Veljko SamardzicME-215 Engineering Materials and Processes

Chapter 33:

Other Welding Processes,

Brazing and Soldering

Veljko SamardzicME-215 Engineering Materials and Processes

33.1 Introduction

Veljko SamardzicME-215 Engineering Materials and Processes

33.2 Other Welding and Cutting

Processes

Veljko SamardzicME-215 Engineering Materials and Processes

Electroslag Welding

FIGURE 33-1 (a) Arrangement of equipment and workpieces for making a vertical weld by the

electroslag process. (b) Cross section of an electroslag weld, looking through the water-cooled

copper slide.

Veljko SamardzicME-215 Engineering Materials and Processes

Electron Beam Welding

FIGURE 33-2 Schematic diagram

of the electron-beam welding

process

Veljko SamardzicME-215 Engineering Materials and Processes

Examples of Electron Beam

Welding

FIGURE 33-3 (Left to

right) Electronbeam

welds in 19-mm-thick

7079 aluminum and 102-

mm-thick stainless

steel. (Courtesy of

Hamilton Standard

Division of United

Technologies

Corporation, Hartford,

CT.)

Veljko SamardzicME-215 Engineering Materials and Processes

Process Summary of EBW

Veljko SamardzicME-215 Engineering Materials and Processes

Examples of Laser Welding

FIGURE 33-4 Laser butt weld

of 3-mm (0.125-in.) stainless

steel, made at 1.5 m/min with a

1250-watt laser. (Courtesy of

Coherent, Inc., Santa Clara, CA.)

Veljko SamardzicME-215 Engineering Materials and Processes

Process Summary of LBW

Veljko SamardzicME-215 Engineering Materials and Processes

Comparison of Power Densities

FIGURE 33-5 Comparison of the power densities of various welding processes. The high power

densities of the electronbeam and laser-beam welding processes enable the production of deep,

narrow welds with small heat-affected zones. Welds can be made quickly and at high travel speeds.

Veljko SamardzicME-215 Engineering Materials and Processes

Schematic of Laser Beam Cutting

FIGURE 33-6 Schematic of

laser-beam cutting. The laser

provides the heat, and the flow

of assist gas propels the molten

droplets from the cut.

Veljko SamardzicME-215 Engineering Materials and Processes

Cutting Surface

FIGURE 33-7 Surface of

6-mm-thick carbon steel cut

with a 1250-watt laser at 1.8

m/min. (Courtesy of Coherent,

Inc., Santa Clara, CA.)

Veljko SamardzicME-215 Engineering Materials and Processes

Schematic of Flash Welding

FIGURE 33-8 Schematic

diagram of the flash-welding

process. (a) Equipment and

setup; (b) completed weld.

Veljko SamardzicME-215 Engineering Materials and Processes

33.3 Surface Modification by Welding

Related Processes

Veljko SamardzicME-215 Engineering Materials and Processes

Schematic of a Metal Spray Gun

FIGURE 33-9 Schematic diagram of an oxyacetylene

metal-spraying gun. (Courtesy of Sulzer Metco,

Winterthur, Switzerland.)

Veljko SamardzicME-215 Engineering Materials and Processes

Plasma Arc Spray Gun

FIGURE 33-10 Diagram of a

plasma-arc spray gun. (Courtesy

of Sulzer Metco, Winterthur,

Switzerland.)

Veljko SamardzicME-215 Engineering Materials and Processes

Comparison of Thermal Spray

Deposition

Veljko SamardzicME-215 Engineering Materials and Processes

33.4 Brazing

Veljko SamardzicME-215 Engineering Materials and Processes

Joint Strength

FIGURE 33-11 Typical variation of tensile strength with

clearance in a butt-joint braze. (Courtesy of Handy & Harman, Rye, NY.)

Veljko SamardzicME-215 Engineering Materials and Processes

Joint Clearance in Brazing

FIGURE 33-12 When brazing dissimilar metals, the initial joint clearance should be adjusted for

the different thermal expansions (here brass expands more than steel). Proper brazing

clearances should exist at the temperature where the filler metal flows.

Veljko SamardzicME-215 Engineering Materials and Processes

Common Joint Design

FIGURE 33-13 The two most common

types of braze joints are butt and lap. Butt

offers uniform thickness across the joint,

whereas lap offers greater bonding area and

higher strength

Veljko SamardzicME-215 Engineering Materials and Processes

Variations of Butt Joints

FIGURE 33-14 Variations of

the butt and lap configurations

include the butt-lap and scarf.

The four types are shown for

both flat and tubular parts.

Veljko SamardzicME-215 Engineering Materials and Processes

Common Joint Designs for

Brazing

FIGURE 33-15 Some common

joint designs for assembling

parts by brazing

Veljko SamardzicME-215 Engineering Materials and Processes

Compatibility of Brazing

Materials

Veljko SamardzicME-215 Engineering Materials and Processes

Brazing Material Families

Veljko SamardzicME-215 Engineering Materials and Processes

Furnace Assembly

FIGURE 33-16 Two

views of an array of

furnace-brazed

assemblies.

(www.franklinbrazing.com

Veljko SamardzicME-215 Engineering Materials and Processes

Schematic of Braze-Welding

Process

FIGURE 33-17 Schematic of the

braze-welding process

Veljko SamardzicME-215 Engineering Materials and Processes

33.5 Soldering

Veljko SamardzicME-215 Engineering Materials and Processes

Solder Joints

FIGURE 33-18 Some common

designs for soldered joints.

Veljko SamardzicME-215 Engineering Materials and Processes

Compatibility of Soldering

Veljko SamardzicME-215 Engineering Materials and Processes

Common Solder

Veljko SamardzicME-215 Engineering Materials and Processes

Wave Soldering

FIGURE 33-19 Schematic of wave

soldering