diapositivas de procesos de union -kaljpajian

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Manufacturing Processes for Engineering Materials, 4th ed.

Kalpakjian • Schmid

Prentice Hall, 2003

Chapter 12 Joining and Fastening Processes

Prentice Hall, 2003

Joints

FIGURE 12.1 Examples of joints that can be made through the various joining processes

described in Chapter 12.

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Joining Processes

TABLE 12.1

Comparison of various

joining processes.

Note: 1, very good; 2, good; 3, poor.

CHARACTERISTICS

METHOD

Arc wed!"gRe#!#t$"ce wed!"g%r$&!"g%ot# $"d "'t#R!vet!"g($#te"er#Se$)!"g, cr!)p!"g

Ad*e#!ve +o"d!"g

11111223

22122321

31133311

11111132

33321233

13111212

23313233

23211113

21332312

Prentice Hall, 2003

Characteristics of Joining Processes

TABLE 12.2 General characteristics of joining processes.

* 1, highes t ; 5, lowe st

OININ-ROCESS

OPERATION ADVANTAGE SKILLLEVEL

REQUIRED

E LDINGPOSITION

!URRENTT"PE

DISTOR #TION

*!O S T O $

EQUIP#%E N T

Shiel&e&

'et(l#()

%(+(l P o)t(- le

(+& . le/i-le

0 igh A ll (, & 1 to Low

S-'e)ge&()

Ato'(ti 0 igh&e2osit io+

Low to'e&i'

$l(t ( +&ho)i3o+t(l

(, & 1 to % e& i'

G(s 'e t(l #( )

Se'i(to'(tio) (o'(ti

% os t'et(ls

Low tohigh

A ll & to 4 % e& i' tohigh

G( s t+ g#

ste+#()

%(+(l o)

(to'(ti

% os t

'et(ls

Low to

A ll (, & to 4 % e& i'

$l/#o)e&

Se'i(to'(ti

o) (to'(ti

&e2osit io+

Low to

A ll & 1 to 4 % e& i'

O / .el %(+(l P o)t(- le(+& . le/i-le

0 igh A ll # to 6 Low

Elet)o+#-e(', l(se)#-e('

Se'i(to'(tio) (to'(ti

% os t'et(ls

%e& i' tohigh

A ll # 4 to 5 0 igh

Prentice Hall, 2003

Shielded Metal-Arc-Welding Process

FIGURE 12.2 (a) Schematic illustration of the shielded metal-arc-welding process. About 50% of alllarge-scale industrial welding operations use this process. (b) Schematic illustration of the shielded metal-

arc-welding operation, also known as stick welding, because the electrode is in the shape of a stick.

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Weld Zone Build-Up Seuence

FIGURE 12.3 A weld zone showing the build-up sequence of individual weld beads in deep

welds.

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Su!"erged Arc-Welding Process

FIGURE 12.4 Schematic illustration of the submerged arc-welding process and equipment.Unfused flux is recovered and reused.

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M#$ Welding Basic %uip"ent

FIGURE 12.5 (a) Gas metal-arc-welding process, formerly known as MIG welding (for

metal inert gas). (b) Basic equipment used in gas metal-arc-welding operations.

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Flu&-Cored Arc-Welding Process

FIGURE 12.6 Schematic illustration of the flux-cored arc-welding process. This operation

is similar to gas metal-arc welding, shown in Fig. 12.5.

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%lectrogas-Welding Process

FIGURE 12.7 Schematic illustration of theelectrogas-welding process. Source:

Courtesy of the American Welding Society.

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%lectroslag-Welding 'perations

FIGURE 12.8 Equipment used forelectroslag-welding operations. Source:

Courtesy of the American Welding Society.

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(#$ Welding Process

FIGURE 12.9 (a) Gas tungsten-arc-welding process, formerly known as TIG welding ( for

tungsten inert gas). (b) Equipment for gas tungsten-arc-welding operations.

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Plas"a-Arc-Welding Processes

FIGURE 12.10 Two types of plasma-arc-welding processes: (a) transferred and (b)

nontransferred. Deep and narrow welds are made by this process at high welding speeds.

