Download - 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

Transcript
Page 1: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

1

2008 Design amp ManufacturingII

Spring 2004

Welding amp Joining

2008-spring-2004SKim

2

Today

Ask ldquoDave and Patrdquo1048708 Joining amp Welding1048708 PP 771-861 Kalpakjian1048708 Quiz 1 on March 17th 1230 PM1048708 Closed book calculator1048708 Lecture notes HWs1048708 QampA session March 15th Monday 5-6PM 1048708 HW 4 due next Monday

2008-spring-2004 SKim

3

Joining

1048708 Cost1048708 Cheap but expensive labor

1048708 Quality1048708 Wide range

1048708 Flexibility1048708 Manual vs automated

1048708 Rate1048708 Slow in genera

Very Large Crude Carrier (VLCC)

2008-spring-2004 SKim

4

Joining processes

engine fasteners door

Mechanical nutsbolts

rivets c-clips pressure fits

Solid-liquid Adhesives

Soldering Brazing

Solid Friction Diffusion Explosion Ultrasound

Liquid

Chemical Oxyfuel Thermit

ECUS emission controller windshield plastic fans

Body muffler

Resistance Spot Seam Flash

door hingesConsumable electrode Shielded metal arc Submerged arc Gas metal arc

nonConsumable electrodeGas Tungsten Plasma Arc Electron Beam Laser welding

Arc Welding

2008-spring-2004 SKim

5

Mechanical Fastening

1048708 Any shape and material almost1048708 Disassemblable (except Rivets etc)1048708 Least expensive for low volume (standardized)1048708 Problems strength seal insertion loosening

Threaded Bolted Rivets Snap fit

Figures B Benhabib2008-spring-2004 SKim

6

Rivets

1048708 Cheap light weight donrsquot get loose1048708 Permanent less strong than bolts1048708 Rule of thumb1048708 Minimum spacing = 3 x d1048708 Maximum spacing = 16 x thickness of the outer plate

Rivets

2008-spring-2004 SKim

7

Mechanical fastening

1048708 Crimping1048708 Embossed protrusions1048708 Plastic deformation interference1048708 Appliance1048708 Automotive

Lego assembly elastic averaging

M Culpepper MIT2008-spring-2004 SKim

8

Mechanical Joining

1048708 Hemming seaming1048708 Bend edge of one component over another1048708 Automobile door stampings and trunk lids

2008-spring-2004 SKim

9

Adhesive Bonding

1048708 Quick and non-invasive1048708 Most materials with high surface to volume ratio1048708 Insulation (thermal electrical) conducting adhesives available1048708 Good damping1048708 Clean surface preparation1048708 Long curing hold time low service T1048708 Reliability quality1048708 Disassembly

2008-spring-2004 SKim

10

Stefan Equation

1048708 Squeeze a drop of liquid

1048708 hf goes down and

1048708 Viscosity goes up (curing)

1048708 Ft goes up (to separate)

When pullin apart

2008-spring-2004 SKim

11

DFA for bonding

1048708 Weak to tensile loading strong to shear and compressive1048708 Organic1048708 Epoxy acrylic etc1048708 Inorganic1048708 solder cement etc

2008-spring-2004 SKim

12

Solid-Liquid Brazing and Soldering

1048708 In brazing the filler material (silver brass bronze) has a melting point above 425 ordmC and in soldering the filler material (lead tin) has a melting point well below 425 ordmC1048708 Capillary forces for the wetting and flow of the liquid metal into the gaps1048708 Proper fluxes for lowering surface tension remove oxides and prevent oxidation

2008-spring-2004 SKim B Benhabib

13

Wave soldering

1048708 Exposed metal joints are passed over a wave in a continuous motion where liquid solder penetrates into the joint by capillary forces

2008-spring-2004 SKim B Benhabib

Enlarged area

Circuitboard

Solderfountain

Moltensolder

Heater Pump

Enlarged area

14

Welding

1048708 Solid-state welding

10487081048708 No liquid electrical chemical mechanical

1048708 Resistance diffusion ultrasonic

10487081048708 Fusion welding

10487081048708 Chemical Oxyfuel

10487081048708 Electrical Arc welding

1048708 1048708 Consumable electrode

10487081048708 Non-consumable electrode

2008-spring-2004 SKim

15

Fusion Welding

1048708 Heat source chemical electrical1048708 Heat intensity1048708 Control1048708 Incomplete fusion penetration1048708 Underfilling undercutting cracks1048708 Heat affected zone (HAZ)1048708 Feed rate

2008-spring-2004 SKim

16

Underfill and undercut

2008-spring-2004 SKim

underfill

undercut

Good weld

17

Heat Intensity

1048708 A measure of radiation intensity Wcm2

1048708 High intensity high heat flux the faster the melting1048708 Automation needed to prevent overmelting vaporizing1048708 For a planar heat source on steel tm= (5000HI)2

Oxy 20-30 sec E-beam μ sec

2008-spring-2004 SKim

AirFuelGas Flame

OxyacetyleneThermit

Friction

ArcWelding

Resistance Welding(Oxygen Cutting)

Electron BeamLaser Beam

18

Laser for Razor

- 500 μm spots- 3 million spots per hour

How fast the welding speed is required

Kalpakjian2008-spring-2004 SKim

19

Melting front speed2D simplification

The Jacob number

The thermal diffusivity is given by

The melt front moves as

2008-spring-2004 SKim

20

Welding speed

1048708 tm = (sm)2 (2 α Ja)1048708 Any longer over-melt

1048708 If the weld pool size is d in diameter then you must feed at a rate that exceeds dtmax1048708 HI increases welding speed must go up1048708 α Ja increases interaction time must go up

Weld pool size d

2008-spring-2004 SKim

21

Weld Pool ndash Heat SourceInteraction Time

2008-spring-2004 SKim J Chun

22

HAZ(Heat Affected Zone)

1048708 Bad microstructure course grains weak to corrosion1048708 Plastic vs Metal

Temp

Base metal

HAZ

Weld metalMolten metal

Melting point

Microstructure change temperature

Base metal temperature

2008-spring-2004 SKim

23

Heat Affected Zone

1048708 Region near the weld pool is affected by heat Microstructure changes1048708 s ~ (α t)05

1048708 The size of the heat affected zone is controlled by the thermal diffusivity α Al Cu1048708 HI time (speed)1048708 Metal vs Plastic

2008-spring-2004 SKim

24

Heat Affected Zone (HAZ)

2008-spring-2004 SKim

Grain structureWeld lineIntergranular corrosionrecrystallization

25

Oxyfuel Gas Welding

1048708 Low cost manual1048708 Oxyfuel Oxygen + Fuel (Acetylene methyacetylene- propedieneetc) can reach 3300oC1048708 Stoichiometry neutral flame

1048708 More oxygen will cause oxidization (Oxidizing flame) bad for steels OK for copper1048708 More fuel will cause carburization (carburizing flame) Low heat for brazing soldering flame hardening

2008-spring-2004 SKim

26

Arc fusion welding

1048708 Temperature up to 30000oC1048708 Heat travels with the electrons1048708 Straight polarity workpiece + electrode ndash1048708 Shallow penetration sheet metal wide gaps1048708 reverse polarity1048708 Deeper penetration

Arrangement forconsumable electrodes

Heat generated at anode isabout 15 of the heatgenerated at cathode

Eelectron at cathode is given bythree components

Kinetic energyDrop across cool gas boundary

Work function(heat of condensation)

2008-spring-2004 SKim

27

Consumable electrode processes

1048708 Shielded metal arc welding1048708 Cheapest and most basic process lt $15001048708 50A-300A lt10KW1048708 Workpiece thickness 3-20mm

2008-spring-2004 SKim

SlagCoating deoxidizes weld and provides shielding gas

Multiple passSlag removal

28

Fusion Arc Welding

1048708 Preventing oxidation is the most important problem1048708 Coated electrodes to provide shielding gas1048708 Coatings fluorides silicate binders(clay) cellulose carbonates1048708 Electrodes different materials such as mild steel1048708 Submerged arc welding covered by granular flux1048708 Flat surfaces high throughput good quality1048708 Inert gas from external source1048708 Gas metal arc welding (MIG)1048708 Flux-cored arc welding etc (very versatile with proper fluxes)

2008-spring-2004 SKim

29

Gas Metal Arc Welding

Metal transfer- Spray transfer- Globular transfer- Short circuiting

Gas metal arc welding is aspecial variation on arc weldingin which the electrode fillermetal is fed directly through thetorch tip As arcing occurs theelectrode instantly meltsforming molten droplets that fallinto the weld pool Shielding gasis supplied through the torch tipto prevent chemical interactionswith the surroundingatmosphere

2008-spring-2004 SKim

30

Non-consumable electrode weldingGas Tungsten Arc Welding

1048708 Gas tungsten arc welding formerly known as TIG welding10487081048708 Tungsten electrode + filler wire10487081048708 Good for thin materials better control Al MgTi etc10487081048708 High quality and finish10487081048708 Tungsten electrode contamination10487081048708 200A DC-500A AC 8kW-50kW

2008-spring-2004 SKim

31

Other non-consumable electrodeprocesses

1048708 Plasma arc welding1048708 very higher energy concentration (33000oC) high feed rate 120-1000 mmmin arc stablility less thermal distortion deep penetration (keyhole technology)1048708 Laser beam welding electron beam welding etc

2008-spring-2004 SKim

32

Resistance Welding

1048708 Spot seam projection welding1048708 High current through the weld 3000A-100000A (05 ndash 10 V)

1048708 Extremely high heat flux (105 Wcm2)1048708 Heat generated H=i2Rt K (K=efficiency)1048708 Ex 5000 A 5 mm dia elctrodes two 1mm thick steel plates1048708 Effective resistance 200 Ω Then H= 500 J1048708 Nugget volume 30 mm3 mass 024 g 1400 Jg needed to melt1048708 336 J for melting lt 500 J

2008-spring-2004 SKim

33

Resistance welding

1048708 Spot welding Sequence1048708 Pressure on1048708 Current on1048708 Current off1048708 Pressure off1048708 Projection welding

2008-spring-2004 SKim

34

Solid-state interatomic bonding

1048708 Ultrasonic1048708 Oscillating tangential shear + static normal forces1048708 10KHz to 75 KHz1048708 Shear rarr plastic deformationrarr breaking up top layer (contaminated) rarr inter-atomic bond1048708 Friction1048708 Rotational part (at least one) flash1048708 Diffusion1048708 Goldsmiths bonded gold over copper1048708 Diffusion T gt 05 Tm1048708 Interface is the same as the bulk1048708 Fuselage frames

2008-spring-2004 SKim

35

Weld quality and defects

1048708 Porosity 1048708 Trapped gases contaminants 1048708 Preheat or increase rate of heat input1048708 Reduce speed allowing gas to escape cleaning1048708 Slag inclusions1048708 Oxides fluxes electrode coating trapped in weld zone1048708 Clean weld bead during multi-weld processes1048708 Provide enough shielding gas

2008-spring-2004 SKim

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
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  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 2: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

2

Today

Ask ldquoDave and Patrdquo1048708 Joining amp Welding1048708 PP 771-861 Kalpakjian1048708 Quiz 1 on March 17th 1230 PM1048708 Closed book calculator1048708 Lecture notes HWs1048708 QampA session March 15th Monday 5-6PM 1048708 HW 4 due next Monday

2008-spring-2004 SKim

3

Joining

1048708 Cost1048708 Cheap but expensive labor

1048708 Quality1048708 Wide range

1048708 Flexibility1048708 Manual vs automated

1048708 Rate1048708 Slow in genera

Very Large Crude Carrier (VLCC)

2008-spring-2004 SKim

4

Joining processes

engine fasteners door

Mechanical nutsbolts

rivets c-clips pressure fits

Solid-liquid Adhesives

Soldering Brazing

Solid Friction Diffusion Explosion Ultrasound

Liquid

Chemical Oxyfuel Thermit

ECUS emission controller windshield plastic fans

Body muffler

Resistance Spot Seam Flash

door hingesConsumable electrode Shielded metal arc Submerged arc Gas metal arc

nonConsumable electrodeGas Tungsten Plasma Arc Electron Beam Laser welding

Arc Welding

2008-spring-2004 SKim

5

Mechanical Fastening

1048708 Any shape and material almost1048708 Disassemblable (except Rivets etc)1048708 Least expensive for low volume (standardized)1048708 Problems strength seal insertion loosening

Threaded Bolted Rivets Snap fit

Figures B Benhabib2008-spring-2004 SKim

6

Rivets

1048708 Cheap light weight donrsquot get loose1048708 Permanent less strong than bolts1048708 Rule of thumb1048708 Minimum spacing = 3 x d1048708 Maximum spacing = 16 x thickness of the outer plate

Rivets

2008-spring-2004 SKim

7

Mechanical fastening

1048708 Crimping1048708 Embossed protrusions1048708 Plastic deformation interference1048708 Appliance1048708 Automotive

Lego assembly elastic averaging

M Culpepper MIT2008-spring-2004 SKim

8

Mechanical Joining

1048708 Hemming seaming1048708 Bend edge of one component over another1048708 Automobile door stampings and trunk lids

2008-spring-2004 SKim

9

Adhesive Bonding

1048708 Quick and non-invasive1048708 Most materials with high surface to volume ratio1048708 Insulation (thermal electrical) conducting adhesives available1048708 Good damping1048708 Clean surface preparation1048708 Long curing hold time low service T1048708 Reliability quality1048708 Disassembly

2008-spring-2004 SKim

10

Stefan Equation

1048708 Squeeze a drop of liquid

1048708 hf goes down and

1048708 Viscosity goes up (curing)

1048708 Ft goes up (to separate)

When pullin apart

2008-spring-2004 SKim

11

DFA for bonding

1048708 Weak to tensile loading strong to shear and compressive1048708 Organic1048708 Epoxy acrylic etc1048708 Inorganic1048708 solder cement etc

2008-spring-2004 SKim

12

Solid-Liquid Brazing and Soldering

1048708 In brazing the filler material (silver brass bronze) has a melting point above 425 ordmC and in soldering the filler material (lead tin) has a melting point well below 425 ordmC1048708 Capillary forces for the wetting and flow of the liquid metal into the gaps1048708 Proper fluxes for lowering surface tension remove oxides and prevent oxidation

2008-spring-2004 SKim B Benhabib

13

Wave soldering

1048708 Exposed metal joints are passed over a wave in a continuous motion where liquid solder penetrates into the joint by capillary forces

2008-spring-2004 SKim B Benhabib

Enlarged area

Circuitboard

Solderfountain

Moltensolder

Heater Pump

Enlarged area

14

Welding

1048708 Solid-state welding

10487081048708 No liquid electrical chemical mechanical

1048708 Resistance diffusion ultrasonic

10487081048708 Fusion welding

10487081048708 Chemical Oxyfuel

10487081048708 Electrical Arc welding

1048708 1048708 Consumable electrode

10487081048708 Non-consumable electrode

2008-spring-2004 SKim

15

Fusion Welding

1048708 Heat source chemical electrical1048708 Heat intensity1048708 Control1048708 Incomplete fusion penetration1048708 Underfilling undercutting cracks1048708 Heat affected zone (HAZ)1048708 Feed rate

2008-spring-2004 SKim

16

Underfill and undercut

2008-spring-2004 SKim

underfill

undercut

Good weld

17

Heat Intensity

1048708 A measure of radiation intensity Wcm2

1048708 High intensity high heat flux the faster the melting1048708 Automation needed to prevent overmelting vaporizing1048708 For a planar heat source on steel tm= (5000HI)2

Oxy 20-30 sec E-beam μ sec

2008-spring-2004 SKim

AirFuelGas Flame

OxyacetyleneThermit

Friction

ArcWelding

Resistance Welding(Oxygen Cutting)

Electron BeamLaser Beam

18

Laser for Razor

- 500 μm spots- 3 million spots per hour

How fast the welding speed is required

Kalpakjian2008-spring-2004 SKim

19

Melting front speed2D simplification

The Jacob number

The thermal diffusivity is given by

The melt front moves as

2008-spring-2004 SKim

20

Welding speed

1048708 tm = (sm)2 (2 α Ja)1048708 Any longer over-melt

1048708 If the weld pool size is d in diameter then you must feed at a rate that exceeds dtmax1048708 HI increases welding speed must go up1048708 α Ja increases interaction time must go up

Weld pool size d

2008-spring-2004 SKim

21

Weld Pool ndash Heat SourceInteraction Time

2008-spring-2004 SKim J Chun

22

HAZ(Heat Affected Zone)

1048708 Bad microstructure course grains weak to corrosion1048708 Plastic vs Metal

Temp

Base metal

HAZ

Weld metalMolten metal

Melting point

Microstructure change temperature

Base metal temperature

2008-spring-2004 SKim

23

Heat Affected Zone

1048708 Region near the weld pool is affected by heat Microstructure changes1048708 s ~ (α t)05

1048708 The size of the heat affected zone is controlled by the thermal diffusivity α Al Cu1048708 HI time (speed)1048708 Metal vs Plastic

2008-spring-2004 SKim

24

Heat Affected Zone (HAZ)

2008-spring-2004 SKim

Grain structureWeld lineIntergranular corrosionrecrystallization

25

Oxyfuel Gas Welding

1048708 Low cost manual1048708 Oxyfuel Oxygen + Fuel (Acetylene methyacetylene- propedieneetc) can reach 3300oC1048708 Stoichiometry neutral flame

1048708 More oxygen will cause oxidization (Oxidizing flame) bad for steels OK for copper1048708 More fuel will cause carburization (carburizing flame) Low heat for brazing soldering flame hardening

2008-spring-2004 SKim

26

Arc fusion welding

1048708 Temperature up to 30000oC1048708 Heat travels with the electrons1048708 Straight polarity workpiece + electrode ndash1048708 Shallow penetration sheet metal wide gaps1048708 reverse polarity1048708 Deeper penetration

Arrangement forconsumable electrodes

Heat generated at anode isabout 15 of the heatgenerated at cathode

Eelectron at cathode is given bythree components

Kinetic energyDrop across cool gas boundary

Work function(heat of condensation)

2008-spring-2004 SKim

27

Consumable electrode processes

1048708 Shielded metal arc welding1048708 Cheapest and most basic process lt $15001048708 50A-300A lt10KW1048708 Workpiece thickness 3-20mm

2008-spring-2004 SKim

SlagCoating deoxidizes weld and provides shielding gas

Multiple passSlag removal

28

Fusion Arc Welding

1048708 Preventing oxidation is the most important problem1048708 Coated electrodes to provide shielding gas1048708 Coatings fluorides silicate binders(clay) cellulose carbonates1048708 Electrodes different materials such as mild steel1048708 Submerged arc welding covered by granular flux1048708 Flat surfaces high throughput good quality1048708 Inert gas from external source1048708 Gas metal arc welding (MIG)1048708 Flux-cored arc welding etc (very versatile with proper fluxes)

2008-spring-2004 SKim

29

Gas Metal Arc Welding

Metal transfer- Spray transfer- Globular transfer- Short circuiting

Gas metal arc welding is aspecial variation on arc weldingin which the electrode fillermetal is fed directly through thetorch tip As arcing occurs theelectrode instantly meltsforming molten droplets that fallinto the weld pool Shielding gasis supplied through the torch tipto prevent chemical interactionswith the surroundingatmosphere

2008-spring-2004 SKim

30

Non-consumable electrode weldingGas Tungsten Arc Welding

1048708 Gas tungsten arc welding formerly known as TIG welding10487081048708 Tungsten electrode + filler wire10487081048708 Good for thin materials better control Al MgTi etc10487081048708 High quality and finish10487081048708 Tungsten electrode contamination10487081048708 200A DC-500A AC 8kW-50kW

2008-spring-2004 SKim

31

Other non-consumable electrodeprocesses

1048708 Plasma arc welding1048708 very higher energy concentration (33000oC) high feed rate 120-1000 mmmin arc stablility less thermal distortion deep penetration (keyhole technology)1048708 Laser beam welding electron beam welding etc

2008-spring-2004 SKim

32

Resistance Welding

1048708 Spot seam projection welding1048708 High current through the weld 3000A-100000A (05 ndash 10 V)

1048708 Extremely high heat flux (105 Wcm2)1048708 Heat generated H=i2Rt K (K=efficiency)1048708 Ex 5000 A 5 mm dia elctrodes two 1mm thick steel plates1048708 Effective resistance 200 Ω Then H= 500 J1048708 Nugget volume 30 mm3 mass 024 g 1400 Jg needed to melt1048708 336 J for melting lt 500 J

2008-spring-2004 SKim

33

Resistance welding

1048708 Spot welding Sequence1048708 Pressure on1048708 Current on1048708 Current off1048708 Pressure off1048708 Projection welding

2008-spring-2004 SKim

34

Solid-state interatomic bonding

1048708 Ultrasonic1048708 Oscillating tangential shear + static normal forces1048708 10KHz to 75 KHz1048708 Shear rarr plastic deformationrarr breaking up top layer (contaminated) rarr inter-atomic bond1048708 Friction1048708 Rotational part (at least one) flash1048708 Diffusion1048708 Goldsmiths bonded gold over copper1048708 Diffusion T gt 05 Tm1048708 Interface is the same as the bulk1048708 Fuselage frames

2008-spring-2004 SKim

35

Weld quality and defects

1048708 Porosity 1048708 Trapped gases contaminants 1048708 Preheat or increase rate of heat input1048708 Reduce speed allowing gas to escape cleaning1048708 Slag inclusions1048708 Oxides fluxes electrode coating trapped in weld zone1048708 Clean weld bead during multi-weld processes1048708 Provide enough shielding gas

2008-spring-2004 SKim

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
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  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 3: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

3

Joining

1048708 Cost1048708 Cheap but expensive labor

1048708 Quality1048708 Wide range

1048708 Flexibility1048708 Manual vs automated

1048708 Rate1048708 Slow in genera

Very Large Crude Carrier (VLCC)

2008-spring-2004 SKim

4

Joining processes

engine fasteners door

Mechanical nutsbolts

rivets c-clips pressure fits

Solid-liquid Adhesives

Soldering Brazing

Solid Friction Diffusion Explosion Ultrasound

Liquid

Chemical Oxyfuel Thermit

ECUS emission controller windshield plastic fans

Body muffler

Resistance Spot Seam Flash

door hingesConsumable electrode Shielded metal arc Submerged arc Gas metal arc

nonConsumable electrodeGas Tungsten Plasma Arc Electron Beam Laser welding

Arc Welding

2008-spring-2004 SKim

5

Mechanical Fastening

1048708 Any shape and material almost1048708 Disassemblable (except Rivets etc)1048708 Least expensive for low volume (standardized)1048708 Problems strength seal insertion loosening

Threaded Bolted Rivets Snap fit

Figures B Benhabib2008-spring-2004 SKim

6

Rivets

1048708 Cheap light weight donrsquot get loose1048708 Permanent less strong than bolts1048708 Rule of thumb1048708 Minimum spacing = 3 x d1048708 Maximum spacing = 16 x thickness of the outer plate

Rivets

2008-spring-2004 SKim

7

Mechanical fastening

1048708 Crimping1048708 Embossed protrusions1048708 Plastic deformation interference1048708 Appliance1048708 Automotive

Lego assembly elastic averaging

M Culpepper MIT2008-spring-2004 SKim

8

Mechanical Joining

1048708 Hemming seaming1048708 Bend edge of one component over another1048708 Automobile door stampings and trunk lids

2008-spring-2004 SKim

9

Adhesive Bonding

1048708 Quick and non-invasive1048708 Most materials with high surface to volume ratio1048708 Insulation (thermal electrical) conducting adhesives available1048708 Good damping1048708 Clean surface preparation1048708 Long curing hold time low service T1048708 Reliability quality1048708 Disassembly

2008-spring-2004 SKim

10

Stefan Equation

1048708 Squeeze a drop of liquid

1048708 hf goes down and

1048708 Viscosity goes up (curing)

1048708 Ft goes up (to separate)

When pullin apart

2008-spring-2004 SKim

11

DFA for bonding

1048708 Weak to tensile loading strong to shear and compressive1048708 Organic1048708 Epoxy acrylic etc1048708 Inorganic1048708 solder cement etc

2008-spring-2004 SKim

12

Solid-Liquid Brazing and Soldering

1048708 In brazing the filler material (silver brass bronze) has a melting point above 425 ordmC and in soldering the filler material (lead tin) has a melting point well below 425 ordmC1048708 Capillary forces for the wetting and flow of the liquid metal into the gaps1048708 Proper fluxes for lowering surface tension remove oxides and prevent oxidation

2008-spring-2004 SKim B Benhabib

13

Wave soldering

1048708 Exposed metal joints are passed over a wave in a continuous motion where liquid solder penetrates into the joint by capillary forces

2008-spring-2004 SKim B Benhabib

Enlarged area

Circuitboard

Solderfountain

Moltensolder

Heater Pump

Enlarged area

14

Welding

1048708 Solid-state welding

10487081048708 No liquid electrical chemical mechanical

1048708 Resistance diffusion ultrasonic

10487081048708 Fusion welding

10487081048708 Chemical Oxyfuel

10487081048708 Electrical Arc welding

1048708 1048708 Consumable electrode

10487081048708 Non-consumable electrode

2008-spring-2004 SKim

15

Fusion Welding

1048708 Heat source chemical electrical1048708 Heat intensity1048708 Control1048708 Incomplete fusion penetration1048708 Underfilling undercutting cracks1048708 Heat affected zone (HAZ)1048708 Feed rate

2008-spring-2004 SKim

16

Underfill and undercut

2008-spring-2004 SKim

underfill

undercut

Good weld

17

Heat Intensity

1048708 A measure of radiation intensity Wcm2

1048708 High intensity high heat flux the faster the melting1048708 Automation needed to prevent overmelting vaporizing1048708 For a planar heat source on steel tm= (5000HI)2

Oxy 20-30 sec E-beam μ sec

2008-spring-2004 SKim

AirFuelGas Flame

OxyacetyleneThermit

Friction

ArcWelding

Resistance Welding(Oxygen Cutting)

Electron BeamLaser Beam

18

Laser for Razor

- 500 μm spots- 3 million spots per hour

How fast the welding speed is required

Kalpakjian2008-spring-2004 SKim

19

Melting front speed2D simplification

The Jacob number

The thermal diffusivity is given by

The melt front moves as

2008-spring-2004 SKim

20

Welding speed

1048708 tm = (sm)2 (2 α Ja)1048708 Any longer over-melt

1048708 If the weld pool size is d in diameter then you must feed at a rate that exceeds dtmax1048708 HI increases welding speed must go up1048708 α Ja increases interaction time must go up

