Diapositivas Procesos Union Part 1

7/24/2019 Diapositivas Procesos Union Part 1

1/35

Chapter:

Manufacturing processes by joining


2/35

Importance of joining processes

1. Introduction

2. Oxifuel gas

welding

3. Arc welding.a) Non

consumableelectrode.

GTAW

PAW

AHWb) Consumable

electrode.

SMAW

SAW

GMAW

FCAW

EGW

ESWc) Electrodesd) Gases

e) Others: EBW

LBWf) Quality and

defectsg) Weldabilityh) Design

4. Resistance

welding RSW

RSEW

HFRW

5. Economy

6. Brazing

(soldadura

fuerte)

7. Soldering

(soldadura

blanda)

8. Adhesive

bonding

15.000 parts

Assembly and joining processes are very important:

1. Impossible to manufacture products in one part2. More economical to manufacture parts for assembly.

3. Easier remove parts from assemblies.

4. Different properties in different parts.

5. Easier handling and transportation.


3/35

Classification of joining processes

consumable electrode

1. Introduction

2. Oxifuel gas

welding



GTAW

PAW

AHWb) Consumable

electrode.

SMAW

SAW

GMAW

FCAW

EGW


e) Others: EBW

LBWf) Quality and


4. Resistance

welding RSW

RSEW

HFRW

5. Economy

6. Brazing

(soldadura

fuerte)

7. Soldering

(soldadura

blanda)

8. Adhesive

bonding Micro-structural and physical changes

Mechanical properties affected

Assemble

&

Disassemble

Sealing

Thermal or electrical

insulation

Vibration reduction

Corrosion resistance

between different metals


4/35

Classification of joining processes

1. Introduction

2. Oxifuel gas

welding



GTAW

PAW

AHWb) Consumable

electrode.

SMAW

SAW

GMAW

FCAW

EGW


e) Others: EBW

LBWf) Quality and


4. Resistance

welding RSW

RSEW

HFRW

5. Economy

6. Brazing

(soldadura

fuerte)

7. Soldering

(soldadura

blanda)

8. Adhesive

bonding

Fastening Seaming

StitchingCrimping

http://www.metalockaustralia.com/met

al_stitching.phpv

Riveting
http://www.metalockaustralia.com/metal_stitching.phpvhttp://www.metalockaustralia.com/metal_stitching.phpvhttp://www.metalockaustralia.com/metal_stitching.phpv


5/35


6/35

Welding positions

1. Introduction

2. Oxifuel gas

welding



GTAW

PAW

AHWb) Consumable

electrode.

SMAW

SAW

GMAW

FCAW

EGW


e) Others: EBW

LBWf) Quality and


4. Resistance

welding RSW

RSEW

HFRW

5. Economy

6. Brazing

(soldadura

fuerte)

7. Soldering

(soldadura

blanda)

8. Adhesive

bonding

Conceptos de

pendiente S

y rotacin R (ver norma) UNE- EN ISO 6947
http://localhost/var/www/apps/conversion/tmp/scratch_2/Docs%20complementarios%20vinculados%20a%20apuntes%20o%20diapo/ASME_&_ISO_EN_Welding_Position_Comparison.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_2/Docs%20complementarios%20vinculados%20a%20apuntes%20o%20diapo/ASME_&_ISO_EN_Welding_Position_Comparison.pdf


7/35

Welding positions

1. Introduction

2. Oxifuel gas

welding



GTAW

PAW

AHWb) Consumable

electrode.

SMAW

SAW

GMAW

FCAW

EGW


e) Others: EBW

LBWf) Quality and


4. Resistance

welding RSW

RSEW

HFRW

5. Economy

6. Brazing

(soldadura

fuerte)

7. Soldering

(soldadura

blanda)

8. Adhesive

bonding

Conceptos de pendiente S y rotacin R (ver norma)


8/35

Welding positions

1. Introduction

2. Oxifuel gas

welding



GTAW

PAW

AHWb) Consumable

electrode.

SMAW

SAW

GMAW

FCAW

EGW


e) Others: EBW

LBWf) Quality and


4. Resistance

welding RSW

RSEW

HFRW

5. Economy

6. Brazing

(soldadura

fuerte)

7. Soldering

(soldadura

blanda)

8. Adhesive

bonding


9/35

Welding positions

1. Introduction

2. Oxifuel gas

welding



GTAW

PAW

AHWb) Consumable

electrode.

