1

dec. 2005 1 / 27 Traian CICONE

PERMANENT JOINTS
Riveting - Nituire
Brazing - Brazare
Soldering - Lipire
Bonding (with adhesives) - Incleiere
Welding
Sudare
dec. 2005 2 / 27 Traian CICONE
filler
parental (base)
material
thermally influenced base material
(structurally modified)
inter-diffusion and alloying
WELDING
.
Structural modifications during welding Reduced mechanical properties of
the welded seam in respect with base material
High residual stresses and deformations are induced due to local heating
Thermal or thermo-mechanical stress relieving treatment is recommended
2
dec. 2005 3 / 27 Traian CICONE
WELDING-Methods of welding
electric-arc welding
Shielded Metal Arc Welding (SMAW)
Gas Metal Arc Welding (GMAW)
Gas Tungsten Arc Welding (GTAW)
Flux-Cored Arc Welding (FCAW)
Submerged Arc Welding (SAW)
gas welding (oxyacetylene or hydrogen flame)
resistance welding (percussion welding, resistance spot welding)
thermit welding (superheated liquid metal from a chemical reaction )
NON FUSION (friction welding, ultrasonic welding, etc)
other (plasma arc welding, laser beam welding, induction welding, etc)
F
U
S
I
O
N
dec. 2005 4 / 27 Traian CICONE
C
e
< 0.5%
WELDING - Weldability
15 5 6
Cu Ni V Mo Cr Mn
C C
e
+
+
+ +
+ + =
Composition
Material
Thickness 1 mm < g < 30 mm
Carbon steel - the best
Cast iron - pre-heated & special electrodes
Aluminum - MIG (inert gas) & ultrasonic heating
3
dec. 2005 5 / 27 Traian CICONE
Material
Arc
Welding
Oxy-
acetylenic
Welding
Electron
Beam
Welding
Resistance
Welding
Brazing Soldering
Adhesive
Bonding
Cast iron 7 9 1 1 3 1 7
Carbon steel & low-alloy
steel
10 10 7 10 10 3 7
Stainless steel 10 7 7 10 10 5 7
Aluminum 7 7 7 7 7 1 10
Magnesium 7 7 7 7 7 1 10
Copper & Copper alloys 7 7 7 7 10 10 7
Nickel & Nickel alloys 10 7 7 10 10 5 7
Titanium 7 1 7 7 3 1 7
Lead 7 7 1 3 1 10 10
Zinc 7 7 1 3 1 7 10
Thermoplastics 10
*
10
**
1 7
***
1 1 7
Thermosets 1 1 1 1 1 1 7
Elastomers 1 1 1 1 1 1 10
Ceramics 1 1 7 1 1 1 10
Dissimilar metals 3 3 7 3 3 - 7 N/A 10
Note: 10 = Excellent, 5 = Fair, 1 = Seldom/never used. * : Heated tool; ** : Hot gas; *** : Induction.
Weldability and Joinability of Common Materials
dec. 2005 6 / 27 Traian CICONE
flexibility (combine simple shapes into very complicated structures
economy of materials & labor
adaptability to automatization
sealing capacity
uniform force flow (reduced stress concentration)
WELDING - Characterisation
Advantages
residual stresses and thermal deformations
requires positioning devices
operator ability is important
requires costly control procedures (X-rays, ultrasonic tests, etc)
Shortcomings
4
dec. 2005 7 / 27 Traian CICONE
butt
edge
corner
lap
Tee
WELDING-Classification
relative position of the welded parts shape of the seam
fillet weld
square weld
V-groove weld
dec. 2005 8 / 27 Traian CICONE
WELDING-Nomenclature
Root
Fusion zone
(Filler penetration)
Theoretical
throat
Face
Actual
throat
Size of weld
(Leg)
Toe
Toe
Fillet weld
Original
surface
Toe Toe
Face
Fusion zone
(Filler penetration)
Root Root
Root penetration
Size of weld
(Leg)
Square weld
5
dec. 2005 9 / 27 Traian CICONE
WELDING-STRENGTH calculation
Welded seams should be always considered critical sections
Residual stresses are neglected
Cross section of the welded seam effective height and effective length.
a
eff
2 = l l
Stress calculation has a conventional character
( )
2
//
2 2
+ + =
e
=12.5 compound stresses
Permissible stress calculated on the basis of the strength of parental materials
a as
k k
1 0
=
k
0
= 0.751
GENERAL PRINCIPLES
dec. 2005 10 / 27 Traian CICONE
WELDING-STRENGTH calculation
Butt welds
s
b
case A. Traction F
as
eff
s
s
F
< =
l
s
eff
2 = l l
case B. bending M
b
as
eff
b
s
s
M
< =
2
6
l
case C. traction +bending F+M
b
as
eff
b
eff
s
s
M
s
F
< + =
2
6
l
l
F F
F F
M
b
M
b
a=s
6
dec. 2005 11 / 27 Traian CICONE
F F
b
b)