Weld pool size d

2008-spring-2004 SKim

21

Weld Pool ndash Heat SourceInteraction Time

2008-spring-2004 SKim J Chun

22

HAZ(Heat Affected Zone)

1048708 Bad microstructure course grains weak to corrosion1048708 Plastic vs Metal

Temp

Base metal

HAZ

Weld metalMolten metal

Melting point

Microstructure change temperature

Base metal temperature

2008-spring-2004 SKim

23

Heat Affected Zone

1048708 Region near the weld pool is affected by heat Microstructure changes1048708 s ~ (α t)05

1048708 The size of the heat affected zone is controlled by the thermal diffusivity α Al Cu1048708 HI time (speed)1048708 Metal vs Plastic

2008-spring-2004 SKim

24

Heat Affected Zone (HAZ)

2008-spring-2004 SKim

Grain structureWeld lineIntergranular corrosionrecrystallization

25

Oxyfuel Gas Welding

1048708 Low cost manual1048708 Oxyfuel Oxygen + Fuel (Acetylene methyacetylene- propedieneetc) can reach 3300oC1048708 Stoichiometry neutral flame

1048708 More oxygen will cause oxidization (Oxidizing flame) bad for steels OK for copper1048708 More fuel will cause carburization (carburizing flame) Low heat for brazing soldering flame hardening

2008-spring-2004 SKim

26

Arc fusion welding

1048708 Temperature up to 30000oC1048708 Heat travels with the electrons1048708 Straight polarity workpiece + electrode ndash1048708 Shallow penetration sheet metal wide gaps1048708 reverse polarity1048708 Deeper penetration

Arrangement forconsumable electrodes

Heat generated at anode isabout 15 of the heatgenerated at cathode

Eelectron at cathode is given bythree components

Kinetic energyDrop across cool gas boundary

Work function(heat of condensation)

2008-spring-2004 SKim

27

Consumable electrode processes

1048708 Shielded metal arc welding1048708 Cheapest and most basic process lt $15001048708 50A-300A lt10KW1048708 Workpiece thickness 3-20mm

2008-spring-2004 SKim

SlagCoating deoxidizes weld and provides shielding gas

Multiple passSlag removal

28

Fusion Arc Welding

1048708 Preventing oxidation is the most important problem1048708 Coated electrodes to provide shielding gas1048708 Coatings fluorides silicate binders(clay) cellulose carbonates1048708 Electrodes different materials such as mild steel1048708 Submerged arc welding covered by granular flux1048708 Flat surfaces high throughput good quality1048708 Inert gas from external source1048708 Gas metal arc welding (MIG)1048708 Flux-cored arc welding etc (very versatile with proper fluxes)

2008-spring-2004 SKim

29

Gas Metal Arc Welding

Metal transfer- Spray transfer- Globular transfer- Short circuiting

Gas metal arc welding is aspecial variation on arc weldingin which the electrode fillermetal is fed directly through thetorch tip As arcing occurs theelectrode instantly meltsforming molten droplets that fallinto the weld pool Shielding gasis supplied through the torch tipto prevent chemical interactionswith the surroundingatmosphere

2008-spring-2004 SKim

30

Non-consumable electrode weldingGas Tungsten Arc Welding

1048708 Gas tungsten arc welding formerly known as TIG welding10487081048708 Tungsten electrode + filler wire10487081048708 Good for thin materials better control Al MgTi etc10487081048708 High quality and finish10487081048708 Tungsten electrode contamination10487081048708 200A DC-500A AC 8kW-50kW

2008-spring-2004 SKim

31

Other non-consumable electrodeprocesses

1048708 Plasma arc welding1048708 very higher energy concentration (33000oC) high feed rate 120-1000 mmmin arc stablility less thermal distortion deep penetration (keyhole technology)1048708 Laser beam welding electron beam welding etc

2008-spring-2004 SKim

32

Resistance Welding

1048708 Spot seam projection welding1048708 High current through the weld 3000A-100000A (05 ndash 10 V)

1048708 Extremely high heat flux (105 Wcm2)1048708 Heat generated H=i2Rt K (K=efficiency)1048708 Ex 5000 A 5 mm dia elctrodes two 1mm thick steel plates1048708 Effective resistance 200 Ω Then H= 500 J1048708 Nugget volume 30 mm3 mass 024 g 1400 Jg needed to melt1048708 336 J for melting lt 500 J

2008-spring-2004 SKim

33

Resistance welding

1048708 Spot welding Sequence1048708 Pressure on1048708 Current on1048708 Current off1048708 Pressure off1048708 Projection welding

2008-spring-2004 SKim

34

Solid-state interatomic bonding

1048708 Ultrasonic1048708 Oscillating tangential shear + static normal forces1048708 10KHz to 75 KHz1048708 Shear rarr plastic deformationrarr breaking up top layer (contaminated) rarr inter-atomic bond1048708 Friction1048708 Rotational part (at least one) flash1048708 Diffusion1048708 Goldsmiths bonded gold over copper1048708 Diffusion T gt 05 Tm1048708 Interface is the same as the bulk1048708 Fuselage frames

2008-spring-2004 SKim

35

Weld quality and defects

1048708 Porosity 1048708 Trapped gases contaminants 1048708 Preheat or increase rate of heat input1048708 Reduce speed allowing gas to escape cleaning1048708 Slag inclusions1048708 Oxides fluxes electrode coating trapped in weld zone1048708 Clean weld bead during multi-weld processes1048708 Provide enough shielding gas

2008-spring-2004 SKim

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 4: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

4

Joining processes

engine fasteners door

Mechanical nutsbolts

rivets c-clips pressure fits

Solid-liquid Adhesives

Soldering Brazing

Solid Friction Diffusion Explosion Ultrasound

Liquid

Chemical Oxyfuel Thermit

ECUS emission controller windshield plastic fans

Body muffler

Resistance Spot Seam Flash

door hingesConsumable electrode Shielded metal arc Submerged arc Gas metal arc

nonConsumable electrodeGas Tungsten Plasma Arc Electron Beam Laser welding

Arc Welding

2008-spring-2004 SKim

5

Mechanical Fastening

1048708 Any shape and material almost1048708 Disassemblable (except Rivets etc)1048708 Least expensive for low volume (standardized)1048708 Problems strength seal insertion loosening

Threaded Bolted Rivets Snap fit

Figures B Benhabib2008-spring-2004 SKim

6

Rivets

1048708 Cheap light weight donrsquot get loose1048708 Permanent less strong than bolts1048708 Rule of thumb1048708 Minimum spacing = 3 x d1048708 Maximum spacing = 16 x thickness of the outer plate

Rivets

2008-spring-2004 SKim

7

Mechanical fastening

1048708 Crimping1048708 Embossed protrusions1048708 Plastic deformation interference1048708 Appliance1048708 Automotive

Lego assembly elastic averaging

M Culpepper MIT2008-spring-2004 SKim

8

Mechanical Joining

1048708 Hemming seaming1048708 Bend edge of one component over another1048708 Automobile door stampings and trunk lids

2008-spring-2004 SKim

9

Adhesive Bonding

1048708 Quick and non-invasive1048708 Most materials with high surface to volume ratio1048708 Insulation (thermal electrical) conducting adhesives available1048708 Good damping1048708 Clean surface preparation1048708 Long curing hold time low service T1048708 Reliability quality1048708 Disassembly

2008-spring-2004 SKim

10

Stefan Equation

1048708 Squeeze a drop of liquid

1048708 hf goes down and

1048708 Viscosity goes up (curing)

1048708 Ft goes up (to separate)

When pullin apart

2008-spring-2004 SKim

11

DFA for bonding

1048708 Weak to tensile loading strong to shear and compressive1048708 Organic1048708 Epoxy acrylic etc1048708 Inorganic1048708 solder cement etc

2008-spring-2004 SKim

12

Solid-Liquid Brazing and Soldering

1048708 In brazing the filler material (silver brass bronze) has a melting point above 425 ordmC and in soldering the filler material (lead tin) has a melting point well below 425 ordmC1048708 Capillary forces for the wetting and flow of the liquid metal into the gaps1048708 Proper fluxes for lowering surface tension remove oxides and prevent oxidation

2008-spring-2004 SKim B Benhabib

13

Wave soldering

1048708 Exposed metal joints are passed over a wave in a continuous motion where liquid solder penetrates into the joint by capillary forces

2008-spring-2004 SKim B Benhabib

Enlarged area

Circuitboard

Solderfountain

Moltensolder

Heater Pump

Enlarged area

14

Welding

1048708 Solid-state welding

10487081048708 No liquid electrical chemical mechanical

1048708 Resistance diffusion ultrasonic

10487081048708 Fusion welding

10487081048708 Chemical Oxyfuel

10487081048708 Electrical Arc welding

1048708 1048708 Consumable electrode

10487081048708 Non-consumable electrode

2008-spring-2004 SKim

15

Fusion Welding

1048708 Heat source chemical electrical1048708 Heat intensity1048708 Control1048708 Incomplete fusion penetration1048708 Underfilling undercutting cracks1048708 Heat affected zone (HAZ)1048708 Feed rate

2008-spring-2004 SKim

16

Underfill and undercut

2008-spring-2004 SKim

underfill

undercut

Good weld

17

Heat Intensity

1048708 A measure of radiation intensity Wcm2

1048708 High intensity high heat flux the faster the melting1048708 Automation needed to prevent overmelting vaporizing1048708 For a planar heat source on steel tm= (5000HI)2

Oxy 20-30 sec E-beam μ sec

2008-spring-2004 SKim

AirFuelGas Flame

OxyacetyleneThermit

Friction

ArcWelding

Resistance Welding(Oxygen Cutting)

Electron BeamLaser Beam

18

Laser for Razor

- 500 μm spots- 3 million spots per hour

How fast the welding speed is required

Kalpakjian2008-spring-2004 SKim

19

Melting front speed2D simplification

The Jacob number

The thermal diffusivity is given by

The melt front moves as

2008-spring-2004 SKim

20

Welding speed

1048708 tm = (sm)2 (2 α Ja)1048708 Any longer over-melt

1048708 If the weld pool size is d in diameter then you must feed at a rate that exceeds dtmax1048708 HI increases welding speed must go up1048708 α Ja increases interaction time must go up

Weld pool size d

2008-spring-2004 SKim

21

Weld Pool ndash Heat SourceInteraction Time

2008-spring-2004 SKim J Chun

22

HAZ(Heat Affected Zone)

1048708 Bad microstructure course grains weak to corrosion1048708 Plastic vs Metal

Temp

Base metal

HAZ

Weld metalMolten metal

Melting point

Microstructure change temperature

Base metal temperature

2008-spring-2004 SKim

23

Heat Affected Zone

1048708 Region near the weld pool is affected by heat Microstructure changes1048708 s ~ (α t)05

1048708 The size of the heat affected zone is controlled by the thermal diffusivity α Al Cu1048708 HI time (speed)1048708 Metal vs Plastic

2008-spring-2004 SKim

24

Heat Affected Zone (HAZ)

2008-spring-2004 SKim

Grain structureWeld lineIntergranular corrosionrecrystallization

25

Oxyfuel Gas Welding

1048708 Low cost manual1048708 Oxyfuel Oxygen + Fuel (Acetylene methyacetylene- propedieneetc) can reach 3300oC1048708 Stoichiometry neutral flame

1048708 More oxygen will cause oxidization (Oxidizing flame) bad for steels OK for copper1048708 More fuel will cause carburization (carburizing flame) Low heat for brazing soldering flame hardening

2008-spring-2004 SKim

26

Arc fusion welding

1048708 Temperature up to 30000oC1048708 Heat travels with the electrons1048708 Straight polarity workpiece + electrode ndash1048708 Shallow penetration sheet metal wide gaps1048708 reverse polarity1048708 Deeper penetration

Arrangement forconsumable electrodes

Heat generated at anode isabout 15 of the heatgenerated at cathode

Eelectron at cathode is given bythree components

Kinetic energyDrop across cool gas boundary

Work function(heat of condensation)

2008-spring-2004 SKim

27

Consumable electrode processes

1048708 Shielded metal arc welding1048708 Cheapest and most basic process lt $15001048708 50A-300A lt10KW1048708 Workpiece thickness 3-20mm

2008-spring-2004 SKim

SlagCoating deoxidizes weld and provides shielding gas

Multiple passSlag removal

28

Fusion Arc Welding

1048708 Preventing oxidation is the most important problem1048708 Coated electrodes to provide shielding gas1048708 Coatings fluorides silicate binders(clay) cellulose carbonates1048708 Electrodes different materials such as mild steel1048708 Submerged arc welding covered by granular flux1048708 Flat surfaces high throughput good quality1048708 Inert gas from external source1048708 Gas metal arc welding (MIG)1048708 Flux-cored arc welding etc (very versatile with proper fluxes)

2008-spring-2004 SKim

29

Gas Metal Arc Welding

Metal transfer- Spray transfer- Globular transfer- Short circuiting

Gas metal arc welding is aspecial variation on arc weldingin which the electrode fillermetal is fed directly through thetorch tip As arcing occurs theelectrode instantly meltsforming molten droplets that fallinto the weld pool Shielding gasis supplied through the torch tipto prevent chemical interactionswith the surroundingatmosphere

2008-spring-2004 SKim

30

Non-consumable electrode weldingGas Tungsten Arc Welding

1048708 Gas tungsten arc welding formerly known as TIG welding10487081048708 Tungsten electrode + filler wire10487081048708 Good for thin materials better control Al MgTi etc10487081048708 High quality and finish10487081048708 Tungsten electrode contamination10487081048708 200A DC-500A AC 8kW-50kW

2008-spring-2004 SKim

31

Other non-consumable electrodeprocesses

1048708 Plasma arc welding1048708 very higher energy concentration (33000oC) high feed rate 120-1000 mmmin arc stablility less thermal distortion deep penetration (keyhole technology)1048708 Laser beam welding electron beam welding etc

2008-spring-2004 SKim

32

Resistance Welding

1048708 Spot seam projection welding1048708 High current through the weld 3000A-100000A (05 ndash 10 V)

1048708 Extremely high heat flux (105 Wcm2)1048708 Heat generated H=i2Rt K (K=efficiency)1048708 Ex 5000 A 5 mm dia elctrodes two 1mm thick steel plates1048708 Effective resistance 200 Ω Then H= 500 J1048708 Nugget volume 30 mm3 mass 024 g 1400 Jg needed to melt1048708 336 J for melting lt 500 J

2008-spring-2004 SKim

33

Resistance welding

1048708 Spot welding Sequence1048708 Pressure on1048708 Current on1048708 Current off1048708 Pressure off1048708 Projection welding

2008-spring-2004 SKim

34

Solid-state interatomic bonding

1048708 Ultrasonic1048708 Oscillating tangential shear + static normal forces1048708 10KHz to 75 KHz1048708 Shear rarr plastic deformationrarr breaking up top layer (contaminated) rarr inter-atomic bond1048708 Friction1048708 Rotational part (at least one) flash1048708 Diffusion1048708 Goldsmiths bonded gold over copper1048708 Diffusion T gt 05 Tm1048708 Interface is the same as the bulk1048708 Fuselage frames

2008-spring-2004 SKim

35

Weld quality and defects

1048708 Porosity 1048708 Trapped gases contaminants 1048708 Preheat or increase rate of heat input1048708 Reduce speed allowing gas to escape cleaning1048708 Slag inclusions1048708 Oxides fluxes electrode coating trapped in weld zone1048708 Clean weld bead during multi-weld processes1048708 Provide enough shielding gas

2008-spring-2004 SKim

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 5: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

5

Mechanical Fastening

1048708 Any shape and material almost1048708 Disassemblable (except Rivets etc)1048708 Least expensive for low volume (standardized)1048708 Problems strength seal insertion loosening

Threaded Bolted Rivets Snap fit

Figures B Benhabib2008-spring-2004 SKim

6

Rivets

1048708 Cheap light weight donrsquot get loose1048708 Permanent less strong than bolts1048708 Rule of thumb1048708 Minimum spacing = 3 x d1048708 Maximum spacing = 16 x thickness of the outer plate

Rivets

2008-spring-2004 SKim

7

Mechanical fastening

1048708 Crimping1048708 Embossed protrusions1048708 Plastic deformation interference1048708 Appliance1048708 Automotive

Lego assembly elastic averaging

M Culpepper MIT2008-spring-2004 SKim

8

Mechanical Joining

1048708 Hemming seaming1048708 Bend edge of one component over another1048708 Automobile door stampings and trunk lids

2008-spring-2004 SKim

9

Adhesive Bonding

1048708 Quick and non-invasive1048708 Most materials with high surface to volume ratio1048708 Insulation (thermal electrical) conducting adhesives available1048708 Good damping1048708 Clean surface preparation1048708 Long curing hold time low service T1048708 Reliability quality1048708 Disassembly

2008-spring-2004 SKim

10

Stefan Equation

1048708 Squeeze a drop of liquid

1048708 hf goes down and

1048708 Viscosity goes up (curing)

1048708 Ft goes up (to separate)

When pullin apart

2008-spring-2004 SKim

11

DFA for bonding

1048708 Weak to tensile loading strong to shear and compressive1048708 Organic1048708 Epoxy acrylic etc1048708 Inorganic1048708 solder cement etc

2008-spring-2004 SKim

12

Solid-Liquid Brazing and Soldering

1048708 In brazing the filler material (silver brass bronze) has a melting point above 425 ordmC and in soldering the filler material (lead tin) has a melting point well below 425 ordmC1048708 Capillary forces for the wetting and flow of the liquid metal into the gaps1048708 Proper fluxes for lowering surface tension remove oxides and prevent oxidation

2008-spring-2004 SKim B Benhabib

13

Wave soldering

1048708 Exposed metal joints are passed over a wave in a continuous motion where liquid solder penetrates into the joint by capillary forces

2008-spring-2004 SKim B Benhabib

Enlarged area

Circuitboard

Solderfountain

Moltensolder

Heater Pump

Enlarged area

14

Welding

1048708 Solid-state welding

10487081048708 No liquid electrical chemical mechanical

1048708 Resistance diffusion ultrasonic

10487081048708 Fusion welding

10487081048708 Chemical Oxyfuel

10487081048708 Electrical Arc welding

1048708 1048708 Consumable electrode

10487081048708 Non-consumable electrode

2008-spring-2004 SKim

15

Fusion Welding

1048708 Heat source chemical electrical1048708 Heat intensity1048708 Control1048708 Incomplete fusion penetration1048708 Underfilling undercutting cracks1048708 Heat affected zone (HAZ)1048708 Feed rate

2008-spring-2004 SKim

16

Underfill and undercut

2008-spring-2004 SKim

underfill

undercut

Good weld

17

Heat Intensity

1048708 A measure of radiation intensity Wcm2

1048708 High intensity high heat flux the faster the melting1048708 Automation needed to prevent overmelting vaporizing1048708 For a planar heat source on steel tm= (5000HI)2

Oxy 20-30 sec E-beam μ sec

2008-spring-2004 SKim

AirFuelGas Flame

OxyacetyleneThermit

Friction

ArcWelding

Resistance Welding(Oxygen Cutting)

Electron BeamLaser Beam

18

Laser for Razor

- 500 μm spots- 3 million spots per hour

How fast the welding speed is required

Kalpakjian2008-spring-2004 SKim

19

Melting front speed2D simplification

The Jacob number

The thermal diffusivity is given by

The melt front moves as

2008-spring-2004 SKim

20

Welding speed

1048708 tm = (sm)2 (2 α Ja)1048708 Any longer over-melt

1048708 If the weld pool size is d in diameter then you must feed at a rate that exceeds dtmax1048708 HI increases welding speed must go up1048708 α Ja increases interaction time must go up

Weld pool size d

2008-spring-2004 SKim

21

Weld Pool ndash Heat SourceInteraction Time

2008-spring-2004 SKim J Chun

22

HAZ(Heat Affected Zone)

1048708 Bad microstructure course grains weak to corrosion1048708 Plastic vs Metal

Temp

Base metal

HAZ

Weld metalMolten metal

Melting point

Microstructure change temperature

Base metal temperature

2008-spring-2004 SKim

23

Heat Affected Zone

1048708 Region near the weld pool is affected by heat Microstructure changes1048708 s ~ (α t)05

1048708 The size of the heat affected zone is controlled by the thermal diffusivity α Al Cu1048708 HI time (speed)1048708 Metal vs Plastic

2008-spring-2004 SKim

24

Heat Affected Zone (HAZ)

2008-spring-2004 SKim

Grain structureWeld lineIntergranular corrosionrecrystallization

25

Oxyfuel Gas Welding

1048708 Low cost manual1048708 Oxyfuel Oxygen + Fuel (Acetylene methyacetylene- propedieneetc) can reach 3300oC1048708 Stoichiometry neutral flame

1048708 More oxygen will cause oxidization (Oxidizing flame) bad for steels OK for copper1048708 More fuel will cause carburization (carburizing flame) Low heat for brazing soldering flame hardening

2008-spring-2004 SKim

26

Arc fusion welding

1048708 Temperature up to 30000oC1048708 Heat travels with the electrons1048708 Straight polarity workpiece + electrode ndash1048708 Shallow penetration sheet metal wide gaps1048708 reverse polarity1048708 Deeper penetration

Arrangement forconsumable electrodes

Heat generated at anode isabout 15 of the heatgenerated at cathode

Eelectron at cathode is given bythree components

Kinetic energyDrop across cool gas boundary

Work function(heat of condensation)

2008-spring-2004 SKim

27

Consumable electrode processes

1048708 Shielded metal arc welding1048708 Cheapest and most basic process lt $15001048708 50A-300A lt10KW1048708 Workpiece thickness 3-20mm

2008-spring-2004 SKim

SlagCoating deoxidizes weld and provides shielding gas

Multiple passSlag removal

28

Fusion Arc Welding

1048708 Preventing oxidation is the most important problem1048708 Coated electrodes to provide shielding gas1048708 Coatings fluorides silicate binders(clay) cellulose carbonates1048708 Electrodes different materials such as mild steel1048708 Submerged arc welding covered by granular flux1048708 Flat surfaces high throughput good quality1048708 Inert gas from external source1048708 Gas metal arc welding (MIG)1048708 Flux-cored arc welding etc (very versatile with proper fluxes)

2008-spring-2004 SKim

29

Gas Metal Arc Welding

Metal transfer- Spray transfer- Globular transfer- Short circuiting

Gas metal arc welding is aspecial variation on arc weldingin which the electrode fillermetal is fed directly through thetorch tip As arcing occurs theelectrode instantly meltsforming molten droplets that fallinto the weld pool Shielding gasis supplied through the torch tipto prevent chemical interactionswith the surroundingatmosphere

2008-spring-2004 SKim

30

Non-consumable electrode weldingGas Tungsten Arc Welding

1048708 Gas tungsten arc welding formerly known as TIG welding10487081048708 Tungsten electrode + filler wire10487081048708 Good for thin materials better control Al MgTi etc10487081048708 High quality and finish10487081048708 Tungsten electrode contamination10487081048708 200A DC-500A AC 8kW-50kW

2008-spring-2004 SKim

31

Other non-consumable electrodeprocesses

1048708 Plasma arc welding1048708 very higher energy concentration (33000oC) high feed rate 120-1000 mmmin arc stablility less thermal distortion deep penetration (keyhole technology)1048708 Laser beam welding electron beam welding etc

2008-spring-2004 SKim

32

Resistance Welding

1048708 Spot seam projection welding1048708 High current through the weld 3000A-100000A (05 ndash 10 V)

1048708 Extremely high heat flux (105 Wcm2)1048708 Heat generated H=i2Rt K (K=efficiency)1048708 Ex 5000 A 5 mm dia elctrodes two 1mm thick steel plates1048708 Effective resistance 200 Ω Then H= 500 J1048708 Nugget volume 30 mm3 mass 024 g 1400 Jg needed to melt1048708 336 J for melting lt 500 J

2008-spring-2004 SKim

33

Resistance welding

1048708 Spot welding Sequence1048708 Pressure on1048708 Current on1048708 Current off1048708 Pressure off1048708 Projection welding

2008-spring-2004 SKim

34

Solid-state interatomic bonding

1048708 Ultrasonic1048708 Oscillating tangential shear + static normal forces1048708 10KHz to 75 KHz1048708 Shear rarr plastic deformationrarr breaking up top layer (contaminated) rarr inter-atomic bond1048708 Friction1048708 Rotational part (at least one) flash1048708 Diffusion1048708 Goldsmiths bonded gold over copper1048708 Diffusion T gt 05 Tm1048708 Interface is the same as the bulk1048708 Fuselage frames

2008-spring-2004 SKim

35

Weld quality and defects

1048708 Porosity 1048708 Trapped gases contaminants 1048708 Preheat or increase rate of heat input1048708 Reduce speed allowing gas to escape cleaning1048708 Slag inclusions1048708 Oxides fluxes electrode coating trapped in weld zone1048708 Clean weld bead during multi-weld processes1048708 Provide enough shielding gas

2008-spring-2004 SKim

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 6: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

6

Rivets

1048708 Cheap light weight donrsquot get loose1048708 Permanent less strong than bolts1048708 Rule of thumb1048708 Minimum spacing = 3 x d1048708 Maximum spacing = 16 x thickness of the outer plate

Rivets

2008-spring-2004 SKim

7

Mechanical fastening

1048708 Crimping1048708 Embossed protrusions1048708 Plastic deformation interference1048708 Appliance1048708 Automotive

Lego assembly elastic averaging

M Culpepper MIT2008-spring-2004 SKim

8

Mechanical Joining

1048708 Hemming seaming1048708 Bend edge of one component over another1048708 Automobile door stampings and trunk lids

2008-spring-2004 SKim

9

Adhesive Bonding

1048708 Quick and non-invasive1048708 Most materials with high surface to volume ratio1048708 Insulation (thermal electrical) conducting adhesives available1048708 Good damping1048708 Clean surface preparation1048708 Long curing hold time low service T1048708 Reliability quality1048708 Disassembly

