Post on 03-Jun-2018
8/12/2019 Welding 101 Presentation
1/42
Jason King, Paula Lobaccaro,
Meghan Olson & Lindsey Rappleyea
8/12/2019 Welding 101 Presentation
2/42
Introduction Welding Joints
Welding Processes
Equipment and Technology Advantages and Disadvantages
Welding in Present Day Manufacturing
Safety
Economics Case Study
8/12/2019 Welding 101 Presentation
3/42
Welding is a fabrication or sculptural processthat joins materials, such as metals orthermoplastics, by melting the parts and thenusing a filler to form a joint
Estimated: 50% of the gross national productof the U.S.A. is related to welding in one wayor another
Welding has done in unusual conditions,including underwater and in outer space
8/12/2019 Welding 101 Presentation
4/42
Welding Processes
A materials joining process whichproduces coalescence of materials by
heating them to suitable temperatures
with or without the application of
pressure or by the application of
pressure alone and with or without
the use of filler material. - AWS
8/12/2019 Welding 101 Presentation
5/42
8/12/2019 Welding 101 Presentation
6/42
Bronze Age: Welded Gold Boxes & EgyptianTools
Middle Ages: Blacksmiths 1800s: Use of open flames for welding 1880-1900: Development of arc welding 1920s: Automatic Welding 1940s: Development of Heliarc welding and
Gas Shielded Metal Arc Welding 1960s: Plasma Arc Welding Modern: Friction Welding, Laser Welding
8/12/2019 Welding 101 Presentation
7/42
Advantages Simpler, faster and more cost effective than otherjoining methods
Parts do not need to fit together perfectly
Joint can potentially be stronger than the individualparts that are going to be joined
Can weld a wide range of metals and plastics
Can be used in unique environments
Can be an automatized process Equipment can be less expensive than other
manufacturing equipment
8/12/2019 Welding 101 Presentation
8/42
Disadvantages Welds can contain defects; less reliable and
predictable
Joint is permanent, preventing future alterations
Not applicable to all materials Can be a liability due to training, expertise, and
safety required
8/12/2019 Welding 101 Presentation
9/42
8/12/2019 Welding 101 Presentation
10/42
Pieces to be welded are laid side by side
8/12/2019 Welding 101 Presentation
11/42
One piece to be welded in laid down andanother pieces is overlapped
Fillet, plug, and slot welds can be applied to
Lap Joints
8/12/2019 Welding 101 Presentation
12/42
One piece to be welded in placed on anotherso that a corner is formed
8/12/2019 Welding 101 Presentation
13/42
Two pieced to be welded come together andthe two edges are welded
8/12/2019 Welding 101 Presentation
14/42
One piece of metal to be welded is placedvertically on top of another piece that ishorizontal, forming a T
Fillet welds are applied to T Joints
8/12/2019 Welding 101 Presentation
15/42
Created in 1890 Commonly known as stick welding
Works with: carbon steel
high alloy steel
stainless steel
cast iron
ductile iron
copper
nickel
8/12/2019 Welding 101 Presentation
16/42
8/12/2019 Welding 101 Presentation
17/42
Advantages Versatility - readily
applied to a variety ofapplications and a widechoice of electrodes
Relative simplicity and
portability of equipment Low Cost Adaptable to confined
spaces and remotelocations
Suitable for out-of-position welding
Disadvantages Not as productive as
continuous wireprocesses
Frequent stop/starts to
change electrodes Relatively high metal
wastage (electrodestubs)
Current limits are lowerthan for continuous orautomatic processes(reduces deposition rate)
Advantages vs Disadvantages
8/12/2019 Welding 101 Presentation
18/42
8/12/2019 Welding 101 Presentation
19/42
8/12/2019 Welding 101 Presentation
20/42
Advantages Higher Productivity
Simple to Learn
Clean and Efficient
Versatile High Welding Speed
Simple and greatwelds
Disadvantages High start up cost
Limited Positions
Not Suitable for
Outdoor Welding Fast Cooling Rates
Unsuitable for ThickMetals
Shielding Gas Metal Preparation
Time
Advantages vs Disadvantages
8/12/2019 Welding 101 Presentation
21/42
Created in 1941 Commonly Known as TIG Welding Works with:
Mild Steel
Stainless Steel Aluminum Copper Nickel Copper Nickel Inconel Magnesium Titanium
8/12/2019 Welding 101 Presentation
22/42
8/12/2019 Welding 101 Presentation
23/42
Advantages Applicable to a very
