Download ADVANCED MANUFACTURING SYSTEMS INDEN 5303

INDUSTRIAL PROCESSES II
INDEN 3313
Lecture 6 – Case Study
Fusion Welding -- Oxyfuel and
Electric (Arc) Welding Processes
Industrial Processes II
OVERVIEW
• Case Study
– Overview and Phases
• Fusion Welding
– Oxyfuel
– Arc
– Resistance
Industrial Processes II
QUESTIONS
TO START ??
Industrial Processes II
CASE STUDY
• Goal to Study the Design and
Manufacture of Tooling
– Phase I (15%)
• Identify Possible Parts for Case Study
• Each Student to Identify Three (3) Parts for Case
Study
– One part => Cast
– One Part => Machined
– One Part => Other Than Cast/Machined that will
require tooling for its Production (Forging Dies,
Stamping/Bending Dies, …)
• Form/Format on Web
– Part (Name, Function, Sketch)
• Due Next Thursday
– Hard Copy and Electronic Submission (e-mail)
Industrial Processes II
CASE STUDY
– Phase II (15%) – Part Processing Concepts
• Following Part Submission (Phase I) Instructor
•
•
•
•
will select/modify Parts and Assign
A processing sequence will be designed for the
part and the tooling requirement(s) for its
production via this sequence will be determined.
Each student will execute this phase for one part
concept.
Due 2/22/00
Format on Web
Industrial Processes II
CASE STUDY
– Phase III (70%)
• Each Student will detail the design and
manufacture (parameters, costs, …) of an
assigned piece of tooling. For part concepts
requiring more than one piece of tooling, one
student will be assigned each piece and one
report will be developed for each part.
– 10% -- Schedule for Project (Due 3/8/00) and
Progress/Adherence to Schedule (Due 3/29/00)
– 20% -- Completed Draft (Due 4/12) Evaluation of
Technical Data and Report Format/Content
Completeness (Format on Web IEM Tech. Writing)
– 40% -- Final Draft with all Technical Corrections
and Presentation of Results to Class. (Slides Due
4/26, Final Report Due 4/28)
• Schedule may be modified to accommodate ENGL
3323
Industrial Processes II
FUSION WELDING METHODS
• Fusion => Use of Heat to Melt
• Types (Source of Heat)
– Chemical Reaction (Combustion)
• OxyFuel
• Thermit
– Electric Arc
• Consumable Electrode
• Non-Consumable Electrode
Industrial Processes II
FUSION WELDING METHODS
• Types(cont.)
– Beam
• Electron Beam
• Laser
– Electrical Resistance
• Note: Text Classifies as Solid State Process --
Nugget is Molten, But Contained
Industrial Processes II
OXYFUEL WELDING
• Basic Process Description
– Use the Heat Produced by the Combustion
of Acetylene and Oxygen to Cause
Coalescence
• Parameters
– Rate of Combustion
• Affects Heat, Not Temperature
• Size of (Nozzle) Tip
– Maintenance of Non-Corrosive Shield
– Operator Skill, Preparation of Parts
Industrial Processes II
OXYFUEL WELDING
• Reactions
– 1.
– 2.
