Welding Lecture 1 Welding Introduction

7/29/2019 Welding Lecture 1 Welding Introduction

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3/29/2013 Prof.Dr.Adel M. abdelmaboud 1

1-Welding Definition

Welding is a material joining process inwhich two or more parts arejoined together

at their contacting surfaces by a suitable

application ofheatand/orpressure. In some welding process a filler materialis

added to facilitate coalescence.

Welding is most commonly associatedwith metallic partsbut for plastics also it is

used.


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\ \..Resistance Welding\9-Weld Procedures UtubeWelding Videos - ARO Technologies - Projection Welding.flv

\ \..ARC WELDING\1-Arcwelding . MPG

\ \..Gas Welding\2 - oxy acetylene welding andbrazing.flv

\ \..Friction Welding\9-Weld Procedures Utube

Welding Videos - Inertia Friction Welding Demonstration -Manufacturing Technology_ Inc..flv

\ \..Resistance Welding\5-Seam

welding machine.flv\ \..Resistance Welding\2-Spot

welding 99.9% Aluminum with DeltaSpot.flv
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8%A7%D9%85%20%20%D9%82%D9%88%D8%B3%20%D9%83%D9%87%D8%B1%D8%A8%D9%89.MPGhttp://localhost/var/www/apps/conversion/tmp/%D9%84%D8%AD%D8%A7%D9%85%20%D8%A7%D9%84%D8%A8%D8%A7%D8%AD%D8%A9%20%D9%81%D9%8A%D8%AF%D9%88/ARC%20%20WELDING/1-Arcwelding%20%20%D8%B9%D8%A7%D9%85%20%20%D9%82%D9%88%D8%B3%20%D9%83%D9%87%D8%B1%D8%A8%D9%89.MPGhttp://localhost/var/www/apps/conversion/tmp/%D9%84%D8%AD%D8%A7%D9%85%20%D8%A7%D9%84%D8%A8%D8%A7%D8%AD%D8%A9%20%D9%81%D9%8A%D8%AF%D9%88/ARC%20%20WELDING/1-Arcwelding%20%20%D8%B9%D8%A7%D9%85%20%20%D9%82%D9%88%D8%B3%20%D9%83%D9%87%D8%B1%D8%A8%D9%89.MPGhttp://localhost/var/www/apps/conversion/tmp/%D9%84%D8%AD%D8%A7%D9%85%20%D8%A7%D9%84%D8%A8%D8%A7%D8%AD%D8%A9%20%D9%81%D9%8A%D8%AF%D9%88/ARC%20%20WELDING/1-Arcwelding%20%20%D8%B9%D8%A7%D9%85%20%20%D9%82%D9%88%D8%B3%20%D9%83%D9%87%D8%B1%D8%A8%D9%89.MPGhttp://localhost/var/www/apps/conversion/tmp/%D9%84%D8%AD%D8%A7%D9%85%20%D8%A7%D9%84%D8%A8%D8%A7%D8%AD%D8%A9%20%D9%81%D9%8A%D8%AF%D9%88/ARC%20%20WELDING/1-Arcwelding%20%20%D8%B9%D8%A7%D9%85%20%20%D9%82%D9%88%D8%B3%20%D9%83%D9%87%D8%B1%D8%A8%D9%89.MPGhttp://localhost/var/www/apps/conversion/tmp/%D9%84%D8%AD%D8%A7%D9%85%20%D8%A7%D9%84%D8%A8%D8%A7%D8%AD%D8%A9%20%D9%81%D9%8A%D8%AF%D9%88/ARC%20%20WELDING/1-Arcwelding%20%20%D8%B9%D8%A7%D9%85%20%20%D9%82%D9%88%D8%B3%20%D9%83%D9%87%D8%B1%D8%A8%D9%89.MPGhttp://localhost/var/www/apps/conversion/tmp/%D9%84%D8%AD%D8%A7%D9%85%20%D8%A7%D9%84%D8%A8%D8%A7%D8%AD%D8%A9%20%D9%81%D9%8A%D8%AF%D9%88/ARC%20%20WELDING/1-Arcwelding%20%20%D8%B9%D8%A7%D9%85%20%20%D9%82%D9%88%D8%B3%20%D9%83%D9%87%D8%B1%D8%A8%D9%89.MPGhttp://localhost/var/www/apps/conversion/tmp/%D9%84%D8%AD%D8%A7%D9%85%20%D8%A7%D9%84%D8%A8%D8%A7%D8%AD%D8%A9%20%D9%81%D9%8A%D8%AF%D9%88/ARC%20%20WELDING/1-Arcwelding%20%20%D8%B9%D8%A7%D9%85%20%20%D9%82%D9%88%D8%B3%20%D9%83%D9%87%D8%B1%D8%A8%D9%89.MPGhttp://localhost/var/www/apps/conversion/tmp/%D9%84%D8%AD%D8%A7%D9%85%20%D8%A7%D9%84%D8%A8%D8%A7%D8%AD%D8%A9%20%D9%81%D9%8A%D8%AF%D9%88/ARC%20%20WELDING/1-Arcwelding%20%20%D8%B9%D8%A7%D9%85%20%20%D9%82%D9%88%D8%B3%20%D9%83%D9%87%D8%B1%D8%A8%D9%89.MPGhttp://localhost/var/www/apps/conversion/tmp/%D9%84%D8%AD%D8%A7%D9%85%20%D8%A7%D9%84%D8%A8%D8%A7%D8%AD%D8%A9%20%D9%81%D9%8A%D8%AF%D9%88/ARC%20%20WELDING/1-Arcwelding%20%20%D8%B9%D8%A7%D9%85%20%20%D9%82%D9%88%D8%B3%20%D9%83%D9%87%D8%B1%D8%A8%D9%89.MPGhttp://localhost/var/www/apps/conversion/tmp/%D9%84%D8%AD%D8%A7%D9%85%20%D8%A7%D9%84%D8%A8%D8%A7%D8%AD%D8%A9%20%D9%81%D9%8A%D8%AF%D9%88/Resistance%20Welding/9-Weld%20Procedures%20Utube%20Welding%20Videos%20-%20ARO%20Technologies%20-%20Projection%20Welding.flvhttp://localhost/var/www/apps/conversion/tmp/%D9%84%D8%AD%D8%A7%D9%85%20%D8%A7%D9%84%D8%A8%D8%A7%D8%AD%D8%A9%20%D9%81%D9%8A%D8%AF%D9%88/Resistance%20Welding/9-Weld%20Procedures%20Utube%20Welding%20Videos%20-%20ARO%20Technologies%20-%20Projection%20Welding.flvhttp://localhost/var/www/apps/conversion/tmp/%D9%84%D8%AD%D8%A7%D9%85%20%D8%A7%D9%84%D8%A8%D8%A7%D8%AD%D8%A9%20%D9%81%D9%8A%D8%AF%D9%88/Resistance%20Welding/9-Weld%20Procedures%20Utube%20Welding%20Videos%20-%20ARO%20Technologies%20-%20Projection%20Welding.flvhttp://localhost/var/www/apps/conversion/tmp/%D9%84%D8%AD%D8%A7%D9%85%20%D8%A7%D9%84%D8%A8%D8%A7%D8%AD%D8%A9%20%D9%81%D9%8A%D8%AF%D9%88/Resistance%20Welding/9-Weld%20Procedures%20Utube%20Welding%20Videos%20-%20ARO%20Technologies%20-%20Projection%20Welding.flvhttp://localhost/var/www/apps/conversion/tmp/%D9%84%D8%AD%D8%A7%D9%85%20%D8%A7%D9%84%D8%A8%D8%A7%D8%AD%D8%A9%20%D9%81%D9%8A%D8%AF%D9%88/Resistance%20Welding/9-Weld%20Procedures%20Utube%20Welding%20Videos%20-%20ARO%20Technologies%20-%20Projection%20Welding.flvhttp://localhost/var/www/apps/conversion/tmp/%D9%84%D8%AD%D8%A7%D9%85%20%D8%A7%D9%84%D8%A8%D8%A7%D8%AD%D8%A9%20%D9%81%D9%8A%D8%AF%D9%88/Resistance%20Welding/9-Weld%20Procedures%20Utube%20Welding%20Videos%20-%20ARO%20Technologies%20-%20Projection%20Welding.flvhttp://localhost/var/www/apps/conversion/tmp/%D9%84%D8%AD%D8%A7%D9