wide range ofmaterials
Especially good for
welding thin sectionsand delicate workpieces
Capable of producingwelds of high quality
and appearance
Disadvantages Generally restricted to
flat or horizontalwelding
Requires a higher levelof skill
Slower welds
Advantages vs Disadvantages
8/12/2019 Welding 101 Presentation
24/42
Electrical resistance across the two joiningcomponents produces the heat required forwelding
Typically used when welding particular types ofsheet metal
Disadvantages Bond strength depends on surface roughness & cleanliness Requires specialized machinery (generally non-portable)
Advantages: Many facilities now automated Commonly selected for use with robotics in automotive
manufacturing
8/12/2019 Welding 101 Presentation
25/42
8/12/2019 Welding 101 Presentation
26/42
8/12/2019 Welding 101 Presentation
27/42
Resistance spot welding
Electrical energy is
the heat sourcenecessary for thecoalescence of twoor more metals
8/12/2019 Welding 101 Presentation
28/42
joins metals without base metalmelting
produces coalescence attemperatures essentially belowthe melting point of the basematerials being joined
brazing filler material is notrequired
8/12/2019 Welding 101 Presentation
29/42
Two processes: Electron beam
Laser
Beam can be used tomelt and vaporizemetals because suchhigh energy intensity
Energy transfer - notthermal transfer processes
8/12/2019 Welding 101 Presentation
30/42
An electron beam (of high velocity electrons)generated in a vacuum creates a fusing heatsource
Advantages:
Can unite almost any metals Deep weld without adding excessive heat that can
adversely affect the properties of the surroundingmaterial
High Tolerances
Problems/Disadvantages Undercutting, cracking, lack of fusion, missedjoints, porosity, under fill, and shrinkage voids
8/12/2019 Welding 101 Presentation
31/42
8/12/2019 Welding 101 Presentation
32/42
Joining takes place without fusion at theinterface Two surfaces brought together under pressure
No liquid or molten phase is present at thejoint
For strong bond, both surfaces must beclean:
No oxide films, residues, metalworking fluids,contaminants
8/12/2019 Welding 101 Presentation
33/42
A group of 8 welding processes cold welding
diffusion welding
explosion welding forge welding
friction welding
hot pressure welding
roll welding ultrasonic welding
8/12/2019 Welding 101 Presentation
34/42
8/12/2019 Welding 101 Presentation
35/42
8/12/2019 Welding 101 Presentation
36/42
Ventilation
Grounded
Protect neighboringworkers from
exposure to arc
radiation by shielding
your station.
8/12/2019 Welding 101 Presentation
37/42
11. Time for changing electrodes.
12. Time to move the welder fromone location to another.
13. Time to change welding machine
settings.14. Time spent by personnel for
personal purposes.
15. Time to repair or re-workdefective welds.
16. Costs associated with any
required stress relief.17. Cost of electrodes.
18. Cost of shielding materials.
19. Cost of electric power.
20. Cost of fuel gas for pre-heat(when required).
1. Time for joint preparation.
2. Time to prepare the material forwelding (blasting, removal of oils,etc.).
3. Time for assembly.4. Time to preheat the joint (when
required).
5. Time for tack-up.
6. Time for positioning.
7. Time for welding.
8. Time to remove slag (whenapplicable).
9. Time to remove spatter.
10. Time for inspection.
Machines: $400-$7000+, Helmets: $20 - $500+,
Guns: $200-$3000+
8/12/2019 Welding 101 Presentation
38/42
=
=
&
+
=
3
=
Most accurate method
Useful for welded parts that will move throughout a workspace
&
=
&
8/12/2019 Welding 101 Presentation
39/42
Best when applied to single pass welds
=
&
+
&
= &
=
=
3
=
8/12/2019 Welding 101 Presentation
40/42
Easiest and most used (and misused) Best applied to large, multipass welds
=
&
+
&
=&
=
=
3
=
8/12/2019 Welding 101 Presentation
41/42
Robotic vs. Fixed Robotic arm moves on multiple axis
Increased productivity
Improved weld quality
Increased profitability Reduced labor costs 70% of welding costs
Single machine can replace3 workers
Reduced material waste
Used increasingly more often The car industry is a huge user of automated
welding
8/12/2019 Welding 101 Presentation
42/42
Case study, looking at real time welding in theautomotive world
http://www.youtube.com/watch?v=spRyegwBhKg