INDUSTRIAL PROCESSES II INDEN 3313
description
Transcript of INDUSTRIAL PROCESSES II INDEN 3313
Industrial Processes II
INDUSTRIAL PROCESSES IIINDUSTRIAL PROCESSES II
INDEN 3313INDEN 3313
Lecture 7 – Welding,Lecture 7 – Welding, Welding Design, Welding Design,
Brazing and SolderingBrazing and Soldering
Industrial Processes II
OVERVIEWOVERVIEW
• Directions to LabDirections to Lab• Remaining Welding ProcessesRemaining Welding Processes• Welding DesignWelding Design• Brazing and SolderingBrazing and Soldering
Industrial Processes II
QUESTIONSQUESTIONSTO START ??TO START ??
Industrial Processes II
UPCOMING WELDING UPCOMING WELDING LABSLABS
• Three Lab SequenceThree Lab Sequence– Introduction and
•Oxyfuel•Arc Welding•MIG (SMAW) Welding
• LocationLocation– Bio-Systems and Agricultural
Engineering Laboratories– SE Corner of Hall of Fame and
Cleveland• Park Across from Colvin Center
Industrial Processes II
UPCOMING WELDING UPCOMING WELDING LABSLABS• Three Lab SequenceThree Lab Sequence
– Oxyfuel -> Arc Welding ->MIG (SMAW)– 12:00 Lab
Group A Gas ->Arc ->Stick
Billy
Group B Arc ->Stick->Gas
Sally
Group C Stick->Gas->Arc
Charley
Industrial Processes II
UPCOMING WELDING UPCOMING WELDING LABSLABS• Three Lab SequenceThree Lab Sequence
– Oxyfuel -> Arc Welding ->MIG (SMAW)– 3:00 Lab
Group A Gas ->Arc ->Stick
Billy
Group B Arc ->Stick->Gas
Sally
Group C Stick->Gas->Arc
Charley
Industrial Processes II
UPCOMING WELDING UPCOMING WELDING LABSLABS• Location Location --Corner of Cleveland and Hall of Fame--Corner of Cleveland and Hall of Fame
Colvin Center
OSU TrackColvin Parking
AG Labs
Cle
vela
nd
Industrial Processes II
UPCOMING WELDING UPCOMING WELDING LABSLABS
WELDING LABEntry Door
N
HALL OF FAME
CL
EV
EL
AN
D
Industrial Processes II
COLD WELDINGCOLD WELDING• Basic Process DescriptionBasic Process Description
– Use of Pressure to Cause Coalescence• Clean Mating Surfaces• Press Together and Plastically Deform, as in
Rolling, Cladding• If Dissimilar Metals, Inter-metallic
Compounds Form - Act as (Weak) Adhesive• ParametersParameters
– Pressure Used– Cleanliness of Surfaces– Similarity of Metals
Industrial Processes II
COLD WELDINGCOLD WELDING• Sources/Causes of DefectsSources/Causes of Defects
– Inclusions, Delamination– Inadequate Ductility of Base
Material(s)• ““Cures” For DefectsCures” For Defects
– Adequate, Uniform Pressures– Surface Preparation
Industrial Processes II
COLD WELDINGCOLD WELDING
Kalpakjian, Figure 28.1, p. 886
Industrial Processes II
ULTRASONIC WELDINGULTRASONIC WELDING
• Basic Process DescriptionBasic Process Description– Mechanically Induced Vibrations Used
to Breakup Oxides and Provide Energy for Coalescence
• ParametersParameters– Vibration Frequency and Amplitude– Temperature Induced (.33 - .50 Tmelt)
• DefectsDefects– Inclusions, Incomplete Fusion
Industrial Processes II
ULTRASONIC WELDINGULTRASONIC WELDING
Kalpakjian, Figure 28.2a&b, p. 887
Industrial Processes II
FRICTION WELDINGFRICTION WELDING• Basic Process DescriptionBasic Process Description
– Production of Heat By “Rubbing” the Surfaces to be Mated Against One Another and Holding the Heated Surfaces Against One Another Until Coalescence Occurs.
• ParametersParameters– Force Applied/Means (Linear or Rotational)– Rotational Speed
• Sources/Causes of DefectsSources/Causes of Defects– Preparation of Surface (Oxides)– Misalignment
Industrial Processes II
FRICTION WELDINGFRICTION WELDING
Kalpakjian, Figure 28.3, p. 888
Industrial Processes II
EXPLOSION WELDINGEXPLOSION WELDING• Basic Process DescriptionBasic Process Description
– Use of Pressure (Wave) Produced by the Detonation of an Explosive and the Use of this Pressure to Cause Coalescence. Oxides Broken and Expelled from Weld by Pressure Wave.