SMAW

SAW

GMAW

FCAW

EGW


e) Others: EBW

LBWf) Quality and


4. Resistance

welding RSW

RSEW

HFRW

5. Economy

6. Brazing

(soldadura

fuerte)

7. Soldering

(soldadura

blanda)

8. Adhesive

bonding


10/35

Welding positions

1. Introduction

2. Oxifuel gas

welding



GTAW

PAW

AHWb) Consumable

electrode.

SMAW

SAW

GMAW

FCAW

EGW


e) Others: EBW

LBWf) Quality and


4. Resistance

welding RSW

RSEW

HFRW

5. Economy

6. Brazing

(soldadura

fuerte)

7. Soldering

(soldadura

blanda)

8. Adhesive

bonding


11/35

Welding positions

1. Introduction

2. Oxifuel gas

welding



GTAW

PAW

AHWb) Consumable

electrode.

SMAW

SAW

GMAW

FCAW

EGW


e) Others: EBW

LBWf) Quality and


4. Resistance

welding RSW

RSEW

HFRW

5. Economy

6. Brazing

(soldadura

fuerte)

7. Soldering

(soldadura

blanda)

8. Adhesive

bonding


12/35

Preparation of welding borders

1. Introduction

2. Oxifuel gas

welding



GTAW

PAW

AHWb) Consumable

electrode.

SMAW

SAW

GMAW

FCAW

EGW


e) Others: EBW

LBWf) Quality and


4. Resistance

welding RSW

RSEW

HFRW

5. Economy

6. Brazing

(soldadura

fuerte)

7. Soldering

(soldadura

blanda)

8. Adhesive

bonding

FUNCTION:

To enable a quality welding withcomplete penetration, obtaining good

stress transmission and seaming

between parts.

DEFINITION:

UNE-EN 9692-1
http://localhost/var/www/apps/conversion/tmp/scratch_2/Docs%20complementarios%20vinculados%20a%20apuntes%20o%20diapo/Normas/UNE-EN_ISO_9692-1_2004.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_2/Docs%20complementarios%20vinculados%20a%20apuntes%20o%20diapo/Normas/UNE-EN_ISO_9692-1_2004.pdf


13/35


1. Introduction

2. Oxifuel gas

welding



GTAW

PAW

AHWb) Consumable

electrode.

SMAW

SAW

GMAW

FCAW

EGW


e) Others: EBW

LBWf) Quality and


4. Resistance

welding RSW

RSEW

HFRW

5. Economy

6. Brazing

(soldadura

fuerte)

7. Soldering

(soldadura

blanda)

8. Adhesive

bonding

Butt joining simple side welded


14/35


1. Introduction

2. Oxifuel gas

welding



GTAW

PAW

AHWb) Consumable

electrode.

SMAW

SAW

GMAW

FCAW

EGW


e) Others: EBW

LBWf) Quality and


4. Resistance

welding RSW

RSEW

HFRW

5. Economy

6. Brazing

(soldadura

fuerte)

7. Soldering

(soldadura

blanda)

8. Adhesive

bonding

Butt joining simple

side welded (cont.)


15/35


1. Introduction

2. Oxifuel gas

welding



GTAW

PAW

AHWb) Consumable

electrode.

SMAW

SAW

GMAW

FCAW

EGW


e) Others: EBW

LBWf) Quality and


4. Resistance

welding RSW

RSEW

HFRW

5. Economy

6. Brazing

(soldadura

fuerte)

7. Soldering

(soldadura

blanda)

8. Adhesive

bonding

Butt joining

both sides

welded


16/35


1. Introduction

2. Oxifuel gas

welding



GTAW

PAW

AHWb) Consumable

electrode.

SMAW

SAW

GMAW

FCAW

EGW


e) Others: EBW

LBWf) Quality and


4. Resistance

welding RSW

RSEW

HFRW

5. Economy

6. Brazing

(soldadura

fuerte)

7. Soldering

(soldadura

blanda)

8. Adhesive

bonding

Butt joining both sides

welded (cont.)


17/35


1. Introduction

2. Oxifuel gas

welding



GTAW

PAW

AHWb) Consumable

electrode.

SMAW

SAW

GMAW

FCAW

EGW


e) Others: EBW

LBWf) Quality and


4. Resistance

welding RSW

RSEW

HFRW

5. Economy

6. Brazing

(soldadura

fuerte)

7. Soldering

(soldadura

blanda)

8. Adhesive

bonding

Fillet joining one side

welded

Fillet joining both sides

welded


18/35


1. Introduction

2. Oxifuel gas

welding



GTAW

PAW

AHWb) Consumable

electrode.