C2H2 + O2 -> 2 CO + H2 + Heat
4 CO + 2 H +3 O2 -> 4 CO2 +2 H2O + Heat
• Discussion of Flame
O2
5500o F
2300o F
C2H2
– Reducing
Neutral
Industrial Processes II
Oxidizing
OXYFUEL WELDING
• Common Defects
–
–
–
–
–
Hydrogen Embrittlement
Corrosion (Neutral/Reducing Flame)
Spatter
Inadequate Penetration
Incomplete Fusion
• Advantages
– Low Cost, Skill Requirements
– Portability
Industrial Processes II
THERMIT WELDING
• Basic Process Description
– Use of Heat Produced by Thermite Reaction
to Superheat Fe and Use Superheated Fe to
Effect Weld
• Reactions
– 1. 3 Fe3O4 + 8 Al -> 9 Fe + 4 Al203 + Heat
– 2. 3 FeO + 2 Al -> 3 Fe + Al203 + Heat
– 3. Fe203 + 2 Al -> 2 Fe + Al203 + Heat
• Iron for Weld, Aluminum Oxide Slag
(Protects Weld as It Cools)
Industrial Processes II
THERMIT WELDING
• Sources/Causes of Defects
– Inclusions
– Large Grooves Required (Superheat of Base)
• Advantages
– Large Amounts of Filler Metal Available
Quickly
Industrial Processes II
THERMIT WELDING
[Amstead et al, Figure 8.26, p. 186]
Industrial Processes II
CONSUMABLE ELECTRIC ARC
WELDING
• Basic Process Description
– Creation of an Electrical Potential and
Exceeding the Initiation Voltage to Produce
an Electrical Arc, the Heat of Which
(~55,000o F) Effects the Weld; the
Electrode is Melted by the Arc and Supplies
Filler Metal to the Weld
• Parameters
– Distance from Electrode to Work Determines
Initiation Voltage, Temperature,
Current/Frequency Determines Heat Flux
Industrial Processes II
CONSUMABLE ELECTRIC ARC
WELDING
• Two Types
– Consumable Electrode
– Non-consumable Electrode
• Advantages
– Automated
– High Temperature
– High Heat Flux
– Shielding from Corrosion
Industrial Processes II
CONSUMABLE ELECTRIC ARC
WELDING
• Provision of Non-Corrosive Environment
– Shielded Metal Arc Welding (SMAW)
• Flux Coated Stick Electrode
– Submerged Arc Welding (SAW)
• Flux Supplied by Separate Delivery System
– Gas Metal Arc Welding (GMAW)
• Inert Gas Supplied - Local Inert Atmosphere
Around Weld
– Flux Cored Arc Welding (FCAW)
• Flux Embedded in ‘Hollow’ Electrode (Wire)
Industrial Processes II
CONSUMABLE ELECTRIC ARC
WELDING
• Provision of Non-Corrosive Environment
– Electro-Gas Welding (EGW)
• Inert Gas Supplied
– Electroslag Welding (ESW)
• Slag Used to Shield
• Technically, Arc is Extinguished - Resistance Used
To Heat
Industrial Processes II
SHIELDED METAL ARC
WELDING
[Kalpakjian, Figure 27.4, p. 862]
Industrial Processes II
SUBMERGED METAL ARC
WELDING
[Kalpakjian, Figure 27.7, p. 864]
Industrial Processes II
GAS METAL ARC WELDING
[Kalpakjian, Figure 27.8, p. 865]
Industrial Processes II
FLUX CORED ARC WELDING
[Kalpakjian, Figure 27.10, p. 867]
Industrial Processes II
ELECTRO-GAS WELDING
[Kalpakjian, Figure 27.11, p. 868]
Industrial Processes II
ELECTROSLAG WELDING
[Kalpakjian, Figure 27.12, p. 869]
Industrial Processes II
NON-CONSUMABLE ELECTRIC
ARC WELDING
• Basic Process Description
– Creation of an Electrical Potential and
Exceeding the Initiation Voltage to Produce
an Electrical Arc, the Heat of Which
(~55,000o F) Effects the Weld; the
Electrode is Not Melted by the Arc and a
Separate Rod (Optional) Supplies Filler
Metal to the Weld
• Parameters
– Distance from Electrode to Work Determines
Initiation Voltage, Temperature,
