diapositivas procesos union part 2
TRANSCRIPT
-
7/25/2019 Diapositivas Procesos Union Part 2
1/24
Chapter:Manufacturing processes by joining
-
7/25/2019 Diapositivas Procesos Union Part 2
2/24
ARC WELDING: consumable electrode
1. Introduction
2. Oxifuel gaswelding
3. Arc welding.a) Non
consumableelectrode.
GTAW
PAW AHW
b) Consumable
electrode. SMAW
SAW
GMAW FCAW
EGW
ESWc) Electrodes
d) Gases
e) Others: EBW
Shielded-Metal Arc Welding - SMAW
Manual welding 50% of the processes
f) Quality and
defectsg) Weldability
h) Design
4. Resistancewelding
RSW RSEW
HFRW
5. Economy
6. Brazing(soldadurafuerte)
7. Soldering(soldadurablanda)
8. Adhesive
bonding
DC or AC 50-300A10kW
ADVANTAGES AND LIMITATIONS:1. Useful in inaccessible places.2. Portability, flexibility, simple.3. Manual process difficult to automate.
APPLICATIONS:- Plate welding between 3-19 mm thickness.
- For deeper welding
-
7/25/2019 Diapositivas Procesos Union Part 2
3/24
ARC WELDING: consumable electrode
1. Introduction
2. Oxifuel gaswelding
3. Arc welding.a) Non
consumableelectrode.
GTAW
PAW AHW
b) Consumable
electrode. SMAW
SAW
GMAW FCAW
EGW
ESWc) Electrodes
d) Gases
e) Others: EBW
Submerged Arc Welding - SAW
f) Quality and
defectsg) Weldability
h) Design
4. Resistancewelding
RSW RSEW
HFRW
5. Economy
6. Brazing(soldadurafuerte)
7. Soldering(soldadurablanda)
8. Adhesive
bonding
Flux: lime, silica, oxide of magnesium, fluoride of calcium and other compounds
Avoids sparks and splashes.Avoids dangerous ultraviolet radiation and smoke typical of SMAW.Thermal insulation -> deep penetration of heat.
DC or AC 300-2000A
ADVANTAGES AND LIMITATIONS:1. Automated process (5m/min) -> 4-10 filler material/h than SMAW2. Ferrous and Non-Ferrous materials.
3. Excellent quality and good mechanical properties.
4. Plane position welding with backup.
APPLICATIONS:- Railways.- Ship plates (thick)
- Pressure vessels.
-
7/25/2019 Diapositivas Procesos Union Part 2
4/24
ARC WELDING: consumable electrode
1. Introduction
2. Oxifuel gaswelding
3. Arc welding.a) Non
consumableelectrode.
GTAW
PAW AHW
b) Consumable
electrode. SMAW
SAW
GMAW FCAW
EGW
ESWc) Electrodes
d) Gases
e) Others: EBW
Gas metal Arc Welding - GMAW MIG or semiautomatic
f) Quality and
defectsg) Weldability
h) Design
4. Resistancewelding
RSW RSEW
HFRW
5. Economy
6. Brazing(soldadurafuerte)
7. Soldering(soldadurablanda)
8. Adhesive
bonding
-
7/25/2019 Diapositivas Procesos Union Part 2
5/24
ARC WELDING: consumable electrode
1. Introduction
2. Oxifuel gaswelding
3. Arc welding.a) Non
consumableelectrode.
GTAW
PAW AHW
b) Consumable
electrode. SMAW
SAW
GMAW FCAW
EGW
ESWc) Electrodes
d) Gases
e) Others: EBW
Gas metal Arc Welding - GMAW
f) Quality and
defectsg) Weldability
h) Design
4. Resistancewelding
RSW RSEW
HFRW
5. Economy
6. Brazing(soldadurafuerte)
7. Soldering(soldadurablanda)
8. Adhesive
bonding
Stable Arc no splash Ar DC with very high curr High diameter electro Very Thick plates
Splashes CO2 High currents Thick plates
Splashes bad quality CO2 Low currents low energy Low diameter electrodes Thin plates
-
7/25/2019 Diapositivas Procesos Union Part 2
6/24
ARC WELDING: consumable electrode
1. Introduction
2. Oxifuel gaswelding
3. Arc welding.a) Non
consumableelectrode.
GTAW
PAW AHW
b) Consumable
electrode. SMAW
SAW
GMAW FCAW
EGW
ESWc) Electrodes
d) Gases
e) Others: EBW
Gas metal Arc Welding - GMAW
Power source:DC Tension constant
f) Quality and
defectsg) Weldability
h) Design
4. Resistancewelding
RSW RSEW
HFRW
5. Economy
6. Brazing(soldadurafuerte)
7. Soldering(soldadurablanda)
8. Adhesive
bonding
Auto-regulation
-
7/25/2019 Diapositivas Procesos Union Part 2
7/24
ARC WELDING: consumable electrode
1. Introduction
2. Oxifuel gaswelding
3. Arc welding.a) Non
consumableelectrode.
GTAW
PAW AHW
b) Consumable
electrode. SMAW
SAW
GMAW FCAW
EGW
ESWc) Electrodes
d) Gases
e) Others: EBW
Gas metal Arc Welding - GMAW
f) Quality and
defectsg) Weldability
h) Design
4. Resistancewelding
RSW RSEW
HFRW
5. Economy
6. Brazing(soldadurafuerte)
7. Soldering(soldadurablanda)
8. Adhesive
bonding
A Pulsed Arc. A1 !ime bac" current# A$ !ime pic" current.
B Selector of !ension.
C Post-burning time. Pre%ents the &ire from touching the part.
D: Wire 'eed speed.
E: General s&itch.F !ype of cycle
$t Start-Stop
(t Gas start) Wire feed and current start ) Wire and current stop ) Gas Stop
Spot &elding
H: Slo& &ire mo%ement setup time
I : *rater filling *urrent and tension reduction.J: Amperimeter and %oltmeter.
K: Positi%e pole + L ,egati%e pole.
-
7/25/2019 Diapositivas Procesos Union Part 2
8/24
ARC WELDING: consumable electrode
1. Introduction
2. Oxifuel gaswelding
3. Arc welding.a) Non
consumableelectrode.
GTAW
PAW AHW
b) Consumable
electrode. SMAW
SAW
GMAW FCAW
EGW
ESWc) Electrodes
d) Gases
e) Others: EBW
Gas metal Arc Welding - GMAW
GMAW parameters
Tensin / energy in the arc 0 1/ energy in the &ire.
Wire feed:as higher the &ire feed higher the current intensity.
Welding speed:function of filler rate and penetration grade. relacionada con
la tasa de depsito y penetracin.
f) Quality and
defectsg) Weldability
h) Design
4. Resistancewelding
RSW RSEW
HFRW
5. Economy
6. Brazing(soldadurafuerte)
7. Soldering(soldadurablanda)
8. Adhesive
bonding
ADVANTAGES AND LIMITATIONS:1. Ferrous and Non-Ferrous materials.2. Simple process and easy qualification for welders in all positions.3. Flexible, rapid and economical. Double productivity than SMAW.4. Easy to automate with robots and flexible cells.
5. Low temperatures.
APPLICATIONS:- Plates up to 6 mm.
n%erse po ar y pre rerre e er arc s a y6 goo
penetration6 little splashes5. ,o A* used.
!as flo": lo& flo& means bad protection and o7idation# e7cessi%e flo&
means turbulences and corrosion.
-
7/25/2019 Diapositivas Procesos Union Part 2
9/24
ARC WELDING: consumable electrode
1. Introduction
2. Oxifuel gaswelding
3. Arc welding.a) Non
consumableelectrode.
GTAW
PAW AHW
b) Consumable
electrode. SMAW
SAW
GMAW FCAW
EGW
ESWc) Electrodes
d) Gases
e) Others: EBW
'undent *ore Arc Welding - '*AW
f) Quality and
defectsg) Weldability
h) Design
4. Resistancewelding
RSW RSEW
HFRW
5. Economy
6. Brazing(soldadurafuerte)
7. Soldering(soldadurablanda)
8. Adhesive
bonding
ADVANTAGES AND LIMITATIONS:The same as GMAW and:
1. Better stability of arc.2. Better productivity3. Better mechanical properties.4. Flexible wire -> continuous feed with regard to SMAW.
5. Can produce all kind of alloys.
5. Low temperatures.
-
7/25/2019 Diapositivas Procesos Union Part 2
10/24
ARC WELDING: consumable electrode
1. Introduction
2. Oxifuel gaswelding
3. Arc welding.a) Non
consumableelectrode.
GTAW
PAW AHW
b) Consumable
electrode. SMAW
SAW
GMAW FCAW
EGW
ESWc) Electrodes
d) Gases
e) Others: EBW
4lectro-Gas Welding - 4GW
DCEP Constant Tension (30-50 V) 100-800 A
f) Quality and
defectsg) Weldability
h) Design
4. Resistancewelding
RSW RSEW
HFRW
5. Economy
6. Brazing(soldadurafuerte)
7. Soldering(soldadurablanda)
8. Adhesive
bonding
ADVANTAGES AND LIMITATIONS:1. Low skill requirements.2. Plate thickness 12-75 mm
3. Ferrous and Non-Ferrous alloys.4. High Deposition Rate 20 times faster than
manual weldingOver 2.5 m long vertical seam in 50 min. by a
single operator. (50 mm/min)5. Welds in single pass, no inter-pass cleaning.6. High quality weld with minimum distortion.
7. Both gas shielded or flux cored wire are available.
8. Cost of equipment and transportation.
APPLICATIONS:- Ship welding- Structural welding
-
7/25/2019 Diapositivas Procesos Union Part 2
11/24
ARC WELDING: consumable electrode
1. Introduction
2. Oxifuel gaswelding
3. Arc welding.a) Non
consumableelectrode.
GTAW
PAW AHW
b) Consumable
electrode. SMAW
SAW
GMAW FCAW
EGW
ESWc) Electrodes
d) Gases
e) Others: EBW
4lectro-Slag Welding - 4SWSimilar to EGW, except:
- Arc starts at different position(between electrode andbottom of part).
- The arc is not continuous andit acts the electrical resistanceof slag (not a electrical arcrocess .
f) Quality and
defectsg) Weldability
h) Design
4. Resistancewelding
RSW RSEW
HFRW
5. Economy
6. Brazing(soldadurafuerte)
7. Soldering(soldadurablanda)
8. Adhesive
bonding
ADVANTAGES AND LIMITATIONS: same as EGW but1. Plate thickness 25-900 mm2. High Deposition Rate 10 times faster than manual welding
(12-25 mm/min)
APPLICATIONS:- Ship welding- Structural welding- Railway welding- Large tanks..
-
7/25/2019 Diapositivas Procesos Union Part 2
12/24
ARC WELDING: ELECTRODES
1. Introduction
2. Oxifuel gaswelding
3. Arc welding.a) Non
consumableelectrode.
GTAW
PAW AHW
b) Consumable
electrode. SMAW
SAW
GMAW FCAW
EGW
ESWc) Electrodes
d) Gases
e) Others: EBW
? Strength of deposited
metal Current (DC or AC). Type of coating.
Parameters: Diameter Length Intensity Core material
f) Quality and
defectsg) Weldability
h) Design
4. Resistancewelding
RSW RSEW
HFRW
5. Economy
6. Brazing(soldadurafuerte)
7. Soldering(soldadurablanda)
8. Adhesive
bonding
-
7/25/2019 Diapositivas Procesos Union Part 2
13/24
ARC WELDING: ELECTRODES: Covering
1. Introduction
2. Oxifuel gaswelding
3. Arc welding.a) Non
consumableelectrode.
GTAW
PAW AHW
b) Consumable
electrode. SMAW
SAW
GMAW FCAW
EGW
ESWc) Electrodes
d) Gases
e) Others: EBW
Coveringpo&ders of o7ides6 carbonates6 fluorides6 metallic
alloys6 cellulose together &ith silicate agglutinants.
'unctions Electrical
- Arc strike: dissociable and ionisable substances
carbonates, silicates, oxides of Fe, Ti favour the arc strike.
- Arc stability: to maintain the state of ionization in the plasma column
*lay materials that includes
f) Quality and
defectsg) Weldability
h) Design
4. Resistancewelding
RSW RSEW
HFRW
5. Economy
6. Brazing(soldadurafuerte)
7. Soldering(soldadurablanda)
8. Adhesive
bonding
, , .
Metallurgical:
- Provides alloy elements to improvemechanical ro erties.
Physical:- Protective gas generation:
CO2 H2O CO H2
- Controls the speed of electrode melting
- Fundent (fux): the slag protects the liquid metal from oxygen, nitrogen, inclusions
- Helps to transfer the melted drops towards the joining.
