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Welding

1. There are three main joining processes: brazing, soldering, and welding. Brazing and soldering involve melting only the filler rod, while welding involves melting the filler rod and base metals. 2. Different welding processes include shielded metal arc welding (stick welding), gas metal arc welding (MIG), gas tungsten arc welding (TIG), and resistance spot welding. They vary in terms of complexity, required skill level, heat input, and ability to be automated. 3. Distortion from welding can occur due to non-uniform shrinkage of the weld bead. Techniques like using fixtures and pre-compensating can help minimize distortion. Slightly convex w

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100 views

Welding

1. There are three main joining processes: brazing, soldering, and welding. Brazing and soldering involve melting only the filler rod, while welding involves melting the filler rod and base metals. 2. Different welding processes include shielded metal arc welding (stick welding), gas metal arc welding (MIG), gas tungsten arc welding (TIG), and resistance spot welding. They vary in terms of complexity, required skill level, heat input, and ability to be automated. 3. Distortion from welding can occur due to non-uniform shrinkage of the weld bead. Techniques like using fixtures and pre-compensating can help minimize distortion. Slightly convex w

Uploaded by

rockmanmax
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Joining Processes: Welding, Brazing, Soldering

1. Brazing and Soldering: Melting of filler rod only


• Brazing: higher temperature, ~brass filler, strong
• Soldering: lower temp, ~tin-lead filler, weak

2. Welding: Melting of filler rod and base metals


3. Both: Join inexpensive parts to form complex product

sales.nordex-online.com
Types of Joints

Kalpakjian
Brazing
en.wikipedia.org
• Steel base metal + Brass filler rod is common
• Lower temp than welding: retains heat treatment (if
present), minimizes grain growth.
• Strong but slow (careful preparation, cleanup)
• Furnace brazing is easily automated

Kalpakjian
www.kirkframeworks.com
Shielded Metal Arc Welding (SMAW): “Stick welding”
• Older, simple technology
• The electrode is also the filler rod
• Only for steel
• Strong welds if done properly (but often not)
• Very high heat input: good for thick parts, bad for grain growth and distortion

Kalpakjian
Gas Metal Arc Welding (GMAW): “MIG” (Metal-Inert-Gas)
• ~Complex mechanism but simple to perform and easy to automate
• The electrode is also the filler rod, fed continuously from a spool. It melts in the arc.
• For steel or aluminum
• Low skill level can achieve good weld
• Medium heat input: distortion and grain growth are significant

Kalpakjian
Gas Metal Arc Welding (GMAW): “MIG” (Metal-Inert-Gas)

A fair/typical quality MIG weld (still hot!)

www.scenta.co.uk

www.mig-welding.co.uk

www.difflock.com
Gas Tungsten Arc Welding (GTAW): “TIG” (Tungsten-Inert-Gas)
• The electrode is tungsten (not consumed)
• The filler rod is separate and fed manually
• High skill level required to achieve good weld
• Difficult to automate
• Low heat input and small weld bead: distortion and grain growth are minimized

Kalpakjian
Gas Tungsten Arc Welding (GTAW): “TIG” (Tungsten-Inert-Gas)
• Typical good quality TIG welds

www.steelmancycles.com

www.kosman.net
Resistance Spot Welding (RSW): “Spot Welding”
• No filler rod: electrical current is passed through metal under pressure
• Low skill level required
• Easy to automate
• Low heat input and no weld bead: distortion and grain growth are minimized

Kalpakjian
Distortion from Welding Processes
• Non-uniform shrinkage of weld bead
• Difficult to maintain alignments
• Solution: Rigid fixtures, pre-compensate for warping, loose tolerances

Kalpakjian
Weld bead profile: Convex or Concave?
• Solidification of molten bead leads to shrinkage
• Shrinkage of a concave bead leads to tension on surface  tends to crack
• Shrinkage of a convex bead leads to compression on surface  does not crack
• Generally, slightly convex beads are preferred.

Lincoln Electric
Welding Flaws

Kalpakjian
Welding Flaws:
Incomplete Penetration
(not enough heat input)

www.mig-welding.co.uk

www.ndt-ed.org/EducationResources
References

Kalpakjian: http://www.nd.edu/~manufact/index3.htm

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