SMAW

SAW

GMAW

FCAW

EGW


e) Others: EBW

LBWf) Quality and


4. Resistance

welding RSW

RSEW

HFRW

5. Economy

6. Brazing

(soldadura

fuerte)

7. Soldering

(soldadura

blanda)

8. Adhesive

bonding

V

Thickness from 4-6 mm up to 20-25 mm.

One face welding with complete penetration.

Drawback: angular deformation due to thermal asymmetry.

U

Thickness from 25 mm.

One face welding with complete penetration.Less thermal stresses.

Double V

Thickness up to 40 mm.

Both faces welding with complete penetration.

Less thermal stresses

Simple bevels:For vertical and inclined positions for retaining the material.

Assure full penetration in a

strength joining only one face is

accessible.

Welding with support


19/35


1. Introduction

2. Oxifuel gas

welding



GTAW

PAW

AHWb) Consumable

electrode.

SMAW

SAW

GMAW

FCAW

EGW


e) Others: EBW

LBWf) Quality and


4. Resistance

welding RSW

RSEW

HFRW

5. Economy

6. Brazing

(soldadura

fuerte)

7. Soldering

(soldadura

blanda)

8. Adhesive

bonding

ANSI / AWS A2.4

UNE EN 22553


20/35

Fusion welding

1. Introduction

2. Oxifuel gas

welding



GTAW

PAW

AHWb) Consumable

electrode.

SMAW

SAW

GMAW

FCAW

EGW


e) Others: EBW

LBWf) Quality and


4. Resistance

welding RSW

RSEW

HFRW

5. Economy

6. Brazing

(soldadura

fuerte)

7. Soldering

(soldadura

blanda)

8. Adhesive

bonding

FUSION WELDING

Non filler material With filler material

Basic principles of each process.

Required equipment.

Advantages, limitations and capacities of each process.

Economic considerations. Defects of welded unions.

Weldability of diverse metals and alloys.

Design approaches for welding.


21/35

1. Introduction

2. Oxifuel gas

welding



GTAW

PAW

AHWb) Consumable

electrode.

SMAW

SAW

GMAW

FCAW

EGW


e) Others: EBW

LBWf) Quality and


4. Resistance

welding RSW

RSEW

HFRW

5. Economy

6. Brazing

(soldadura

fuerte)

7. Soldering

(soldadura

blanda)

8. Adhesive

bonding

1. OXIFUEL WELDING (OFW)

OXI-ACETYLEN WELDING (OAW)

1

2

3

4


22/35

1. Introduction

2. Oxifuel gas

welding



GTAW

PAW

AHWb) Consumable

electrode.

SMAW

SAW

GMAW

FCAW

EGW


e) Others: EBW

LBWf) Quality and


4. Resistance

welding RSW

RSEW

HFRW

5. Economy

6. Brazing

(soldadura

fuerte)

7. Soldering

(soldadura

blanda)

8. Adhesive

bonding

1. OXIFUEL WELDING (OFW)


23/35

Uncoated rod

Flux-coated rod

OXIFUEL WELDING (OFW)

1. Introduction

2. Oxifuel gas

welding



GTAW

PAW

AHWb) Consumable

electrode.

SMAW

SAW

GMAW

FCAW

EGW


e) Others: EBW

LBWf) Quality and


4. Resistance

welding RSW

RSEW

HFRW

5. Economy

6. Brazing

(soldadura

fuerte)

7. Soldering

(soldadura

blanda)

8. Adhesive

bonding

Filler metal

a) To retard the oxidation of part surfaces, since it melts before the

rod and it generates a protective gas.

b) To help to dissolve and to eliminate the oxides and sludge of

welding area.

c) The formed slag (made up of oxides, fusing agents andmaterials of the electrode coating) protects the fused material

against oxidation while cooling.

Steels Stainless steels Aluminum alloys

ADVANTAGES AND LIMITATIONS:1. Low cost process.

2. Portability.

3. Low temperature of flame.

4. Manual process difficult to automate.

APPLICATIONS:- Sheet metal welding up to

6 mm.

- Automotive sheet

reparations.

- Non-ferrous and Ferrous

alloys


24/35

OXIFUEL WELDING (OFW)

1. Introduction

2. Oxifuel gas

welding



GTAW

PAW

AHWb) Consumable

electrode.