%85%20%D8%A7%D9%84%D8%A8%D8%A7%D8%AD%D8%A9%20%D9%81%D9%8A%D8%AF%D9%88/Resistance%20Welding/9-Weld%20Procedures%20Utube%20Welding%20Videos%20-%20ARO%20Technologies%20-%20Projection%20Welding.flvhttp://localhost/var/www/apps/conversion/tmp/%D9%84%D8%AD%D8%A7%D9%85%20%D8%A7%D9%84%D8%A8%D8%A7%D8%AD%D8%A9%20%D9%81%D9%8A%D8%AF%D9%88/Resistance%20Welding/9-Weld%20Procedures%20Utube%20Welding%20Videos%20-%20ARO%20Technologies%20-%20Projection%20Welding.flvhttp://localhost/var/www/apps/conversion/tmp/%D9%84%D8%AD%D8%A7%D9%85%20%D8%A7%D9%84%D8%A8%D8%A7%D8%AD%D8%A9%20%D9%81%D9%8A%D8%AF%D9%88/Resistance%20Welding/9-Weld%20Procedures%20Utube%20Welding%20Videos%20-%20ARO%20Technologies%20-%20Projection%20Welding.flvhttp://localhost/var/www/apps/conversion/tmp/%D9%84%D8%AD%D8%A7%D9%85%20%D8%A7%D9%84%D8%A8%D8%A7%D8%AD%D8%A9%20%D9%81%D9%8A%D8%AF%D9%88/Resistance%20Welding/9-Weld%20Procedures%20Utube%20Welding%20Videos%20-%20ARO%20Technologies%20-%20Projection%20Welding.flvhttp://localhost/var/www/apps/conversion/tmp/%D9%84%D8%AD%D8%A7%D9%85%20%D8%A7%D9%84%D8%A8%D8%A7%D8%AD%D8%A9%20%D9%81%D9%8A%D8%AF%D9%88/Resistance%20Welding/9-Weld%20Procedures%20Utube%20Welding%20Videos%20-%20ARO%20Technologies%20-%20Projection%20Welding.flvhttp://localhost/var/www/apps/conversion/tmp/%D9%84%D8%AD%D8%A7%D9%85%20%D8%A7%D9%84%D8%A8%D8%A7%D8%AD%D8%A9%20%D9%81%D9%8A%D8%AF%D9%88/Resistance%20Welding/9-Weld%20Procedures%20Utube%20Welding%20Videos%20-%20ARO%20Technologies%20-%20Projection%20Welding.flvhttp://localhost/var/www/apps/conversion/tmp/%D9%84%D8%AD%D8%A7%D9%85%20%D8%A7%D9%84%D8%A8%D8%A7%D8%AD%D8%A9%20%D9%81%D9%8A%D8%AF%D9%88/Resistance%20Welding/9-Weld%20Procedures%20Utube%20Welding%20Videos%20-%20ARO%20Technologies%20-%20Projection%20Welding.flvhttp://localhost/var/www/apps/conversion/tmp/%D9%84%D8%AD%D8%A7%D9%85%20%D8%A7%D9%84%D8%A8%D8%A7%D8%AD%D8%A9%20%D9%81%D9%8A%D8%AF%D9%88/Resistance%20Welding/9-Weld%20Procedures%20Utube%20Welding%20Videos%20-%20ARO%20Technologies%20-%20Projection%20Welding.flvhttp://localhost/var/www/apps/conversion/tmp/%D9%84%D8%AD%D8%A7%D9%85%20%D8%A7%D9%84%D8%A8%D8%A7%D8%AD%D8%A9%20%D9%81%D9%8A%D8%AF%D9%88/Resistance%20Welding/9-Weld%20Procedures%20Utube%20Welding%20Videos%20-%20ARO%20Technologies%20-%20Projection%20Welding.flvhttp://localhost/var/www/apps/conversion/tmp/%D9%84%D8%AD%D8%A7%D9%85%20%D8%A7%D9%84%D8%A8%D8%A7%D8%AD%D8%A9%20%D9%81%D9%8A%D8%AF%D9%88/Resistance%20Welding/9-Weld%20Procedures%20Utube%20Welding%20Videos%20-%20ARO%20Technologies%20-%20Projection%20Welding.flv


