims to avoid This!

Courtesy / Source: TWI




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Industrial Application of FSWApple iMAC 2012

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A-Tig Welding

Micro-Plasma Welding

Hot-Wire Welding and Coating

Narrow Gap Welding (w/ TIG hot wire; MIG; SAW)

Advanced SAW: ICE Variant

Advanced GMAW: Synergic Control + CMT + 3D Printing

Hybrid Laser Welding with GMAW

Friction Stir Based Innovations: FSChannelling + FSpot Welding

Friction Welding (conventional axisymmetric)

Friction Based Techniques: FHydro Pillar + FRiveting

Friction Surfacing

Other Advanced Welding Techniques




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Advanced TIG Technique

A-TIG

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Advanced PAW Technique

Micro-Plasma (0.1 to 15 A)




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Advanced GMAW Technique

Robotized Welding + 3D Printing

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Advanced Welding Technique

Hybrid Laser Welding w/ GMAW




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Epitaxial Solidification by

Nucleation and grain growth

• Oriented (e.g. epitaxial) grain growth

• Segregation of elements into last

zone solidifying (middle of fusion

zone), that may promote nucleation

effect

• Space between dendrites

• Cooling rate (e.g. welding

parameters)

• Shape factor (penetration/width)

Joining Mechanism…in Fusion Welding

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E.g.:

SMAW;

SAW;

TIG;

MIG

E.g.:

Plasma Welding;

Electron Beam

Welding;

Laser Welding

keyhole Weld versus Conduction Weld

Fusion Zone Heat Affected Zone

Shape and Sub-Zones…in Fusion Welding




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Autogeneous – No filler material

Homogeneous – Filler metal similar to base material

Heterogeneous – Filler metal dissimilar to base material

Dilution – (Def.) Contribution of Base Material

into weld metal (e.g. Base Materials + Filler

Metal):

TD=0% - Brasing and soldering

TD=100% - Autogeneous

Formulation of Dilution Rate

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Joining Mechanisms…Activated During Solid State Welding

Aproximation to Interatomic

Distances of Equilibrium

Diffusion

Clinching

Atomic bonding at joining

materials interfaces

Bonding over an interferential layer

which can reach up to

continuous metallic conditions

Mechanical interference




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NomenclatureStandards Supporting Vocabulary (EN ISO 17659)

EN ISO 17659:2002 – Welding - Multilingual terms for welded joints

with illustrations

This International Standard describes by pictorial representation

most of the more common terms, in English, French and German, for

types of joints, joint preparation and welds.

This International Standard can be used on its own or in conjunction

with other similar standards. E.g.: AWS A3.0:2001 - Standard

Welding Terms and Definitions - Including Terms for Adhesive

Bonding, Brazing, Soldering, Thermal Cutting, and Thermal

Spraying

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NomenclatureParts of a Fusion Weld




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NomenclatureParts of a Fusion Weld

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NomenclatureSizes in Welds




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NomenclatureSizes in Fillet Welds

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Nomenclature Joints Types




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Nomenclature Flanged Joints

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NomenclatureSpliced Butt Joints




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Nomenclature Joint Root

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Nomenclature Groove Face; Root Edge; Root Face




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Nomenclature Bevel: Depth, Angle, Face and Radius; Root Opening

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Nomenclature Edge Shape




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Nomenclature Single Groove Welds

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Nomenclature Welds Joints with Backing… alternative solutions




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Nomenclature Double Groove Welds

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Nomenclature Welds in Flanged Joints




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Nomenclature Seam Welds and Spot Welds

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Nomenclature Other types of Welds




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Weldability ConceptTowards the Correct Welding Technological Solution

Fulfillment of product properties and client demands

Solution: Welding Process

Assure Metallic Continuity

Certain Application(e.g. mechanical and corrosion properties)

Materials (composition + thermal treat.)

Geometric features (thickness, global dimensions, accessibility, mobility, …)

Place (indoor/outdoor)

Series to produce (productivity)

Certain Level Quality level demanded by application

Lim

its

Ap

plic

atio

n

Ap

plic

atio

n D

eter

min

es W

eld

ing

Pro

cess

Certain PrecautionsWelding specification proceduresWelders approval + Security

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Weldability ConceptJoint Design to Avoid Incomplete Penetration

Incomplete Penetration does not Assure Metallic Continuity




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Weldability ConceptComplete Penetration

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Weldability ConceptTowards the Correct Welding Technological Solution

Design of joints and their influence on the overall quality of

the welded structure

Type of joints

Type of edge shape for each component

Tolerances

Design of joints criterion, depends on:

Welding process

Material

Thickness of components

Joint accessibility

Assure Metallic Continuity

e.g.: Stress Flow in

complete penetration butt joint




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Literature supporting the achievement of the learning outcomes

1. J. F. Lancaster (1986) The Physics of Welding”, 2nd ed., Pergamon Press.

2. Robert W. Messler (2004) Principles of Welding – Processes Physics,

Chemistry, and Metallurgy, Jr. Wiley-VCH ed.

Chapter 1: Introduction to the Process of Welding (pages 1–16)

Chapter 5: Energy for Welding

Closing Thoughts

Other references

ASM Metals Handbook – Vol. 6 – Welding Brazing and Soldering. 1993. ASM

International.

AWS Welding Handbook – Vol. 1 to 4 –9th ed. American Welding Society.

References

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