• ParametersParameters– Pressure Reached– Detonation/Speed of Pressure Wave
• Rate Dependant Deformation Process
Industrial Processes II
EXPLOSION WELDINGEXPLOSION WELDING
• Sources/Causes of DefectsSources/Causes of Defects– Inclusions– Tearing, Cracks
Industrial Processes II
EXPLOSION WELDINGEXPLOSION WELDING
Amstead, Figure 8.30, p. 190
Industrial Processes II
DIFFUSION WELDINGDIFFUSION WELDING• Basic Process DescriptionBasic Process Description
– Uses Heat and Pressure to Promote Diffusion of Atoms Across Interface. Diffusion of One Crystalline Structure into Another (Can be Dissimilar Metals)
• ParametersParameters– Temperature– Pressure– Surface Preparation– Material Compatibility
Industrial Processes II
WELDING DESIGN REVIEWWELDING DESIGN REVIEW• Design Considerations Design Considerations [[Boltz, pgs. 53-35 to 55]Boltz, pgs. 53-35 to 55]
– Analysis of Current Design• Define Previous Design Requirements• Analysis of Previous Failures/Problems
– Over/Under Design ?– Determination of Load Conditions
• Type and Magnitude of Forces, Safety Limits• Determine Desired “Fail Safe” Mode(s)
– Determine Major Design Factors• Satisfy Strength. Stiffness, Safety Requirements• Add Stiffness By Use of Bosses, • If Bending, Use Deep, Symmetrical Sections• Appearance Only where Critical (On Print)
Industrial Processes II
WELDING DESIGN REVIEWWELDING DESIGN REVIEW• Design Considerations Design Considerations [[Boltz, pgs. 53-35 to 55]Boltz, pgs. 53-35 to 55]
– Determine Major Design Factors (Cont.)• Minimize Weight, Material Used• Used Closed (Tubular) Sections to Provide
Torsion Resistance• Use Non-Premium Material Grades where
Possible• Use Standard Sections, Plates, and Bar
– Use ‘Scrap’ for Stiffeners, etc.– Allow for Edge Preparation
• Provide all Necessary Maintenance Access• Compare Process Capability and Tolerance• Use Subassemblies to Distribute Tasks (Line)
Industrial Processes II
WELDING DESIGN REVIEWWELDING DESIGN REVIEW• Design Considerations Design Considerations [[Boltz, pgs. 53-35 Boltz, pgs. 53-35
to 55]to 55]– Joint/Bead Design Factors
• Select Joint Needing Least Material– If Thick, Use Double Grooves– Minimize Root Opening and Included Angle– Minimize Leg Size
• Select One Pass Joint/Process Combination• Balance Joint Preparation and Welding Time• Provide Welder Access to Joint• Continuous vs. Intermittent Weld Bead
– Lower Strength -- Intermittent– Automated -- Continuous– Distortion -- Intermittent
• Size Weld Based on Thinner Member
Industrial Processes II
WELDING DESIGN REVIEWWELDING DESIGN REVIEW• Design Considerations Design Considerations [[Boltz, pgs. 53-35 Boltz, pgs. 53-35
to 55]to 55]– Welding Operations
• Use Properly Designed Fixtures (Strength, Allow for Distortion, Rotate for Positioning)
• Use “Two-Up” Design for Higher Production• Weld Thinner Sections First to Facilitate
Straightening• Use Backup Bars as Needed (Grooves)• Use Properly Sized Equipment• Weld One Side, If Possible• Weld Flat, Downhand when Possible• Use Recommended Electrodes, Polarity,
Speed, Voltage, Current
Industrial Processes II
WELDING DESIGN REVIEWWELDING DESIGN REVIEW• Proper Gaps (Bridging or Burn Proper Gaps (Bridging or Burn
Through)Through)
Too Small Proper Gap Too Large
[Bolz, Figure 53.37, p 53-46)
Industrial Processes II
WELDING DESIGN REVIEWWELDING DESIGN REVIEW• Backup PlatesBackup Plates
[Bolz, Figure 53.38, p 53-46)
Industrial Processes II
WELDING DESIGN REVIEWWELDING DESIGN REVIEW• Design Considerations Design Considerations [[Boltz, pgs. 53-35 Boltz, pgs. 53-35
to 55]to 55]– Distortion Control
• Use High Heat Flux, Deposition Rate Processes
• Use Least Weld Material Possible• Use Fewest Passes Possible• Weld Alternate Ends Inward or Backstep• Weld Joints with Greatest Contraction First
Industrial Processes II
WELDING DESIGN REVIEWWELDING DESIGN REVIEW• Distortion ControlDistortion Control
[Bolz, Figure 53.41 a,b , p 53-49)
Industrial Processes II
WELDING DESIGN REVIEWWELDING DESIGN REVIEW• Distortion ControlDistortion Control