2008-spring-2004 SKim

10

Stefan Equation

1048708 Squeeze a drop of liquid

1048708 hf goes down and

1048708 Viscosity goes up (curing)

1048708 Ft goes up (to separate)

When pullin apart

2008-spring-2004 SKim

11

DFA for bonding

1048708 Weak to tensile loading strong to shear and compressive1048708 Organic1048708 Epoxy acrylic etc1048708 Inorganic1048708 solder cement etc

2008-spring-2004 SKim

12

Solid-Liquid Brazing and Soldering

1048708 In brazing the filler material (silver brass bronze) has a melting point above 425 ordmC and in soldering the filler material (lead tin) has a melting point well below 425 ordmC1048708 Capillary forces for the wetting and flow of the liquid metal into the gaps1048708 Proper fluxes for lowering surface tension remove oxides and prevent oxidation

2008-spring-2004 SKim B Benhabib

13

Wave soldering

1048708 Exposed metal joints are passed over a wave in a continuous motion where liquid solder penetrates into the joint by capillary forces

2008-spring-2004 SKim B Benhabib

Enlarged area

Circuitboard

Solderfountain

Moltensolder

Heater Pump

Enlarged area

14

Welding

1048708 Solid-state welding

10487081048708 No liquid electrical chemical mechanical

1048708 Resistance diffusion ultrasonic

10487081048708 Fusion welding

10487081048708 Chemical Oxyfuel

10487081048708 Electrical Arc welding

1048708 1048708 Consumable electrode

10487081048708 Non-consumable electrode

2008-spring-2004 SKim

15

Fusion Welding

1048708 Heat source chemical electrical1048708 Heat intensity1048708 Control1048708 Incomplete fusion penetration1048708 Underfilling undercutting cracks1048708 Heat affected zone (HAZ)1048708 Feed rate

2008-spring-2004 SKim

16

Underfill and undercut

2008-spring-2004 SKim

underfill

undercut

Good weld

17

Heat Intensity

1048708 A measure of radiation intensity Wcm2

1048708 High intensity high heat flux the faster the melting1048708 Automation needed to prevent overmelting vaporizing1048708 For a planar heat source on steel tm= (5000HI)2

Oxy 20-30 sec E-beam μ sec

2008-spring-2004 SKim

AirFuelGas Flame

OxyacetyleneThermit

Friction

ArcWelding

Resistance Welding(Oxygen Cutting)

Electron BeamLaser Beam

18

Laser for Razor

- 500 μm spots- 3 million spots per hour

How fast the welding speed is required

Kalpakjian2008-spring-2004 SKim

19

Melting front speed2D simplification

The Jacob number

The thermal diffusivity is given by

The melt front moves as

2008-spring-2004 SKim

20

Welding speed

1048708 tm = (sm)2 (2 α Ja)1048708 Any longer over-melt

1048708 If the weld pool size is d in diameter then you must feed at a rate that exceeds dtmax1048708 HI increases welding speed must go up1048708 α Ja increases interaction time must go up

Weld pool size d

2008-spring-2004 SKim

21

Weld Pool ndash Heat SourceInteraction Time

2008-spring-2004 SKim J Chun

22

HAZ(Heat Affected Zone)

1048708 Bad microstructure course grains weak to corrosion1048708 Plastic vs Metal

Temp

Base metal

HAZ

Weld metalMolten metal

Melting point

Microstructure change temperature

Base metal temperature

2008-spring-2004 SKim

23

Heat Affected Zone

1048708 Region near the weld pool is affected by heat Microstructure changes1048708 s ~ (α t)05

1048708 The size of the heat affected zone is controlled by the thermal diffusivity α Al Cu1048708 HI time (speed)1048708 Metal vs Plastic

2008-spring-2004 SKim

24

Heat Affected Zone (HAZ)

2008-spring-2004 SKim

Grain structureWeld lineIntergranular corrosionrecrystallization

25

Oxyfuel Gas Welding

1048708 Low cost manual1048708 Oxyfuel Oxygen + Fuel (Acetylene methyacetylene- propedieneetc) can reach 3300oC1048708 Stoichiometry neutral flame

1048708 More oxygen will cause oxidization (Oxidizing flame) bad for steels OK for copper1048708 More fuel will cause carburization (carburizing flame) Low heat for brazing soldering flame hardening

2008-spring-2004 SKim

26

Arc fusion welding

1048708 Temperature up to 30000oC1048708 Heat travels with the electrons1048708 Straight polarity workpiece + electrode ndash1048708 Shallow penetration sheet metal wide gaps1048708 reverse polarity1048708 Deeper penetration

Arrangement forconsumable electrodes

Heat generated at anode isabout 15 of the heatgenerated at cathode

Eelectron at cathode is given bythree components

Kinetic energyDrop across cool gas boundary

Work function(heat of condensation)

2008-spring-2004 SKim

27

Consumable electrode processes

1048708 Shielded metal arc welding1048708 Cheapest and most basic process lt $15001048708 50A-300A lt10KW1048708 Workpiece thickness 3-20mm

2008-spring-2004 SKim

SlagCoating deoxidizes weld and provides shielding gas

Multiple passSlag removal

28

Fusion Arc Welding

1048708 Preventing oxidation is the most important problem1048708 Coated electrodes to provide shielding gas1048708 Coatings fluorides silicate binders(clay) cellulose carbonates1048708 Electrodes different materials such as mild steel1048708 Submerged arc welding covered by granular flux1048708 Flat surfaces high throughput good quality1048708 Inert gas from external source1048708 Gas metal arc welding (MIG)1048708 Flux-cored arc welding etc (very versatile with proper fluxes)

2008-spring-2004 SKim

29

Gas Metal Arc Welding

Metal transfer- Spray transfer- Globular transfer- Short circuiting

Gas metal arc welding is aspecial variation on arc weldingin which the electrode fillermetal is fed directly through thetorch tip As arcing occurs theelectrode instantly meltsforming molten droplets that fallinto the weld pool Shielding gasis supplied through the torch tipto prevent chemical interactionswith the surroundingatmosphere

2008-spring-2004 SKim

30

Non-consumable electrode weldingGas Tungsten Arc Welding

1048708 Gas tungsten arc welding formerly known as TIG welding10487081048708 Tungsten electrode + filler wire10487081048708 Good for thin materials better control Al MgTi etc10487081048708 High quality and finish10487081048708 Tungsten electrode contamination10487081048708 200A DC-500A AC 8kW-50kW

2008-spring-2004 SKim

31

Other non-consumable electrodeprocesses

1048708 Plasma arc welding1048708 very higher energy concentration (33000oC) high feed rate 120-1000 mmmin arc stablility less thermal distortion deep penetration (keyhole technology)1048708 Laser beam welding electron beam welding etc

2008-spring-2004 SKim

32

Resistance Welding

1048708 Spot seam projection welding1048708 High current through the weld 3000A-100000A (05 ndash 10 V)

1048708 Extremely high heat flux (105 Wcm2)1048708 Heat generated H=i2Rt K (K=efficiency)1048708 Ex 5000 A 5 mm dia elctrodes two 1mm thick steel plates1048708 Effective resistance 200 Ω Then H= 500 J1048708 Nugget volume 30 mm3 mass 024 g 1400 Jg needed to melt1048708 336 J for melting lt 500 J

2008-spring-2004 SKim

33

Resistance welding

1048708 Spot welding Sequence1048708 Pressure on1048708 Current on1048708 Current off1048708 Pressure off1048708 Projection welding

2008-spring-2004 SKim

34

Solid-state interatomic bonding

1048708 Ultrasonic1048708 Oscillating tangential shear + static normal forces1048708 10KHz to 75 KHz1048708 Shear rarr plastic deformationrarr breaking up top layer (contaminated) rarr inter-atomic bond1048708 Friction1048708 Rotational part (at least one) flash1048708 Diffusion1048708 Goldsmiths bonded gold over copper1048708 Diffusion T gt 05 Tm1048708 Interface is the same as the bulk1048708 Fuselage frames

2008-spring-2004 SKim

35

Weld quality and defects

1048708 Porosity 1048708 Trapped gases contaminants 1048708 Preheat or increase rate of heat input1048708 Reduce speed allowing gas to escape cleaning1048708 Slag inclusions1048708 Oxides fluxes electrode coating trapped in weld zone1048708 Clean weld bead during multi-weld processes1048708 Provide enough shielding gas

2008-spring-2004 SKim

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 7: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

7

Mechanical fastening

1048708 Crimping1048708 Embossed protrusions1048708 Plastic deformation interference1048708 Appliance1048708 Automotive

Lego assembly elastic averaging

M Culpepper MIT2008-spring-2004 SKim

8

Mechanical Joining

1048708 Hemming seaming1048708 Bend edge of one component over another1048708 Automobile door stampings and trunk lids

2008-spring-2004 SKim

9

Adhesive Bonding

1048708 Quick and non-invasive1048708 Most materials with high surface to volume ratio1048708 Insulation (thermal electrical) conducting adhesives available1048708 Good damping1048708 Clean surface preparation1048708 Long curing hold time low service T1048708 Reliability quality1048708 Disassembly

2008-spring-2004 SKim

10

Stefan Equation

1048708 Squeeze a drop of liquid

1048708 hf goes down and

1048708 Viscosity goes up (curing)

1048708 Ft goes up (to separate)

When pullin apart

2008-spring-2004 SKim

11

DFA for bonding

1048708 Weak to tensile loading strong to shear and compressive1048708 Organic1048708 Epoxy acrylic etc1048708 Inorganic1048708 solder cement etc

2008-spring-2004 SKim

12

Solid-Liquid Brazing and Soldering

1048708 In brazing the filler material (silver brass bronze) has a melting point above 425 ordmC and in soldering the filler material (lead tin) has a melting point well below 425 ordmC1048708 Capillary forces for the wetting and flow of the liquid metal into the gaps1048708 Proper fluxes for lowering surface tension remove oxides and prevent oxidation

2008-spring-2004 SKim B Benhabib

13

Wave soldering

1048708 Exposed metal joints are passed over a wave in a continuous motion where liquid solder penetrates into the joint by capillary forces

2008-spring-2004 SKim B Benhabib

Enlarged area

Circuitboard

Solderfountain

Moltensolder

Heater Pump

Enlarged area

14

Welding

1048708 Solid-state welding

10487081048708 No liquid electrical chemical mechanical

1048708 Resistance diffusion ultrasonic

10487081048708 Fusion welding

10487081048708 Chemical Oxyfuel

10487081048708 Electrical Arc welding

1048708 1048708 Consumable electrode

10487081048708 Non-consumable electrode

2008-spring-2004 SKim

15

Fusion Welding

1048708 Heat source chemical electrical1048708 Heat intensity1048708 Control1048708 Incomplete fusion penetration1048708 Underfilling undercutting cracks1048708 Heat affected zone (HAZ)1048708 Feed rate

2008-spring-2004 SKim

16

Underfill and undercut

2008-spring-2004 SKim

underfill

undercut

Good weld

17

Heat Intensity

1048708 A measure of radiation intensity Wcm2

1048708 High intensity high heat flux the faster the melting1048708 Automation needed to prevent overmelting vaporizing1048708 For a planar heat source on steel tm= (5000HI)2

Oxy 20-30 sec E-beam μ sec

2008-spring-2004 SKim

AirFuelGas Flame

OxyacetyleneThermit

Friction

ArcWelding

Resistance Welding(Oxygen Cutting)

Electron BeamLaser Beam

18

Laser for Razor

- 500 μm spots- 3 million spots per hour

How fast the welding speed is required

Kalpakjian2008-spring-2004 SKim

19

Melting front speed2D simplification

The Jacob number

The thermal diffusivity is given by

The melt front moves as

2008-spring-2004 SKim

20

Welding speed

1048708 tm = (sm)2 (2 α Ja)1048708 Any longer over-melt

1048708 If the weld pool size is d in diameter then you must feed at a rate that exceeds dtmax1048708 HI increases welding speed must go up1048708 α Ja increases interaction time must go up

Weld pool size d

2008-spring-2004 SKim

21

Weld Pool ndash Heat SourceInteraction Time

2008-spring-2004 SKim J Chun

22

HAZ(Heat Affected Zone)

1048708 Bad microstructure course grains weak to corrosion1048708 Plastic vs Metal

Temp

Base metal

HAZ

Weld metalMolten metal

Melting point

Microstructure change temperature

Base metal temperature

2008-spring-2004 SKim

23

Heat Affected Zone

1048708 Region near the weld pool is affected by heat Microstructure changes1048708 s ~ (α t)05

1048708 The size of the heat affected zone is controlled by the thermal diffusivity α Al Cu1048708 HI time (speed)1048708 Metal vs Plastic

2008-spring-2004 SKim

24

Heat Affected Zone (HAZ)

2008-spring-2004 SKim

Grain structureWeld lineIntergranular corrosionrecrystallization

25

Oxyfuel Gas Welding

1048708 Low cost manual1048708 Oxyfuel Oxygen + Fuel (Acetylene methyacetylene- propedieneetc) can reach 3300oC1048708 Stoichiometry neutral flame

1048708 More oxygen will cause oxidization (Oxidizing flame) bad for steels OK for copper1048708 More fuel will cause carburization (carburizing flame) Low heat for brazing soldering flame hardening

2008-spring-2004 SKim

26

Arc fusion welding

1048708 Temperature up to 30000oC1048708 Heat travels with the electrons1048708 Straight polarity workpiece + electrode ndash1048708 Shallow penetration sheet metal wide gaps1048708 reverse polarity1048708 Deeper penetration

Arrangement forconsumable electrodes

Heat generated at anode isabout 15 of the heatgenerated at cathode

Eelectron at cathode is given bythree components

Kinetic energyDrop across cool gas boundary

Work function(heat of condensation)

2008-spring-2004 SKim

27

Consumable electrode processes

1048708 Shielded metal arc welding1048708 Cheapest and most basic process lt $15001048708 50A-300A lt10KW1048708 Workpiece thickness 3-20mm

2008-spring-2004 SKim

SlagCoating deoxidizes weld and provides shielding gas

Multiple passSlag removal

28

Fusion Arc Welding

1048708 Preventing oxidation is the most important problem1048708 Coated electrodes to provide shielding gas1048708 Coatings fluorides silicate binders(clay) cellulose carbonates1048708 Electrodes different materials such as mild steel1048708 Submerged arc welding covered by granular flux1048708 Flat surfaces high throughput good quality1048708 Inert gas from external source1048708 Gas metal arc welding (MIG)1048708 Flux-cored arc welding etc (very versatile with proper fluxes)

2008-spring-2004 SKim

29

Gas Metal Arc Welding

Metal transfer- Spray transfer- Globular transfer- Short circuiting

Gas metal arc welding is aspecial variation on arc weldingin which the electrode fillermetal is fed directly through thetorch tip As arcing occurs theelectrode instantly meltsforming molten droplets that fallinto the weld pool Shielding gasis supplied through the torch tipto prevent chemical interactionswith the surroundingatmosphere

2008-spring-2004 SKim

30

Non-consumable electrode weldingGas Tungsten Arc Welding

1048708 Gas tungsten arc welding formerly known as TIG welding10487081048708 Tungsten electrode + filler wire10487081048708 Good for thin materials better control Al MgTi etc10487081048708 High quality and finish10487081048708 Tungsten electrode contamination10487081048708 200A DC-500A AC 8kW-50kW

2008-spring-2004 SKim

31

Other non-consumable electrodeprocesses

1048708 Plasma arc welding1048708 very higher energy concentration (33000oC) high feed rate 120-1000 mmmin arc stablility less thermal distortion deep penetration (keyhole technology)1048708 Laser beam welding electron beam welding etc

2008-spring-2004 SKim

32

Resistance Welding

1048708 Spot seam projection welding1048708 High current through the weld 3000A-100000A (05 ndash 10 V)

1048708 Extremely high heat flux (105 Wcm2)1048708 Heat generated H=i2Rt K (K=efficiency)1048708 Ex 5000 A 5 mm dia elctrodes two 1mm thick steel plates1048708 Effective resistance 200 Ω Then H= 500 J1048708 Nugget volume 30 mm3 mass 024 g 1400 Jg needed to melt1048708 336 J for melting lt 500 J

2008-spring-2004 SKim

33

Resistance welding

1048708 Spot welding Sequence1048708 Pressure on1048708 Current on1048708 Current off1048708 Pressure off1048708 Projection welding

2008-spring-2004 SKim

34

Solid-state interatomic bonding

1048708 Ultrasonic1048708 Oscillating tangential shear + static normal forces1048708 10KHz to 75 KHz1048708 Shear rarr plastic deformationrarr breaking up top layer (contaminated) rarr inter-atomic bond1048708 Friction1048708 Rotational part (at least one) flash1048708 Diffusion1048708 Goldsmiths bonded gold over copper1048708 Diffusion T gt 05 Tm1048708 Interface is the same as the bulk1048708 Fuselage frames

2008-spring-2004 SKim

35

Weld quality and defects

1048708 Porosity 1048708 Trapped gases contaminants 1048708 Preheat or increase rate of heat input1048708 Reduce speed allowing gas to escape cleaning1048708 Slag inclusions1048708 Oxides fluxes electrode coating trapped in weld zone1048708 Clean weld bead during multi-weld processes1048708 Provide enough shielding gas

2008-spring-2004 SKim

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 8: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

8

Mechanical Joining

1048708 Hemming seaming1048708 Bend edge of one component over another1048708 Automobile door stampings and trunk lids

2008-spring-2004 SKim

9

Adhesive Bonding

1048708 Quick and non-invasive1048708 Most materials with high surface to volume ratio1048708 Insulation (thermal electrical) conducting adhesives available1048708 Good damping1048708 Clean surface preparation1048708 Long curing hold time low service T1048708 Reliability quality1048708 Disassembly

2008-spring-2004 SKim

10

Stefan Equation

1048708 Squeeze a drop of liquid

1048708 hf goes down and

1048708 Viscosity goes up (curing)

1048708 Ft goes up (to separate)

When pullin apart

2008-spring-2004 SKim

11

DFA for bonding

1048708 Weak to tensile loading strong to shear and compressive1048708 Organic1048708 Epoxy acrylic etc1048708 Inorganic1048708 solder cement etc

2008-spring-2004 SKim

12

Solid-Liquid Brazing and Soldering

1048708 In brazing the filler material (silver brass bronze) has a melting point above 425 ordmC and in soldering the filler material (lead tin) has a melting point well below 425 ordmC1048708 Capillary forces for the wetting and flow of the liquid metal into the gaps1048708 Proper fluxes for lowering surface tension remove oxides and prevent oxidation

2008-spring-2004 SKim B Benhabib

13

Wave soldering

1048708 Exposed metal joints are passed over a wave in a continuous motion where liquid solder penetrates into the joint by capillary forces

2008-spring-2004 SKim B Benhabib

Enlarged area

Circuitboard

Solderfountain

Moltensolder

Heater Pump

Enlarged area

14

Welding

1048708 Solid-state welding

10487081048708 No liquid electrical chemical mechanical

1048708 Resistance diffusion ultrasonic

10487081048708 Fusion welding

10487081048708 Chemical Oxyfuel

10487081048708 Electrical Arc welding

1048708 1048708 Consumable electrode

10487081048708 Non-consumable electrode

2008-spring-2004 SKim

15

Fusion Welding

1048708 Heat source chemical electrical1048708 Heat intensity1048708 Control1048708 Incomplete fusion penetration1048708 Underfilling undercutting cracks1048708 Heat affected zone (HAZ)1048708 Feed rate

2008-spring-2004 SKim

16

Underfill and undercut

2008-spring-2004 SKim

underfill

undercut

Good weld

17

Heat Intensity

1048708 A measure of radiation intensity Wcm2

1048708 High intensity high heat flux the faster the melting1048708 Automation needed to prevent overmelting vaporizing1048708 For a planar heat source on steel tm= (5000HI)2

Oxy 20-30 sec E-beam μ sec

2008-spring-2004 SKim

AirFuelGas Flame

OxyacetyleneThermit

Friction

ArcWelding

Resistance Welding(Oxygen Cutting)

Electron BeamLaser Beam

18

Laser for Razor

- 500 μm spots- 3 million spots per hour

How fast the welding speed is required

Kalpakjian2008-spring-2004 SKim

19

Melting front speed2D simplification

The Jacob number

The thermal diffusivity is given by

The melt front moves as

2008-spring-2004 SKim

20

Welding speed

1048708 tm = (sm)2 (2 α Ja)1048708 Any longer over-melt

1048708 If the weld pool size is d in diameter then you must feed at a rate that exceeds dtmax1048708 HI increases welding speed must go up1048708 α Ja increases interaction time must go up

Weld pool size d

2008-spring-2004 SKim

21

Weld Pool ndash Heat SourceInteraction Time

2008-spring-2004 SKim J Chun

22

HAZ(Heat Affected Zone)

1048708 Bad microstructure course grains weak to corrosion1048708 Plastic vs Metal

Temp

Base metal

HAZ

Weld metalMolten metal

Melting point

Microstructure change temperature

Base metal temperature

2008-spring-2004 SKim

23

Heat Affected Zone

1048708 Region near the weld pool is affected by heat Microstructure changes1048708 s ~ (α t)05

1048708 The size of the heat affected zone is controlled by the thermal diffusivity α Al Cu1048708 HI time (speed)1048708 Metal vs Plastic

2008-spring-2004 SKim

24

Heat Affected Zone (HAZ)

2008-spring-2004 SKim

Grain structureWeld lineIntergranular corrosionrecrystallization

25

Oxyfuel Gas Welding

1048708 Low cost manual1048708 Oxyfuel Oxygen + Fuel (Acetylene methyacetylene- propedieneetc) can reach 3300oC1048708 Stoichiometry neutral flame

1048708 More oxygen will cause oxidization (Oxidizing flame) bad for steels OK for copper1048708 More fuel will cause carburization (carburizing flame) Low heat for brazing soldering flame hardening

2008-spring-2004 SKim

26

Arc fusion welding

1048708 Temperature up to 30000oC1048708 Heat travels with the electrons1048708 Straight polarity workpiece + electrode ndash1048708 Shallow penetration sheet metal wide gaps1048708 reverse polarity1048708 Deeper penetration

Arrangement forconsumable electrodes

Heat generated at anode isabout 15 of the heatgenerated at cathode

Eelectron at cathode is given bythree components

Kinetic energyDrop across cool gas boundary

Work function(heat of condensation)

2008-spring-2004 SKim

27

Consumable electrode processes

1048708 Shielded metal arc welding1048708 Cheapest and most basic process lt $15001048708 50A-300A lt10KW1048708 Workpiece thickness 3-20mm

2008-spring-2004 SKim

SlagCoating deoxidizes weld and provides shielding gas

Multiple passSlag removal

28

Fusion Arc Welding

1048708 Preventing oxidation is the most important problem1048708 Coated electrodes to provide shielding gas1048708 Coatings fluorides silicate binders(clay) cellulose carbonates1048708 Electrodes different materials such as mild steel1048708 Submerged arc welding covered by granular flux1048708 Flat surfaces high throughput good quality1048708 Inert gas from external source1048708 Gas metal arc welding (MIG)1048708 Flux-cored arc welding etc (very versatile with proper fluxes)

2008-spring-2004 SKim

29

Gas Metal Arc Welding

Metal transfer- Spray transfer- Globular transfer- Short circuiting

Gas metal arc welding is aspecial variation on arc weldingin which the electrode fillermetal is fed directly through thetorch tip As arcing occurs theelectrode instantly meltsforming molten droplets that fallinto the weld pool Shielding gasis supplied through the torch tipto prevent chemical interactionswith the surroundingatmosphere

2008-spring-2004 SKim

30

Non-consumable electrode weldingGas Tungsten Arc Welding

1048708 Gas tungsten arc welding formerly known as TIG welding10487081048708 Tungsten electrode + filler wire10487081048708 Good for thin materials better control Al MgTi etc10487081048708 High quality and finish10487081048708 Tungsten electrode contamination10487081048708 200A DC-500A AC 8kW-50kW

2008-spring-2004 SKim

31

Other non-consumable electrodeprocesses

1048708 Plasma arc welding1048708 very higher energy concentration (33000oC) high feed rate 120-1000 mmmin arc stablility less thermal distortion deep penetration (keyhole technology)1048708 Laser beam welding electron beam welding etc

2008-spring-2004 SKim

32

Resistance Welding

1048708 Spot seam projection welding1048708 High current through the weld 3000A-100000A (05 ndash 10 V)

1048708 Extremely high heat flux (105 Wcm2)1048708 Heat generated H=i2Rt K (K=efficiency)1048708 Ex 5000 A 5 mm dia elctrodes two 1mm thick steel plates1048708 Effective resistance 200 Ω Then H= 500 J1048708 Nugget volume 30 mm3 mass 024 g 1400 Jg needed to melt1048708 336 J for melting lt 500 J

2008-spring-2004 SKim

33

Resistance welding

1048708 Spot welding Sequence1048708 Pressure on1048708 Current on1048708 Current off1048708 Pressure off1048708 Projection welding

2008-spring-2004 SKim

34

Solid-state interatomic bonding

1048708 Ultrasonic1048708 Oscillating tangential shear + static normal forces1048708 10KHz to 75 KHz1048708 Shear rarr plastic deformationrarr breaking up top layer (contaminated) rarr inter-atomic bond1048708 Friction1048708 Rotational part (at least one) flash1048708 Diffusion1048708 Goldsmiths bonded gold over copper1048708 Diffusion T gt 05 Tm1048708 Interface is the same as the bulk1048708 Fuselage frames

2008-spring-2004 SKim

35

Weld quality and defects

1048708 Porosity 1048708 Trapped gases contaminants 1048708 Preheat or increase rate of heat input1048708 Reduce speed allowing gas to escape cleaning1048708 Slag inclusions1048708 Oxides fluxes electrode coating trapped in weld zone1048708 Clean weld bead during multi-weld processes1048708 Provide enough shielding gas

2008-spring-2004 SKim

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 9: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

9

Adhesive Bonding

1048708 Quick and non-invasive1048708 Most materials with high surface to volume ratio1048708 Insulation (thermal electrical) conducting adhesives available1048708 Good damping1048708 Clean surface preparation1048708 Long curing hold time low service T1048708 Reliability quality1048708 Disassembly

2008-spring-2004 SKim

10

Stefan Equation

1048708 Squeeze a drop of liquid

1048708 hf goes down and

1048708 Viscosity goes up (curing)

1048708 Ft goes up (to separate)

When pullin apart

2008-spring-2004 SKim

11

DFA for bonding

1048708 Weak to tensile loading strong to shear and compressive1048708 Organic1048708 Epoxy acrylic etc1048708 Inorganic1048708 solder cement etc