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Welding

Advantage:1. Provides permanent joint.

2. The welded joint can be stronger than the parentmaterials .

3. The welding joint most economical method to join interms of material usage and fabrication costs.

Limitations:

1. Expensive in the terms of Labor costs (performedmanually).

2. Dangerous because they involve the use of highenergy.

3. Can suffer from certain quality defects that are difficultto detect.


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2-Welding History

Thermit Welding (1903)

Cellulosic Electrodes (1918)

Arc Stud Welding (1918)

Seam Welding of Tubes (1922) Mechanical Flash Welder for Joining Rails

(1924)

Extruded Coating for MMAW Electrodes (1926)

Submerged Arc Welding (1935)

Air Arc Gouging (1939)


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Welding history

Inert Gas Tungsten Arc (TIG) Welding (1941)

Iron Powder Electrodes with High Recovery (1944)

Inert Gas Metal Arc (MIG) Welding (1948)

Electro Slag Welding (1951)

Flux Cored Wire with CO 2 Shielding (1954)

Electron Beam Welding (1954)

Constricted Arc (Plasma) for Cutting (1955)

Friction Welding (1956)

Plasma Arc Welding (1957)

Electro Gas Welding (1957)


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Welding history

Short Circuit Transfer for Low Current, LowVoltage Welding with CO 2 Shielding (1957)

Vacuum Diffusion Welding (1959)

Explosive Welding (1960) Laser Beam Welding (1961)

High Power CO 2 Laser Beam Welding (1964)

All welded Liberty ' ships failure in 1942, gave abig jolt to application of welding. However, it haddrawn attention to fracture problem in weldedstructures


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3-Welding Applications

General Applications

Welding is vastly being used forconstruction of transporttankers for transporting oil, water, milk and fabrication ofwelded tubes andpipes, chains, LPG cylinders and otheritems. Steel furniture, gates, doors and door frames,body and other parts of white goods items such asrefrigerators, washing machines, microwave ovens andmany other items of general applications are fabricatedby welding.

Pressure Vessels

One of the first major use of welding was in the fabricationofpressure vessels. Welding made considerableincreases in the operating temperatures and pressurespossible as compared to riveted pressure vessels.


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Welding Applications

Building Structures

Aircraft and Spacecraft

Railways

Micro-Joining Electrical Industry:Nuclear Installations

Defense Industry

Electrical Industry:

Nuclear InstallationsDefense Industry

Micro-Joining


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4-Type of welding joints


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Type of welding joints


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5-Types of Welds

A :inside single fillet corner joint

B :out side single fillet corner joint

C: Double fillet lap joint

D: Double fillet tee jointDashed lines show the original part edges


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Types of groove welds

A: Square groove weld one side

B: Single bevel groove weld C: Single V groove weld


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Types of groove welds

D: Single U groove weld

E: Single J groove weld F: Double V groove weldDashed lines show the original part edges


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Types of Welds

A: Plug weld

B: Slot weld


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Types of Welds

A: Spot weld

B: Seam weld


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Types of Welds

A : Flange weld

B: Surface welding


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Joint Configuration

Butt Weld

1= Groove Face

2= Root Opening 3= Groove Angle

4= Root Face

5=Plate thickness

6=Bevel Angle 1 2

3

4

5

6


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Joint Configuration

Parts of a butt weld

Weld Face

Weld Root

Toe of Weld

both side

Face or Weld

Reinforcement


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Joint Configuration

Parts of a butt weld

Heat Affected

Zone (HAZ)

Weld Metal

Groove Faces

Cap

Root

Base

Metal


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6-Welding Classification (Types)

Types of Welding Processes

I-Liquid state welding processes (Fusion).

II-Solid state welding processes.III-Solid / Liquid state bonding processes.


