Fi WldiFusion Weldingver. 1ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 20091Fusion weldingFusion welding • Intimate interfacial contact by using a liquid of substantially gq ysimilar composition to the base materials.•Heat + filler material = weld•Heat + filler material = weldME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 20092TypesTypes• Flame-Ai / f l–Air / fuel– Oxygen / fuel (oxy-acetylene)•Oxygen (oxyfuel) cutting•Oxygen (oxy-fuel) cutting• ThermitElectric arc•Electric arc• ResistanceLb•Laser beam• Electron beamME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 20093OxyAcetylene WeldingOxy-Acetylene WeldingME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 20094Oxyacetylene weldingOxy-acetylene weldingME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 20095Oxyacetylene weldingOxy-acetylene weldingME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 20096Oxygen (oxyfuel) cuttingOxygen (oxy-fuel) cuttingME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 20097Oxygen (oxyfuel) cuttingOxygen (oxy-fuel) cutting• Fuel + oxygen burns away iron oxide•Oxygen reacts with atomic iron to form ygiron oxide•Process repeatsProcess repeats• One torch provides the fuel and oxygenIron is not melted by the flame rather•Iron is not melted by the flame, rather burned (oxidized) awayME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 20098ThermitME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 20099ThermitThermit•Fuel for space shuttle solid•Fuel for space shuttle solid rocket booster (SRB)• In skin of Hindenburg dirigible– electrostatic discharge caused fireME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 200910Arc WeldingArc WeldingME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 200911Electric ArcElectric ArcVoltage /currentsourceV/Aelectrodearcld tweldmentfillerME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 200912Manual Arc WeldingManual Arc WeldingME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 200913Solid Wire Metal Inert Gas (MIG) WeldingME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 200914Tungsten Inert Gas (TIG) WeldingTungsten Inert Gas (TIG) WeldingME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 200915Submerged Arc WeldingSubmerged Arc WeldingME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 200916Resistance WeldingResistance WeldingME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 200917Spot WeldingProjection Welding ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 200918Seam WeldingSeam WeldingME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 200919Tube WeldingTube WeldingME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 200920Rail Butt WeldinggME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 200921Laser WeldingLaser WeldingME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 200922Laser typesLaser types•Carbon dioxideCarbon dioxide• Diode–Solid state LEDSolid state LED• Excimer–excited dimer: diatomic molecule of an inert gas gatom and a halide atom• fluorine, chlorine, bromine, iodineNd YAG•Nd:YAG– neodymium/yttrium/argon/garnetME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 200923Laser BeamME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 200924Electron BeamME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 200925Electron beamElectron beamME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 200926Weld ComparisonWeld ComparisonComparison of the size of weld beads in (a) electron-beam or laser-beam welding to that in (b) conventional (tungsten-arc) weldingSource: American Welding SocietyME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 200927that in (b) conventional (tungstenarc) welding. Source: American Welding Society, Welding Handbook (8th ed.), 1991.Fusion Welding ZoneFusion Welding ZoneME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 200928Heat affected zone (HAZ)Heat affected zone (HAZ)ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 200929Joint PreparationJoint Preparation• Clean joint thoroughly•Minimize assembly inaccuraciesMinimize assembly inaccuraciesME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 200930Design GuidelinesDesign GuidelinesME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 200931ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 200932Corrosion of WeldIntergranular corrosion of a 310-stainless-steel welded tube after exposure to a caustic solution. The weld line is at the center of the photograph. Scanning electron micrograph at 20 X. Source: Courtesy of B. R. Jack, Allegheny Ludlum Steel Corp.ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 200933Weld CrackCrack in a weld bead, due to the fact that the two components were not allowed to contract after the weld was completed. Source: S. L. Meiley, Packer Engineering AitIME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 200934Associates, Inc.ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT