Raya University

Engineering and Technology College

Manufacturing Engineering Department

Advanced Manufacturing Process [MaEngn5301]

CHAPTER-4: ADVANCED WELDING PROCESSES

 Advanced Welding Process

Lesson Objectives Learning Activities

1. Look up
In this chapter we shall discuss the following:
 Introduction Keywords

 Submerged arc welding, 2. View Slides;

3. Read Notes,
 EBW 4. Listen to
 LBW lecture
 USW
 Solid state welding
 Explosive welding
 Introduction to welding

Welding is a process of joining two similar or dissimilar

metals by:
 Fusion (application of heat),
 with or with out the application of pressure and
 with or with out the use of filler metal.
Welding processes can categorized into two basic types:
1. Fusion welding
2. Solid state welding
 Introduction to welding

a) Fusion welding in which coalescence is accomplished by

melting the two surfaces to be joined, in some cases adding
filler metal to the joint.
b) Solid state welding in which heat and/or pressure are used
to achieve coalescence, but no melting of the base metals
occurs and no filler metal is added.
 Submerged Arc welding (SAW)
 SAW is an arc welding that uses a continuous, consumable bare wire

electrode, and arc shielding is provided by a cover of granular flux

 The electrode wire is fed automatically from a coil into the arc.
 The flux is introduced in to the joint slightly ahead of the weld arc by gravity
from hopper.

 The blanket of granular flux completely submerges the arc welding process.
 The portion of the flux closest to the arc is melted mixing with the molten weld
SAW
 SAW: Principle:
 In this process instead of
flux covered electrode,
granulated flux & bare
electrode is used.
 The flux serves as a shield
& protect molten weld
pool from atmospheric
contamination.
 SAW: Components

 Welding head:

 It feeds flux & filler metal welding electrode.

 Flux hopper:

 It stores the flux and controls rate of flux position on welding joint

 Welding power source:

 AC transformer or DC generator rated up to 1500 Amperes may be used.

 Flux:

 It shields and protects molten weld metal from atmospheric contamination

Applications of SAW
 Advantages of SAW

 High deposition rates & productivity

 Tolerance to variations in joint edge preparation & fit up
 Good weld mechanical properties
 Excellent weld quality
 High weld speed
 Simplified joint preparation
 Screening of the arc under flux
 Active chemical control of weld pool
 Minimal operator training necessary
 Collection & utilization of unfused flux
 Controllable deep or shallow penetration
 Disadvantages of SAW

 Flat or horizontal position only

 Mostly limited to steel, stainless steel & Nickel alloys

 Slag removal necessary

 High cost of equipment:

 Power supply

 Electrode feeder

 Flux handling

 Boom carriage
 Electron Beam Welding (EBW)

 is a welding process that produces coalescence with a concentrated

beam, composed of high-velocity electrons impinging on the joint.

 The process is used without shielding gas, except in some

non vacuum applications, and without the application of
pressure.
 Variations of this process are high-vacuum electron beam
welding, medium-vacuum electron beam welding, and non
vacuum electron beam welding.
 EBW

 is a fusion welding process in which a beam of high

velocity electrons is applied to the material to be
joined.
 The electrons are raised to a high-energy state by
acceleration to velocities in the range of 30% to 70%
of the speed of light.
 The w/p melt as the KE of the electrons is transformed
into heat upon impact.
 Electrons are fundamental particles of matter,
characterized by a negative charge and a very small
mass.
 EBW
 The EBW process is well- positioned to provide

industries with highest quality welds & machine designs that

have proven to be adaptable to specific welding tasks &

production environments.
 How does the Process Work?

I. The EB gun has a tungsten filament which is heated, freeing electrons.

II. The electrons are accelerated from the source with high voltage potential b/n

a cathode & anode.

III. The stream of electrons then pass through a hole in the anode. The beam is

directed by magnetic forces of focusing and deflecting coils.

IV. The beam is directed out of the gun column & strikes the w/p.

V. The KE of the electrons is transferred to heat upon impact of the w/p & cuts

a perfect hole at the weld joint. Molten metal fills in behind the beam,

creating a deep finished weld.

Steps in EBW
Classification of EBW Machines
 Comparison of conventional weld and EB weld

 EBW is suitable for a variety of difficult applications, such as welding

structures on which the reverse side of the butt is inaccessible ; gravity welding

of thin metal ; and welding in various spatial positions.

 This Provides a low level of over all heating of the

structures ; and has the ability to vacuumed the inner
volume simultaneously, which is suitable for sealing
instruments.
 Comparison of conventional weld and EB weld

 Because EBW is an automated process, the welded joint

quality is consistent.
 The process does not require shielding gases , tungsten

electrodes , or edge preparation for welding thick metal .

 Finally , it can be used to weld some joints that cannot be
made by other welding processes.
 Comparison of conventional weld and EB weld

 Compared with arc welding, EBW improves joint strength 15%-25%.

 It has a narrow heat-affected zone (HAZ), which results in
lighter- weight products.
 Comparison of conventional weld and EB weld

 Geometric shapes & dimensions are highly stable,

particularly when it is used as a finish operation.
 It eliminates oxide & tungsten inclusion sand removes
impurities.
 The weld metal has a fine crystalline structure.
 Advantage of EBW
In Vacuum
 Thin and thick plate welding (0.1 mm bis300 mm).
 Extremely narrow seams (t:b= 50:1).
 Low overall heat input => low distortion =>Welding of
completely processed components.
 High welding speed possible.
 No shielding gas required.
 High process and plant efficiency.
 Material dependence, often the only welding method.
At atmosphere
 Very high welding velocity.
 Good gap bridging. No problems with reflection during
energy entry into work piece
 Disadvantageof EBW
In Vacuum
 Electrical conductivity of materials is required.
 High cooling rates => hardening => cracks.
 High precision of seam preparation.
 Beam may be deflected by magnetism.
 X-ray formation.
 Size of work piece limited by chamber size.
 High investment.
At Atmosphere
 X-ray formation.
 Limited sheet thickness (max. 10 mm).
 High investment.
 Small working distance.
 Field of Application

 Automotive industries
 Aircraft and space industries
 Mechanical engineering
 Tool construction
 Nuclear power industries
 Power plants
 Fine mechanics and electrical
 Industries
 Job shop
 Materials

 Almost all steels.

Aluminium and its alloys.
Magnesium alloys.
Copper and its alloys.
Titanium.
Tungsten.
Gold.
Material combinations (e.g. Cu-steel, bronze-steel).
Ceramics (electrically conductive).
 Ultrasonic Welding (USW)

 is a solid-state welding process that produces a weld by the local application of

high-frequency vibratory energy as the workpieces are held together under

pressure.

 The vibratory energy creates a relative transverse motion b/n the two
surfaces, disperses interface oxides and contaminants from the
interface to achieve metal-to-metal contact, and produces the weld.
 A sound metallurgical bond is produced without melting of the base
metal. There is minor thickness deformation at the weld location.
 Ultrasonic Welding

 The components of USW system are:

 an electronic power source,

 a transducer,

 an acoustic coupling system, a sonotrode, an anvil and a clamping

system.

 The power source provides high-frequency electrical power to the

ultrasonic transducer.
 Ultrasonic Welding

 The workpieces, supported by the anvil, are firmly held

together during welding by a clamping force applied through
the coupling system and anvil.
 USW generally is accomplished with either a lateral drive or
a wedge-reed system.
 The lateral-drive and wedge-reed USW systems have three
components in common:
 power source,
 an ultrasonic transducer, and
 a horn.
 The type of weld required for the specific application,
several USW systems can be implemented to produce spot,
seam, and torsion (circular pattern) welds.
Ultrasonic Welding

Figure (A) Lateral-drive and (B) Wedge-reed

ultrasonic spot welding systems, with weld
zone common to both systems
Ultrasonic Welding

Figure Schematic of an ultrasonic seam welding machine

(Not including bearings and drive mechanisms)
 Ultrasonic Welding

 The key parameters of the USW process are:

 vibration frequency,

 vibration amplitude,

 Clamping force,

 weld power,

 weld energy,

 weld time,
 Solid State Welding

Classification of solid state-welding processes:

1.Friction Welding
2.Friction Stir Welding

 Both are a type of welding where heat is generated by mechanical

friction b/n two components along with an additional mechanical

force.
 1.Friction Welding (FW)

 It is a solid state welding process wherein coalescence is formed by

the heat which is obtained from mechanically induced sliding

motion b/n rubbing surfaces.

 FW: working principle

 Initially the components to be welded are held under pressure.

