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Fundamentals of Joining and

Oxyfuel-gas and Arc Welding


Processes

Introduction to Consolidation Processes


Consolidation Processes consist of
Welding
Brazing
Soldering
Fasteners
Adhesives
Shrink Fits
Slots and Tabs

Soldering

Brazing

Low- High Temperature

Welding

Welding
Consolidation of two
materials by means of
Temperature

Pressure

Can be done in a wide


variety of conditions and
methods and is therefore
on of the most common
consolidation processes.

Two Forms of Welding


Solid State
welding where pressure
pressure and
heat are used to cause the
heat
diffusion at the joint, causing
the parts to fuse together
Fusion welding
heat is applied to
where heat
create molten material at the
joint, which fuses the parts
upon solidification
Both
process
can
cause
changes in the structure of the
material,
and
must
be
considered when selecting a
process

Classification of Weld Process

Classification of
common welding
processes
along with their
AWS (American
Welding Society)
designations.

Some Common Concerns


Proper joint design is critical to a successful
weld
Heating, melting, and resolidification can all
produce changes in microstructure of the material
and produce residual stress
Welding can result in

Cracks
Inclusions
Incomplete fusion
Arc Strikes
Metallurgical changes

Cavities
Unacceptable weld shape
Incomplete penetration
Spatter
Excessive Distortion

Common Weld Defects

Types of Fusion Welds


Bead welds: Limited
penetration so used on thin
materials, or surface
modifications
Groove welds: Used on thick
materials, requires joint
preparation, used for single
and multiple passes
Fillet welds: Use for tee, lap
and corner joints
Plug welds: Used a
permanent replacement for
rivets or bolts

Basic Joint Designs of Fusion


Welds
Five basic joint
designs for fusion welding.

Basic Fusion Welds

Preferred shape and the method of


measuring the size of fillet welds.

Weld Procedures

Various weld
procedures used to
produce welded
joints. (Courtesy
Republic Steel
Corporation,
Youngstown, OH).

Design Considerations
Welding produces monolithic structures
Welded joints do not stop crack propagation,
cracks propagation typically does not travel
through a bolted joint
Vibration stresses are transferred through a weld
joint

Welded structure are more rigid than bolted


assemblies

Heat Effects
In fusion welding, the heat melts some of the
base material, which is then rapidly cooled,
creating changes in the granular structure.
The pool of metal bonding the base material is
a blend of each material, and forms a cast
structure in the joint zone.
Surrounding the pool of metal is the heat
affected zone, where metallurgical properties
have been changed.

Microstructure of a Fusion Weld

Grain structure
and various zones in
a fusion weld.

Butt Weld with Backing Plate


Schematic of a butt weld between a plate of
metal A and a plate of metal B, with a
backing plate of metal C and filler of metal
D. The resulting weld nugget becomes a
complex alloy of all four metals.

Zone in a Fusion Weld

Heat affected zone is subjected to enough heat to


cause metallurgical changes, leading to phase
transformations, embrittlement, precipitation, or
cracking.

Heat Affected Zone

Heat Rate of Welding Processes

Heat Effects
Post weld heat treatment can be used to
reduce the impact of the heat affected zone.
Welding techniques can be used to reduce the
heat distortion in welds
Distortion is the result of thermally induced
stresses

Preheating the base metal also reduces weld


distortion

Warpage as a Result of Welding


V-groove

One-side fillet
weld in a T-joint

Two-fillet weld in a
T-joint with a
high vertical web

Cracking as a Result of Welding

Various types and locations of cracking that can occur as a result of welding.

AWS Weldability

Summary
Proper weld considerations
Selection of the process and fillers
Design of the Joint
Effects of heating and cooling on weld and parent
materials

Parallel considerations apply to brazing and


soldering

Gas Flame and Arc Processes

OXYFUEL-GAS WELDING

Oxyfuel-Gas Welding
Group of welding processes that use the flame
produced by the combustion of a fuel gas and
oxygen as the source of heat

Oxyacetylene Welding Torch

Oxyfuel-gas Welding

Oxyacetylene Flame
Temperatures

Typical
oxyacetylene flame and the
associated temperature
distribution.

Maximum temperature and


first stage of combustion is
complete.