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Co"parison of Weld Bead Si)e

FIGURE 12.11 Comparison of the size of weld beads in (a) electron-beam or laser-beam

welding with that in (b) conventional (tungsten-arc) welding. Source: American WeldingSociety, Welding Handbook , 8th ed., 1991.

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*aser-Bea" Welds

FIGURE 12.12 Gillette Sensor razor cartridge, with laser-beam welds.

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Fusion-Weld Zone

FIGURE 12.13 Characteristics of a typical fusion-weld zone in oxyfuel-gas and arc

welding.

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$rain Structure

FIGURE 12.14 Grain structure in (a) deep weld and (b) a shallow weld. Note that the grains in the solidified weld metal arcperpendicular to their interface with the base metal are perpendicular to their interface with the base metal. In a good weld,the solidification line at the center in the deep weld shown in (a) has grain migration, thus developing uniform strength in theweld bead.

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Weld Bead Microhardness Pro+le

FIGURE 12.15 (a) Weld bead on a cold-rolled nickel strip produced by a laser beam. (b)

Microhardness profile across the weld bead. Note the softer condition of the weld beadcompared with the base metal. Source: IIT Research Institute.

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Fusion-Weld ZoneFIGURE 12.16 Schematic illustration of variousregions in a fusion-weld zone and the correspondingphase diagram for 0.30% C steel. Source: Courtesy

of the American Welding Society.

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#ntergranular Corrosion

FIGURE 12.17 Intergranular corrosion of a weld in ferritic stainless-steel welded tube afterexposure to a caustic solution. The weld line is at the center of the photograph. Scanningelectron micrograph at 20X. Source: Courtesy of B, R, Jack, Allegheny Ludlum Steel Corp.

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,iscontinuities in Fusion Welds

FIGURE 12.18 Examples of various discontinuities in fusion welds.

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,efects in Fusion Welds

FIGURE 12.19 Examples of various defects in fusion welds.

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(pes of Crac.s in Welded Joints

FIGURE 12.20 Types of cracks in welded joints. The cracks re caused by thermal stresses

that develop during solidification and contraction of the weld bead and the welded structure:

(a) crater cracks; (b) various types of cracks in butt and T joints.

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Crac. in a Weld Bead

FIGURE 12.21 Crack in a weld bead. The two components

were not allowed to contract after the weld was completed.Source: S.L. Meiley, Packer Engineering Associates, Inc.

Prentice Hall, 2003

,istortion of Parts After Welding

FIGURE 12.22 Distortion of parts after welding: (a) butt joints and (b) fillet welds. Distortion is caused

by differential thermal expansion and contraction of different parts of the welded assembly. Warping can

be reduced or eliminated by proper weld design and part fixturing prior to welding.

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/esidual Stresses in Straight Butt Joint

FIGURE 12.23 Residual stresses developed in a straight butt joint. Source

: Courtesy of theAmerican Welding Society.

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(ension-Shear (esting

FIGURE 12.24 (a) Types of specimens for tension-shear testing of welds. (b) Wraparoundbend test method. (c) Three-point bending of welded specimens. (See also Fig. 2.23.)

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(ension-Shear0 Cross-(ension0 (ist andPeel (est for Spot Welds

FIGURE 12.25 (a) Tension-shear test for spot welds. (b)

Cross-tension test. (c) Twisttest. (d) Peel test.

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Cladding Process

FIGURE 12.26 Schematic illustration of the roll-bonding, or cladding, process.

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Ultrasonic-Welding

FIGURE 12.27 (a) Components of an ultrasonic-welding machine for lap welds. The lateral vibrations

of the tool tip case plastic deformation and bonding at the interface of the workpieces. (b) Ultrasonic

seam welding using a roller.

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Friction-Welding Process

FIGURE 12.28 Sequence of operations in the friction-welding process. (a) The part on the left is rotated at high speed.(b) The part on the right is brought into contact under an axial force. (c) The axial force is increased; flash begins to form.(d) The part on the left stops rotating. The weld is completed. Flash can be removed by machining or grinding.

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Fusion Zone in Friction Welding

FIGURE 12.29 Shape of the fusion zone in friction welding as a function of the force

applied and the rotational speed.

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Friction Stir-Welding Process

FIGURE 12.30 The principle of the friction stir-welding process. Aluminum-allot plates up to75mm (3 in.) thick have been wended by this process. Source: TWI, Cambridge, UnitedKingdom.

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Seuence in /esistance Spot-Welding

FIGURE 12.31 (a) Sequence in the resistance spot-weldingprocess. (b) Cross-section of a spot weld, showing weld nuggetand light indentation by the electrode on sheet surfaces. Thismethod is one of the most common processes used in sheet-

metal fabrication and automotive-body assembly.

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Special %lectrodes for Spot-Welding

FIGURE 12.32 Types of special electrodes designed for easy access in spot-welding

operations for complex shapes.

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Sea"-Welding Process

FIGURE 12.33 (a) Seam-welding process, with rolls acting as electrodes. (b) Overlapping

spots in a seam weld. (c) Roll spot welds.

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/esistance Proection Welding

FIGURE 12.34 Schematic illustration of resistance projection welding: (a) before and (b)

after. The projections are produced by embossing operations, as described in Section 7.12.2.

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Flash-Welding Process

FIGURE 12.35 Flash-welding process for end-to-end welding of solid rods or tubular parts.

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Stud Arc Welding

FIGURE 12.36 Sequence of operations in stud arc welding, which is used for welding bars,

threaded rods, and various fasteners on metal plates.

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%&plosion-Welding Process

FIGURE 12.37 Schematic illustration of the explosion-welding process: (a) constant-

interface clearance gap and (b) angular-interface clearance gap.

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%&plosion-Welded Joints

FIGURE 12.38 Cross-sections of explosion-welded joints: (a) titanium (top) on low-carbon steel (bottom) and (b) incoloy 800(iron-nickel-base alloy on low-carbon steel. The wavy interfaces shown improve the shear strength of the joint. Some combinationsof metals, such as tantalum and vanadium, produce a much less wavy interface. If the two metals have little metallurgicalcompatibility, and interlayer may be added that has compatibility with both metals. Source: Courtesy of DuPont Company.

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,i3usion Bonding and SuperplasticFor"ing

FIGURE 12.39 (a) Sequence of operations in diffusion bonding and superplatic forming of a

structure with three flat sheets. Source: After D. Stephen and S, J. Swadling. (b) Typicalstructures fabricated. Source: Rockwell International Corp.

Prentice Hall, 2003

Bra)ing and Bra)e-Welding

FIGURE 12.40 (a) Brazing and (b) braze-welding operations.

FIGURE 12.41 An

example of furnace

brazing: (a) before and

(b) after. Note that the

metal is a shaped wire.

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Bra)ing Filler Metals

TABLE 12.3 Typical filler metals for brazing various metals and alloys.

%ASE META/ (I//ER META/ %RA0IN-TEMERATRE

A')!"') $"d !t# $oy# A')!"')5#!!co" 6785928M$g"e#!') $oy# M$g"e#!')5$')!"') 685926Copper $"d !t# $oy# Copper5p*o#p*or'# 788526(erro'# $"d "o"<erro'# $oy# e=cept$')!"') $"d )$g"e#!')4

S!ver $"d copper $oy#,copper5p*o#p*or'#

92851168

Iro"5, "!c>e5, $"d co+$t5+$#e $oy# -od 8851188St$!"e## #tee#, "!c>e5 $"d co+$t5+$#e $oy# N!c>e5#!ver 2651288

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Joint ,esigns

FIGURE 12.42 Joint designs commonly used in brazing operations.

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Joint ,esigns in Soldering

FIGURE 12.43 Joint designs commonly used for soldering.

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Solders

TABLE 12.4 Types of solders and their applications.

T!"5e$dT!"5&!"c/e$d5#!ver C$d)!')5#!ver

0!"c5$')!"')T!"5#!ver T!"5+!#)'t*

-e"er$ p'rpo#e A')!"')Stre"gt* $t *!g*er t*$" roo) te)per$t'reStre"gt* $t *!g* te)per$t're#

A')!"'); corro#!o" re#!#t$"ceEectro"!c#Eectro"!c#

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/e4o Soldering

FIGURE 12.44 Screening solder paste onto a printed circuit board in reflow soldering.