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I-Liquid state welding processes (Fusion)

Use heat to melt the base metals.

A fillermetal is added.

A fusion welding with no filleris referred to as autogenousweld.

There are two inherentproblems with fusion welding:

Effect of localized heating and rapid cooling on themicrostructure and properties of the parent metals.

Effect ofresidual stresses developed in the parent

metals due to restrained expansion or contraction.This effect the impact of fatigue life of weldment


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Liquid state welding processes (Fusion)

Examples

1. Arc Welding (AW).

2. Resistance welding (RW) .

3. Oxyfuel Welding (OFW) .4. Other Processes:

(Electron beam welding and Laser beam welding.)


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1-Arc Welding (AW)

Heating of the metals with electric arc


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2-Resistance welding (RW)

Using heat from electric resistance to the

flow of a current passing between the

faying surface of two parts held together

under pressure.


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3-Oxyfuel Welding (OFW)

Heating with a mixture oxygen and

acetylene (oxyfuel gas).


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II-Solid state welding processes.

In solid state welding the surfaces to be joinedare brought into close proximity by:

1. Heating the surfaces without causing meltingand applying normal pressure.

2. Providing relative motion between the twosurfaces and applying light normal pressure.

3. Applying high pressure without heating.

In these processes the materials remain in solid

state and welding is achieved through theapplication of heat and pressure, or highpressure only (No melting, No fillers ).


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Solid state welding processes

Examples

1. Friction welding (FW).

2. Diffusion welding (DFW).

3. Ultrasonic welding (USW ).


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1-Friction welding (FRW)

Coalescence is achieved by the heat of

friction between two surfaces.


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2-Diffusion welding (DFW)

Two surfaces are held together under pressure at an at

an elevated temperature and the parts coalesce by solid

state fusion.


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Diffusion welding (DFW) is a solid state

welding process by which two metals (which

may be dissimilar) can be bonded together.

Diffusion involves the migration ofatoms across

the joint, due to concentration gradients.

The two materials are pressed together at anelevated temperature usually between 50 and

70% of the melting point.

The pressure is used to relieve the void that may

occur due to the different surface topographies.
http://en.wikipedia.org/wiki/Weldinghttp://en.wikipedia.org/wiki/Metalhttp://en.wikipedia.org/wiki/Atomhttp://en.wikipedia.org/wiki/Melting_pointhttp://en.wikipedia.org/wiki/Melting_pointhttp://en.wikipedia.org/wiki/Atomhttp://en.wikipedia.org/wiki/Metalhttp://en.wikipedia.org/wiki/Welding


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3-Ultrasonic welding (USW )

Moderate

pressure is

applied

between the

two parts withultrasonic

oscillating

motion


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Ultrasonic welding


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III-Solid / Liquid state bonding processes

In these processes, the braze metal, solder,

or an adhesive is applied to the joint in

liquid state while the materials to be

joined remains in a solid state, that is,they do not melt.


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7-Features of a fusion welded joint

Fusion zone

Weld

interface

Heat affected

zone (HAZ) Unaffected

base metal

(BM


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Regions of a Fusion Weld

Fusion zone (FZ)

Weld interface

Heat affected zone (HAZ) Unaffected base metal (BM)

BMHAZFZ
http://upload.wikimedia.org/wikipedia/commons/0/0d/Welded_butt_joint_x-section.pnghttp://upload.wikimedia.org/wikipedia/commons/0/0d/Welded_butt_joint_x-section.pnghttp://upload.wikimedia.org/wikipedia/commons/0/0d/Welded_butt_joint_x-section.pnghttp://upload.wikimedia.org/wikipedia/commons/0/0d/Welded_butt_joint_x-section.png


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8-Welding Symbols

Examples: Single V Butt Weld

1/8

1/8 root

opening

1/875 deg

75 deg

75 deg. groove angle


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WELDING SYMBOL

Staggered intermittent fillet weld

3-10

3-10

Fillet weld side view

10

3

(3/8)

(3/8)

3/8


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WELDING SYMBOL

Single V Groove

Double V Groove

Single Bevel Groove

Double Bevel Groove

Documents

Welding Lecture 1 Welding Introduction