Preheat the metal and provide


shielding from oxidation

Three Different Types of Flames

Neutral Flame: 1:1 or 1.15:1

Oxidizing Flame: 1.5:1

Carburizing Flame: excess fuel

Three Different Types of Flames


Pure Acetylene

Neutralizing Flame

Oxidizing Flame

Carburizing Flame

Three Different Types of Flames


Neutral Flame
most welding is done with a neutral flame
least chemical effect on heated metal

Oxidizing Flame
hotter than the neutral flame ( 3600C)
used when welding copper and copper alloys
harmful for welding steel

Carburizing Flame
Flame temperature is 3050C
Used in welding Monel (nickel-copper alloy), high
carbon steels and some alloy steels

Alternative Fuel Gas

Propane
Propylene
Butane
Natural Gas
Hydrogen
With air and oxygen, can be used to weld lowmelting-temperature nonferrous metal
Not suited for ferrous metals

Oxyfuel-Gas Welding Process

Oxyfuel Application

OXYGEN TORCH CUTTING

Oxygen Torch Cutting


Oxy-fuel gas cutting (flame cutting)
Most common thermal cutting process
Metal is melted by the flame of the oxyfuel gas
torch

Oxyacetylene Cutting Torch

(Courtesy of Victor Equipment Company, Denton, TX)

Underwater Cutting Torch

(Courtesy of Bastian-Blessing Company, Chicago, IL)

FLAME STRAIGHTENING

Flame Straightening
Uses controlled, localized upsetting as a
means of straightening warped or buckled
material

ARC WELDING

Arc Welding

Arc Welding Schematic

FIGURE 31-8 The basic


electrical circuit for arc welding.

Three modes of metal transfer


during arc welding

(Courtesy of Republic Steel Corporation, Youngstown, OH)

Consumable-electrode Arc
Welding

Consumable-Electrode Arc Welding


Medium rate of heat input
Produce a fusion zone whose depth is
approximately equal to its width
Cannot be used to join dissimilar metals or
ceramics

Four Processes

Shielded metal arc welding (SMAW)


Flux-cored arc welding (FCAW)
Gas metal arc welding (GMAW)
Submerged arc welding (SAW)

SHIELDED METAL ARC WELDING


(SMAW)

Shielded Metal Arc Welding


Stick welding
Most widely used process because of its versatility and
low-cost equipment

Best used for


welding ferrous
metals ( carbon
steels, alloy steels,
stainless steels
and cast iron

Bonded Coating Characteristics


Provides a gas shield around the arc pool of
molten metal
Provide ionizing elements that helps reduce
weld metal spatter
Act as flux to remove impurities
Add alloying elements
Add additional filler metal

Schematic of SMAW

Schematic diagram of shielded metal arc welding (SMAW).


(Courtesy of American Iron and Steel Institute, Washington, DC.)

Process Summary of SMAW

FLUX-CORED ARC WELDING


(FCAW)

Flux-Cored Arc Welding


Powdered flux is in the
interior of a continuous
tubular electrode

The flux-cored arc welding (FCAW) process.


(Courtesy of The American Welding Society, New York.)

Flux-Cored Arc Welding


Best used for welding steels
Equipment cost greater than SMAW
Needs good ventilation to remove fumes
generated by the vaporizing flux

Process Summary of FCAW

GAS METAL ARC WELDING


(GMAW)

Schematic of Gas Metal Arc


Welding
Formerly known as Metal Inert-gas welding or MIG
Supplemental shielding gas flows through the torch
Consumable electrode: continuous, solid,
uncoated wire or a continuous hollow tube
with powdered alloy additions as
consumable electrode

Schematic diagram of gas metal arc


welding (GMAW).
(Courtesy of American Iron and Steel Institute,
Washington, DC.)

Process Summary of GMAW

SUBMERGED ARC WELDING


(SAW)

Schematic of Submerged Arc


Welding
Granular flux is deposited just ahead of bare-wire
consumable electrode, and the arc is maintained beneath
the blanket of flux.

Submerged Arc Welding


Melted flux: removes impurities
Unmelted flux: provides shielding

Submerged Arc Welding


No shielding gas used
Most suitable for making butt or fillet welds in
low-carbon steels
High welding speed, high deposition rates,
deep penetration
Limitations: extensive flux handling and
possible flux contamination by moisture

Process Summary of SAW

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