- Controls the cooling and tempering
-
7/25/2019 Diapositivas Procesos Union Part 2
14/24
ARC WELDING: ELECTRODES: Covering
1. Introduction
2. Oxifuel gaswelding
3. Arc welding.a) Non
consumableelectrode.
GTAW
PAW AHW
b) Consumable
electrode. SMAW
SAW
GMAW FCAW
EGW
ESWc) Electrodes
d) Gases
e) Others: EBW
*o%ering types Rutile (TiO2): dense and viscous slag.- Welding in all positions. Easy to use.
- Poor strength Hydrogen fragility
Basic (calcic carbonate and calcic fluoride (fundent)):
dense slag which ascends easy- Low hydrogen content Fix Mn, Cr, Ni, Mo in the bead.
- Good mechanical and corrosion characteristics
- Dissolve impurities (FeS)
f) Quality anddefects
g) Weldability
h) Design
4. Resistancewelding
RSW RSEW
HFRW
5. Economy
6. Brazing(soldadurafuerte)
7. Soldering(soldadurablanda)
8. Adhesive
bonding
Acid (FeS, FeMn, FeO, MnO): dissolve basic oxides as MnO
- Dense and abundant slag Smooth bead finish Easy to weld
- Rapid melting
- Medium strength Hydrogen fragility Slag in the bead
- Difficult to use Hygroscopic
Cellulosic(organic substances): very good gas envelope
- Oxidizing protection Better arc transference Good penetration due to H2heat and gas pressure Good quality in descending and pipe welding
- Welding splashes Smoke
Not used(only 2%)
-
7/25/2019 Diapositivas Procesos Union Part 2
15/24
-
7/25/2019 Diapositivas Procesos Union Part 2
16/24
ARC WELDING: GASES
1. Introduction
2. Oxifuel gaswelding
3. Arc welding.a) Non
consumableelectrode.
GTAW
PAW AHW
b) Consumable
electrode.
SMAW SAW
GMAW FCAW
EGW
ESWc) Electrodes
d) Gases
e) Others: EBW
UNE-EN ISO 14175
f) Quality and
defectsg) Weldability
h) Design
4. Resistancewelding
RSW RSEW
HFRW
5. Economy
6. Brazing(soldadurafuerte)
7. Soldering(soldadurablanda)
8. Adhesive
bonding
-
7/25/2019 Diapositivas Procesos Union Part 2
17/24
ARC WELDING: GASES
1. Introduction
2. Oxifuel gaswelding
3. Arc welding.a) Non
consumableelectrode.
GTAW
PAW AHW
b) Consumable
electrode.
SMAW SAW
GMAW FCAW
EGW
ESWc) Electrodes
d) Gases
e) Others: EBW
UNE-EN ISO 14175
f) Quality and
defectsg) Weldability
h) Design
4. Resistancewelding
RSW RSEW
HFRW
5. Economy
6. Brazing(soldadurafuerte)
7. Soldering(soldadurablanda)
8. Adhesive
bonding
-
7/25/2019 Diapositivas Procesos Union Part 2
18/24
ARC WELDING: GASES
1. Introduction
2. Oxifuel gaswelding
3. Arc welding.a) Non
consumableelectrode.
GTAW
PAW AHW
b) Consumable
electrode.
SMAW SAW
GMAW FCAW
EGW
ESWc) Electrodes
d) Gases
e) Others: EBW
UNE-EN ISO 14175
f) Quality and
defectsg) Weldability
h) Design
4. Resistancewelding
RSW RSEW
HFRW
5. Economy
6. Brazing(soldadurafuerte)
7. Soldering(soldadurablanda)
8. Adhesive
bonding
-
7/25/2019 Diapositivas Procesos Union Part 2
19/24
ARC WELDING: GASES
1. Introduction
2. Oxifuel gaswelding
3. Arc welding.a) Non
consumableelectrode.
GTAW
PAW AHW
b) Consumable
electrode.
SMAW SAW
GMAW FCAW
EGW
ESWc) Electrodes
d) Gases
e) Others: EBW
Inert gases (Ar, He) Non-ferrous alloys (Al and Cu)
Low thermal conductivityHigh electrical conductivity
High thermal conductivityLow electrical conductivity
Helium only for thickness higher than 4 mm
f) Quality and
defectsg) Weldability
h) Design
4. Resistancewelding
RSW RSEW
HFRW
5. Economy
6. Brazing(soldadurafuerte)
7. Soldering(soldadurablanda)
8. Adhesive
bonding
Less tension
meansbetter arc stability
-
7/25/2019 Diapositivas Procesos Union Part 2
20/24
ARC WELDING: GASES
1. Introduction
2. Oxifuel gaswelding
3. Arc welding.a) Non
consumableelectrode.