 One part is rotated at high speed and other part is held
stationary.
 In this process the movable clamp is moved and contacted
with the rotating component.
 The heat is produced in b/n contact surfaces.
 This heat is used to weld the components under pressure
range in b/n 40 Mpa to 450 Mpa,
 Time required for joining metals 2 to 30Seconds,
 The rotational speed is 3000rpm.
 1.Friction Welding (FW)

Figure Friction welding (FW): (1) rotating part, no contact; (2) parts brought into
contact to generate friction heat; (3) rotation stopped and axial pressure
applied; and (4) weld created.
 1.Friction Welding (FW)

Advantages
1. Power consumption is low.
2. Operation is easy
3. It is smooth and clean process
4. Heat is quickly dissipated
5. There is no need filler metal flux.
Dis-Advantages
1. Heavy components are not used for weld
2. Heavy rigid machines required
3. It is not suitable for flat angular weld
Applications
1. It is used for super alloys and all steel alloys.
2. It is used in produce axle shafts, valves and gears and refrigerators.
3.
It used for making simple forgings.
 2.Friction Stir Welding: Working Principle

 FSW a cylindrical, shouldered tool

with a profiled probe is rotated and
 Slowly plunged into the joint line
b/n w/p butted together.
 Frictional heat is generated b/n
the wear resistant welding tool
and the material of the w/p.
 2.Friction Stir Welding

Fig. Friction stir welding (FSW): (1) rotating tool just prior to feeding into joint and
(2) partially completed weld seam. N ¼ tool rotation, f ¼ tool feed.
 2.FSW: Working Principle

 This heat is without reaching the melting point and

allows traversing of the tool along the weld line.
 The plasticized material is transferred the front
edge of the tool to back edge of the tool probe and
it’s forged by the intimate contact of the tool
shoulder and pin profile
 2.Friction Stir Welding

Advantages

 good mechanical properties of the weld joint,

 avoidance of toxic fumes, warping, shielding issues, and other problems

associated with arc welding,

 little distortion or shrinkage, and

 good weld appearance.
Disadvantages

 an exit hole is produced when the tool is withdrawn from the work, and
 heavy-duty clamping of the parts is required.
 2.Friction Stir Welding

Applications:

 used in the aerospace, automotive, railway, and shipbuilding industries.

 Typical applications are butt joints on large aluminum parts.
 Other metals, including steel, copper, and titanium, as well as
polymers and composites have also been joined using FSW.
 Explosion welding

 is a process that uses energy from the detonation of an explosive to join two

pieces of metal extremely high velocity through the use of chemical

explosives.
 The explosion accelerates the pieces to a speed at which a metallic
bond will form b/n them when they collide.
 The weld is produced in a fraction of a second without the addition of
filler metal.
 This is essentially a room temperature process in that gross heating
of the work pieces does not occur.
 Explosion welding

 The faying surfaces, however, are heated to some extent by the energy of the

collision, and welding is accomplished through plastic flow of the metal on

those surfaces.

 Welding takes place progressively as the explosion and the forces it

creates advance from one end of the joint to the other.
 Deformation of the weldment varies with the type of joint.

 There may be no noticeable deformation at all in some weldments, and

there is no loss of metal.

 Explosion welding

 Welding is invariably done in air, although it can be done in other atmospheres

or in a vacuum.

 Most explosion welding is done on sections with relatively large

surface areas, although there are applications for sections with small
surface areas as well.
 The three fundamental components of an explosion welding system
include the prime metal, the base metal, and the explosive agent.

 The base metal, or backer plate, remains stationary as the prime metal

is welded to it.
 Explosion welding

 To make a weld, the workpiece (the prime metal) is accelerated across a short

distance with the force of the explosion and collides with a stationary metal

surface, the base metal.

 As the explosion progresses at high velocity across the surface of the

prime metal, the force of the explosion causes this metal to conform

to an advancing bend angle as it accelerates and collides with the backer

plate.

 A jet is formed in the collapsing space preceding the collision point. The
 Explosion welding

Fig. Typical arrangement of components for

explosion welding

Fig. Action between components

during explosion welding
 Explosion welding

The three essential process variables are:

1. Standoff distance;

2. Explosive detonation velocity; and

3. Explosive load, that is, the quantity and thickness ofthe explosive layer or

“bed” spread evenly on the prime metal, and the energy of the explosive

agent.

The following are important interrelated variables of the explosion welding

process: