INDUSTRIAL PROCESSES II INDEN 3313

1. INDUSTRIAL PROCESSES IIINDEN 3313 Lecture 7 – Welding, Welding Design, Brazing and Soldering Industrial Processes II

2. OVERVIEW • Directions to Lab • Remaining Welding Processes • Welding Design • Brazing and Soldering Industrial Processes II

3. QUESTIONSTO START ?? Industrial Processes II

4. UPCOMING WELDING LABS • Three Lab Sequence • Introduction and • Oxyfuel • Arc Welding • MIG (SMAW) Welding • Location • Bio-Systems and Agricultural Engineering Laboratories • SE Corner of Hall of Fame and Cleveland • Park Across from Colvin Center Industrial Processes II

5. UPCOMING WELDING LABS • Three 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

6. UPCOMING WELDING LABS • Three 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

7. UPCOMING WELDING LABS • Location --Corner of Cleveland and Hall of Fame Colvin Parking OSU Track Colvin Center Cleveland AG Labs Industrial Processes II

8. UPCOMING WELDING LABS HALL OF FAME WELDING LAB Entry Door CLEVELAND N Industrial Processes II

9. COLD WELDING • Basic 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 • Parameters • Pressure Used • Cleanliness of Surfaces • Similarity of Metals Industrial Processes II

10. COLD WELDING • Sources/Causes of Defects • Inclusions, Delamination • Inadequate Ductility of Base Material(s) • “Cures” For Defects • Adequate, Uniform Pressures • Surface Preparation Industrial Processes II

11. COLD WELDING Kalpakjian, Figure 28.1, p. 886 Industrial Processes II

12. ULTRASONIC WELDING • Basic Process Description • Mechanically Induced Vibrations Used to Breakup Oxides and Provide Energy for Coalescence • Parameters • Vibration Frequency and Amplitude • Temperature Induced (.33 - .50 Tmelt) • Defects • Inclusions, Incomplete Fusion Industrial Processes II

13. ULTRASONIC WELDING Kalpakjian, Figure 28.2a&b, p. 887 Industrial Processes II

14. FRICTION WELDING • Basic 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. • Parameters • Force Applied/Means (Linear or Rotational) • Rotational Speed • Sources/Causes of Defects • Preparation of Surface (Oxides) • Misalignment Industrial Processes II

15. FRICTION WELDING Kalpakjian, Figure 28.3, p. 888 Industrial Processes II

16. EXPLOSION WELDING • Basic 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. • Parameters • Pressure Reached • Detonation/Speed of Pressure Wave • Rate Dependant Deformation Process Industrial Processes II

17. EXPLOSION WELDING • Sources/Causes of Defects • Inclusions • Tearing, Cracks Industrial Processes II

18. EXPLOSION WELDING Amstead, Figure 8.30, p. 190 Industrial Processes II

19. DIFFUSION WELDING • Basic Process Description • Uses Heat and Pressure to Promote Diffusion of Atoms Across Interface. Diffusion of One Crystalline Structure into Another (Can be Dissimilar Metals) • Parameters • Temperature • Pressure • Surface Preparation • Material Compatibility Industrial Processes II

20. WELDING DESIGN REVIEW • Design Considerations [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

21. WELDING DESIGN REVIEW • Design Considerations [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

22. WELDING DESIGN REVIEW • Design Considerations [Boltz, pgs. 53-35 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

23. WELDING DESIGN REVIEW • Design Considerations [Boltz, pgs. 53-35 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

24. WELDING DESIGN REVIEW • Proper Gaps (Bridging or Burn Through) Too Small Proper Gap Too Large [Bolz, Figure 53.37, p 53-46) Industrial Processes II

25. WELDING DESIGN REVIEW • Backup Plates [Bolz, Figure 53.38, p 53-46) Industrial Processes II

26. WELDING DESIGN REVIEW • Design Considerations [Boltz, pgs. 53-35 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

27. WELDING DESIGN REVIEW • Distortion Control [Bolz, Figure 53.41 a,b , p 53-49) Industrial Processes II

28. WELDING DESIGN REVIEW • Distortion Control [Bolz, Figure 53.41 c-f , p 53-49) Industrial Processes II

29. WELDING DESIGN REVIEW • Distortion Control [Bolz, Figure 53.41 g,h , p 53-49) Industrial Processes II

30. WELDING DESIGN REVIEW • Distortion Control [Bolz, Figure 53.41 i,j , p 53-49) Industrial Processes II

31. WELDING DESIGN REVIEW • Distortion Control [Bolz, Figure 53.41 k,l , p 53-49) Industrial Processes II

32. WELDING DESIGN REVIEW • Cost/Strength/Joint Design [Bolz, Figure 53.30, p 53-42) Industrial Processes II

33. WELDING DESIGN REVIEW • Cost/Strength/Joint Design [Bolz, Figure 53.33, p. 53-43) Industrial Processes II

34. WELDING DESIGN REVIEW • Cost/Strength/Joint Design [Bolz, Table 35-1, p 53-44) Industrial Processes II

35. SUMMARY OF WELDING PROCESSES • 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

36. SUMMARY OF WELDING -- BASIC PROCESS REVIEW • Part/Weld Function and Operating Environment is Defined • Type of Joint Selected/Analyzed • Component Parts Manufactured • Surfaces to Be Welded Are Cleaned • Components Are Aligned and Clamped • Non-Corrosive/Protective Environment Formed Around Area to Be Welded Industrial Processes II

37. SUMMARY OF WELDING -- BASIC PROCESS REVIEW • Heat and/or Pressure Applied to Components • Portion of Components Melt/Coalesce • Grain Structure Revised/Reformed • (Optional) Add Molten (Filler) Material • Heat From Process Affects Non-Melted Portion of Components • Grain Structure Affected • Expansion, Warping • Out Gassing, Corrosion Industrial Processes II

38. SUMMARY OF WELDING -- BASIC PROCESS REVIEW • Heat and/or Pressure Removed • Molten 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 Complete Industrial Processes II

39. INTRODUCTION TO JOINING PROCESSES • Brazing, 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 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

40. INTRODUCTION TO JOINING PROCESSES • 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

41. BRAZING AND SOLDERING • Brazing/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 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

42. BRAZING AND SOLDERING • 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

43. BRAZING • Basic 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 • Parameters • Brazing Material • Brazing Method Industrial Processes II

44. BRAZING • Brazing 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 • Defects • Incomplete Wetting/Filling of Space • Inclusions Industrial Processes II

45. SOLDERING • Basic 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 • Types • Torch - Oven • Wave Industrial Processes II

46. SOLDERING/BRAZING Kalpakjian, Figure 30.1a, p. 929 Industrial Processes II

47. SOLDERING JOINTS Groover, Figure 30.7, p. 778 Industrial Processes II

48. SOLDERING JOINTS Groover, Figure 30.8, p. 778 Industrial Processes II

49. WAVE SOLDERING Groover, Figure 30.9 p. 780 Industrial Processes II

50. QUESTIONSOR CLARIFICATIONS ??? Reminder : Industrial Processes II