Post on 05-Jul-2018
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Introduction to Consolidation Processes
• Consolidation Processes consist of – Welding – Brazing – Soldering – Fasteners – Adhesives –
Shrink Fits – Slots and Tabs
Soldering Brazing Welding
Low- High Temperature
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Types of Fusion Welds
• Bead welds : Limitedpenetration so used on thinmaterials , or surfacemodifications
• Groove welds : Used on thickmaterials , requires jointpreparation, used for singleand multiple passes
• Fillet welds : Use for tee, lapand corner joints
• Plug welds : Used apermanent replacement forrivets or bolts
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Weld Procedures
Various weldprocedures used toproduce welded
joints. (CourtesyRepublic SteelCorporation,Youngstown, OH).
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Heat Effects
• In fusion welding , the heat melts some of thebase material, which is then rapidly cooled,creating changes in the granular structure.
• The pool of metal bonding the base material isa blend of each material, and forms a caststructure in the joint zone.
•
Surrounding the pool of metal is the heataffected zone , where metallurgical propertieshave been changed.
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Butt Weld with Backing Plate
Schematic of a butt weld between a plate ofmetal A and a plate of metal B, with abacking plate of metal C and filler of metalD. The resulting weld nugget becomes a
complex alloy of all four metals.
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Heat Affected Zone
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AWS Weldability
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Summary
• Proper weld considerations – Selection of the process and fillers – Design of the Joint – Effects of heating and cooling on weld and parent
materials• Parallel considerations apply to brazing and
soldering
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Oxyacetylene FlameTemperatures
Typicaloxyacetylene flame and the
associated temperaturedistribution.
Preheat the metal and provide
shielding from oxidation
Maximum temperature andfirst stage of combustion iscomplete.
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Oxyfuel-Gas Welding Process
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Oxygen Torch Cutting
• Oxy-fuel gas cutting (flame cutting) – Most common thermal cutting process – Metal is melted by the flame of the oxyfuel gas
torch
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ARC WELDING
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Consumable-electrode ArcWelding
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Schematic of SMAW
Schematic diagram of shielded metal arc welding (SMAW).(Courtesy of American Iron and Steel Institute, Washington, DC.)
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Flux-Cored Arc Welding
• Best used for welding steels• Equipment cost greater than SMAW• Needs good ventilation to remove fumes
generated by the vaporizing flux
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