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Wa5e-Soldering Process

FIGURE 12.45 (a) Schematic illustration of the wave-soldering process. (b) SEM image of

a wave-soldered joint on a surface-mount device.

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Adhesi5el Bonded JointsFIGURE 12.46 Various configurations for

adhesively bonded joints: (a) single lap, (b)

double lap, (c) scarf, and (d) strap.

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Adhesi5es

TABLE 12.5 Typical properties and characteristics of chemically reactive structural

adhesives.

So'rce: Advanced Materials & Processes, 'y 18, ASM I"ter"$t!o"$.

EPO7" POL"URET0ANE %ODI$IEDA!R"LI!

!"ANO!R"LATE ANAERO8I!

I)p$ct re#!#t$"ce oor E=cee"t -ood oor ($!r Te"#!o"5#*e$r #tre"gt*,M$ 18

3 p#!4 16.? 2.24 16.? 2.24 26. 3.74 1. 2.74 17.6 2.64

ee #tre"gt*,N@) +@!".4 626 34 1?,888 84 6268 384 626 34 1768 184S'+#tr$te# +o"ded Mo#t Mo#t #)oot*,

"o"poro'#Mo#t

#)oot*,"o"poro'#

Mo#t"o"poro'#)et$# or p$#t!c#

Met$#, g$##,t*er)o#et#

Serv!ce te)per$t'rer$"ge, C (4

566 to 128578 to 2684

5198 to 85268 to 1764

578 to 1285188 to

566 to 8578 to 1764

566 to 168578 to 3884

He$t c're or )!=!"greB'!red

e# e# No No No

Sove"t re#!#t$"ce E=cee"t -ood -ood -ood E=cee"tMo!#t're re#!#t$"ce E=cee"t ($!r -ood oor -ood-$p !)!t$t!o", ))!".4 No"e No"e 8.76 8.834 8.26 8.814 8.98 8.8264Odor M!d M!d Stro"g Moder$te M!dTo=!c!ty Moder$te Moder$te Moder$te /ow /ow($))$+!!ty /ow /ow H!g* /ow /ow

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Brittle and (ough Adhesi5es in Peeling

FIGURE 12.47 Characteristic behavior of (a) brittle and (b) tough adhesives in a peeling test.This test is similar to peeling adhesive tape from a solid surface. Adhesive joints. Should notbe subjected to this type of loading in service.

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%&a"ples of /i5ets and Stitching

FIGURE 12.48 Examples of rivets: (a) solid, (b) tubular, (c) split (or bifurcated), and (d)

compression.

FIGURE 12.49 Examples of metal stitching.

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,ou!le-*oc. Sea" and Cri"ping

FIGURE 12.50 Stages in forming a double-lock seam.

FIGURE 12.51 Two examples

of mechanical joining by

crimping.

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Spring and Snap Fasteners

FIGURE 12.52 Examples ofspring and snap-in fasteners to

facilitate assembly.

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,esign $uidelines for Welding

FIGURE 12.53 Design guidelines for welding. Source: J. G. Bralla (ed.), Handbook ofProduct Design for Manufacturing. Copyright © 1986, McGraw-Hill Publishing Company.Reproduced by permission of the McGraw-Hill Companies.

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Flash Welding $uidelines

FIGURE 12.54 Design guidelines for flash welding.

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Weld ,esigns

FIGURE 12.55 Weld designs for Example 12.4.

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$ood and Poor ,esigns for Bra)ing

FIGURE 12.56 Examples of good

and poor designs for brazing.

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Joint ,esigns in Adhesi5e Bonding

FIGURE 12.57 Various joint

designs in adhesive bonding.

Note that good design requireslarge contact areas between the

members to be joined.

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,esigns $uidelines for /i5eting

FIGURE 12.58 Design guidelines for riveting. Source: J. G. Bralla.

Blood /eser5oir

FIGURE 12.59 The Cobe Laboratories blood reservoir. Thelid is bonded to the bowl with an airtight adhesive joint and

tongue-in-groove joint. Source: Cobe Laboratories.

diapositivas de procesos de union -kaljpajian

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