2008-spring-2004 SKim

12

Solid-Liquid Brazing and Soldering

1048708 In brazing the filler material (silver brass bronze) has a melting point above 425 ordmC and in soldering the filler material (lead tin) has a melting point well below 425 ordmC1048708 Capillary forces for the wetting and flow of the liquid metal into the gaps1048708 Proper fluxes for lowering surface tension remove oxides and prevent oxidation

2008-spring-2004 SKim B Benhabib

13

Wave soldering

1048708 Exposed metal joints are passed over a wave in a continuous motion where liquid solder penetrates into the joint by capillary forces

2008-spring-2004 SKim B Benhabib

Enlarged area

Circuitboard

Solderfountain

Moltensolder

Heater Pump

Enlarged area

14

Welding

1048708 Solid-state welding

10487081048708 No liquid electrical chemical mechanical

1048708 Resistance diffusion ultrasonic

10487081048708 Fusion welding

10487081048708 Chemical Oxyfuel

10487081048708 Electrical Arc welding

1048708 1048708 Consumable electrode

10487081048708 Non-consumable electrode

2008-spring-2004 SKim

15

Fusion Welding

1048708 Heat source chemical electrical1048708 Heat intensity1048708 Control1048708 Incomplete fusion penetration1048708 Underfilling undercutting cracks1048708 Heat affected zone (HAZ)1048708 Feed rate

2008-spring-2004 SKim

16

Underfill and undercut

2008-spring-2004 SKim

underfill

undercut

Good weld

17

Heat Intensity

1048708 A measure of radiation intensity Wcm2

1048708 High intensity high heat flux the faster the melting1048708 Automation needed to prevent overmelting vaporizing1048708 For a planar heat source on steel tm= (5000HI)2

Oxy 20-30 sec E-beam μ sec

2008-spring-2004 SKim

AirFuelGas Flame

OxyacetyleneThermit

Friction

ArcWelding

Resistance Welding(Oxygen Cutting)

Electron BeamLaser Beam

18

Laser for Razor

- 500 μm spots- 3 million spots per hour

How fast the welding speed is required

Kalpakjian2008-spring-2004 SKim

19

Melting front speed2D simplification

The Jacob number

The thermal diffusivity is given by

The melt front moves as

2008-spring-2004 SKim

20

Welding speed

1048708 tm = (sm)2 (2 α Ja)1048708 Any longer over-melt

1048708 If the weld pool size is d in diameter then you must feed at a rate that exceeds dtmax1048708 HI increases welding speed must go up1048708 α Ja increases interaction time must go up

Weld pool size d

2008-spring-2004 SKim

21

Weld Pool ndash Heat SourceInteraction Time

2008-spring-2004 SKim J Chun

22

HAZ(Heat Affected Zone)

1048708 Bad microstructure course grains weak to corrosion1048708 Plastic vs Metal

Temp

Base metal

HAZ

Weld metalMolten metal

Melting point

Microstructure change temperature

Base metal temperature

2008-spring-2004 SKim

23

Heat Affected Zone

1048708 Region near the weld pool is affected by heat Microstructure changes1048708 s ~ (α t)05

1048708 The size of the heat affected zone is controlled by the thermal diffusivity α Al Cu1048708 HI time (speed)1048708 Metal vs Plastic

2008-spring-2004 SKim

24

Heat Affected Zone (HAZ)

2008-spring-2004 SKim

Grain structureWeld lineIntergranular corrosionrecrystallization

25

Oxyfuel Gas Welding

1048708 Low cost manual1048708 Oxyfuel Oxygen + Fuel (Acetylene methyacetylene- propedieneetc) can reach 3300oC1048708 Stoichiometry neutral flame

1048708 More oxygen will cause oxidization (Oxidizing flame) bad for steels OK for copper1048708 More fuel will cause carburization (carburizing flame) Low heat for brazing soldering flame hardening

2008-spring-2004 SKim

26

Arc fusion welding

1048708 Temperature up to 30000oC1048708 Heat travels with the electrons1048708 Straight polarity workpiece + electrode ndash1048708 Shallow penetration sheet metal wide gaps1048708 reverse polarity1048708 Deeper penetration

Arrangement forconsumable electrodes

Heat generated at anode isabout 15 of the heatgenerated at cathode

Eelectron at cathode is given bythree components

Kinetic energyDrop across cool gas boundary

Work function(heat of condensation)

2008-spring-2004 SKim

27

Consumable electrode processes

1048708 Shielded metal arc welding1048708 Cheapest and most basic process lt $15001048708 50A-300A lt10KW1048708 Workpiece thickness 3-20mm

2008-spring-2004 SKim

SlagCoating deoxidizes weld and provides shielding gas

Multiple passSlag removal

28

Fusion Arc Welding

1048708 Preventing oxidation is the most important problem1048708 Coated electrodes to provide shielding gas1048708 Coatings fluorides silicate binders(clay) cellulose carbonates1048708 Electrodes different materials such as mild steel1048708 Submerged arc welding covered by granular flux1048708 Flat surfaces high throughput good quality1048708 Inert gas from external source1048708 Gas metal arc welding (MIG)1048708 Flux-cored arc welding etc (very versatile with proper fluxes)

2008-spring-2004 SKim

29

Gas Metal Arc Welding

Metal transfer- Spray transfer- Globular transfer- Short circuiting

Gas metal arc welding is aspecial variation on arc weldingin which the electrode fillermetal is fed directly through thetorch tip As arcing occurs theelectrode instantly meltsforming molten droplets that fallinto the weld pool Shielding gasis supplied through the torch tipto prevent chemical interactionswith the surroundingatmosphere

2008-spring-2004 SKim

30

Non-consumable electrode weldingGas Tungsten Arc Welding

1048708 Gas tungsten arc welding formerly known as TIG welding10487081048708 Tungsten electrode + filler wire10487081048708 Good for thin materials better control Al MgTi etc10487081048708 High quality and finish10487081048708 Tungsten electrode contamination10487081048708 200A DC-500A AC 8kW-50kW

2008-spring-2004 SKim

31

Other non-consumable electrodeprocesses

1048708 Plasma arc welding1048708 very higher energy concentration (33000oC) high feed rate 120-1000 mmmin arc stablility less thermal distortion deep penetration (keyhole technology)1048708 Laser beam welding electron beam welding etc

2008-spring-2004 SKim

32

Resistance Welding

1048708 Spot seam projection welding1048708 High current through the weld 3000A-100000A (05 ndash 10 V)

1048708 Extremely high heat flux (105 Wcm2)1048708 Heat generated H=i2Rt K (K=efficiency)1048708 Ex 5000 A 5 mm dia elctrodes two 1mm thick steel plates1048708 Effective resistance 200 Ω Then H= 500 J1048708 Nugget volume 30 mm3 mass 024 g 1400 Jg needed to melt1048708 336 J for melting lt 500 J

2008-spring-2004 SKim

33

Resistance welding

1048708 Spot welding Sequence1048708 Pressure on1048708 Current on1048708 Current off1048708 Pressure off1048708 Projection welding

2008-spring-2004 SKim

34

Solid-state interatomic bonding

1048708 Ultrasonic1048708 Oscillating tangential shear + static normal forces1048708 10KHz to 75 KHz1048708 Shear rarr plastic deformationrarr breaking up top layer (contaminated) rarr inter-atomic bond1048708 Friction1048708 Rotational part (at least one) flash1048708 Diffusion1048708 Goldsmiths bonded gold over copper1048708 Diffusion T gt 05 Tm1048708 Interface is the same as the bulk1048708 Fuselage frames

2008-spring-2004 SKim

35

Weld quality and defects

1048708 Porosity 1048708 Trapped gases contaminants 1048708 Preheat or increase rate of heat input1048708 Reduce speed allowing gas to escape cleaning1048708 Slag inclusions1048708 Oxides fluxes electrode coating trapped in weld zone1048708 Clean weld bead during multi-weld processes1048708 Provide enough shielding gas

2008-spring-2004 SKim

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 10: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

10

Stefan Equation

1048708 Squeeze a drop of liquid

1048708 hf goes down and

1048708 Viscosity goes up (curing)

1048708 Ft goes up (to separate)

When pullin apart

2008-spring-2004 SKim

11

DFA for bonding

1048708 Weak to tensile loading strong to shear and compressive1048708 Organic1048708 Epoxy acrylic etc1048708 Inorganic1048708 solder cement etc

2008-spring-2004 SKim

12

Solid-Liquid Brazing and Soldering

1048708 In brazing the filler material (silver brass bronze) has a melting point above 425 ordmC and in soldering the filler material (lead tin) has a melting point well below 425 ordmC1048708 Capillary forces for the wetting and flow of the liquid metal into the gaps1048708 Proper fluxes for lowering surface tension remove oxides and prevent oxidation

2008-spring-2004 SKim B Benhabib

13

Wave soldering

1048708 Exposed metal joints are passed over a wave in a continuous motion where liquid solder penetrates into the joint by capillary forces

2008-spring-2004 SKim B Benhabib

Enlarged area

Circuitboard

Solderfountain

Moltensolder

Heater Pump

Enlarged area

14

Welding

1048708 Solid-state welding

10487081048708 No liquid electrical chemical mechanical

1048708 Resistance diffusion ultrasonic

10487081048708 Fusion welding

10487081048708 Chemical Oxyfuel

10487081048708 Electrical Arc welding

1048708 1048708 Consumable electrode

10487081048708 Non-consumable electrode

2008-spring-2004 SKim

15

Fusion Welding

1048708 Heat source chemical electrical1048708 Heat intensity1048708 Control1048708 Incomplete fusion penetration1048708 Underfilling undercutting cracks1048708 Heat affected zone (HAZ)1048708 Feed rate

2008-spring-2004 SKim

16

Underfill and undercut

2008-spring-2004 SKim

underfill

undercut

Good weld

17

Heat Intensity

1048708 A measure of radiation intensity Wcm2

1048708 High intensity high heat flux the faster the melting1048708 Automation needed to prevent overmelting vaporizing1048708 For a planar heat source on steel tm= (5000HI)2

Oxy 20-30 sec E-beam μ sec

2008-spring-2004 SKim

AirFuelGas Flame

OxyacetyleneThermit

Friction

ArcWelding

Resistance Welding(Oxygen Cutting)

Electron BeamLaser Beam

18

Laser for Razor

- 500 μm spots- 3 million spots per hour

How fast the welding speed is required

Kalpakjian2008-spring-2004 SKim

19

Melting front speed2D simplification

The Jacob number

The thermal diffusivity is given by

The melt front moves as

2008-spring-2004 SKim

20

Welding speed

1048708 tm = (sm)2 (2 α Ja)1048708 Any longer over-melt

1048708 If the weld pool size is d in diameter then you must feed at a rate that exceeds dtmax1048708 HI increases welding speed must go up1048708 α Ja increases interaction time must go up

Weld pool size d

2008-spring-2004 SKim

21

Weld Pool ndash Heat SourceInteraction Time

2008-spring-2004 SKim J Chun

22

HAZ(Heat Affected Zone)

1048708 Bad microstructure course grains weak to corrosion1048708 Plastic vs Metal

Temp

Base metal

HAZ

Weld metalMolten metal

Melting point

Microstructure change temperature

Base metal temperature

2008-spring-2004 SKim

23

Heat Affected Zone

1048708 Region near the weld pool is affected by heat Microstructure changes1048708 s ~ (α t)05

1048708 The size of the heat affected zone is controlled by the thermal diffusivity α Al Cu1048708 HI time (speed)1048708 Metal vs Plastic

2008-spring-2004 SKim

24

Heat Affected Zone (HAZ)

2008-spring-2004 SKim

Grain structureWeld lineIntergranular corrosionrecrystallization

25

Oxyfuel Gas Welding

1048708 Low cost manual1048708 Oxyfuel Oxygen + Fuel (Acetylene methyacetylene- propedieneetc) can reach 3300oC1048708 Stoichiometry neutral flame

1048708 More oxygen will cause oxidization (Oxidizing flame) bad for steels OK for copper1048708 More fuel will cause carburization (carburizing flame) Low heat for brazing soldering flame hardening

2008-spring-2004 SKim

26

Arc fusion welding

1048708 Temperature up to 30000oC1048708 Heat travels with the electrons1048708 Straight polarity workpiece + electrode ndash1048708 Shallow penetration sheet metal wide gaps1048708 reverse polarity1048708 Deeper penetration

Arrangement forconsumable electrodes

Heat generated at anode isabout 15 of the heatgenerated at cathode

Eelectron at cathode is given bythree components

Kinetic energyDrop across cool gas boundary

Work function(heat of condensation)

2008-spring-2004 SKim

27

Consumable electrode processes

1048708 Shielded metal arc welding1048708 Cheapest and most basic process lt $15001048708 50A-300A lt10KW1048708 Workpiece thickness 3-20mm

2008-spring-2004 SKim

SlagCoating deoxidizes weld and provides shielding gas

Multiple passSlag removal

28

Fusion Arc Welding

1048708 Preventing oxidation is the most important problem1048708 Coated electrodes to provide shielding gas1048708 Coatings fluorides silicate binders(clay) cellulose carbonates1048708 Electrodes different materials such as mild steel1048708 Submerged arc welding covered by granular flux1048708 Flat surfaces high throughput good quality1048708 Inert gas from external source1048708 Gas metal arc welding (MIG)1048708 Flux-cored arc welding etc (very versatile with proper fluxes)

2008-spring-2004 SKim

29

Gas Metal Arc Welding

Metal transfer- Spray transfer- Globular transfer- Short circuiting

Gas metal arc welding is aspecial variation on arc weldingin which the electrode fillermetal is fed directly through thetorch tip As arcing occurs theelectrode instantly meltsforming molten droplets that fallinto the weld pool Shielding gasis supplied through the torch tipto prevent chemical interactionswith the surroundingatmosphere

2008-spring-2004 SKim

30

Non-consumable electrode weldingGas Tungsten Arc Welding

1048708 Gas tungsten arc welding formerly known as TIG welding10487081048708 Tungsten electrode + filler wire10487081048708 Good for thin materials better control Al MgTi etc10487081048708 High quality and finish10487081048708 Tungsten electrode contamination10487081048708 200A DC-500A AC 8kW-50kW

2008-spring-2004 SKim

31

Other non-consumable electrodeprocesses

1048708 Plasma arc welding1048708 very higher energy concentration (33000oC) high feed rate 120-1000 mmmin arc stablility less thermal distortion deep penetration (keyhole technology)1048708 Laser beam welding electron beam welding etc

2008-spring-2004 SKim

32

Resistance Welding

1048708 Spot seam projection welding1048708 High current through the weld 3000A-100000A (05 ndash 10 V)

1048708 Extremely high heat flux (105 Wcm2)1048708 Heat generated H=i2Rt K (K=efficiency)1048708 Ex 5000 A 5 mm dia elctrodes two 1mm thick steel plates1048708 Effective resistance 200 Ω Then H= 500 J1048708 Nugget volume 30 mm3 mass 024 g 1400 Jg needed to melt1048708 336 J for melting lt 500 J

2008-spring-2004 SKim

33

Resistance welding

1048708 Spot welding Sequence1048708 Pressure on1048708 Current on1048708 Current off1048708 Pressure off1048708 Projection welding

2008-spring-2004 SKim

34

Solid-state interatomic bonding

1048708 Ultrasonic1048708 Oscillating tangential shear + static normal forces1048708 10KHz to 75 KHz1048708 Shear rarr plastic deformationrarr breaking up top layer (contaminated) rarr inter-atomic bond1048708 Friction1048708 Rotational part (at least one) flash1048708 Diffusion1048708 Goldsmiths bonded gold over copper1048708 Diffusion T gt 05 Tm1048708 Interface is the same as the bulk1048708 Fuselage frames

2008-spring-2004 SKim

35

Weld quality and defects

1048708 Porosity 1048708 Trapped gases contaminants 1048708 Preheat or increase rate of heat input1048708 Reduce speed allowing gas to escape cleaning1048708 Slag inclusions1048708 Oxides fluxes electrode coating trapped in weld zone1048708 Clean weld bead during multi-weld processes1048708 Provide enough shielding gas

2008-spring-2004 SKim

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 11: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

11

DFA for bonding

1048708 Weak to tensile loading strong to shear and compressive1048708 Organic1048708 Epoxy acrylic etc1048708 Inorganic1048708 solder cement etc

2008-spring-2004 SKim

12

Solid-Liquid Brazing and Soldering

1048708 In brazing the filler material (silver brass bronze) has a melting point above 425 ordmC and in soldering the filler material (lead tin) has a melting point well below 425 ordmC1048708 Capillary forces for the wetting and flow of the liquid metal into the gaps1048708 Proper fluxes for lowering surface tension remove oxides and prevent oxidation

2008-spring-2004 SKim B Benhabib

13

Wave soldering

1048708 Exposed metal joints are passed over a wave in a continuous motion where liquid solder penetrates into the joint by capillary forces

2008-spring-2004 SKim B Benhabib

Enlarged area

Circuitboard

Solderfountain

Moltensolder

Heater Pump

Enlarged area

14

Welding

1048708 Solid-state welding

10487081048708 No liquid electrical chemical mechanical

1048708 Resistance diffusion ultrasonic

10487081048708 Fusion welding

10487081048708 Chemical Oxyfuel

10487081048708 Electrical Arc welding

1048708 1048708 Consumable electrode

10487081048708 Non-consumable electrode

2008-spring-2004 SKim

15

Fusion Welding

1048708 Heat source chemical electrical1048708 Heat intensity1048708 Control1048708 Incomplete fusion penetration1048708 Underfilling undercutting cracks1048708 Heat affected zone (HAZ)1048708 Feed rate

2008-spring-2004 SKim

16

Underfill and undercut

2008-spring-2004 SKim

underfill

undercut

Good weld

17

Heat Intensity

1048708 A measure of radiation intensity Wcm2

1048708 High intensity high heat flux the faster the melting1048708 Automation needed to prevent overmelting vaporizing1048708 For a planar heat source on steel tm= (5000HI)2

Oxy 20-30 sec E-beam μ sec

2008-spring-2004 SKim

AirFuelGas Flame

OxyacetyleneThermit

Friction

ArcWelding

Resistance Welding(Oxygen Cutting)

Electron BeamLaser Beam

18

Laser for Razor

- 500 μm spots- 3 million spots per hour

How fast the welding speed is required

Kalpakjian2008-spring-2004 SKim

19

Melting front speed2D simplification

The Jacob number

The thermal diffusivity is given by

The melt front moves as

2008-spring-2004 SKim

20

Welding speed

1048708 tm = (sm)2 (2 α Ja)1048708 Any longer over-melt

1048708 If the weld pool size is d in diameter then you must feed at a rate that exceeds dtmax1048708 HI increases welding speed must go up1048708 α Ja increases interaction time must go up

Weld pool size d

2008-spring-2004 SKim

21

Weld Pool ndash Heat SourceInteraction Time

2008-spring-2004 SKim J Chun

22

HAZ(Heat Affected Zone)

1048708 Bad microstructure course grains weak to corrosion1048708 Plastic vs Metal

Temp

Base metal

HAZ

Weld metalMolten metal

Melting point

Microstructure change temperature

Base metal temperature

2008-spring-2004 SKim

23

Heat Affected Zone

1048708 Region near the weld pool is affected by heat Microstructure changes1048708 s ~ (α t)05

1048708 The size of the heat affected zone is controlled by the thermal diffusivity α Al Cu1048708 HI time (speed)1048708 Metal vs Plastic

2008-spring-2004 SKim

24

Heat Affected Zone (HAZ)

2008-spring-2004 SKim

Grain structureWeld lineIntergranular corrosionrecrystallization

25

Oxyfuel Gas Welding

1048708 Low cost manual1048708 Oxyfuel Oxygen + Fuel (Acetylene methyacetylene- propedieneetc) can reach 3300oC1048708 Stoichiometry neutral flame

1048708 More oxygen will cause oxidization (Oxidizing flame) bad for steels OK for copper1048708 More fuel will cause carburization (carburizing flame) Low heat for brazing soldering flame hardening

2008-spring-2004 SKim

26

Arc fusion welding

1048708 Temperature up to 30000oC1048708 Heat travels with the electrons1048708 Straight polarity workpiece + electrode ndash1048708 Shallow penetration sheet metal wide gaps1048708 reverse polarity1048708 Deeper penetration

Arrangement forconsumable electrodes

Heat generated at anode isabout 15 of the heatgenerated at cathode

Eelectron at cathode is given bythree components

Kinetic energyDrop across cool gas boundary

Work function(heat of condensation)

2008-spring-2004 SKim

27

Consumable electrode processes

1048708 Shielded metal arc welding1048708 Cheapest and most basic process lt $15001048708 50A-300A lt10KW1048708 Workpiece thickness 3-20mm

2008-spring-2004 SKim

SlagCoating deoxidizes weld and provides shielding gas

Multiple passSlag removal

28

Fusion Arc Welding

1048708 Preventing oxidation is the most important problem1048708 Coated electrodes to provide shielding gas1048708 Coatings fluorides silicate binders(clay) cellulose carbonates1048708 Electrodes different materials such as mild steel1048708 Submerged arc welding covered by granular flux1048708 Flat surfaces high throughput good quality1048708 Inert gas from external source1048708 Gas metal arc welding (MIG)1048708 Flux-cored arc welding etc (very versatile with proper fluxes)

2008-spring-2004 SKim

29

Gas Metal Arc Welding

Metal transfer- Spray transfer- Globular transfer- Short circuiting

Gas metal arc welding is aspecial variation on arc weldingin which the electrode fillermetal is fed directly through thetorch tip As arcing occurs theelectrode instantly meltsforming molten droplets that fallinto the weld pool Shielding gasis supplied through the torch tipto prevent chemical interactionswith the surroundingatmosphere

2008-spring-2004 SKim

30

Non-consumable electrode weldingGas Tungsten Arc Welding

1048708 Gas tungsten arc welding formerly known as TIG welding10487081048708 Tungsten electrode + filler wire10487081048708 Good for thin materials better control Al MgTi etc10487081048708 High quality and finish10487081048708 Tungsten electrode contamination10487081048708 200A DC-500A AC 8kW-50kW

2008-spring-2004 SKim

31

Other non-consumable electrodeprocesses

1048708 Plasma arc welding1048708 very higher energy concentration (33000oC) high feed rate 120-1000 mmmin arc stablility less thermal distortion deep penetration (keyhole technology)1048708 Laser beam welding electron beam welding etc

2008-spring-2004 SKim

32

Resistance Welding

1048708 Spot seam projection welding1048708 High current through the weld 3000A-100000A (05 ndash 10 V)

1048708 Extremely high heat flux (105 Wcm2)1048708 Heat generated H=i2Rt K (K=efficiency)1048708 Ex 5000 A 5 mm dia elctrodes two 1mm thick steel plates1048708 Effective resistance 200 Ω Then H= 500 J1048708 Nugget volume 30 mm3 mass 024 g 1400 Jg needed to melt1048708 336 J for melting lt 500 J

2008-spring-2004 SKim

33

Resistance welding

1048708 Spot welding Sequence1048708 Pressure on1048708 Current on1048708 Current off1048708 Pressure off1048708 Projection welding

2008-spring-2004 SKim

34

Solid-state interatomic bonding

1048708 Ultrasonic1048708 Oscillating tangential shear + static normal forces1048708 10KHz to 75 KHz1048708 Shear rarr plastic deformationrarr breaking up top layer (contaminated) rarr inter-atomic bond1048708 Friction1048708 Rotational part (at least one) flash1048708 Diffusion1048708 Goldsmiths bonded gold over copper1048708 Diffusion T gt 05 Tm1048708 Interface is the same as the bulk1048708 Fuselage frames

2008-spring-2004 SKim

35

Weld quality and defects

1048708 Porosity 1048708 Trapped gases contaminants 1048708 Preheat or increase rate of heat input1048708 Reduce speed allowing gas to escape cleaning1048708 Slag inclusions1048708 Oxides fluxes electrode coating trapped in weld zone1048708 Clean weld bead during multi-weld processes1048708 Provide enough shielding gas

2008-spring-2004 SKim

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 12: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

12

Solid-Liquid Brazing and Soldering

1048708 In brazing the filler material (silver brass bronze) has a melting point above 425 ordmC and in soldering the filler material (lead tin) has a melting point well below 425 ordmC1048708 Capillary forces for the wetting and flow of the liquid metal into the gaps1048708 Proper fluxes for lowering surface tension remove oxides and prevent oxidation

2008-spring-2004 SKim B Benhabib

13

Wave soldering

1048708 Exposed metal joints are passed over a wave in a continuous motion where liquid solder penetrates into the joint by capillary forces

2008-spring-2004 SKim B Benhabib

Enlarged area

Circuitboard

Solderfountain

Moltensolder

Heater Pump

Enlarged area

14

Welding

1048708 Solid-state welding

10487081048708 No liquid electrical chemical mechanical

1048708 Resistance diffusion ultrasonic

10487081048708 Fusion welding

10487081048708 Chemical Oxyfuel

10487081048708 Electrical Arc welding

1048708 1048708 Consumable electrode

10487081048708 Non-consumable electrode

2008-spring-2004 SKim

15

Fusion Welding

1048708 Heat source chemical electrical1048708 Heat intensity1048708 Control1048708 Incomplete fusion penetration1048708 Underfilling undercutting cracks1048708 Heat affected zone (HAZ)1048708 Feed rate

2008-spring-2004 SKim

16

Underfill and undercut

2008-spring-2004 SKim

underfill

undercut

Good weld

17

Heat Intensity

1048708 A measure of radiation intensity Wcm2

1048708 High intensity high heat flux the faster the melting1048708 Automation needed to prevent overmelting vaporizing1048708 For a planar heat source on steel tm= (5000HI)2

Oxy 20-30 sec E-beam μ sec

2008-spring-2004 SKim

AirFuelGas Flame

OxyacetyleneThermit

Friction

ArcWelding

Resistance Welding(Oxygen Cutting)

Electron BeamLaser Beam

18

Laser for Razor

- 500 μm spots- 3 million spots per hour

How fast the welding speed is required

Kalpakjian2008-spring-2004 SKim

19

Melting front speed2D simplification

The Jacob number

The thermal diffusivity is given by

The melt front moves as

2008-spring-2004 SKim

20

Welding speed

1048708 tm = (sm)2 (2 α Ja)1048708 Any longer over-melt

1048708 If the weld pool size is d in diameter then you must feed at a rate that exceeds dtmax1048708 HI increases welding speed must go up1048708 α Ja increases interaction time must go up