Current/Frequency Determines Heat Flux
Industrial Processes II
NON-CONSUMABLE ELECTRIC
ARC WELDING
• Gas Tungsten- Arc Welding
– Gas Shielding
• Atomic Hydrogen Welding
– Uses Hydrogen as Shielding
• Plasma Arc Welding
– Plasma (60,000o F)
– Shielding Gas Used
Industrial Processes II
Gas Tungsten- Arc Welding
•
[Kalpakjian, Figure 27.13, p. 872]
Industrial Processes II
Plasma Arc Welding
[Kalpakjian, Figure 27.15, p. 874]
Industrial Processes II
ELECTRON BEAM WELDING
• Basic Process Description
– Use of Heat Produced by High Velocity
Stream of Electrons to Effect Deep
Penetration Welds
• Advantages
– High Penetration
• Shielding
– Performed in a Vacuum
• Disadvantages
– Cost, X-Rays Produced
Industrial Processes II
LASER BEAM WELDING
• Basic Process Description
– Use of Heat Produced by High Intensity
Beam of Light to Effect Deep Penetration
Welds
• Advantages
– High Penetration
• Shielding
– Performed in a Vacuum
Industrial Processes II
SOLID STATE METHODS
• Coalescence Through Pressure
• Types
–
–
–
–
–
–
Resistance Welding
Cold Welding
Ultrasonic Welding
Friction Welding
Explosion Welding
Diffusion Welding
Industrial Processes II
RESISTANCE WELDING
• Basic Process Description
– The Heating of the Base Materials Through
Electrical Resistance at Material
Interfaces/Discontinuities to Produce
Coalescence.
• Sequence
– Material Surfaces Cleaned and Aligned
– Electrodes Used to Clamp Components in
Place
– Current Passed Through Components
(Electrodes Water Cooled), Nugget Melted
– Current Turned Off, Coalescence, Unclamped
Industrial Processes II
RESISTANCE WELDING
• Parameters
– Voltage
• Usually Low Voltage
– Current (Amperage)
• Controls Heat Flux
• Usually High Current
– Time of Current Passage
• Heat = I2 * Ω * t
– Total Resistance
• Power = I2 * Ω
– Clamping Time/Pressure
– Area of Electrode/Workpiece Contact
Industrial Processes II
RESISTANCE WELDING
• Types
– Spot
– Projection
– Seam
• Lap
• Mash
• Finish
–
–
–
–
Butt
Flash
Percussion
Induction
Industrial Processes II
RESISTANCE WELDING
• Spot - Temperature Distribution
Amstead, Figure 8.10, p. 168
Industrial Processes II
RESISTANCE WELDING
• Spot
Kalpakjian, Figure 28.6b, p. 892
Industrial Processes II
RESISTANCE WELDING
• Projection
Amstead, Figure 8.11, p. 169
Industrial Processes II
RESISTANCE WELDING
• Seam -- Lap Seam
Amstead, Figure 8.12, p. 170
Industrial Processes II
RESISTANCE WELDING
• Seam -- Mash Seam
Amstead, Figure 8.12, p. 170
Industrial Processes II
RESISTANCE WELDING
• Seam -- Finish Seam
Amstead, Figure 8.12, p. 170
Industrial Processes II
RESISTANCE WELDING
• Butt -- Pipe
Amstead, Figure 8.14a, p. 171
Industrial Processes II
RESISTANCE WELDING
• Butt -- Bar Stock
Amstead, Figure 8.14b, p. 171
Industrial Processes II
RESISTANCE WELDING
• Flash (Also Considered Arc Welding)
Kalpakjian, Figure 28.15a, p. 892
Industrial Processes II
RESISTANCE WELDING
• Stud --(Also Considered Arc Welding)
Kalpakjian, Figure 28.16, p. 898
Industrial Processes II
RESISTANCE WELDING
• Percussion
Modified from Kalpakjian, Figure 28.15, p. 897
Industrial Processes II
RESISTANCE WELDING
• Induction
Part to be
Welded
Modified from Kalpakjian, Figure 4.26a,b, p. 147
Industrial Processes II
QUESTIONS
OR
CLARIFICATIONS
???
Reminder :
Industrial Processes II