Chapter 33: Other Welding Processes, Brazing and Soldering · ME-215 Engineering Materials and...
Transcript of Chapter 33: Other Welding Processes, Brazing and Soldering · ME-215 Engineering Materials and...
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Veljko SamardzicME-215 Engineering Materials and Processes
Chapter 33:
Other Welding Processes,
Brazing and Soldering
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Veljko SamardzicME-215 Engineering Materials and Processes
33.1 Introduction
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Veljko SamardzicME-215 Engineering Materials and Processes
33.2 Other Welding and Cutting
Processes
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Veljko SamardzicME-215 Engineering Materials and Processes
Electroslag Welding
FIGURE 33-1 (a) Arrangement of equipment and workpieces for making a vertical weld by the
electroslag process. (b) Cross section of an electroslag weld, looking through the water-cooled
copper slide.
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Veljko SamardzicME-215 Engineering Materials and Processes
Electron Beam Welding
FIGURE 33-2 Schematic diagram
of the electron-beam welding
process
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Veljko SamardzicME-215 Engineering Materials and Processes
Examples of Electron Beam
Welding
FIGURE 33-3 (Left to
right) Electronbeam
welds in 19-mm-thick
7079 aluminum and 102-
mm-thick stainless
steel. (Courtesy of
Hamilton Standard
Division of United
Technologies
Corporation, Hartford,
CT.)
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Veljko SamardzicME-215 Engineering Materials and Processes
Process Summary of EBW
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Veljko SamardzicME-215 Engineering Materials and Processes
Examples of Laser Welding
FIGURE 33-4 Laser butt weld
of 3-mm (0.125-in.) stainless
steel, made at 1.5 m/min with a
1250-watt laser. (Courtesy of
Coherent, Inc., Santa Clara, CA.)
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Veljko SamardzicME-215 Engineering Materials and Processes
Process Summary of LBW
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Veljko SamardzicME-215 Engineering Materials and Processes
Comparison of Power Densities
FIGURE 33-5 Comparison of the power densities of various welding processes. The high power
densities of the electronbeam and laser-beam welding processes enable the production of deep,
narrow welds with small heat-affected zones. Welds can be made quickly and at high travel speeds.
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Veljko SamardzicME-215 Engineering Materials and Processes
Schematic of Laser Beam Cutting
FIGURE 33-6 Schematic of
laser-beam cutting. The laser
provides the heat, and the flow
of assist gas propels the molten
droplets from the cut.
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Veljko SamardzicME-215 Engineering Materials and Processes
Cutting Surface
FIGURE 33-7 Surface of
6-mm-thick carbon steel cut
with a 1250-watt laser at 1.8
m/min. (Courtesy of Coherent,
Inc., Santa Clara, CA.)
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Veljko SamardzicME-215 Engineering Materials and Processes
Schematic of Flash Welding
FIGURE 33-8 Schematic
diagram of the flash-welding
process. (a) Equipment and
setup; (b) completed weld.
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Veljko SamardzicME-215 Engineering Materials and Processes
33.3 Surface Modification by Welding
Related Processes
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Veljko SamardzicME-215 Engineering Materials and Processes
Schematic of a Metal Spray Gun
FIGURE 33-9 Schematic diagram of an oxyacetylene
metal-spraying gun. (Courtesy of Sulzer Metco,
Winterthur, Switzerland.)
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Veljko SamardzicME-215 Engineering Materials and Processes
Plasma Arc Spray Gun
FIGURE 33-10 Diagram of a
plasma-arc spray gun. (Courtesy
of Sulzer Metco, Winterthur,
Switzerland.)
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Veljko SamardzicME-215 Engineering Materials and Processes
Comparison of Thermal Spray
Deposition
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Veljko SamardzicME-215 Engineering Materials and Processes
33.4 Brazing
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Veljko SamardzicME-215 Engineering Materials and Processes
Joint Strength
FIGURE 33-11 Typical variation of tensile strength with
clearance in a butt-joint braze. (Courtesy of Handy & Harman, Rye, NY.)
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Veljko SamardzicME-215 Engineering Materials and Processes
Joint Clearance in Brazing
FIGURE 33-12 When brazing dissimilar metals, the initial joint clearance should be adjusted for
the different thermal expansions (here brass expands more than steel). Proper brazing
clearances should exist at the temperature where the filler metal flows.
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Veljko SamardzicME-215 Engineering Materials and Processes
Common Joint Design
FIGURE 33-13 The two most common
types of braze joints are butt and lap. Butt
offers uniform thickness across the joint,
whereas lap offers greater bonding area and
higher strength
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Veljko SamardzicME-215 Engineering Materials and Processes
Variations of Butt Joints
FIGURE 33-14 Variations of
the butt and lap configurations
include the butt-lap and scarf.
The four types are shown for
both flat and tubular parts.
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Veljko SamardzicME-215 Engineering Materials and Processes
Common Joint Designs for
Brazing
FIGURE 33-15 Some common
joint designs for assembling
parts by brazing
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Veljko SamardzicME-215 Engineering Materials and Processes
Compatibility of Brazing
Materials
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Veljko SamardzicME-215 Engineering Materials and Processes
Brazing Material Families
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Veljko SamardzicME-215 Engineering Materials and Processes
Furnace Assembly
FIGURE 33-16 Two
views of an array of
furnace-brazed
assemblies.
(www.franklinbrazing.com
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Veljko SamardzicME-215 Engineering Materials and Processes
Schematic of Braze-Welding
Process
FIGURE 33-17 Schematic of the
braze-welding process
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Veljko SamardzicME-215 Engineering Materials and Processes
33.5 Soldering
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Veljko SamardzicME-215 Engineering Materials and Processes
Solder Joints
FIGURE 33-18 Some common
designs for soldered joints.
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Veljko SamardzicME-215 Engineering Materials and Processes
Compatibility of Soldering
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Veljko SamardzicME-215 Engineering Materials and Processes
Common Solder
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Veljko SamardzicME-215 Engineering Materials and Processes
Wave Soldering
FIGURE 33-19 Schematic of wave
soldering