Weld pool size d

2008-spring-2004 SKim

21

Weld Pool ndash Heat SourceInteraction Time

2008-spring-2004 SKim J Chun

22

HAZ(Heat Affected Zone)

1048708 Bad microstructure course grains weak to corrosion1048708 Plastic vs Metal

Temp

Base metal

HAZ

Weld metalMolten metal

Melting point

Microstructure change temperature

Base metal temperature

2008-spring-2004 SKim

23

Heat Affected Zone

1048708 Region near the weld pool is affected by heat Microstructure changes1048708 s ~ (α t)05

1048708 The size of the heat affected zone is controlled by the thermal diffusivity α Al Cu1048708 HI time (speed)1048708 Metal vs Plastic

2008-spring-2004 SKim

24

Heat Affected Zone (HAZ)

2008-spring-2004 SKim

Grain structureWeld lineIntergranular corrosionrecrystallization

25

Oxyfuel Gas Welding

1048708 Low cost manual1048708 Oxyfuel Oxygen + Fuel (Acetylene methyacetylene- propedieneetc) can reach 3300oC1048708 Stoichiometry neutral flame

1048708 More oxygen will cause oxidization (Oxidizing flame) bad for steels OK for copper1048708 More fuel will cause carburization (carburizing flame) Low heat for brazing soldering flame hardening

2008-spring-2004 SKim

26

Arc fusion welding

1048708 Temperature up to 30000oC1048708 Heat travels with the electrons1048708 Straight polarity workpiece + electrode ndash1048708 Shallow penetration sheet metal wide gaps1048708 reverse polarity1048708 Deeper penetration

Arrangement forconsumable electrodes

Heat generated at anode isabout 15 of the heatgenerated at cathode

Eelectron at cathode is given bythree components

Kinetic energyDrop across cool gas boundary

Work function(heat of condensation)

2008-spring-2004 SKim

27

Consumable electrode processes

1048708 Shielded metal arc welding1048708 Cheapest and most basic process lt $15001048708 50A-300A lt10KW1048708 Workpiece thickness 3-20mm

2008-spring-2004 SKim

SlagCoating deoxidizes weld and provides shielding gas

Multiple passSlag removal

28

Fusion Arc Welding

1048708 Preventing oxidation is the most important problem1048708 Coated electrodes to provide shielding gas1048708 Coatings fluorides silicate binders(clay) cellulose carbonates1048708 Electrodes different materials such as mild steel1048708 Submerged arc welding covered by granular flux1048708 Flat surfaces high throughput good quality1048708 Inert gas from external source1048708 Gas metal arc welding (MIG)1048708 Flux-cored arc welding etc (very versatile with proper fluxes)

2008-spring-2004 SKim

29

Gas Metal Arc Welding

Metal transfer- Spray transfer- Globular transfer- Short circuiting

Gas metal arc welding is aspecial variation on arc weldingin which the electrode fillermetal is fed directly through thetorch tip As arcing occurs theelectrode instantly meltsforming molten droplets that fallinto the weld pool Shielding gasis supplied through the torch tipto prevent chemical interactionswith the surroundingatmosphere

2008-spring-2004 SKim

30

Non-consumable electrode weldingGas Tungsten Arc Welding

1048708 Gas tungsten arc welding formerly known as TIG welding10487081048708 Tungsten electrode + filler wire10487081048708 Good for thin materials better control Al MgTi etc10487081048708 High quality and finish10487081048708 Tungsten electrode contamination10487081048708 200A DC-500A AC 8kW-50kW

2008-spring-2004 SKim

31

Other non-consumable electrodeprocesses

1048708 Plasma arc welding1048708 very higher energy concentration (33000oC) high feed rate 120-1000 mmmin arc stablility less thermal distortion deep penetration (keyhole technology)1048708 Laser beam welding electron beam welding etc

2008-spring-2004 SKim

32

Resistance Welding

1048708 Spot seam projection welding1048708 High current through the weld 3000A-100000A (05 ndash 10 V)

1048708 Extremely high heat flux (105 Wcm2)1048708 Heat generated H=i2Rt K (K=efficiency)1048708 Ex 5000 A 5 mm dia elctrodes two 1mm thick steel plates1048708 Effective resistance 200 Ω Then H= 500 J1048708 Nugget volume 30 mm3 mass 024 g 1400 Jg needed to melt1048708 336 J for melting lt 500 J

2008-spring-2004 SKim

33

Resistance welding

1048708 Spot welding Sequence1048708 Pressure on1048708 Current on1048708 Current off1048708 Pressure off1048708 Projection welding

2008-spring-2004 SKim

34

Solid-state interatomic bonding

1048708 Ultrasonic1048708 Oscillating tangential shear + static normal forces1048708 10KHz to 75 KHz1048708 Shear rarr plastic deformationrarr breaking up top layer (contaminated) rarr inter-atomic bond1048708 Friction1048708 Rotational part (at least one) flash1048708 Diffusion1048708 Goldsmiths bonded gold over copper1048708 Diffusion T gt 05 Tm1048708 Interface is the same as the bulk1048708 Fuselage frames

2008-spring-2004 SKim

35

Weld quality and defects

1048708 Porosity 1048708 Trapped gases contaminants 1048708 Preheat or increase rate of heat input1048708 Reduce speed allowing gas to escape cleaning1048708 Slag inclusions1048708 Oxides fluxes electrode coating trapped in weld zone1048708 Clean weld bead during multi-weld processes1048708 Provide enough shielding gas

2008-spring-2004 SKim

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 13: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

13

Wave soldering

1048708 Exposed metal joints are passed over a wave in a continuous motion where liquid solder penetrates into the joint by capillary forces

2008-spring-2004 SKim B Benhabib

Enlarged area

Circuitboard

Solderfountain

Moltensolder

Heater Pump

Enlarged area

14

Welding

1048708 Solid-state welding

10487081048708 No liquid electrical chemical mechanical

1048708 Resistance diffusion ultrasonic

10487081048708 Fusion welding

10487081048708 Chemical Oxyfuel

10487081048708 Electrical Arc welding

1048708 1048708 Consumable electrode

10487081048708 Non-consumable electrode

2008-spring-2004 SKim

15

Fusion Welding

1048708 Heat source chemical electrical1048708 Heat intensity1048708 Control1048708 Incomplete fusion penetration1048708 Underfilling undercutting cracks1048708 Heat affected zone (HAZ)1048708 Feed rate

2008-spring-2004 SKim

16

Underfill and undercut

2008-spring-2004 SKim

underfill

undercut

Good weld

17

Heat Intensity

1048708 A measure of radiation intensity Wcm2

1048708 High intensity high heat flux the faster the melting1048708 Automation needed to prevent overmelting vaporizing1048708 For a planar heat source on steel tm= (5000HI)2

Oxy 20-30 sec E-beam μ sec

2008-spring-2004 SKim

AirFuelGas Flame

OxyacetyleneThermit

Friction

ArcWelding

Resistance Welding(Oxygen Cutting)

Electron BeamLaser Beam

18

Laser for Razor

- 500 μm spots- 3 million spots per hour

How fast the welding speed is required

Kalpakjian2008-spring-2004 SKim

19

Melting front speed2D simplification

The Jacob number

The thermal diffusivity is given by

The melt front moves as

2008-spring-2004 SKim

20

Welding speed

1048708 tm = (sm)2 (2 α Ja)1048708 Any longer over-melt

1048708 If the weld pool size is d in diameter then you must feed at a rate that exceeds dtmax1048708 HI increases welding speed must go up1048708 α Ja increases interaction time must go up

Weld pool size d

2008-spring-2004 SKim

21

Weld Pool ndash Heat SourceInteraction Time

2008-spring-2004 SKim J Chun

22

HAZ(Heat Affected Zone)

1048708 Bad microstructure course grains weak to corrosion1048708 Plastic vs Metal

Temp

Base metal

HAZ

Weld metalMolten metal

Melting point

Microstructure change temperature

Base metal temperature

2008-spring-2004 SKim

23

Heat Affected Zone

1048708 Region near the weld pool is affected by heat Microstructure changes1048708 s ~ (α t)05

1048708 The size of the heat affected zone is controlled by the thermal diffusivity α Al Cu1048708 HI time (speed)1048708 Metal vs Plastic

2008-spring-2004 SKim

24

Heat Affected Zone (HAZ)

2008-spring-2004 SKim

Grain structureWeld lineIntergranular corrosionrecrystallization

25

Oxyfuel Gas Welding

1048708 Low cost manual1048708 Oxyfuel Oxygen + Fuel (Acetylene methyacetylene- propedieneetc) can reach 3300oC1048708 Stoichiometry neutral flame

1048708 More oxygen will cause oxidization (Oxidizing flame) bad for steels OK for copper1048708 More fuel will cause carburization (carburizing flame) Low heat for brazing soldering flame hardening

2008-spring-2004 SKim

26

Arc fusion welding

1048708 Temperature up to 30000oC1048708 Heat travels with the electrons1048708 Straight polarity workpiece + electrode ndash1048708 Shallow penetration sheet metal wide gaps1048708 reverse polarity1048708 Deeper penetration

Arrangement forconsumable electrodes

Heat generated at anode isabout 15 of the heatgenerated at cathode

Eelectron at cathode is given bythree components

Kinetic energyDrop across cool gas boundary

Work function(heat of condensation)

2008-spring-2004 SKim

27

Consumable electrode processes

1048708 Shielded metal arc welding1048708 Cheapest and most basic process lt $15001048708 50A-300A lt10KW1048708 Workpiece thickness 3-20mm

2008-spring-2004 SKim

SlagCoating deoxidizes weld and provides shielding gas

Multiple passSlag removal

28

Fusion Arc Welding

1048708 Preventing oxidation is the most important problem1048708 Coated electrodes to provide shielding gas1048708 Coatings fluorides silicate binders(clay) cellulose carbonates1048708 Electrodes different materials such as mild steel1048708 Submerged arc welding covered by granular flux1048708 Flat surfaces high throughput good quality1048708 Inert gas from external source1048708 Gas metal arc welding (MIG)1048708 Flux-cored arc welding etc (very versatile with proper fluxes)

2008-spring-2004 SKim

29

Gas Metal Arc Welding

Metal transfer- Spray transfer- Globular transfer- Short circuiting

Gas metal arc welding is aspecial variation on arc weldingin which the electrode fillermetal is fed directly through thetorch tip As arcing occurs theelectrode instantly meltsforming molten droplets that fallinto the weld pool Shielding gasis supplied through the torch tipto prevent chemical interactionswith the surroundingatmosphere

2008-spring-2004 SKim

30

Non-consumable electrode weldingGas Tungsten Arc Welding

1048708 Gas tungsten arc welding formerly known as TIG welding10487081048708 Tungsten electrode + filler wire10487081048708 Good for thin materials better control Al MgTi etc10487081048708 High quality and finish10487081048708 Tungsten electrode contamination10487081048708 200A DC-500A AC 8kW-50kW

2008-spring-2004 SKim

31

Other non-consumable electrodeprocesses

1048708 Plasma arc welding1048708 very higher energy concentration (33000oC) high feed rate 120-1000 mmmin arc stablility less thermal distortion deep penetration (keyhole technology)1048708 Laser beam welding electron beam welding etc

2008-spring-2004 SKim

32

Resistance Welding

1048708 Spot seam projection welding1048708 High current through the weld 3000A-100000A (05 ndash 10 V)

1048708 Extremely high heat flux (105 Wcm2)1048708 Heat generated H=i2Rt K (K=efficiency)1048708 Ex 5000 A 5 mm dia elctrodes two 1mm thick steel plates1048708 Effective resistance 200 Ω Then H= 500 J1048708 Nugget volume 30 mm3 mass 024 g 1400 Jg needed to melt1048708 336 J for melting lt 500 J

2008-spring-2004 SKim

33

Resistance welding

1048708 Spot welding Sequence1048708 Pressure on1048708 Current on1048708 Current off1048708 Pressure off1048708 Projection welding

2008-spring-2004 SKim

34

Solid-state interatomic bonding

1048708 Ultrasonic1048708 Oscillating tangential shear + static normal forces1048708 10KHz to 75 KHz1048708 Shear rarr plastic deformationrarr breaking up top layer (contaminated) rarr inter-atomic bond1048708 Friction1048708 Rotational part (at least one) flash1048708 Diffusion1048708 Goldsmiths bonded gold over copper1048708 Diffusion T gt 05 Tm1048708 Interface is the same as the bulk1048708 Fuselage frames

2008-spring-2004 SKim

35

Weld quality and defects

1048708 Porosity 1048708 Trapped gases contaminants 1048708 Preheat or increase rate of heat input1048708 Reduce speed allowing gas to escape cleaning1048708 Slag inclusions1048708 Oxides fluxes electrode coating trapped in weld zone1048708 Clean weld bead during multi-weld processes1048708 Provide enough shielding gas

2008-spring-2004 SKim

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 14: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

14

Welding

1048708 Solid-state welding

10487081048708 No liquid electrical chemical mechanical

1048708 Resistance diffusion ultrasonic

10487081048708 Fusion welding

10487081048708 Chemical Oxyfuel

10487081048708 Electrical Arc welding

1048708 1048708 Consumable electrode

10487081048708 Non-consumable electrode

2008-spring-2004 SKim

15

Fusion Welding

1048708 Heat source chemical electrical1048708 Heat intensity1048708 Control1048708 Incomplete fusion penetration1048708 Underfilling undercutting cracks1048708 Heat affected zone (HAZ)1048708 Feed rate

2008-spring-2004 SKim

16

Underfill and undercut

2008-spring-2004 SKim

underfill

undercut

Good weld

17

Heat Intensity

1048708 A measure of radiation intensity Wcm2

1048708 High intensity high heat flux the faster the melting1048708 Automation needed to prevent overmelting vaporizing1048708 For a planar heat source on steel tm= (5000HI)2

Oxy 20-30 sec E-beam μ sec

2008-spring-2004 SKim

AirFuelGas Flame

OxyacetyleneThermit

Friction

ArcWelding

Resistance Welding(Oxygen Cutting)

Electron BeamLaser Beam

18

Laser for Razor

- 500 μm spots- 3 million spots per hour

How fast the welding speed is required

Kalpakjian2008-spring-2004 SKim

19

Melting front speed2D simplification

The Jacob number

The thermal diffusivity is given by

The melt front moves as

2008-spring-2004 SKim

20

Welding speed

1048708 tm = (sm)2 (2 α Ja)1048708 Any longer over-melt

1048708 If the weld pool size is d in diameter then you must feed at a rate that exceeds dtmax1048708 HI increases welding speed must go up1048708 α Ja increases interaction time must go up

Weld pool size d

2008-spring-2004 SKim

21

Weld Pool ndash Heat SourceInteraction Time

2008-spring-2004 SKim J Chun

22

HAZ(Heat Affected Zone)

1048708 Bad microstructure course grains weak to corrosion1048708 Plastic vs Metal

Temp

Base metal

HAZ

Weld metalMolten metal

Melting point

Microstructure change temperature

Base metal temperature

2008-spring-2004 SKim

23

Heat Affected Zone

1048708 Region near the weld pool is affected by heat Microstructure changes1048708 s ~ (α t)05

1048708 The size of the heat affected zone is controlled by the thermal diffusivity α Al Cu1048708 HI time (speed)1048708 Metal vs Plastic

2008-spring-2004 SKim

24

Heat Affected Zone (HAZ)

2008-spring-2004 SKim

Grain structureWeld lineIntergranular corrosionrecrystallization

25

Oxyfuel Gas Welding

1048708 Low cost manual1048708 Oxyfuel Oxygen + Fuel (Acetylene methyacetylene- propedieneetc) can reach 3300oC1048708 Stoichiometry neutral flame

1048708 More oxygen will cause oxidization (Oxidizing flame) bad for steels OK for copper1048708 More fuel will cause carburization (carburizing flame) Low heat for brazing soldering flame hardening

2008-spring-2004 SKim

26

Arc fusion welding

1048708 Temperature up to 30000oC1048708 Heat travels with the electrons1048708 Straight polarity workpiece + electrode ndash1048708 Shallow penetration sheet metal wide gaps1048708 reverse polarity1048708 Deeper penetration

Arrangement forconsumable electrodes

Heat generated at anode isabout 15 of the heatgenerated at cathode

Eelectron at cathode is given bythree components

Kinetic energyDrop across cool gas boundary

Work function(heat of condensation)

2008-spring-2004 SKim

27

Consumable electrode processes

1048708 Shielded metal arc welding1048708 Cheapest and most basic process lt $15001048708 50A-300A lt10KW1048708 Workpiece thickness 3-20mm

2008-spring-2004 SKim

SlagCoating deoxidizes weld and provides shielding gas

Multiple passSlag removal

28

Fusion Arc Welding

1048708 Preventing oxidation is the most important problem1048708 Coated electrodes to provide shielding gas1048708 Coatings fluorides silicate binders(clay) cellulose carbonates1048708 Electrodes different materials such as mild steel1048708 Submerged arc welding covered by granular flux1048708 Flat surfaces high throughput good quality1048708 Inert gas from external source1048708 Gas metal arc welding (MIG)1048708 Flux-cored arc welding etc (very versatile with proper fluxes)

2008-spring-2004 SKim

29

Gas Metal Arc Welding

Metal transfer- Spray transfer- Globular transfer- Short circuiting

Gas metal arc welding is aspecial variation on arc weldingin which the electrode fillermetal is fed directly through thetorch tip As arcing occurs theelectrode instantly meltsforming molten droplets that fallinto the weld pool Shielding gasis supplied through the torch tipto prevent chemical interactionswith the surroundingatmosphere

2008-spring-2004 SKim

30

Non-consumable electrode weldingGas Tungsten Arc Welding

1048708 Gas tungsten arc welding formerly known as TIG welding10487081048708 Tungsten electrode + filler wire10487081048708 Good for thin materials better control Al MgTi etc10487081048708 High quality and finish10487081048708 Tungsten electrode contamination10487081048708 200A DC-500A AC 8kW-50kW

2008-spring-2004 SKim

31

Other non-consumable electrodeprocesses

1048708 Plasma arc welding1048708 very higher energy concentration (33000oC) high feed rate 120-1000 mmmin arc stablility less thermal distortion deep penetration (keyhole technology)1048708 Laser beam welding electron beam welding etc

2008-spring-2004 SKim

32

Resistance Welding

1048708 Spot seam projection welding1048708 High current through the weld 3000A-100000A (05 ndash 10 V)

1048708 Extremely high heat flux (105 Wcm2)1048708 Heat generated H=i2Rt K (K=efficiency)1048708 Ex 5000 A 5 mm dia elctrodes two 1mm thick steel plates1048708 Effective resistance 200 Ω Then H= 500 J1048708 Nugget volume 30 mm3 mass 024 g 1400 Jg needed to melt1048708 336 J for melting lt 500 J

2008-spring-2004 SKim

33

Resistance welding

1048708 Spot welding Sequence1048708 Pressure on1048708 Current on1048708 Current off1048708 Pressure off1048708 Projection welding

2008-spring-2004 SKim

34

Solid-state interatomic bonding

1048708 Ultrasonic1048708 Oscillating tangential shear + static normal forces1048708 10KHz to 75 KHz1048708 Shear rarr plastic deformationrarr breaking up top layer (contaminated) rarr inter-atomic bond1048708 Friction1048708 Rotational part (at least one) flash1048708 Diffusion1048708 Goldsmiths bonded gold over copper1048708 Diffusion T gt 05 Tm1048708 Interface is the same as the bulk1048708 Fuselage frames

2008-spring-2004 SKim

35

Weld quality and defects

1048708 Porosity 1048708 Trapped gases contaminants 1048708 Preheat or increase rate of heat input1048708 Reduce speed allowing gas to escape cleaning1048708 Slag inclusions1048708 Oxides fluxes electrode coating trapped in weld zone1048708 Clean weld bead during multi-weld processes1048708 Provide enough shielding gas

2008-spring-2004 SKim

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 15: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

15

Fusion Welding

1048708 Heat source chemical electrical1048708 Heat intensity1048708 Control1048708 Incomplete fusion penetration1048708 Underfilling undercutting cracks1048708 Heat affected zone (HAZ)1048708 Feed rate

2008-spring-2004 SKim

16

Underfill and undercut

2008-spring-2004 SKim

underfill

undercut

Good weld

17

Heat Intensity

1048708 A measure of radiation intensity Wcm2

1048708 High intensity high heat flux the faster the melting1048708 Automation needed to prevent overmelting vaporizing1048708 For a planar heat source on steel tm= (5000HI)2

Oxy 20-30 sec E-beam μ sec

2008-spring-2004 SKim

AirFuelGas Flame

OxyacetyleneThermit

Friction

ArcWelding

Resistance Welding(Oxygen Cutting)

Electron BeamLaser Beam

18

Laser for Razor

- 500 μm spots- 3 million spots per hour

How fast the welding speed is required

Kalpakjian2008-spring-2004 SKim

19

Melting front speed2D simplification

The Jacob number

The thermal diffusivity is given by

The melt front moves as

2008-spring-2004 SKim

20

Welding speed

1048708 tm = (sm)2 (2 α Ja)1048708 Any longer over-melt

1048708 If the weld pool size is d in diameter then you must feed at a rate that exceeds dtmax1048708 HI increases welding speed must go up1048708 α Ja increases interaction time must go up

Weld pool size d

2008-spring-2004 SKim

21

Weld Pool ndash Heat SourceInteraction Time

2008-spring-2004 SKim J Chun

22

HAZ(Heat Affected Zone)

1048708 Bad microstructure course grains weak to corrosion1048708 Plastic vs Metal

Temp

Base metal

HAZ

Weld metalMolten metal

Melting point

Microstructure change temperature

Base metal temperature

2008-spring-2004 SKim

23

Heat Affected Zone

1048708 Region near the weld pool is affected by heat Microstructure changes1048708 s ~ (α t)05

1048708 The size of the heat affected zone is controlled by the thermal diffusivity α Al Cu1048708 HI time (speed)1048708 Metal vs Plastic

2008-spring-2004 SKim

24

Heat Affected Zone (HAZ)

2008-spring-2004 SKim

Grain structureWeld lineIntergranular corrosionrecrystallization

25

Oxyfuel Gas Welding

1048708 Low cost manual1048708 Oxyfuel Oxygen + Fuel (Acetylene methyacetylene- propedieneetc) can reach 3300oC1048708 Stoichiometry neutral flame

1048708 More oxygen will cause oxidization (Oxidizing flame) bad for steels OK for copper1048708 More fuel will cause carburization (carburizing flame) Low heat for brazing soldering flame hardening

2008-spring-2004 SKim

26

Arc fusion welding

1048708 Temperature up to 30000oC1048708 Heat travels with the electrons1048708 Straight polarity workpiece + electrode ndash1048708 Shallow penetration sheet metal wide gaps1048708 reverse polarity1048708 Deeper penetration

Arrangement forconsumable electrodes

Heat generated at anode isabout 15 of the heatgenerated at cathode

Eelectron at cathode is given bythree components

Kinetic energyDrop across cool gas boundary

Work function(heat of condensation)

2008-spring-2004 SKim

27

Consumable electrode processes

1048708 Shielded metal arc welding1048708 Cheapest and most basic process lt $15001048708 50A-300A lt10KW1048708 Workpiece thickness 3-20mm

2008-spring-2004 SKim

SlagCoating deoxidizes weld and provides shielding gas

Multiple passSlag removal

28

Fusion Arc Welding

1048708 Preventing oxidation is the most important problem1048708 Coated electrodes to provide shielding gas1048708 Coatings fluorides silicate binders(clay) cellulose carbonates1048708 Electrodes different materials such as mild steel1048708 Submerged arc welding covered by granular flux1048708 Flat surfaces high throughput good quality1048708 Inert gas from external source1048708 Gas metal arc welding (MIG)1048708 Flux-cored arc welding etc (very versatile with proper fluxes)

2008-spring-2004 SKim

29

Gas Metal Arc Welding

Metal transfer- Spray transfer- Globular transfer- Short circuiting

Gas metal arc welding is aspecial variation on arc weldingin which the electrode fillermetal is fed directly through thetorch tip As arcing occurs theelectrode instantly meltsforming molten droplets that fallinto the weld pool Shielding gasis supplied through the torch tipto prevent chemical interactionswith the surroundingatmosphere

2008-spring-2004 SKim

30

Non-consumable electrode weldingGas Tungsten Arc Welding

1048708 Gas tungsten arc welding formerly known as TIG welding10487081048708 Tungsten electrode + filler wire10487081048708 Good for thin materials better control Al MgTi etc10487081048708 High quality and finish10487081048708 Tungsten electrode contamination10487081048708 200A DC-500A AC 8kW-50kW

2008-spring-2004 SKim

31

Other non-consumable electrodeprocesses

1048708 Plasma arc welding1048708 very higher energy concentration (33000oC) high feed rate 120-1000 mmmin arc stablility less thermal distortion deep penetration (keyhole technology)1048708 Laser beam welding electron beam welding etc

2008-spring-2004 SKim

32

Resistance Welding

1048708 Spot seam projection welding1048708 High current through the weld 3000A-100000A (05 ndash 10 V)

1048708 Extremely high heat flux (105 Wcm2)1048708 Heat generated H=i2Rt K (K=efficiency)1048708 Ex 5000 A 5 mm dia elctrodes two 1mm thick steel plates1048708 Effective resistance 200 Ω Then H= 500 J1048708 Nugget volume 30 mm3 mass 024 g 1400 Jg needed to melt1048708 336 J for melting lt 500 J

2008-spring-2004 SKim

33

Resistance welding

1048708 Spot welding Sequence1048708 Pressure on1048708 Current on1048708 Current off1048708 Pressure off1048708 Projection welding

2008-spring-2004 SKim

34

Solid-state interatomic bonding

1048708 Ultrasonic1048708 Oscillating tangential shear + static normal forces1048708 10KHz to 75 KHz1048708 Shear rarr plastic deformationrarr breaking up top layer (contaminated) rarr inter-atomic bond1048708 Friction1048708 Rotational part (at least one) flash1048708 Diffusion1048708 Goldsmiths bonded gold over copper1048708 Diffusion T gt 05 Tm1048708 Interface is the same as the bulk1048708 Fuselage frames