SMAW

SAW

GMAW

FCAW

EGW


e) Others: EBW

LBWf) Quality and


4. Resistance

welding RSW

RSEW

HFRW

5. Economy

6. Brazing

(soldadura

fuerte)

7. Soldering

(soldadura

blanda)

8. Adhesive

bonding

1. Prepare the ends to join and grip the

parts with fixtures.

2. Open the acetylene valve to the required

pressure and flow and to light in the tip of

the torch.

3. Open the oxygen valve to the pressure

and required flow and adjust the flame for

the particular operation.

4. Grasp the torch at 45 of the plane of

part, with the cone of the interior flame

near it and the rod at 30-40.

5. Touch the joining with the rod and control

the movement along the joining in

function of the fusion speed and the

joining filling.6. In deep V-shape welding several beads

can be necessary. Clean slag before

applying a new bead.

Procedure

CONCOA Operation Manual
http://localhost/var/www/apps/conversion/tmp/scratch_2/Docs%20complementarios%20vinculados%20a%20apuntes%20o%20diapo/ASME_&_ISO_EN_Welding_Position_Comparison.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_2/Docs%20complementarios%20vinculados%20a%20apuntes%20o%20diapo/ASME_&_ISO_EN_Welding_Position_Comparison.pdf


25/35

1. Introduction

2. Oxifuel gas

welding

3.Arc welding.a) Non


GTAW

PAW

AHWb) Consumable

electrode.

SMAW

SAW

GMAW

FCAW

EGW


e) Others: EBW

LBWf) Quality and


4. Resistance

welding RSW

RSEW

HFRW

5. Economy

6. Brazing

(soldadura

fuerte)

7. Soldering

(soldadura

blanda)

8. Adhesive

bonding

2. ARC WELDING

Power supply: AC

DC

- Type of electrode.

- Type of metals to join.

- Depth of bead.

- Width of bead.

Direct

POLARITY: Direct (DCEN) (DC-)

Inverse (DCEP) (DC+)30.000 C

For SMAW, GMAW, FCAW and SAW

welding processes.

Opposite effect on penetration for GTAW


26/35

ARC WELDING

1. Introduction

2. Oxifuel gas

welding



GTAW

PAW

AHWb) Consumable

electrode.

SMAW

SAW

GMAW

FCAW

EGW


e) Others: EBW

LBWf) Quality and


4. Resistance

welding RSW

RSEW

HFRW

5. Economy

6. Brazing

(soldadura

fuerte)

7. Soldering

(soldadura

blanda)

8. Adhesive

bonding

Power supply: AC

DC

Coated rod with

Mg, Al, Na, K

or

Gas

Thick sections welding

High diameter electrodes at maximum currents


27/35

ARC WELDING

1. Introduction

2. Oxifuel gas

welding



GTAW

PAW

AHWb) Consumable

electrode.

SMAW

SAW

GMAW

FCAW

EGW


e) Others: EBW

LBWf) Quality and


4. Resistance

welding RSW

RSEW

HFRW

5. Economy

6. Brazing

(soldadura

fuerte)

7. Soldering

(soldadura

blanda)

8. Adhesive

bonding

Power supply: types of control Current constant

Tension constant


28/35

ARC WELDING

1. Introduction

2. Oxifuel gas

welding



GTAW

PAW

AHWb) Consumable

electrode.

SMAW

SAW

GMAW

FCAW

EGW


e) Others: EBW

LBWf) Quality and


4. Resistance

welding RSW

RSEW

HFRW

5. Economy

6. Brazing

(soldadura

fuerte)

7. Soldering

(soldadura

blanda)

8. Adhesive

bonding

Power supply: types of control Current constant

Tension constant


29/35

ARC WELDING

1. Introduction

2. Oxifuel gas

welding



GTAW

PAW

AHWb) Consumable

electrode.

SMAW

SAW

GMAW

FCAW

EGW


e) Others: EBW

LBWf) Quality and


4. Resistance

welding RSW

RSEW

HFRW

5. Economy

6. Brazing

(soldadura

fuerte)

7. Soldering

(soldadura

blanda)

8. Adhesive

bonding

Arc energy

UNE-EN 1011-1

SMAW

GMAW

GTAWPAW

SAW

FCAW


30/35

ARC WELDING: Non-consumable electrode

1. Introduction

2. Oxifuel gas

welding

3. Arc welding.

a) Non

consumable electrode.

GTAW PAW

AHWb) Consumable

electrode.