[Bolz, Figure 53.41 c-f , p 53-49)
Industrial Processes II
WELDING DESIGN REVIEWWELDING DESIGN REVIEW• Distortion ControlDistortion Control
[Bolz, Figure 53.41 g,h , p 53-49)
Industrial Processes II
WELDING DESIGN REVIEWWELDING DESIGN REVIEW• Distortion ControlDistortion Control
[Bolz, Figure 53.41 i,j , p 53-49)
Industrial Processes II
WELDING DESIGN REVIEWWELDING DESIGN REVIEW• Distortion ControlDistortion Control
[Bolz, Figure 53.41 k,l , p 53-49)
Industrial Processes II
WELDING DESIGN REVIEWWELDING DESIGN REVIEW• Cost/Strength/Joint Design Cost/Strength/Joint Design
[Bolz, Figure 53.30, p 53-42)
Industrial Processes II
WELDING DESIGN REVIEWWELDING DESIGN REVIEW• Cost/Strength/Joint Design Cost/Strength/Joint Design
[Bolz, Figure 53.33,
p. 53-43)
Industrial Processes II
WELDING DESIGN REVIEWWELDING DESIGN REVIEW• Cost/Strength/Joint Design Cost/Strength/Joint Design
[Bolz, Table 35-1,
p 53-44)
Industrial Processes II
SUMMARY OF WELDING SUMMARY OF WELDING PROCESSESPROCESSES
• Welding (Definitions)Welding (Definitions)– Metal Joining Process in Which Coalescence is
Obtained Using Heat and/or Pressure• Coalescence - (From The Random House Dictionary)
– 1. to grow together or into one body 2. to unite so as to form one mass, community, etc.; blend; fuse; join; 3. to cause to unite into one body. from the Latin “alere” meaning to grow.
– A Metallurgical Bonding Accomplished by the Attracting Forces Between Atoms
– Joining Two (or More) Pieces of Material by Applying Heat, Pressure, or Both, With or Without Filler Metal to Produce Localized Union Through Fusion or Recrystallization Across the Interface.
Industrial Processes II
SUMMARY OF WELDING -- SUMMARY OF WELDING -- BASIC PROCESS REVIEWBASIC PROCESS REVIEW
• Part/Weld Function and Operating Part/Weld Function and Operating Environment is DefinedEnvironment is Defined
• Type of Joint Selected/AnalyzedType of Joint Selected/Analyzed• Component Parts ManufacturedComponent Parts Manufactured• Surfaces to Be Welded Are CleanedSurfaces to Be Welded Are Cleaned• Components Are Aligned and ClampedComponents Are Aligned and Clamped• Non-Corrosive/Protective Environment Non-Corrosive/Protective Environment
Formed Around Area to Be WeldedFormed Around Area to Be Welded
Industrial Processes II
SUMMARY OF WELDING -- SUMMARY OF WELDING -- BASIC PROCESS REVIEW BASIC PROCESS REVIEW
• Heat and/or Pressure Applied to Heat and/or Pressure Applied to ComponentsComponents
• Portion of Components Melt/Coalesce Portion of Components Melt/Coalesce – Grain Structure Revised/Reformed
• (Optional) Add Molten (Filler) Material(Optional) Add Molten (Filler) Material• Heat From Process Affects Non-Heat From Process Affects Non-
Melted Portion of ComponentsMelted Portion of Components– Grain Structure Affected– Expansion, Warping– Out Gassing, Corrosion
Industrial Processes II
SUMMARY OF WELDING -- SUMMARY OF WELDING -- BASIC PROCESS REVIEW BASIC PROCESS REVIEW
• Heat and/or Pressure RemovedHeat and/or Pressure Removed• Molten Material Begins to SolidifyMolten Material Begins to Solidify
– Coalescence/Grain Formation• Size, Shape, Strength Function of Cooling
Rate– Dissolved Gases Evolve
• Out Gassing, – Shrinkage/Expansion of Weld Nugget
Due to Change in State• Stresses, Shrinkage Voids
• Solidification Of Molten Material Solidification Of Molten Material CompleteComplete
Industrial Processes II
INTRODUCTION TO JOINING INTRODUCTION TO JOINING PROCESSESPROCESSES
• Brazing, Soldering, and Adhesives DefinitionBrazing, Soldering, and Adhesives Definition– Processes in Which Filler Material(s) i.e., Adhesives,
are Introduced Between Two or More Faying Surfaces. The Filler Material Fills the Closely Fitting Space and Wets the Surfaces. The Resulting Physical Bonds Causes the Joining of the Two Faying Surfaces• Faying -- From The Random House Dictionary
– to fit, esp. closely together, as timbers in ship building. From Middle English, “feie” to put together.