2008-spring-2004 SKim

35

Weld quality and defects

1048708 Porosity 1048708 Trapped gases contaminants 1048708 Preheat or increase rate of heat input1048708 Reduce speed allowing gas to escape cleaning1048708 Slag inclusions1048708 Oxides fluxes electrode coating trapped in weld zone1048708 Clean weld bead during multi-weld processes1048708 Provide enough shielding gas

2008-spring-2004 SKim

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 16: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

16

Underfill and undercut

2008-spring-2004 SKim

underfill

undercut

Good weld

17

Heat Intensity

1048708 A measure of radiation intensity Wcm2

1048708 High intensity high heat flux the faster the melting1048708 Automation needed to prevent overmelting vaporizing1048708 For a planar heat source on steel tm= (5000HI)2

Oxy 20-30 sec E-beam μ sec

2008-spring-2004 SKim

AirFuelGas Flame

OxyacetyleneThermit

Friction

ArcWelding

Resistance Welding(Oxygen Cutting)

Electron BeamLaser Beam

18

Laser for Razor

- 500 μm spots- 3 million spots per hour

How fast the welding speed is required

Kalpakjian2008-spring-2004 SKim

19

Melting front speed2D simplification

The Jacob number

The thermal diffusivity is given by

The melt front moves as

2008-spring-2004 SKim

20

Welding speed

1048708 tm = (sm)2 (2 α Ja)1048708 Any longer over-melt

1048708 If the weld pool size is d in diameter then you must feed at a rate that exceeds dtmax1048708 HI increases welding speed must go up1048708 α Ja increases interaction time must go up

Weld pool size d

2008-spring-2004 SKim

21

Weld Pool ndash Heat SourceInteraction Time

2008-spring-2004 SKim J Chun

22

HAZ(Heat Affected Zone)

1048708 Bad microstructure course grains weak to corrosion1048708 Plastic vs Metal

Temp

Base metal

HAZ

Weld metalMolten metal

Melting point

Microstructure change temperature

Base metal temperature

2008-spring-2004 SKim

23

Heat Affected Zone

1048708 Region near the weld pool is affected by heat Microstructure changes1048708 s ~ (α t)05

1048708 The size of the heat affected zone is controlled by the thermal diffusivity α Al Cu1048708 HI time (speed)1048708 Metal vs Plastic

2008-spring-2004 SKim

24

Heat Affected Zone (HAZ)

2008-spring-2004 SKim

Grain structureWeld lineIntergranular corrosionrecrystallization

25

Oxyfuel Gas Welding

1048708 Low cost manual1048708 Oxyfuel Oxygen + Fuel (Acetylene methyacetylene- propedieneetc) can reach 3300oC1048708 Stoichiometry neutral flame

1048708 More oxygen will cause oxidization (Oxidizing flame) bad for steels OK for copper1048708 More fuel will cause carburization (carburizing flame) Low heat for brazing soldering flame hardening

2008-spring-2004 SKim

26

Arc fusion welding

1048708 Temperature up to 30000oC1048708 Heat travels with the electrons1048708 Straight polarity workpiece + electrode ndash1048708 Shallow penetration sheet metal wide gaps1048708 reverse polarity1048708 Deeper penetration

Arrangement forconsumable electrodes

Heat generated at anode isabout 15 of the heatgenerated at cathode

Eelectron at cathode is given bythree components

Kinetic energyDrop across cool gas boundary

Work function(heat of condensation)

2008-spring-2004 SKim

27

Consumable electrode processes

1048708 Shielded metal arc welding1048708 Cheapest and most basic process lt $15001048708 50A-300A lt10KW1048708 Workpiece thickness 3-20mm

2008-spring-2004 SKim

SlagCoating deoxidizes weld and provides shielding gas

Multiple passSlag removal

28

Fusion Arc Welding

1048708 Preventing oxidation is the most important problem1048708 Coated electrodes to provide shielding gas1048708 Coatings fluorides silicate binders(clay) cellulose carbonates1048708 Electrodes different materials such as mild steel1048708 Submerged arc welding covered by granular flux1048708 Flat surfaces high throughput good quality1048708 Inert gas from external source1048708 Gas metal arc welding (MIG)1048708 Flux-cored arc welding etc (very versatile with proper fluxes)

2008-spring-2004 SKim

29

Gas Metal Arc Welding

Metal transfer- Spray transfer- Globular transfer- Short circuiting

Gas metal arc welding is aspecial variation on arc weldingin which the electrode fillermetal is fed directly through thetorch tip As arcing occurs theelectrode instantly meltsforming molten droplets that fallinto the weld pool Shielding gasis supplied through the torch tipto prevent chemical interactionswith the surroundingatmosphere

2008-spring-2004 SKim

30

Non-consumable electrode weldingGas Tungsten Arc Welding

1048708 Gas tungsten arc welding formerly known as TIG welding10487081048708 Tungsten electrode + filler wire10487081048708 Good for thin materials better control Al MgTi etc10487081048708 High quality and finish10487081048708 Tungsten electrode contamination10487081048708 200A DC-500A AC 8kW-50kW

2008-spring-2004 SKim

31

Other non-consumable electrodeprocesses

1048708 Plasma arc welding1048708 very higher energy concentration (33000oC) high feed rate 120-1000 mmmin arc stablility less thermal distortion deep penetration (keyhole technology)1048708 Laser beam welding electron beam welding etc

2008-spring-2004 SKim

32

Resistance Welding

1048708 Spot seam projection welding1048708 High current through the weld 3000A-100000A (05 ndash 10 V)

1048708 Extremely high heat flux (105 Wcm2)1048708 Heat generated H=i2Rt K (K=efficiency)1048708 Ex 5000 A 5 mm dia elctrodes two 1mm thick steel plates1048708 Effective resistance 200 Ω Then H= 500 J1048708 Nugget volume 30 mm3 mass 024 g 1400 Jg needed to melt1048708 336 J for melting lt 500 J

2008-spring-2004 SKim

33

Resistance welding

1048708 Spot welding Sequence1048708 Pressure on1048708 Current on1048708 Current off1048708 Pressure off1048708 Projection welding

2008-spring-2004 SKim

34

Solid-state interatomic bonding

1048708 Ultrasonic1048708 Oscillating tangential shear + static normal forces1048708 10KHz to 75 KHz1048708 Shear rarr plastic deformationrarr breaking up top layer (contaminated) rarr inter-atomic bond1048708 Friction1048708 Rotational part (at least one) flash1048708 Diffusion1048708 Goldsmiths bonded gold over copper1048708 Diffusion T gt 05 Tm1048708 Interface is the same as the bulk1048708 Fuselage frames

2008-spring-2004 SKim

35

Weld quality and defects

1048708 Porosity 1048708 Trapped gases contaminants 1048708 Preheat or increase rate of heat input1048708 Reduce speed allowing gas to escape cleaning1048708 Slag inclusions1048708 Oxides fluxes electrode coating trapped in weld zone1048708 Clean weld bead during multi-weld processes1048708 Provide enough shielding gas

2008-spring-2004 SKim

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 17: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

17

Heat Intensity

1048708 A measure of radiation intensity Wcm2

1048708 High intensity high heat flux the faster the melting1048708 Automation needed to prevent overmelting vaporizing1048708 For a planar heat source on steel tm= (5000HI)2

Oxy 20-30 sec E-beam μ sec

2008-spring-2004 SKim

AirFuelGas Flame

OxyacetyleneThermit

Friction

ArcWelding

Resistance Welding(Oxygen Cutting)

Electron BeamLaser Beam

18

Laser for Razor

- 500 μm spots- 3 million spots per hour

How fast the welding speed is required

Kalpakjian2008-spring-2004 SKim

19

Melting front speed2D simplification

The Jacob number

The thermal diffusivity is given by

The melt front moves as

2008-spring-2004 SKim

20

Welding speed

1048708 tm = (sm)2 (2 α Ja)1048708 Any longer over-melt

1048708 If the weld pool size is d in diameter then you must feed at a rate that exceeds dtmax1048708 HI increases welding speed must go up1048708 α Ja increases interaction time must go up

Weld pool size d

2008-spring-2004 SKim

21

Weld Pool ndash Heat SourceInteraction Time

2008-spring-2004 SKim J Chun

22

HAZ(Heat Affected Zone)

1048708 Bad microstructure course grains weak to corrosion1048708 Plastic vs Metal

Temp

Base metal

HAZ

Weld metalMolten metal

Melting point

Microstructure change temperature

Base metal temperature

2008-spring-2004 SKim

23

Heat Affected Zone

1048708 Region near the weld pool is affected by heat Microstructure changes1048708 s ~ (α t)05

1048708 The size of the heat affected zone is controlled by the thermal diffusivity α Al Cu1048708 HI time (speed)1048708 Metal vs Plastic

2008-spring-2004 SKim

24

Heat Affected Zone (HAZ)

2008-spring-2004 SKim

Grain structureWeld lineIntergranular corrosionrecrystallization

25

Oxyfuel Gas Welding

1048708 Low cost manual1048708 Oxyfuel Oxygen + Fuel (Acetylene methyacetylene- propedieneetc) can reach 3300oC1048708 Stoichiometry neutral flame

1048708 More oxygen will cause oxidization (Oxidizing flame) bad for steels OK for copper1048708 More fuel will cause carburization (carburizing flame) Low heat for brazing soldering flame hardening

2008-spring-2004 SKim

26

Arc fusion welding

1048708 Temperature up to 30000oC1048708 Heat travels with the electrons1048708 Straight polarity workpiece + electrode ndash1048708 Shallow penetration sheet metal wide gaps1048708 reverse polarity1048708 Deeper penetration

Arrangement forconsumable electrodes

Heat generated at anode isabout 15 of the heatgenerated at cathode

Eelectron at cathode is given bythree components

Kinetic energyDrop across cool gas boundary

Work function(heat of condensation)

2008-spring-2004 SKim

27

Consumable electrode processes

1048708 Shielded metal arc welding1048708 Cheapest and most basic process lt $15001048708 50A-300A lt10KW1048708 Workpiece thickness 3-20mm

2008-spring-2004 SKim

SlagCoating deoxidizes weld and provides shielding gas

Multiple passSlag removal

28

Fusion Arc Welding

1048708 Preventing oxidation is the most important problem1048708 Coated electrodes to provide shielding gas1048708 Coatings fluorides silicate binders(clay) cellulose carbonates1048708 Electrodes different materials such as mild steel1048708 Submerged arc welding covered by granular flux1048708 Flat surfaces high throughput good quality1048708 Inert gas from external source1048708 Gas metal arc welding (MIG)1048708 Flux-cored arc welding etc (very versatile with proper fluxes)

2008-spring-2004 SKim

29

Gas Metal Arc Welding

Metal transfer- Spray transfer- Globular transfer- Short circuiting

Gas metal arc welding is aspecial variation on arc weldingin which the electrode fillermetal is fed directly through thetorch tip As arcing occurs theelectrode instantly meltsforming molten droplets that fallinto the weld pool Shielding gasis supplied through the torch tipto prevent chemical interactionswith the surroundingatmosphere

2008-spring-2004 SKim

30

Non-consumable electrode weldingGas Tungsten Arc Welding

1048708 Gas tungsten arc welding formerly known as TIG welding10487081048708 Tungsten electrode + filler wire10487081048708 Good for thin materials better control Al MgTi etc10487081048708 High quality and finish10487081048708 Tungsten electrode contamination10487081048708 200A DC-500A AC 8kW-50kW

2008-spring-2004 SKim

31

Other non-consumable electrodeprocesses

1048708 Plasma arc welding1048708 very higher energy concentration (33000oC) high feed rate 120-1000 mmmin arc stablility less thermal distortion deep penetration (keyhole technology)1048708 Laser beam welding electron beam welding etc

2008-spring-2004 SKim

32

Resistance Welding

1048708 Spot seam projection welding1048708 High current through the weld 3000A-100000A (05 ndash 10 V)

1048708 Extremely high heat flux (105 Wcm2)1048708 Heat generated H=i2Rt K (K=efficiency)1048708 Ex 5000 A 5 mm dia elctrodes two 1mm thick steel plates1048708 Effective resistance 200 Ω Then H= 500 J1048708 Nugget volume 30 mm3 mass 024 g 1400 Jg needed to melt1048708 336 J for melting lt 500 J

2008-spring-2004 SKim

33

Resistance welding

1048708 Spot welding Sequence1048708 Pressure on1048708 Current on1048708 Current off1048708 Pressure off1048708 Projection welding

2008-spring-2004 SKim

34

Solid-state interatomic bonding

1048708 Ultrasonic1048708 Oscillating tangential shear + static normal forces1048708 10KHz to 75 KHz1048708 Shear rarr plastic deformationrarr breaking up top layer (contaminated) rarr inter-atomic bond1048708 Friction1048708 Rotational part (at least one) flash1048708 Diffusion1048708 Goldsmiths bonded gold over copper1048708 Diffusion T gt 05 Tm1048708 Interface is the same as the bulk1048708 Fuselage frames

2008-spring-2004 SKim

35

Weld quality and defects

1048708 Porosity 1048708 Trapped gases contaminants 1048708 Preheat or increase rate of heat input1048708 Reduce speed allowing gas to escape cleaning1048708 Slag inclusions1048708 Oxides fluxes electrode coating trapped in weld zone1048708 Clean weld bead during multi-weld processes1048708 Provide enough shielding gas

2008-spring-2004 SKim

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 18: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

18

Laser for Razor

- 500 μm spots- 3 million spots per hour

How fast the welding speed is required

Kalpakjian2008-spring-2004 SKim

19

Melting front speed2D simplification

The Jacob number

The thermal diffusivity is given by

The melt front moves as

2008-spring-2004 SKim

20

Welding speed

1048708 tm = (sm)2 (2 α Ja)1048708 Any longer over-melt

1048708 If the weld pool size is d in diameter then you must feed at a rate that exceeds dtmax1048708 HI increases welding speed must go up1048708 α Ja increases interaction time must go up

Weld pool size d

2008-spring-2004 SKim

21

Weld Pool ndash Heat SourceInteraction Time

2008-spring-2004 SKim J Chun

22

HAZ(Heat Affected Zone)

1048708 Bad microstructure course grains weak to corrosion1048708 Plastic vs Metal

Temp

Base metal

HAZ

Weld metalMolten metal

Melting point

Microstructure change temperature

Base metal temperature

2008-spring-2004 SKim

23

Heat Affected Zone

1048708 Region near the weld pool is affected by heat Microstructure changes1048708 s ~ (α t)05

1048708 The size of the heat affected zone is controlled by the thermal diffusivity α Al Cu1048708 HI time (speed)1048708 Metal vs Plastic

2008-spring-2004 SKim

24

Heat Affected Zone (HAZ)

2008-spring-2004 SKim

Grain structureWeld lineIntergranular corrosionrecrystallization

25

Oxyfuel Gas Welding

1048708 Low cost manual1048708 Oxyfuel Oxygen + Fuel (Acetylene methyacetylene- propedieneetc) can reach 3300oC1048708 Stoichiometry neutral flame

1048708 More oxygen will cause oxidization (Oxidizing flame) bad for steels OK for copper1048708 More fuel will cause carburization (carburizing flame) Low heat for brazing soldering flame hardening

2008-spring-2004 SKim

26

Arc fusion welding

1048708 Temperature up to 30000oC1048708 Heat travels with the electrons1048708 Straight polarity workpiece + electrode ndash1048708 Shallow penetration sheet metal wide gaps1048708 reverse polarity1048708 Deeper penetration

Arrangement forconsumable electrodes

Heat generated at anode isabout 15 of the heatgenerated at cathode

Eelectron at cathode is given bythree components

Kinetic energyDrop across cool gas boundary

Work function(heat of condensation)

2008-spring-2004 SKim

27

Consumable electrode processes

1048708 Shielded metal arc welding1048708 Cheapest and most basic process lt $15001048708 50A-300A lt10KW1048708 Workpiece thickness 3-20mm

2008-spring-2004 SKim

SlagCoating deoxidizes weld and provides shielding gas

Multiple passSlag removal

28

Fusion Arc Welding

1048708 Preventing oxidation is the most important problem1048708 Coated electrodes to provide shielding gas1048708 Coatings fluorides silicate binders(clay) cellulose carbonates1048708 Electrodes different materials such as mild steel1048708 Submerged arc welding covered by granular flux1048708 Flat surfaces high throughput good quality1048708 Inert gas from external source1048708 Gas metal arc welding (MIG)1048708 Flux-cored arc welding etc (very versatile with proper fluxes)

2008-spring-2004 SKim

29

Gas Metal Arc Welding

Metal transfer- Spray transfer- Globular transfer- Short circuiting

Gas metal arc welding is aspecial variation on arc weldingin which the electrode fillermetal is fed directly through thetorch tip As arcing occurs theelectrode instantly meltsforming molten droplets that fallinto the weld pool Shielding gasis supplied through the torch tipto prevent chemical interactionswith the surroundingatmosphere

2008-spring-2004 SKim

30

Non-consumable electrode weldingGas Tungsten Arc Welding

1048708 Gas tungsten arc welding formerly known as TIG welding10487081048708 Tungsten electrode + filler wire10487081048708 Good for thin materials better control Al MgTi etc10487081048708 High quality and finish10487081048708 Tungsten electrode contamination10487081048708 200A DC-500A AC 8kW-50kW

2008-spring-2004 SKim

31

Other non-consumable electrodeprocesses

1048708 Plasma arc welding1048708 very higher energy concentration (33000oC) high feed rate 120-1000 mmmin arc stablility less thermal distortion deep penetration (keyhole technology)1048708 Laser beam welding electron beam welding etc

2008-spring-2004 SKim

32

Resistance Welding

1048708 Spot seam projection welding1048708 High current through the weld 3000A-100000A (05 ndash 10 V)

1048708 Extremely high heat flux (105 Wcm2)1048708 Heat generated H=i2Rt K (K=efficiency)1048708 Ex 5000 A 5 mm dia elctrodes two 1mm thick steel plates1048708 Effective resistance 200 Ω Then H= 500 J1048708 Nugget volume 30 mm3 mass 024 g 1400 Jg needed to melt1048708 336 J for melting lt 500 J

2008-spring-2004 SKim

33

Resistance welding

1048708 Spot welding Sequence1048708 Pressure on1048708 Current on1048708 Current off1048708 Pressure off1048708 Projection welding

2008-spring-2004 SKim

34

Solid-state interatomic bonding

1048708 Ultrasonic1048708 Oscillating tangential shear + static normal forces1048708 10KHz to 75 KHz1048708 Shear rarr plastic deformationrarr breaking up top layer (contaminated) rarr inter-atomic bond1048708 Friction1048708 Rotational part (at least one) flash1048708 Diffusion1048708 Goldsmiths bonded gold over copper1048708 Diffusion T gt 05 Tm1048708 Interface is the same as the bulk1048708 Fuselage frames

2008-spring-2004 SKim

35

Weld quality and defects

1048708 Porosity 1048708 Trapped gases contaminants 1048708 Preheat or increase rate of heat input1048708 Reduce speed allowing gas to escape cleaning1048708 Slag inclusions1048708 Oxides fluxes electrode coating trapped in weld zone1048708 Clean weld bead during multi-weld processes1048708 Provide enough shielding gas

2008-spring-2004 SKim

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 19: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

19

Melting front speed2D simplification

The Jacob number

The thermal diffusivity is given by

The melt front moves as

2008-spring-2004 SKim

20

Welding speed

1048708 tm = (sm)2 (2 α Ja)1048708 Any longer over-melt

1048708 If the weld pool size is d in diameter then you must feed at a rate that exceeds dtmax1048708 HI increases welding speed must go up1048708 α Ja increases interaction time must go up

Weld pool size d

2008-spring-2004 SKim

21

Weld Pool ndash Heat SourceInteraction Time

2008-spring-2004 SKim J Chun

22

HAZ(Heat Affected Zone)

1048708 Bad microstructure course grains weak to corrosion1048708 Plastic vs Metal

Temp

Base metal

HAZ

Weld metalMolten metal

Melting point

Microstructure change temperature

Base metal temperature

2008-spring-2004 SKim

23

Heat Affected Zone

1048708 Region near the weld pool is affected by heat Microstructure changes1048708 s ~ (α t)05

1048708 The size of the heat affected zone is controlled by the thermal diffusivity α Al Cu1048708 HI time (speed)1048708 Metal vs Plastic

2008-spring-2004 SKim

24

Heat Affected Zone (HAZ)

2008-spring-2004 SKim

Grain structureWeld lineIntergranular corrosionrecrystallization

25

Oxyfuel Gas Welding

1048708 Low cost manual1048708 Oxyfuel Oxygen + Fuel (Acetylene methyacetylene- propedieneetc) can reach 3300oC1048708 Stoichiometry neutral flame

1048708 More oxygen will cause oxidization (Oxidizing flame) bad for steels OK for copper1048708 More fuel will cause carburization (carburizing flame) Low heat for brazing soldering flame hardening

2008-spring-2004 SKim

26

Arc fusion welding

1048708 Temperature up to 30000oC1048708 Heat travels with the electrons1048708 Straight polarity workpiece + electrode ndash1048708 Shallow penetration sheet metal wide gaps1048708 reverse polarity1048708 Deeper penetration

Arrangement forconsumable electrodes

Heat generated at anode isabout 15 of the heatgenerated at cathode

Eelectron at cathode is given bythree components

Kinetic energyDrop across cool gas boundary

Work function(heat of condensation)

2008-spring-2004 SKim

27

Consumable electrode processes

1048708 Shielded metal arc welding1048708 Cheapest and most basic process lt $15001048708 50A-300A lt10KW1048708 Workpiece thickness 3-20mm

2008-spring-2004 SKim

SlagCoating deoxidizes weld and provides shielding gas

Multiple passSlag removal

28

Fusion Arc Welding

1048708 Preventing oxidation is the most important problem1048708 Coated electrodes to provide shielding gas1048708 Coatings fluorides silicate binders(clay) cellulose carbonates1048708 Electrodes different materials such as mild steel1048708 Submerged arc welding covered by granular flux1048708 Flat surfaces high throughput good quality1048708 Inert gas from external source1048708 Gas metal arc welding (MIG)1048708 Flux-cored arc welding etc (very versatile with proper fluxes)

2008-spring-2004 SKim

29

Gas Metal Arc Welding

Metal transfer- Spray transfer- Globular transfer- Short circuiting

Gas metal arc welding is aspecial variation on arc weldingin which the electrode fillermetal is fed directly through thetorch tip As arcing occurs theelectrode instantly meltsforming molten droplets that fallinto the weld pool Shielding gasis supplied through the torch tipto prevent chemical interactionswith the surroundingatmosphere

2008-spring-2004 SKim

30

Non-consumable electrode weldingGas Tungsten Arc Welding

1048708 Gas tungsten arc welding formerly known as TIG welding10487081048708 Tungsten electrode + filler wire10487081048708 Good for thin materials better control Al MgTi etc10487081048708 High quality and finish10487081048708 Tungsten electrode contamination10487081048708 200A DC-500A AC 8kW-50kW

2008-spring-2004 SKim

31

Other non-consumable electrodeprocesses

1048708 Plasma arc welding1048708 very higher energy concentration (33000oC) high feed rate 120-1000 mmmin arc stablility less thermal distortion deep penetration (keyhole technology)1048708 Laser beam welding electron beam welding etc

2008-spring-2004 SKim

32

Resistance Welding

1048708 Spot seam projection welding1048708 High current through the weld 3000A-100000A (05 ndash 10 V)

1048708 Extremely high heat flux (105 Wcm2)1048708 Heat generated H=i2Rt K (K=efficiency)1048708 Ex 5000 A 5 mm dia elctrodes two 1mm thick steel plates1048708 Effective resistance 200 Ω Then H= 500 J1048708 Nugget volume 30 mm3 mass 024 g 1400 Jg needed to melt1048708 336 J for melting lt 500 J

2008-spring-2004 SKim

33

Resistance welding

1048708 Spot welding Sequence1048708 Pressure on1048708 Current on1048708 Current off1048708 Pressure off1048708 Projection welding

2008-spring-2004 SKim

34

Solid-state interatomic bonding

1048708 Ultrasonic1048708 Oscillating tangential shear + static normal forces1048708 10KHz to 75 KHz1048708 Shear rarr plastic deformationrarr breaking up top layer (contaminated) rarr inter-atomic bond1048708 Friction1048708 Rotational part (at least one) flash1048708 Diffusion1048708 Goldsmiths bonded gold over copper1048708 Diffusion T gt 05 Tm1048708 Interface is the same as the bulk1048708 Fuselage frames

2008-spring-2004 SKim

35

Weld quality and defects

1048708 Porosity 1048708 Trapped gases contaminants 1048708 Preheat or increase rate of heat input1048708 Reduce speed allowing gas to escape cleaning1048708 Slag inclusions1048708 Oxides fluxes electrode coating trapped in weld zone1048708 Clean weld bead during multi-weld processes1048708 Provide enough shielding gas

2008-spring-2004 SKim

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 20: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

20

Welding speed

1048708 tm = (sm)2 (2 α Ja)1048708 Any longer over-melt

1048708 If the weld pool size is d in diameter then you must feed at a rate that exceeds dtmax1048708 HI increases welding speed must go up1048708 α Ja increases interaction time must go up

Weld pool size d

2008-spring-2004 SKim

21

Weld Pool ndash Heat SourceInteraction Time

2008-spring-2004 SKim J Chun

22

HAZ(Heat Affected Zone)

1048708 Bad microstructure course grains weak to corrosion1048708 Plastic vs Metal

Temp

Base metal

HAZ

Weld metalMolten metal

Melting point

Microstructure change temperature

Base metal temperature

2008-spring-2004 SKim

23

Heat Affected Zone

1048708 Region near the weld pool is affected by heat Microstructure changes1048708 s ~ (α t)05

1048708 The size of the heat affected zone is controlled by the thermal diffusivity α Al Cu1048708 HI time (speed)1048708 Metal vs Plastic

2008-spring-2004 SKim

24

Heat Affected Zone (HAZ)

2008-spring-2004 SKim

Grain structureWeld lineIntergranular corrosionrecrystallization

25

Oxyfuel Gas Welding

1048708 Low cost manual1048708 Oxyfuel Oxygen + Fuel (Acetylene methyacetylene- propedieneetc) can reach 3300oC1048708 Stoichiometry neutral flame

