ATOMIC HYDROGEN WELDING

Atomic hydrogen welding(AHW) is an arc welding process that uses an arc between two metal tungsten electrodes(NON CONSUMABLE) in a shielding atmosphere of hydrogen. Arc is struck between both electrodes, distance between them can be adjustedH2 is reactive in nature compared to argon & helium. It also prevents molten pool from oxidation, breaks the oxides on w/p metal.Filler material is usedAHW comprises of a Welding torch, H2 gas cylinder & single phase ac power source.Voltage : 50- 75 V,, Current : 15-150 amp

Advantages Intense flame is obtained which can be concentrated at the joint. Hence, less distortion. Welding is faster. Work piece do not form a part of the electric circuit. Hence, problems like striking the arc and maintaining the arc column are eliminated. Separate flux / shielding gas is not required. The hydrogen envelop itself prevents oxidation of the metal and the tungsten electrode..

Disadvantages

Cost of welding by this process is slightly higher than with the other process. Welding is limited to flat positions only.

Applications

Atomic hydrogen welding is used in those applications where rapid welding is necessary, as for stainless steels and other special alloys.

ULTRASONIC WELDING

Solid state typeSimilar-dissimilar metals can be welded( mostly over lapped)Faying surfaces are held together under modest clamping force, & subjected to static normal force & vibrating energy of high frequency(10-50k c/s) & low amplitude(0.02-0.15 mm) with the help of tip of a transducerOscillating shear(tangential) stresses cause small scale plastic deformation & breaks surface oxidesThis results in strong solid state weld nuggetNo external heat is applied, no flux/filler metal

The basic process of ultrasonic welding can be described by the following steps:

The parts to be welded are placed in the anvil or fixture.The horn contacts the parts to be welded.Pressure is applied to keep the horn in contact with the welded materials and to hold them together.The horn delivers ultrasonic vibrations to heat up the materials. The vibrations move less than a millimeter either up-and-down or side-to-side.The materials are welded together.The horn gets retracted and the welded materials can be removed from the anvil.

AdvantagesRapid,reliable,versatileHeat affected zone is minimized Very thin materials can be welded Surface deformation is minimumWelding of glass is also possible No defects due to gases, arc and filler metalEquipment is simple and moderate skill is enoughDissimilar materials can be joined

Disadvantages

Restricted to join thin materials (upto 3 mm)Competitively not economical Materials being welded may tend to weld to the tip and anvilLtd to small parts

Applications Manufacturing of toysJoining of electrical and electronic componentsWelding aluminium wire and sheetMobiles,laminations, cars.Packing , medical industries, computers.

PLASMA ARC WELDINGPlasmais a gaseous mixture of positive ions, electrons and neutral gas molecules.

TRANSFERRED ARC TYPE PLASMA TORCHNON-TRANSFERRED ARC TYPE PLASMA TORCH

Same as TIGW : Non consumable Tungsten electrode & shielding gas (Argon)In TIGW, welding torch tip is FlatIn PAW, Torch is constricted/reduced in c/s area, to constrict the arc which produces plasma jet of small dia & very high energy densityArc Initiation is same as in TIG( Moving the torch too close to w/p without touching)Just after the arc initiation, A high velocity stream of plasma gas(ARGON/ ARGON+H2) is introduced in arc region that forms High velocity-intensity hot PLASMAShielding gases are Argon, helium, mixture of both

Two types of PAW : Transferred Arc & Non Transferred ArcTransferred arc processproduces plasma jet of high energy density and may be used for high speed welding and cutting ofCeramics,steels,Aluminum alloys,Copper alloys,Titanium alloys,Nickel alloys.Non-transferred arc processproduces plasma of relatively low energy density. It is used for welding of various metals and forplasma spraying(coating). Since the work piece in non-transferred plasma arc welding is not a part of electric circuit, the plasma arc torch may move from one work piece to other without extinguishing the arc.

The electric arc efficiently breaks up the hydrogen molecules, which later recombine with tremendous release of heat, reaching temperatures from 3400 to 4000 C.

Without the arc, an oxyhydrogen torch can only reach 2800 C.This is the third hottest flame after cynogen at 4525 C and dicynoacetylene at 4987 C.

Ahw process

An acetylene torch merely reaches 3300 C.

This device may be called an atomic hydrogen torch, nascent hydrogen torch or Langmuir torch.

The process was also known as arc-atom welding.

The heat produced by this torch is sufficient to melt and weld tungsten (3422 C), the most refractory metal.

The presence of hydrogen also acts as a gas shield and protects metals from contamination by carbon,nitrogen, or oxygen, which can severely damage the properties of many metals.

It eliminates the need of flux for this purpose.

The arc is maintained independently of the workpiece or parts being welded.

The hydrogen gas is normally diatomic (H2), but where the temperatures are over 600 C (1100 F) near the arc, the hydrogen breaks down into its atomic form, simultaneously absorbing a large amount of heat from the arc.

When the hydrogen strikes a relatively cold surface (i.e., the weld zone), it recombines into its diatomic form and rapidly releases the stored heat.

The energy in AHW can be varied easily by changing the distance between the arc stream and the workpiece surface.

This process is being replaced by shilded metal arc welding, mainly because of the availability of inexpensive inert gases.

In atomic hydrogen welding, filler metal may or may not be used. In this process, the arc is maintained entirely independent of the work or parts being welded. The work is a part of the electrical circuit only to the extent that a portion of the arc comes in contact with the work, at which time a voltage exists between the work and each electrode