GTAW
PAW AHW
b) Consumable
electrode.
SMAW SAW
GMAW FCAW
EGW
ESWc) Electrodes
d) Gases
e) Others: EBW
Active gases (CO2, N2, H2, O2) Steels No alloyedLow AlloyedHigh AlloyedCarbon steels (> 0,2%C)
80% Ar-20% CO2
100% CO2 only when using flux or shielded wire with deoxidizing elements (Mn, Si) and C
Low alloyed steels
75% Ar-25% CO2
f) Quality and
defectsg) Weldability
h) Design
4. Resistancewelding
RSW RSEW
HFRW
5. Economy
6. Brazing(soldadurafuerte)
7. Soldering(soldadurablanda)
8. Adhesive
bonding
Stainless steels (> 0,2%C)
98% Ar-2% CO22% O2
Active gas provides fluidity, required for penetration
-
7/25/2019 Diapositivas Procesos Union Part 2
21/24
ARC WELDING: GASES
1. Introduction
2. Oxifuel gaswelding
3. Arc welding.a) Non
consumableelectrode.
GTAW
PAW AHW
b) Consumable
electrode.
SMAW SAW
GMAW FCAW
EGW
ESWc) Electrodes
d) Gases
e) Others: EBW
GUA DE SELECCIN DE GASES (Fuente: La flor del rbigo)
f) Quality and
defectsg) Weldability
h) Design
4. Resistancewelding
RSW RSEW
HFRW
5. Economy
6. Brazing(soldadurafuerte)
7. Soldering(soldadurablanda)
8. Adhesive
bonding
-
7/25/2019 Diapositivas Procesos Union Part 2
22/24
ARC WELDING: GASES
1. Introduction
2. Oxifuel gaswelding
3. Arc welding.a) Non
consumableelectrode.
GTAW
PAW AHW
b) Consumable
electrode.
SMAW SAW
GMAW FCAW
EGW
ESWc) Electrodes
d) Gases
e) Others: EBW
GUA DE SELECCIN DE GASES (Fuente: La flor del rbigo)
f) Quality and
defectsg) Weldability
h) Design
4. Resistancewelding
RSW RSEW
HFRW
5. Economy
6. Brazing(soldadurafuerte)
7. Soldering(soldadurablanda)
8. Adhesive
bonding
-
7/25/2019 Diapositivas Procesos Union Part 2
23/24
ARC WELDING: GASES
1. Introduction
2. Oxifuel gaswelding
3. Arc welding.a) Non
consumableelectrode.
GTAW
PAW AHW
b) Consumable
electrode.
SMAW SAW
GMAW FCAW
EGW
ESWc) Electrodes
d) Gases
e) Others: EBW
2::/ Ar ) 1$/ *;$ Spray transference
29/ Ar) $9/ *;$5 Short-cort transference29/ Ar ) 9/ *;
$5 Pulsed transference
2*arbon and lo& alloy steels5
8nfluence of /*;$onarc transference
f) Quality and
defectsg) Weldability
h) Design
4. Resistancewelding
RSW RSEW
HFRW
5. Economy
6. Brazing(soldadurafuerte)
7. Soldering(soldadurablanda)
8. Adhesive
bonding
8nfluence of gases on
penetration
-
7/25/2019 Diapositivas Procesos Union Part 2
24/24
ELECTRON BEAM WELDING (EBW) / LASER BEAN WELDING (LBW)
1. Introduction
2. Oxifuel gaswelding
3. Arc welding.a) Non
consumableelectrode.
GTAW
PAW AHW
b) Consumable
electrode.
SMAW SAW
GMAW FCAW
EGW
ESWc) Electrodes
d) Gases
e) Others: EBW
f) Quality and
defectsg) Weldability
h) Design
4. Resistancewelding
RSW RSEW
HFRW
5. Economy
6. Brazing(soldadurafuerte)
7. Soldering(soldadurablanda)
8. Adhesive
bonding
EBW or LBW MGAW or GTAW