Non-Arc Welding Processes

Submitted By: M. Bilal Awan

Submitted to: Sir Amjad Ahmed Shah

Roll Number: 02

7th Semester Mechanical

Non-Arc Welding Processes

Resistive heating, chemical reactions, focused light and electrons, sound waves, and friction can also be used to join materials Resistance welding Oxy-Fuel Welding Solid State Laser and electron beam welding Brazing and soldering Plastics joining Adhesive bonding Solid state welds are those welding processes where consummation of the weld is cause under pressure with no heating or heating that is below the melting point of the materials being welded. Solid state welding includes, but is not limited to, using friction and sound as a means of joining. A friction weld occurs when two pieces are brought together under pressure and rotated very rapidly relative to each other. The heat produced when the two pieces come into contact brings the materials up to a welding temperature just lower than the materials melting point. The materials become plastic and are welded together by pressure and diffusion.

Solid-State Welding
Processes that produce a weld through the application of pressure at a temperature below the melting temperature of the base material; no filler metal is used Friction welding Diffusion welding Ultrasonic welding Explosion welding

Solid state welds are those welding processes where consummation of the weld is cause under pressure with no heating or heating that is below the melting point of the materials being welded. Solid state welding includes, but is not limited to, using friction and sound as a means of joining. A friction weld occurs when two pieces are brought together under pressure and rotated very rapidly relative to each other. The heat produced when the two pieces come into contact brings the materials up to a welding temperature just lower than the materials melting point. The materials become plastic and are welded together by pressure and diffusion. Friction Welding (FRW)

Friction welding:
It is a process which produces a weld under a compression force. The workpieces are brought into contact and rotated very rapidly to produce heat. Usually one piece is rotated against a stationary piece to produce the heat at the junction. Geometries that have a rotational symmetry are particularly suitable for friction welding. These can include round bars and tubes, as well as bars-sheet and tube-sheet Applications: Linear friction welding is used for parts with non-rotational symmetry. In this application, one part is oscillated back and forth against the other.

Friction Welding - Advantages

For correct part geometry, friction welding is faster than most other processes Can join dissimilar materials together Copper to steel or aluminum Easily automated for high volume production Can join plastics Friction welding requires part geometries with rotational symmetry. The speed of the process,. as well as its ease of automation, promotes high volume production. The joining of dissimilar metals can often be accomplished by the friction process, despite that fact that the metals cannot be joined by conventional fusion processes. For example, copper and steel cannot be joined by arc welding. The two materials are incompatible when melted together. A friction weld between the two metals, however, results in a strong bond. The process is not limited to metals. Indeed, friction welding is a major method for the joining of plastics. Friction welding requires part geometries with rotational symmetry. The speed of the process,. as well as its ease of automation, promotes high volume production. The process is not limited to metals. Indeed, friction welding is a major method for the joining of plastics.

Limitations of Friction Welding

Start-up cost is high Parts must be able to rotate about an axis of symmetry Free machining alloys are difficult to weld Non-forgeable materials cannot be friction welded Despite its advantages of speed and range of materials, the friction welding process has its limitations. As has been mentioned, the parts must be able to rotate on an axis of symmetry. Although linear friction welding is an option, the equipment and fixturing is more expensive. Non-forgeable metals cannot be friction welded. These materials tend to crumble upon the application of heat and pressure. Also, free-machining alloys are often difficult to weld. The inclusion content, which promotes chip formation during cutting, leads to difficulties as the parts are spun and forged together.

Diffusion Welding Working Principles

1st stage
Deformation forming interfacial boundary.

2nd stage
Grain boundary migration and pore elimination.

3rd stage
Volume diffusion and pore elimination.

Diffusion welding is another solid state bonding process. Two necessary conditions must be met before a satisfactory diffusion weld can be made. They are: Mechanical intimacy of the faying surfaces. Disruption and dispersion of surface contaminants Stage 1 involves deformation of asperities. This deformation may be temperature and time dependent, similar to creep.

Stage 2 includes boundary migration, recrystallization, and pore size reduction. Stage 3 involves bulk diffusion phenomenon including oxide and contaminant
dissolution, and further pore size reduction.

When the atoms from one sided of the joint diffuse into the other side, the composition changes in both sides of the joint as illustrated here since atoms from both sides interdiffuse into the other side. If the material is the same on both sides, a symmetric interdiffusion curve such as illustrated here results because the diffusion coefficient is the same on both sides. But when different materials are welded together, each having their won diffusion coefficient (diffusion rate) into the other material, some very different compositions curves can result.

This is an illustration of a typical diffusion bonding furnace. In this case the heating is supplied by electric resistance coils. The chamber is usually evacuated and then backfilled with inert shielding gas.

Ultrasonic Welding Process

Process Description: Components of ultrasonic welding system include: Transducer Sonotrode Anvil The ultrasonic welding process is a solid state welding process in which coalescence is produced at the faying surfaces by the application of high frequency vibratory energy while the work pieces are held together under moderately low static pressure. Linear ultrasonic vibrations are generated in the transducer and transferred to a sonotrode. The anvil holds the components in a fixed position and supports the clamping force. For welding metallic materials, the vibration is a back and forth scrubbing action at 10 to 75 kilohertz frequency.

Ultrasonic Welding Advantages

Fast Can spot or seam weld Limitations Equipment complex, many variables Only use on small parts More on this below for plastics

Principles of Explosion Welding

Welding arrangement consists of three components Base component Prime component Explosive. Base component remains stationary, supported by anvil. In explosive welding, the prime component is propelled toward the base component by an explosive charge (see figure above). The base component is supported on an anvil. The explosion deforms the prime component and accelerates it across the standoff distance between the components.