• Why UseWhy Use– Join Dissimilar Materials– Lower Temperature and Lower Pressure Processes– Weaker Bonds (Compared to Welding)– Range of Bond Strength Can Be Produced
Industrial Processes II
INTRODUCTION TO JOINING INTRODUCTION TO JOINING PROCESSESPROCESSES
• Brazing, Soldering, and Adhesives -- Key Concepts Brazing, Soldering, and Adhesives -- Key Concepts
– Introduction of One or More Layers of Material Between Two (Or More) Components to Be Joined.
– The Introduced Material “Wets” the Surfaces of the Components and the Surface Tension of the Introduced Material is Used to Hold the Components Together.
– Changes in the Surface Tension of the Adhesive are Achieved Via Changes in State, Composition, and/or Area of Contact• Adhesive is Melted, Introduced, and Allowed to Cool,
Increasing Surface Tension.• Adhesive is Composed of Plural Components, Some of
Which May Evaporate or Chemically React • Application of Pressure “Spreads” the Adhesive and
Increases the Surface Contact, Increasing Surface Tension
Industrial Processes II
BRAZING AND SOLDERINGBRAZING AND SOLDERING• Brazing/Soldering DefinitionBrazing/Soldering Definition
– Processes in Which Filler Material(s) i.e., Adhesives, are Introduced Between Two or More Faying Surfaces. The Filler Material Fills the Closely Fitting Space and Wets the Surfaces. The Resulting Physical Bonds Causes the Joining of the Two Faying Surfaces• Faying -- From The Random House Dictionary
– to fit, esp. closely together, as timbers in ship building. From Middle English, “feie” to put together.
• Why UseWhy Use– Join Dissimilar Materials– Lower Temperature and Lower Pressure Processes– Weaker Bonds (Compared to Welding)– Range of Bond Strength Can Be Produced
Industrial Processes II
BRAZING AND SOLDERINGBRAZING AND SOLDERING• Brazing and Soldering-- Key Concepts Brazing and Soldering-- Key Concepts
– Introduction of One or More Layers of Material Between Two (Or More) Components to Be Joined.
– The Introduced Material “Wets” the Surfaces of the Components and the Surface Tension of the Introduced Material is Used to Hold the Components Together.
– Changes in the Surface Tension of the Adhesive are Achieved Via Changes in State, Composition, and/or Area of Contact• Adhesive is Melted, Introduced, and Allowed to Cool,
Increasing Surface Tension.• Adhesive is Composed of Plural Components, Some of
Which May Evaporate or Chemically React • Application of Pressure “Spreads” the Adhesive and
Increases the Surface Contact, Increasing Surface Tension
Industrial Processes II
BRAZINGBRAZING• Basic Process DescriptionBasic Process Description
– Processes in Which Filler Material(s) with Melting Temperatures Greater than 840o F are Introduced Between Two or More Faying Surfaces. The Filler Material Fills the Closely Fitting Space and Wets the Surfaces, Often Aided by Fluxes. The Resulting Physical Bonds Causes the Joining of the Two Surfaces
• ParametersParameters– Brazing Material– Brazing Method
Industrial Processes II
BRAZINGBRAZING• Brazing MethodsBrazing Methods
– Torch (Oxy-Fuel)• Uses Outer Flame to Retard Oxidation
– Furnace (Gas or Electric)• Maybe Vacuum or Inert Gas Filled
– Induction• Switching Magnetic Field Alignment
• DefectsDefects– Incomplete Wetting/Filling of Space– Inclusions
Industrial Processes II
SOLDERINGSOLDERING• Basic Process DescriptionBasic Process Description
– Processes in Which Filler Material(s) with Melting Temperatures Less than 840o F are Introduced Between Two or More Faying Surfaces. The Filler Material Fills the Closely Fitting Space and Wets the Surfaces, Often Aided by Fluxes. The Resulting Physical Bonds Causes the Joining of the Two Surfaces
• TypesTypes– Torch - Oven– Wave
Industrial Processes II
SOLDERING/BRAZINGSOLDERING/BRAZING
Kalpakjian, Figure 30.1a, p. 929
Industrial Processes II
SOLDERING JOINTSSOLDERING JOINTS
Groover, Figure 30.7, p. 778
Industrial Processes II
SOLDERING JOINTSSOLDERING JOINTS
Groover, Figure 30.8, p. 778
Industrial Processes II
WAVE SOLDERINGWAVE SOLDERING
Groover, Figure 30.9 p. 780
Industrial Processes II
QUESTIONSQUESTIONSOR OR
CLARIFICATIONCLARIFICATIONS ???S ???
Reminder :Reminder :