SMAW

SAW

GMAW

FCAW

EGW


e) Others: EBW

LBWf) Quality and


4. Resistance

welding RSW

RSEW

HFRW

5. Economy

6. Brazing

(soldadura

fuerte)

7. Soldering

(soldadura

blanda)

8. Adhesive

bonding

Gas Tungsten Arc Welding (GTAW).

Plasma Arc Welding (PAW).

Atomic Hydrogen Welding (AHW).

TYPES OF PROCESSES:

Gas Tungsten Arc Welding (GTAW)

DC 200-500 A

8-20 KW

Al & Mg &

Stainless Steel

welding

preferable

DC AC

DCEN DCEP


31/35


1. Introduction

2. Oxifuel gas

welding

3. Arc welding.

a) Non


GTAW PAW

AHWb) Consumable

electrode.

SMAW

SAW

GMAW

FCAW

EGW


e) Others: EBW

LBWf) Quality and


4. Resistance

welding RSW

RSEW

HFRW

5. Economy

6. Brazing

(soldadura

fuerte)

7. Soldering

(soldadura

blanda)

8. Adhesive

bonding


ADVANTAGES AND LIMITATIONS:

1. Constant gap due to non-consumable electrode -> stable current.

2. To weld great variety of metals, including Al, Mg, Ti, CrNi and refractory metals in all type of

positions.

3. Slab absence (no flux).

4. Good quality beads with good superficial finish.

5. Portable.

6. Absence of projections since there is no transfer of drops as occurs in SMGW or MGAW.

7. Expensive process due to gas cost.

8. Low deposition rate. Great ability for the welder. Qualified welder.

APPLICATIONS

For applications of little thickness up to 5 mm or thicker with root and several beads.


32/35


1. Introduction

2. Oxifuel gas

welding

3. Arc welding.

a) Non


GTAW PAW

AHWb) Consumable

electrode.

SMAW

SAW

GMAW

FCAW

EGW


e) Others: EBW

LBWf) Quality and


4. Resistance

welding RSW

RSEW

HFRW

5. Economy

6. Brazing

(soldadura

fuerte)

7. Soldering

(soldadura

blanda)

8. Adhesive

bonding


Slope control: starting and ending

(letters D, E, F, G, I and O)


33/35


1. Introduction

2. Oxifuel gas

welding

3. Arc welding.

a) Non


GTAW PAW

AHWb) Consumable

electrode.

SMAW

SAW

GMAW

FCAW

EGW


e) Others: EBW

LBWf) Quality and


4. Resistance

welding RSW

RSEW

HFRW

5. Economy

6. Brazing

(soldadura

fuerte)

7. Soldering

(soldadura

blanda)

8. Adhesive

bonding


Temporization: pre-flux and post-flux (letters K and T)

High frequency HF: (letters Q)

Wave balance, regulation of

penetration and pickling

action: (letter S)

Pulsed arc function: (letters

H, A, B and C)

Penetration Pickling


34/35


1. Introduction

2. Oxifuel gas

welding

3. Arc welding.

a) Non


GTAW PAW

AHWb) Consumable

electrode.

SMAW

SAW

GMAW

FCAW

EGW


e) Others: EBW

LBWf) Quality and


4. Resistance

welding RSW

RSEW

HFRW

5. Economy

6. Brazing

(soldadura

fuerte)

7. Soldering

(soldadura

blanda)

8. Adhesive

bonding


35/35


1. Introduction

2. Oxifuel gas

welding

3. Arc welding.

a) Non


GTAW PAW

AHWb) Consumable

electrode.

SMAW

SAW

GMAW

FCAW

EGW


e) Others: EBW

LBWf) Quality and


4. Resistance

welding RSW

RSEW

HFRW

5. Economy

6. Brazing

(soldadura

fuerte)

7. Soldering

(soldadura

blanda)

8. Adhesive

bonding

Plasma Arc Welding (PAW).

33.000 C

100 A (lower)

Transferred arc Non Transferred arc

ADVANTAGES AND LIMITATIONS:

The same as GTAW and:1. Better arc stability.

2. Less thermal deformation.

3. Major energy concentration.

4. Higher welding speeds (120-1000 mm/min).

APPLICATIONS

Substitutes to GTAW in:

- Butt joints and lap joints.

- Deeper (6-20 mm) and narrower weldings

Hydrogen Arc Welding (HAW).

Diapositivas Procesos Union Part 1

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Transcript of Diapositivas Procesos Union Part 1