1048708 More oxygen will cause oxidization (Oxidizing flame) bad for steels OK for copper1048708 More fuel will cause carburization (carburizing flame) Low heat for brazing soldering flame hardening

2008-spring-2004 SKim

26

Arc fusion welding

1048708 Temperature up to 30000oC1048708 Heat travels with the electrons1048708 Straight polarity workpiece + electrode ndash1048708 Shallow penetration sheet metal wide gaps1048708 reverse polarity1048708 Deeper penetration

Arrangement forconsumable electrodes

Heat generated at anode isabout 15 of the heatgenerated at cathode

Eelectron at cathode is given bythree components

Kinetic energyDrop across cool gas boundary

Work function(heat of condensation)

2008-spring-2004 SKim

27

Consumable electrode processes

1048708 Shielded metal arc welding1048708 Cheapest and most basic process lt $15001048708 50A-300A lt10KW1048708 Workpiece thickness 3-20mm

2008-spring-2004 SKim

SlagCoating deoxidizes weld and provides shielding gas

Multiple passSlag removal

28

Fusion Arc Welding

1048708 Preventing oxidation is the most important problem1048708 Coated electrodes to provide shielding gas1048708 Coatings fluorides silicate binders(clay) cellulose carbonates1048708 Electrodes different materials such as mild steel1048708 Submerged arc welding covered by granular flux1048708 Flat surfaces high throughput good quality1048708 Inert gas from external source1048708 Gas metal arc welding (MIG)1048708 Flux-cored arc welding etc (very versatile with proper fluxes)

2008-spring-2004 SKim

29

Gas Metal Arc Welding

Metal transfer- Spray transfer- Globular transfer- Short circuiting

Gas metal arc welding is aspecial variation on arc weldingin which the electrode fillermetal is fed directly through thetorch tip As arcing occurs theelectrode instantly meltsforming molten droplets that fallinto the weld pool Shielding gasis supplied through the torch tipto prevent chemical interactionswith the surroundingatmosphere

2008-spring-2004 SKim

30

Non-consumable electrode weldingGas Tungsten Arc Welding

1048708 Gas tungsten arc welding formerly known as TIG welding10487081048708 Tungsten electrode + filler wire10487081048708 Good for thin materials better control Al MgTi etc10487081048708 High quality and finish10487081048708 Tungsten electrode contamination10487081048708 200A DC-500A AC 8kW-50kW

2008-spring-2004 SKim

31

Other non-consumable electrodeprocesses

1048708 Plasma arc welding1048708 very higher energy concentration (33000oC) high feed rate 120-1000 mmmin arc stablility less thermal distortion deep penetration (keyhole technology)1048708 Laser beam welding electron beam welding etc

2008-spring-2004 SKim

32

Resistance Welding

1048708 Spot seam projection welding1048708 High current through the weld 3000A-100000A (05 ndash 10 V)

1048708 Extremely high heat flux (105 Wcm2)1048708 Heat generated H=i2Rt K (K=efficiency)1048708 Ex 5000 A 5 mm dia elctrodes two 1mm thick steel plates1048708 Effective resistance 200 Ω Then H= 500 J1048708 Nugget volume 30 mm3 mass 024 g 1400 Jg needed to melt1048708 336 J for melting lt 500 J

2008-spring-2004 SKim

33

Resistance welding

1048708 Spot welding Sequence1048708 Pressure on1048708 Current on1048708 Current off1048708 Pressure off1048708 Projection welding

2008-spring-2004 SKim

34

Solid-state interatomic bonding

1048708 Ultrasonic1048708 Oscillating tangential shear + static normal forces1048708 10KHz to 75 KHz1048708 Shear rarr plastic deformationrarr breaking up top layer (contaminated) rarr inter-atomic bond1048708 Friction1048708 Rotational part (at least one) flash1048708 Diffusion1048708 Goldsmiths bonded gold over copper1048708 Diffusion T gt 05 Tm1048708 Interface is the same as the bulk1048708 Fuselage frames

2008-spring-2004 SKim

35

Weld quality and defects

1048708 Porosity 1048708 Trapped gases contaminants 1048708 Preheat or increase rate of heat input1048708 Reduce speed allowing gas to escape cleaning1048708 Slag inclusions1048708 Oxides fluxes electrode coating trapped in weld zone1048708 Clean weld bead during multi-weld processes1048708 Provide enough shielding gas

2008-spring-2004 SKim

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 21: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

21

Weld Pool ndash Heat SourceInteraction Time

2008-spring-2004 SKim J Chun

22

HAZ(Heat Affected Zone)

1048708 Bad microstructure course grains weak to corrosion1048708 Plastic vs Metal

Temp

Base metal

HAZ

Weld metalMolten metal

Melting point

Microstructure change temperature

Base metal temperature

2008-spring-2004 SKim

23

Heat Affected Zone

1048708 Region near the weld pool is affected by heat Microstructure changes1048708 s ~ (α t)05

1048708 The size of the heat affected zone is controlled by the thermal diffusivity α Al Cu1048708 HI time (speed)1048708 Metal vs Plastic

2008-spring-2004 SKim

24

Heat Affected Zone (HAZ)

2008-spring-2004 SKim

Grain structureWeld lineIntergranular corrosionrecrystallization

25

Oxyfuel Gas Welding

1048708 Low cost manual1048708 Oxyfuel Oxygen + Fuel (Acetylene methyacetylene- propedieneetc) can reach 3300oC1048708 Stoichiometry neutral flame

1048708 More oxygen will cause oxidization (Oxidizing flame) bad for steels OK for copper1048708 More fuel will cause carburization (carburizing flame) Low heat for brazing soldering flame hardening

2008-spring-2004 SKim

26

Arc fusion welding

1048708 Temperature up to 30000oC1048708 Heat travels with the electrons1048708 Straight polarity workpiece + electrode ndash1048708 Shallow penetration sheet metal wide gaps1048708 reverse polarity1048708 Deeper penetration

Arrangement forconsumable electrodes

Heat generated at anode isabout 15 of the heatgenerated at cathode

Eelectron at cathode is given bythree components

Kinetic energyDrop across cool gas boundary

Work function(heat of condensation)

2008-spring-2004 SKim

27

Consumable electrode processes

1048708 Shielded metal arc welding1048708 Cheapest and most basic process lt $15001048708 50A-300A lt10KW1048708 Workpiece thickness 3-20mm

2008-spring-2004 SKim

SlagCoating deoxidizes weld and provides shielding gas

Multiple passSlag removal

28

Fusion Arc Welding

1048708 Preventing oxidation is the most important problem1048708 Coated electrodes to provide shielding gas1048708 Coatings fluorides silicate binders(clay) cellulose carbonates1048708 Electrodes different materials such as mild steel1048708 Submerged arc welding covered by granular flux1048708 Flat surfaces high throughput good quality1048708 Inert gas from external source1048708 Gas metal arc welding (MIG)1048708 Flux-cored arc welding etc (very versatile with proper fluxes)

2008-spring-2004 SKim

29

Gas Metal Arc Welding

Metal transfer- Spray transfer- Globular transfer- Short circuiting

Gas metal arc welding is aspecial variation on arc weldingin which the electrode fillermetal is fed directly through thetorch tip As arcing occurs theelectrode instantly meltsforming molten droplets that fallinto the weld pool Shielding gasis supplied through the torch tipto prevent chemical interactionswith the surroundingatmosphere

2008-spring-2004 SKim

30

Non-consumable electrode weldingGas Tungsten Arc Welding

1048708 Gas tungsten arc welding formerly known as TIG welding10487081048708 Tungsten electrode + filler wire10487081048708 Good for thin materials better control Al MgTi etc10487081048708 High quality and finish10487081048708 Tungsten electrode contamination10487081048708 200A DC-500A AC 8kW-50kW

2008-spring-2004 SKim

31

Other non-consumable electrodeprocesses

1048708 Plasma arc welding1048708 very higher energy concentration (33000oC) high feed rate 120-1000 mmmin arc stablility less thermal distortion deep penetration (keyhole technology)1048708 Laser beam welding electron beam welding etc

2008-spring-2004 SKim

32

Resistance Welding

1048708 Spot seam projection welding1048708 High current through the weld 3000A-100000A (05 ndash 10 V)

1048708 Extremely high heat flux (105 Wcm2)1048708 Heat generated H=i2Rt K (K=efficiency)1048708 Ex 5000 A 5 mm dia elctrodes two 1mm thick steel plates1048708 Effective resistance 200 Ω Then H= 500 J1048708 Nugget volume 30 mm3 mass 024 g 1400 Jg needed to melt1048708 336 J for melting lt 500 J

2008-spring-2004 SKim

33

Resistance welding

1048708 Spot welding Sequence1048708 Pressure on1048708 Current on1048708 Current off1048708 Pressure off1048708 Projection welding

2008-spring-2004 SKim

34

Solid-state interatomic bonding

1048708 Ultrasonic1048708 Oscillating tangential shear + static normal forces1048708 10KHz to 75 KHz1048708 Shear rarr plastic deformationrarr breaking up top layer (contaminated) rarr inter-atomic bond1048708 Friction1048708 Rotational part (at least one) flash1048708 Diffusion1048708 Goldsmiths bonded gold over copper1048708 Diffusion T gt 05 Tm1048708 Interface is the same as the bulk1048708 Fuselage frames

2008-spring-2004 SKim

35

Weld quality and defects

1048708 Porosity 1048708 Trapped gases contaminants 1048708 Preheat or increase rate of heat input1048708 Reduce speed allowing gas to escape cleaning1048708 Slag inclusions1048708 Oxides fluxes electrode coating trapped in weld zone1048708 Clean weld bead during multi-weld processes1048708 Provide enough shielding gas

2008-spring-2004 SKim

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 22: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

22

HAZ(Heat Affected Zone)

1048708 Bad microstructure course grains weak to corrosion1048708 Plastic vs Metal

Temp

Base metal

HAZ

Weld metalMolten metal

Melting point

Microstructure change temperature

Base metal temperature

2008-spring-2004 SKim

23

Heat Affected Zone

1048708 Region near the weld pool is affected by heat Microstructure changes1048708 s ~ (α t)05

1048708 The size of the heat affected zone is controlled by the thermal diffusivity α Al Cu1048708 HI time (speed)1048708 Metal vs Plastic

2008-spring-2004 SKim

24

Heat Affected Zone (HAZ)

2008-spring-2004 SKim

Grain structureWeld lineIntergranular corrosionrecrystallization

25

Oxyfuel Gas Welding

1048708 Low cost manual1048708 Oxyfuel Oxygen + Fuel (Acetylene methyacetylene- propedieneetc) can reach 3300oC1048708 Stoichiometry neutral flame

1048708 More oxygen will cause oxidization (Oxidizing flame) bad for steels OK for copper1048708 More fuel will cause carburization (carburizing flame) Low heat for brazing soldering flame hardening

2008-spring-2004 SKim

26

Arc fusion welding

1048708 Temperature up to 30000oC1048708 Heat travels with the electrons1048708 Straight polarity workpiece + electrode ndash1048708 Shallow penetration sheet metal wide gaps1048708 reverse polarity1048708 Deeper penetration

Arrangement forconsumable electrodes

Heat generated at anode isabout 15 of the heatgenerated at cathode

Eelectron at cathode is given bythree components

Kinetic energyDrop across cool gas boundary

Work function(heat of condensation)

2008-spring-2004 SKim

27

Consumable electrode processes

1048708 Shielded metal arc welding1048708 Cheapest and most basic process lt $15001048708 50A-300A lt10KW1048708 Workpiece thickness 3-20mm

2008-spring-2004 SKim

SlagCoating deoxidizes weld and provides shielding gas

Multiple passSlag removal

28

Fusion Arc Welding

1048708 Preventing oxidation is the most important problem1048708 Coated electrodes to provide shielding gas1048708 Coatings fluorides silicate binders(clay) cellulose carbonates1048708 Electrodes different materials such as mild steel1048708 Submerged arc welding covered by granular flux1048708 Flat surfaces high throughput good quality1048708 Inert gas from external source1048708 Gas metal arc welding (MIG)1048708 Flux-cored arc welding etc (very versatile with proper fluxes)

2008-spring-2004 SKim

29

Gas Metal Arc Welding

Metal transfer- Spray transfer- Globular transfer- Short circuiting

Gas metal arc welding is aspecial variation on arc weldingin which the electrode fillermetal is fed directly through thetorch tip As arcing occurs theelectrode instantly meltsforming molten droplets that fallinto the weld pool Shielding gasis supplied through the torch tipto prevent chemical interactionswith the surroundingatmosphere

2008-spring-2004 SKim

30

Non-consumable electrode weldingGas Tungsten Arc Welding

1048708 Gas tungsten arc welding formerly known as TIG welding10487081048708 Tungsten electrode + filler wire10487081048708 Good for thin materials better control Al MgTi etc10487081048708 High quality and finish10487081048708 Tungsten electrode contamination10487081048708 200A DC-500A AC 8kW-50kW

2008-spring-2004 SKim

31

Other non-consumable electrodeprocesses

1048708 Plasma arc welding1048708 very higher energy concentration (33000oC) high feed rate 120-1000 mmmin arc stablility less thermal distortion deep penetration (keyhole technology)1048708 Laser beam welding electron beam welding etc

2008-spring-2004 SKim

32

Resistance Welding

1048708 Spot seam projection welding1048708 High current through the weld 3000A-100000A (05 ndash 10 V)

1048708 Extremely high heat flux (105 Wcm2)1048708 Heat generated H=i2Rt K (K=efficiency)1048708 Ex 5000 A 5 mm dia elctrodes two 1mm thick steel plates1048708 Effective resistance 200 Ω Then H= 500 J1048708 Nugget volume 30 mm3 mass 024 g 1400 Jg needed to melt1048708 336 J for melting lt 500 J

2008-spring-2004 SKim

33

Resistance welding

1048708 Spot welding Sequence1048708 Pressure on1048708 Current on1048708 Current off1048708 Pressure off1048708 Projection welding

2008-spring-2004 SKim

34

Solid-state interatomic bonding

1048708 Ultrasonic1048708 Oscillating tangential shear + static normal forces1048708 10KHz to 75 KHz1048708 Shear rarr plastic deformationrarr breaking up top layer (contaminated) rarr inter-atomic bond1048708 Friction1048708 Rotational part (at least one) flash1048708 Diffusion1048708 Goldsmiths bonded gold over copper1048708 Diffusion T gt 05 Tm1048708 Interface is the same as the bulk1048708 Fuselage frames

2008-spring-2004 SKim

35

Weld quality and defects

1048708 Porosity 1048708 Trapped gases contaminants 1048708 Preheat or increase rate of heat input1048708 Reduce speed allowing gas to escape cleaning1048708 Slag inclusions1048708 Oxides fluxes electrode coating trapped in weld zone1048708 Clean weld bead during multi-weld processes1048708 Provide enough shielding gas

2008-spring-2004 SKim

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 23: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

23

Heat Affected Zone

1048708 Region near the weld pool is affected by heat Microstructure changes1048708 s ~ (α t)05

1048708 The size of the heat affected zone is controlled by the thermal diffusivity α Al Cu1048708 HI time (speed)1048708 Metal vs Plastic

2008-spring-2004 SKim

24

Heat Affected Zone (HAZ)

2008-spring-2004 SKim

Grain structureWeld lineIntergranular corrosionrecrystallization

25

Oxyfuel Gas Welding

1048708 Low cost manual1048708 Oxyfuel Oxygen + Fuel (Acetylene methyacetylene- propedieneetc) can reach 3300oC1048708 Stoichiometry neutral flame

1048708 More oxygen will cause oxidization (Oxidizing flame) bad for steels OK for copper1048708 More fuel will cause carburization (carburizing flame) Low heat for brazing soldering flame hardening

2008-spring-2004 SKim

26

Arc fusion welding

1048708 Temperature up to 30000oC1048708 Heat travels with the electrons1048708 Straight polarity workpiece + electrode ndash1048708 Shallow penetration sheet metal wide gaps1048708 reverse polarity1048708 Deeper penetration

Arrangement forconsumable electrodes

Heat generated at anode isabout 15 of the heatgenerated at cathode

Eelectron at cathode is given bythree components

Kinetic energyDrop across cool gas boundary

Work function(heat of condensation)

2008-spring-2004 SKim

27

Consumable electrode processes

1048708 Shielded metal arc welding1048708 Cheapest and most basic process lt $15001048708 50A-300A lt10KW1048708 Workpiece thickness 3-20mm

2008-spring-2004 SKim

SlagCoating deoxidizes weld and provides shielding gas

Multiple passSlag removal

28

Fusion Arc Welding

1048708 Preventing oxidation is the most important problem1048708 Coated electrodes to provide shielding gas1048708 Coatings fluorides silicate binders(clay) cellulose carbonates1048708 Electrodes different materials such as mild steel1048708 Submerged arc welding covered by granular flux1048708 Flat surfaces high throughput good quality1048708 Inert gas from external source1048708 Gas metal arc welding (MIG)1048708 Flux-cored arc welding etc (very versatile with proper fluxes)

2008-spring-2004 SKim

29

Gas Metal Arc Welding

Metal transfer- Spray transfer- Globular transfer- Short circuiting

Gas metal arc welding is aspecial variation on arc weldingin which the electrode fillermetal is fed directly through thetorch tip As arcing occurs theelectrode instantly meltsforming molten droplets that fallinto the weld pool Shielding gasis supplied through the torch tipto prevent chemical interactionswith the surroundingatmosphere

2008-spring-2004 SKim

30

Non-consumable electrode weldingGas Tungsten Arc Welding

1048708 Gas tungsten arc welding formerly known as TIG welding10487081048708 Tungsten electrode + filler wire10487081048708 Good for thin materials better control Al MgTi etc10487081048708 High quality and finish10487081048708 Tungsten electrode contamination10487081048708 200A DC-500A AC 8kW-50kW

2008-spring-2004 SKim

31

Other non-consumable electrodeprocesses

1048708 Plasma arc welding1048708 very higher energy concentration (33000oC) high feed rate 120-1000 mmmin arc stablility less thermal distortion deep penetration (keyhole technology)1048708 Laser beam welding electron beam welding etc

2008-spring-2004 SKim

32

Resistance Welding

1048708 Spot seam projection welding1048708 High current through the weld 3000A-100000A (05 ndash 10 V)

1048708 Extremely high heat flux (105 Wcm2)1048708 Heat generated H=i2Rt K (K=efficiency)1048708 Ex 5000 A 5 mm dia elctrodes two 1mm thick steel plates1048708 Effective resistance 200 Ω Then H= 500 J1048708 Nugget volume 30 mm3 mass 024 g 1400 Jg needed to melt1048708 336 J for melting lt 500 J

2008-spring-2004 SKim

33

Resistance welding

1048708 Spot welding Sequence1048708 Pressure on1048708 Current on1048708 Current off1048708 Pressure off1048708 Projection welding

2008-spring-2004 SKim

34

Solid-state interatomic bonding

1048708 Ultrasonic1048708 Oscillating tangential shear + static normal forces1048708 10KHz to 75 KHz1048708 Shear rarr plastic deformationrarr breaking up top layer (contaminated) rarr inter-atomic bond1048708 Friction1048708 Rotational part (at least one) flash1048708 Diffusion1048708 Goldsmiths bonded gold over copper1048708 Diffusion T gt 05 Tm1048708 Interface is the same as the bulk1048708 Fuselage frames

2008-spring-2004 SKim

35

Weld quality and defects

1048708 Porosity 1048708 Trapped gases contaminants 1048708 Preheat or increase rate of heat input1048708 Reduce speed allowing gas to escape cleaning1048708 Slag inclusions1048708 Oxides fluxes electrode coating trapped in weld zone1048708 Clean weld bead during multi-weld processes1048708 Provide enough shielding gas

2008-spring-2004 SKim

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 24: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

24

Heat Affected Zone (HAZ)

2008-spring-2004 SKim

Grain structureWeld lineIntergranular corrosionrecrystallization

25

Oxyfuel Gas Welding

1048708 Low cost manual1048708 Oxyfuel Oxygen + Fuel (Acetylene methyacetylene- propedieneetc) can reach 3300oC1048708 Stoichiometry neutral flame

1048708 More oxygen will cause oxidization (Oxidizing flame) bad for steels OK for copper1048708 More fuel will cause carburization (carburizing flame) Low heat for brazing soldering flame hardening

2008-spring-2004 SKim

26

Arc fusion welding

1048708 Temperature up to 30000oC1048708 Heat travels with the electrons1048708 Straight polarity workpiece + electrode ndash1048708 Shallow penetration sheet metal wide gaps1048708 reverse polarity1048708 Deeper penetration

Arrangement forconsumable electrodes

Heat generated at anode isabout 15 of the heatgenerated at cathode

Eelectron at cathode is given bythree components

Kinetic energyDrop across cool gas boundary

Work function(heat of condensation)

2008-spring-2004 SKim

27

Consumable electrode processes

1048708 Shielded metal arc welding1048708 Cheapest and most basic process lt $15001048708 50A-300A lt10KW1048708 Workpiece thickness 3-20mm

2008-spring-2004 SKim

SlagCoating deoxidizes weld and provides shielding gas

Multiple passSlag removal

28

Fusion Arc Welding

1048708 Preventing oxidation is the most important problem1048708 Coated electrodes to provide shielding gas1048708 Coatings fluorides silicate binders(clay) cellulose carbonates1048708 Electrodes different materials such as mild steel1048708 Submerged arc welding covered by granular flux1048708 Flat surfaces high throughput good quality1048708 Inert gas from external source1048708 Gas metal arc welding (MIG)1048708 Flux-cored arc welding etc (very versatile with proper fluxes)

2008-spring-2004 SKim

29

Gas Metal Arc Welding

Metal transfer- Spray transfer- Globular transfer- Short circuiting

Gas metal arc welding is aspecial variation on arc weldingin which the electrode fillermetal is fed directly through thetorch tip As arcing occurs theelectrode instantly meltsforming molten droplets that fallinto the weld pool Shielding gasis supplied through the torch tipto prevent chemical interactionswith the surroundingatmosphere

2008-spring-2004 SKim

30

Non-consumable electrode weldingGas Tungsten Arc Welding

1048708 Gas tungsten arc welding formerly known as TIG welding10487081048708 Tungsten electrode + filler wire10487081048708 Good for thin materials better control Al MgTi etc10487081048708 High quality and finish10487081048708 Tungsten electrode contamination10487081048708 200A DC-500A AC 8kW-50kW

2008-spring-2004 SKim

31

Other non-consumable electrodeprocesses

1048708 Plasma arc welding1048708 very higher energy concentration (33000oC) high feed rate 120-1000 mmmin arc stablility less thermal distortion deep penetration (keyhole technology)1048708 Laser beam welding electron beam welding etc

2008-spring-2004 SKim

32

Resistance Welding

1048708 Spot seam projection welding1048708 High current through the weld 3000A-100000A (05 ndash 10 V)

1048708 Extremely high heat flux (105 Wcm2)1048708 Heat generated H=i2Rt K (K=efficiency)1048708 Ex 5000 A 5 mm dia elctrodes two 1mm thick steel plates1048708 Effective resistance 200 Ω Then H= 500 J1048708 Nugget volume 30 mm3 mass 024 g 1400 Jg needed to melt1048708 336 J for melting lt 500 J

2008-spring-2004 SKim

33

Resistance welding

1048708 Spot welding Sequence1048708 Pressure on1048708 Current on1048708 Current off1048708 Pressure off1048708 Projection welding

2008-spring-2004 SKim

34

Solid-state interatomic bonding

1048708 Ultrasonic1048708 Oscillating tangential shear + static normal forces1048708 10KHz to 75 KHz1048708 Shear rarr plastic deformationrarr breaking up top layer (contaminated) rarr inter-atomic bond1048708 Friction1048708 Rotational part (at least one) flash1048708 Diffusion1048708 Goldsmiths bonded gold over copper1048708 Diffusion T gt 05 Tm1048708 Interface is the same as the bulk1048708 Fuselage frames

2008-spring-2004 SKim

35

Weld quality and defects

1048708 Porosity 1048708 Trapped gases contaminants 1048708 Preheat or increase rate of heat input1048708 Reduce speed allowing gas to escape cleaning1048708 Slag inclusions1048708 Oxides fluxes electrode coating trapped in weld zone1048708 Clean weld bead during multi-weld processes1048708 Provide enough shielding gas

2008-spring-2004 SKim

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 25: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

25

Oxyfuel Gas Welding

1048708 Low cost manual1048708 Oxyfuel Oxygen + Fuel (Acetylene methyacetylene- propedieneetc) can reach 3300oC1048708 Stoichiometry neutral flame

1048708 More oxygen will cause oxidization (Oxidizing flame) bad for steels OK for copper1048708 More fuel will cause carburization (carburizing flame) Low heat for brazing soldering flame hardening

2008-spring-2004 SKim

26

Arc fusion welding

1048708 Temperature up to 30000oC1048708 Heat travels with the electrons1048708 Straight polarity workpiece + electrode ndash1048708 Shallow penetration sheet metal wide gaps1048708 reverse polarity1048708 Deeper penetration

Arrangement forconsumable electrodes

Heat generated at anode isabout 15 of the heatgenerated at cathode

Eelectron at cathode is given bythree components

Kinetic energyDrop across cool gas boundary

Work function(heat of condensation)

2008-spring-2004 SKim

27

Consumable electrode processes

1048708 Shielded metal arc welding1048708 Cheapest and most basic process lt $15001048708 50A-300A lt10KW1048708 Workpiece thickness 3-20mm

2008-spring-2004 SKim

SlagCoating deoxidizes weld and provides shielding gas

Multiple passSlag removal

28

Fusion Arc Welding

1048708 Preventing oxidation is the most important problem1048708 Coated electrodes to provide shielding gas1048708 Coatings fluorides silicate binders(clay) cellulose carbonates1048708 Electrodes different materials such as mild steel1048708 Submerged arc welding covered by granular flux1048708 Flat surfaces high throughput good quality1048708 Inert gas from external source1048708 Gas metal arc welding (MIG)1048708 Flux-cored arc welding etc (very versatile with proper fluxes)

2008-spring-2004 SKim

29

Gas Metal Arc Welding

Metal transfer- Spray transfer- Globular transfer- Short circuiting

Gas metal arc welding is aspecial variation on arc weldingin which the electrode fillermetal is fed directly through thetorch tip As arcing occurs theelectrode instantly meltsforming molten droplets that fallinto the weld pool Shielding gasis supplied through the torch tipto prevent chemical interactionswith the surroundingatmosphere

2008-spring-2004 SKim

30

Non-consumable electrode weldingGas Tungsten Arc Welding

1048708 Gas tungsten arc welding formerly known as TIG welding10487081048708 Tungsten electrode + filler wire10487081048708 Good for thin materials better control Al MgTi etc10487081048708 High quality and finish10487081048708 Tungsten electrode contamination10487081048708 200A DC-500A AC 8kW-50kW

2008-spring-2004 SKim

31

Other non-consumable electrodeprocesses

1048708 Plasma arc welding1048708 very higher energy concentration (33000oC) high feed rate 120-1000 mmmin arc stablility less thermal distortion deep penetration (keyhole technology)1048708 Laser beam welding electron beam welding etc

2008-spring-2004 SKim

32

Resistance Welding

1048708 Spot seam projection welding1048708 High current through the weld 3000A-100000A (05 ndash 10 V)

1048708 Extremely high heat flux (105 Wcm2)1048708 Heat generated H=i2Rt K (K=efficiency)1048708 Ex 5000 A 5 mm dia elctrodes two 1mm thick steel plates1048708 Effective resistance 200 Ω Then H= 500 J1048708 Nugget volume 30 mm3 mass 024 g 1400 Jg needed to melt1048708 336 J for melting lt 500 J

2008-spring-2004 SKim

33

Resistance welding

1048708 Spot welding Sequence1048708 Pressure on1048708 Current on1048708 Current off1048708 Pressure off1048708 Projection welding

2008-spring-2004 SKim

34

Solid-state interatomic bonding

1048708 Ultrasonic1048708 Oscillating tangential shear + static normal forces1048708 10KHz to 75 KHz1048708 Shear rarr plastic deformationrarr breaking up top layer (contaminated) rarr inter-atomic bond1048708 Friction1048708 Rotational part (at least one) flash1048708 Diffusion1048708 Goldsmiths bonded gold over copper1048708 Diffusion T gt 05 Tm1048708 Interface is the same as the bulk1048708 Fuselage frames

2008-spring-2004 SKim

35

Weld quality and defects

1048708 Porosity 1048708 Trapped gases contaminants 1048708 Preheat or increase rate of heat input1048708 Reduce speed allowing gas to escape cleaning1048708 Slag inclusions1048708 Oxides fluxes electrode coating trapped in weld zone1048708 Clean weld bead during multi-weld processes1048708 Provide enough shielding gas

2008-spring-2004 SKim

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 26: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

26

Arc fusion welding

1048708 Temperature up to 30000oC1048708 Heat travels with the electrons1048708 Straight polarity workpiece + electrode ndash1048708 Shallow penetration sheet metal wide gaps1048708 reverse polarity1048708 Deeper penetration

Arrangement forconsumable electrodes

Heat generated at anode isabout 15 of the heatgenerated at cathode

Eelectron at cathode is given bythree components

Kinetic energyDrop across cool gas boundary

Work function(heat of condensation)

2008-spring-2004 SKim

27

Consumable electrode processes

1048708 Shielded metal arc welding1048708 Cheapest and most basic process lt $15001048708 50A-300A lt10KW1048708 Workpiece thickness 3-20mm

2008-spring-2004 SKim

SlagCoating deoxidizes weld and provides shielding gas

Multiple passSlag removal

28

Fusion Arc Welding

1048708 Preventing oxidation is the most important problem1048708 Coated electrodes to provide shielding gas1048708 Coatings fluorides silicate binders(clay) cellulose carbonates1048708 Electrodes different materials such as mild steel1048708 Submerged arc welding covered by granular flux1048708 Flat surfaces high throughput good quality1048708 Inert gas from external source1048708 Gas metal arc welding (MIG)1048708 Flux-cored arc welding etc (very versatile with proper fluxes)

2008-spring-2004 SKim

29

Gas Metal Arc Welding

Metal transfer- Spray transfer- Globular transfer- Short circuiting

Gas metal arc welding is aspecial variation on arc weldingin which the electrode fillermetal is fed directly through thetorch tip As arcing occurs theelectrode instantly meltsforming molten droplets that fallinto the weld pool Shielding gasis supplied through the torch tipto prevent chemical interactionswith the surroundingatmosphere

2008-spring-2004 SKim

30

Non-consumable electrode weldingGas Tungsten Arc Welding

1048708 Gas tungsten arc welding formerly known as TIG welding10487081048708 Tungsten electrode + filler wire10487081048708 Good for thin materials better control Al MgTi etc10487081048708 High quality and finish10487081048708 Tungsten electrode contamination10487081048708 200A DC-500A AC 8kW-50kW

2008-spring-2004 SKim

31

Other non-consumable electrodeprocesses

1048708 Plasma arc welding1048708 very higher energy concentration (33000oC) high feed rate 120-1000 mmmin arc stablility less thermal distortion deep penetration (keyhole technology)1048708 Laser beam welding electron beam welding etc

2008-spring-2004 SKim

32

Resistance Welding

1048708 Spot seam projection welding1048708 High current through the weld 3000A-100000A (05 ndash 10 V)

1048708 Extremely high heat flux (105 Wcm2)1048708 Heat generated H=i2Rt K (K=efficiency)1048708 Ex 5000 A 5 mm dia elctrodes two 1mm thick steel plates1048708 Effective resistance 200 Ω Then H= 500 J1048708 Nugget volume 30 mm3 mass 024 g 1400 Jg needed to melt1048708 336 J for melting lt 500 J

2008-spring-2004 SKim

33

Resistance welding

1048708 Spot welding Sequence1048708 Pressure on1048708 Current on1048708 Current off1048708 Pressure off1048708 Projection welding

2008-spring-2004 SKim

34

Solid-state interatomic bonding

1048708 Ultrasonic1048708 Oscillating tangential shear + static normal forces1048708 10KHz to 75 KHz1048708 Shear rarr plastic deformationrarr breaking up top layer (contaminated) rarr inter-atomic bond1048708 Friction1048708 Rotational part (at least one) flash1048708 Diffusion1048708 Goldsmiths bonded gold over copper1048708 Diffusion T gt 05 Tm1048708 Interface is the same as the bulk1048708 Fuselage frames

2008-spring-2004 SKim

35

Weld quality and defects

1048708 Porosity 1048708 Trapped gases contaminants 1048708 Preheat or increase rate of heat input1048708 Reduce speed allowing gas to escape cleaning1048708 Slag inclusions1048708 Oxides fluxes electrode coating trapped in weld zone1048708 Clean weld bead during multi-weld processes1048708 Provide enough shielding gas

2008-spring-2004 SKim

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 27: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

27

Consumable electrode processes

1048708 Shielded metal arc welding1048708 Cheapest and most basic process lt $15001048708 50A-300A lt10KW1048708 Workpiece thickness 3-20mm

2008-spring-2004 SKim

SlagCoating deoxidizes weld and provides shielding gas

Multiple passSlag removal

28

Fusion Arc Welding

1048708 Preventing oxidation is the most important problem1048708 Coated electrodes to provide shielding gas1048708 Coatings fluorides silicate binders(clay) cellulose carbonates1048708 Electrodes different materials such as mild steel1048708 Submerged arc welding covered by granular flux1048708 Flat surfaces high throughput good quality1048708 Inert gas from external source1048708 Gas metal arc welding (MIG)1048708 Flux-cored arc welding etc (very versatile with proper fluxes)

2008-spring-2004 SKim

29

Gas Metal Arc Welding

Metal transfer- Spray transfer- Globular transfer- Short circuiting

Gas metal arc welding is aspecial variation on arc weldingin which the electrode fillermetal is fed directly through thetorch tip As arcing occurs theelectrode instantly meltsforming molten droplets that fallinto the weld pool Shielding gasis supplied through the torch tipto prevent chemical interactionswith the surroundingatmosphere

2008-spring-2004 SKim

30

Non-consumable electrode weldingGas Tungsten Arc Welding

1048708 Gas tungsten arc welding formerly known as TIG welding10487081048708 Tungsten electrode + filler wire10487081048708 Good for thin materials better control Al MgTi etc10487081048708 High quality and finish10487081048708 Tungsten electrode contamination10487081048708 200A DC-500A AC 8kW-50kW

2008-spring-2004 SKim

31

Other non-consumable electrodeprocesses

1048708 Plasma arc welding1048708 very higher energy concentration (33000oC) high feed rate 120-1000 mmmin arc stablility less thermal distortion deep penetration (keyhole technology)1048708 Laser beam welding electron beam welding etc

2008-spring-2004 SKim

32

Resistance Welding

1048708 Spot seam projection welding1048708 High current through the weld 3000A-100000A (05 ndash 10 V)

1048708 Extremely high heat flux (105 Wcm2)1048708 Heat generated H=i2Rt K (K=efficiency)1048708 Ex 5000 A 5 mm dia elctrodes two 1mm thick steel plates1048708 Effective resistance 200 Ω Then H= 500 J1048708 Nugget volume 30 mm3 mass 024 g 1400 Jg needed to melt1048708 336 J for melting lt 500 J

2008-spring-2004 SKim

33

Resistance welding

1048708 Spot welding Sequence1048708 Pressure on1048708 Current on1048708 Current off1048708 Pressure off1048708 Projection welding

2008-spring-2004 SKim

34

Solid-state interatomic bonding

1048708 Ultrasonic1048708 Oscillating tangential shear + static normal forces1048708 10KHz to 75 KHz1048708 Shear rarr plastic deformationrarr breaking up top layer (contaminated) rarr inter-atomic bond1048708 Friction1048708 Rotational part (at least one) flash1048708 Diffusion1048708 Goldsmiths bonded gold over copper1048708 Diffusion T gt 05 Tm1048708 Interface is the same as the bulk1048708 Fuselage frames

2008-spring-2004 SKim

35

Weld quality and defects

1048708 Porosity 1048708 Trapped gases contaminants 1048708 Preheat or increase rate of heat input1048708 Reduce speed allowing gas to escape cleaning1048708 Slag inclusions1048708 Oxides fluxes electrode coating trapped in weld zone1048708 Clean weld bead during multi-weld processes1048708 Provide enough shielding gas

2008-spring-2004 SKim

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 28: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

28

Fusion Arc Welding

1048708 Preventing oxidation is the most important problem1048708 Coated electrodes to provide shielding gas1048708 Coatings fluorides silicate binders(clay) cellulose carbonates1048708 Electrodes different materials such as mild steel1048708 Submerged arc welding covered by granular flux1048708 Flat surfaces high throughput good quality1048708 Inert gas from external source1048708 Gas metal arc welding (MIG)1048708 Flux-cored arc welding etc (very versatile with proper fluxes)

2008-spring-2004 SKim

29

Gas Metal Arc Welding

Metal transfer- Spray transfer- Globular transfer- Short circuiting

Gas metal arc welding is aspecial variation on arc weldingin which the electrode fillermetal is fed directly through thetorch tip As arcing occurs theelectrode instantly meltsforming molten droplets that fallinto the weld pool Shielding gasis supplied through the torch tipto prevent chemical interactionswith the surroundingatmosphere

2008-spring-2004 SKim

30

Non-consumable electrode weldingGas Tungsten Arc Welding

1048708 Gas tungsten arc welding formerly known as TIG welding10487081048708 Tungsten electrode + filler wire10487081048708 Good for thin materials better control Al MgTi etc10487081048708 High quality and finish10487081048708 Tungsten electrode contamination10487081048708 200A DC-500A AC 8kW-50kW

2008-spring-2004 SKim

31

Other non-consumable electrodeprocesses

1048708 Plasma arc welding1048708 very higher energy concentration (33000oC) high feed rate 120-1000 mmmin arc stablility less thermal distortion deep penetration (keyhole technology)1048708 Laser beam welding electron beam welding etc

2008-spring-2004 SKim

32

Resistance Welding

1048708 Spot seam projection welding1048708 High current through the weld 3000A-100000A (05 ndash 10 V)

1048708 Extremely high heat flux (105 Wcm2)1048708 Heat generated H=i2Rt K (K=efficiency)1048708 Ex 5000 A 5 mm dia elctrodes two 1mm thick steel plates1048708 Effective resistance 200 Ω Then H= 500 J1048708 Nugget volume 30 mm3 mass 024 g 1400 Jg needed to melt1048708 336 J for melting lt 500 J

2008-spring-2004 SKim

33

Resistance welding

1048708 Spot welding Sequence1048708 Pressure on1048708 Current on1048708 Current off1048708 Pressure off1048708 Projection welding

2008-spring-2004 SKim

34

Solid-state interatomic bonding

1048708 Ultrasonic1048708 Oscillating tangential shear + static normal forces1048708 10KHz to 75 KHz1048708 Shear rarr plastic deformationrarr breaking up top layer (contaminated) rarr inter-atomic bond1048708 Friction1048708 Rotational part (at least one) flash1048708 Diffusion1048708 Goldsmiths bonded gold over copper1048708 Diffusion T gt 05 Tm1048708 Interface is the same as the bulk1048708 Fuselage frames

2008-spring-2004 SKim

35

Weld quality and defects

1048708 Porosity 1048708 Trapped gases contaminants 1048708 Preheat or increase rate of heat input1048708 Reduce speed allowing gas to escape cleaning1048708 Slag inclusions1048708 Oxides fluxes electrode coating trapped in weld zone1048708 Clean weld bead during multi-weld processes1048708 Provide enough shielding gas

2008-spring-2004 SKim

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 29: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

29

Gas Metal Arc Welding

Metal transfer- Spray transfer- Globular transfer- Short circuiting

Gas metal arc welding is aspecial variation on arc weldingin which the electrode fillermetal is fed directly through thetorch tip As arcing occurs theelectrode instantly meltsforming molten droplets that fallinto the weld pool Shielding gasis supplied through the torch tipto prevent chemical interactionswith the surroundingatmosphere

2008-spring-2004 SKim

30

Non-consumable electrode weldingGas Tungsten Arc Welding

1048708 Gas tungsten arc welding formerly known as TIG welding10487081048708 Tungsten electrode + filler wire10487081048708 Good for thin materials better control Al MgTi etc10487081048708 High quality and finish10487081048708 Tungsten electrode contamination10487081048708 200A DC-500A AC 8kW-50kW

2008-spring-2004 SKim

31

Other non-consumable electrodeprocesses

1048708 Plasma arc welding1048708 very higher energy concentration (33000oC) high feed rate 120-1000 mmmin arc stablility less thermal distortion deep penetration (keyhole technology)1048708 Laser beam welding electron beam welding etc

2008-spring-2004 SKim

32

Resistance Welding

1048708 Spot seam projection welding1048708 High current through the weld 3000A-100000A (05 ndash 10 V)

1048708 Extremely high heat flux (105 Wcm2)1048708 Heat generated H=i2Rt K (K=efficiency)1048708 Ex 5000 A 5 mm dia elctrodes two 1mm thick steel plates1048708 Effective resistance 200 Ω Then H= 500 J1048708 Nugget volume 30 mm3 mass 024 g 1400 Jg needed to melt1048708 336 J for melting lt 500 J

2008-spring-2004 SKim

33

Resistance welding

1048708 Spot welding Sequence1048708 Pressure on1048708 Current on1048708 Current off1048708 Pressure off1048708 Projection welding

2008-spring-2004 SKim

34

Solid-state interatomic bonding

1048708 Ultrasonic1048708 Oscillating tangential shear + static normal forces1048708 10KHz to 75 KHz1048708 Shear rarr plastic deformationrarr breaking up top layer (contaminated) rarr inter-atomic bond1048708 Friction1048708 Rotational part (at least one) flash1048708 Diffusion1048708 Goldsmiths bonded gold over copper1048708 Diffusion T gt 05 Tm1048708 Interface is the same as the bulk1048708 Fuselage frames

2008-spring-2004 SKim

35

Weld quality and defects

1048708 Porosity 1048708 Trapped gases contaminants 1048708 Preheat or increase rate of heat input1048708 Reduce speed allowing gas to escape cleaning1048708 Slag inclusions1048708 Oxides fluxes electrode coating trapped in weld zone1048708 Clean weld bead during multi-weld processes1048708 Provide enough shielding gas

2008-spring-2004 SKim

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 30: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

30

Non-consumable electrode weldingGas Tungsten Arc Welding

1048708 Gas tungsten arc welding formerly known as TIG welding10487081048708 Tungsten electrode + filler wire10487081048708 Good for thin materials better control Al MgTi etc10487081048708 High quality and finish10487081048708 Tungsten electrode contamination10487081048708 200A DC-500A AC 8kW-50kW

2008-spring-2004 SKim

31

Other non-consumable electrodeprocesses

1048708 Plasma arc welding1048708 very higher energy concentration (33000oC) high feed rate 120-1000 mmmin arc stablility less thermal distortion deep penetration (keyhole technology)1048708 Laser beam welding electron beam welding etc

2008-spring-2004 SKim

32

Resistance Welding

1048708 Spot seam projection welding1048708 High current through the weld 3000A-100000A (05 ndash 10 V)

1048708 Extremely high heat flux (105 Wcm2)1048708 Heat generated H=i2Rt K (K=efficiency)1048708 Ex 5000 A 5 mm dia elctrodes two 1mm thick steel plates1048708 Effective resistance 200 Ω Then H= 500 J1048708 Nugget volume 30 mm3 mass 024 g 1400 Jg needed to melt1048708 336 J for melting lt 500 J

2008-spring-2004 SKim

33

Resistance welding

1048708 Spot welding Sequence1048708 Pressure on1048708 Current on1048708 Current off1048708 Pressure off1048708 Projection welding

2008-spring-2004 SKim

34

Solid-state interatomic bonding

1048708 Ultrasonic1048708 Oscillating tangential shear + static normal forces1048708 10KHz to 75 KHz1048708 Shear rarr plastic deformationrarr breaking up top layer (contaminated) rarr inter-atomic bond1048708 Friction1048708 Rotational part (at least one) flash1048708 Diffusion1048708 Goldsmiths bonded gold over copper1048708 Diffusion T gt 05 Tm1048708 Interface is the same as the bulk1048708 Fuselage frames

2008-spring-2004 SKim

35

Weld quality and defects

1048708 Porosity 1048708 Trapped gases contaminants 1048708 Preheat or increase rate of heat input1048708 Reduce speed allowing gas to escape cleaning1048708 Slag inclusions1048708 Oxides fluxes electrode coating trapped in weld zone1048708 Clean weld bead during multi-weld processes1048708 Provide enough shielding gas

2008-spring-2004 SKim

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 31: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

31

Other non-consumable electrodeprocesses

1048708 Plasma arc welding1048708 very higher energy concentration (33000oC) high feed rate 120-1000 mmmin arc stablility less thermal distortion deep penetration (keyhole technology)1048708 Laser beam welding electron beam welding etc

2008-spring-2004 SKim

32

Resistance Welding

1048708 Spot seam projection welding1048708 High current through the weld 3000A-100000A (05 ndash 10 V)

1048708 Extremely high heat flux (105 Wcm2)1048708 Heat generated H=i2Rt K (K=efficiency)1048708 Ex 5000 A 5 mm dia elctrodes two 1mm thick steel plates1048708 Effective resistance 200 Ω Then H= 500 J1048708 Nugget volume 30 mm3 mass 024 g 1400 Jg needed to melt1048708 336 J for melting lt 500 J

2008-spring-2004 SKim

33

Resistance welding

1048708 Spot welding Sequence1048708 Pressure on1048708 Current on1048708 Current off1048708 Pressure off1048708 Projection welding

2008-spring-2004 SKim

34

Solid-state interatomic bonding

1048708 Ultrasonic1048708 Oscillating tangential shear + static normal forces1048708 10KHz to 75 KHz1048708 Shear rarr plastic deformationrarr breaking up top layer (contaminated) rarr inter-atomic bond1048708 Friction1048708 Rotational part (at least one) flash1048708 Diffusion1048708 Goldsmiths bonded gold over copper1048708 Diffusion T gt 05 Tm1048708 Interface is the same as the bulk1048708 Fuselage frames

2008-spring-2004 SKim

35

Weld quality and defects

1048708 Porosity 1048708 Trapped gases contaminants 1048708 Preheat or increase rate of heat input1048708 Reduce speed allowing gas to escape cleaning1048708 Slag inclusions1048708 Oxides fluxes electrode coating trapped in weld zone1048708 Clean weld bead during multi-weld processes1048708 Provide enough shielding gas

2008-spring-2004 SKim

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 32: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

32

Resistance Welding

1048708 Spot seam projection welding1048708 High current through the weld 3000A-100000A (05 ndash 10 V)

1048708 Extremely high heat flux (105 Wcm2)1048708 Heat generated H=i2Rt K (K=efficiency)1048708 Ex 5000 A 5 mm dia elctrodes two 1mm thick steel plates1048708 Effective resistance 200 Ω Then H= 500 J1048708 Nugget volume 30 mm3 mass 024 g 1400 Jg needed to melt1048708 336 J for melting lt 500 J

2008-spring-2004 SKim

33

Resistance welding

1048708 Spot welding Sequence1048708 Pressure on1048708 Current on1048708 Current off1048708 Pressure off1048708 Projection welding

2008-spring-2004 SKim

34

Solid-state interatomic bonding

1048708 Ultrasonic1048708 Oscillating tangential shear + static normal forces1048708 10KHz to 75 KHz1048708 Shear rarr plastic deformationrarr breaking up top layer (contaminated) rarr inter-atomic bond1048708 Friction1048708 Rotational part (at least one) flash1048708 Diffusion1048708 Goldsmiths bonded gold over copper1048708 Diffusion T gt 05 Tm1048708 Interface is the same as the bulk1048708 Fuselage frames

2008-spring-2004 SKim

35

Weld quality and defects

1048708 Porosity 1048708 Trapped gases contaminants 1048708 Preheat or increase rate of heat input1048708 Reduce speed allowing gas to escape cleaning1048708 Slag inclusions1048708 Oxides fluxes electrode coating trapped in weld zone1048708 Clean weld bead during multi-weld processes1048708 Provide enough shielding gas

2008-spring-2004 SKim

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 33: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

33

Resistance welding

1048708 Spot welding Sequence1048708 Pressure on1048708 Current on1048708 Current off1048708 Pressure off1048708 Projection welding

2008-spring-2004 SKim

34

Solid-state interatomic bonding

1048708 Ultrasonic1048708 Oscillating tangential shear + static normal forces1048708 10KHz to 75 KHz1048708 Shear rarr plastic deformationrarr breaking up top layer (contaminated) rarr inter-atomic bond1048708 Friction1048708 Rotational part (at least one) flash1048708 Diffusion1048708 Goldsmiths bonded gold over copper1048708 Diffusion T gt 05 Tm1048708 Interface is the same as the bulk1048708 Fuselage frames

2008-spring-2004 SKim

35

Weld quality and defects

1048708 Porosity 1048708 Trapped gases contaminants 1048708 Preheat or increase rate of heat input1048708 Reduce speed allowing gas to escape cleaning1048708 Slag inclusions1048708 Oxides fluxes electrode coating trapped in weld zone1048708 Clean weld bead during multi-weld processes1048708 Provide enough shielding gas

2008-spring-2004 SKim

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 34: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

34

Solid-state interatomic bonding

1048708 Ultrasonic1048708 Oscillating tangential shear + static normal forces1048708 10KHz to 75 KHz1048708 Shear rarr plastic deformationrarr breaking up top layer (contaminated) rarr inter-atomic bond1048708 Friction1048708 Rotational part (at least one) flash1048708 Diffusion1048708 Goldsmiths bonded gold over copper1048708 Diffusion T gt 05 Tm1048708 Interface is the same as the bulk1048708 Fuselage frames

2008-spring-2004 SKim

35

Weld quality and defects

1048708 Porosity 1048708 Trapped gases contaminants 1048708 Preheat or increase rate of heat input1048708 Reduce speed allowing gas to escape cleaning1048708 Slag inclusions1048708 Oxides fluxes electrode coating trapped in weld zone1048708 Clean weld bead during multi-weld processes1048708 Provide enough shielding gas

2008-spring-2004 SKim

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 35: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

35

Weld quality and defects

1048708 Porosity 1048708 Trapped gases contaminants 1048708 Preheat or increase rate of heat input1048708 Reduce speed allowing gas to escape cleaning1048708 Slag inclusions1048708 Oxides fluxes electrode coating trapped in weld zone1048708 Clean weld bead during multi-weld processes1048708 Provide enough shielding gas

2008-spring-2004 SKim

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 36: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

36

Weld quality and defects

1048708 Incomplete fusionpenetration1048708 Preheat and clean joint 1048708 Clean weld area enough shielding gas1048708 Change joint design or type of electrode

2008-spring-2004 SKim

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 37: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

37

Weld quality and defects

1048708 Cracks residual stresses1048708 Temperature gradients embrittlement of grain boundaries1048708 Inability of weld metal to contract during cooling

2008-spring-2004 SKim Kalpakjian

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 38: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

38

DFA - Welding

2008-spring-2004 SKim

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 39: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

39

DFM welding

2008-spring-2004 SKim

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40
Page 40: 2.008 Design & Manufacturing II Spring 2004 Welding & Joining

40

Welding accessibility DFM

2008-spring-2004 SKim

Electrode must be held close to45deg when making these fillers

Easy to draw but the 2nd weldwill be hard to make

Easy to specifyldquoweld allaroundrdquo but hellip

Too close to side to allowproper electrode positioningMay be OK for average work butbad for leakproof welding

Try to avoid placing pipe joints nearwall so that one or two sides areinaccesible These welds must bemade with bent electrodes and mirror

Pipe

Wall

Easy

Very difficult

  • Slide 1
  • Slide 2
  • Slide 3
  • Slide 4
  • Slide 5
  • Slide 6
  • Slide 7
  • Slide 8
  • Slide 9
  • Slide 10
  • Slide 11
  • Slide 12
  • Slide 13
  • Slide 14
  • Slide 15
  • Slide 16
  • Slide 17
  • Slide 18
  • Slide 19
  • Slide 20
  • Slide 21
  • Slide 22
  • Slide 23
  • Slide 24
  • Slide 25
  • Slide 26
  • Slide 27
  • Slide 28
  • Slide 29
  • Slide 30
  • Slide 31
  • Slide 32
  • Slide 33
  • Slide 34
  • Slide 35
  • Slide 36
  • Slide 37
  • Slide 38
  • Slide 39
  • Slide 40