WELDING-STRENGTH calculation
Butt welds
eff
s
F
l
//
//
=
as
eff
s
s
F
< =

l
s
b
eff
2
sin
=

l
sin F F =

cos
//
F F =
( )
2
//
2 2
+ + =
e
compound stresses
F
//
F

a=s
dec. 2005 12 / 27 Traian CICONE
WELDING-STRENGTH calculation
Transverse lap weld
F F
b
s
F
F
a
case A. Traction F
2
2
2 1
F F F = =
eff
1
a
F
l 2
=

eff
2
a
F
l 2
=
a b
eff
2 = l
s a
2
2
=
eff
e
a
F
l 2
2 2
= + =


as
eff
s
a
F
< =
l 2
conventional calculation
F
1
F
2
a=0.707s
7
dec. 2005 13 / 27 Traian CICONE
case B. bending M
b
Transverse lap weld
b
s
a
WELDING-STRENGTH calculation
conventional shear stress
as
eff
b
s
a
M
< =
2
2
6
l
case C. traction +bending F+M
b
as
eff
b
eff
s
s
M
s
F
< + =
2
3
2
l
l
F F
F
F
M
b
M
b
a=0.707s
a b
eff
2 = l
dec. 2005 14 / 27 Traian CICONE
WELDING-STRENGTH calculation
Parallel lap weld
case A. Traction F
F F
b


m ma ax x
a
s
l
as
eff
a
F
=
l 2
//
a
eff
2 = l l s a 707 . 0 =
F
F
F
F
8
dec. 2005 15 / 27 Traian CICONE
WELDING-STRENGTH calculation
Parallel lap weld

b
a
s
( )
as
eff
b
s
a s b
M
<
+
=
l
case B. bending M
b
case C. traction +bending F+M
b
( )
as
eff
b
eff
s
a s b
M
a
F

+
+ =
l l 2
M
b
M
b
T
T
T
T

max max uniform stress distribution
dec. 2005 16 / 27 Traian CICONE
WELDING-STRENGTH calculation
Parallel lap weld
F
F
b+s
s
a
e
2

e
1

b F
s
e
F T
s
e
F T
+
=
+
=
l l
1
2
2
1
;

=
= +
2 2 1 1
2 1
e T e T
F T T
T
1
T
2
9
dec. 2005 17 / 27 Traian CICONE
WELDING-STRENGTH calculation
Tee lap weld
b) double bevel
groove joint
a) double fillet joint
F
s
a
s
F
calculation identical with
that of transverse lap weld
calculation identical with
that of a butt weld
dec. 2005 18 / 27 Traian CICONE
WELDING-STRENGTH calculation
Fillet weld subjected to torsion
s
a
M
t
d
F
t
( )
( )
as
t
s
a d
d a d
M

<
+
+
=
2
2
16
4 4
Version 1
as
m
t
s
a d
M

< =
2
2
Version 2
a d d
m
707 . 0 + =
10
dec. 2005 19 / 27 Traian CICONE
WELDING-Design recommendations
2. Long and thin seams are
preferred to short and thick ones
1. Ensure the accessibility of the
electrode or other welding
devices to the weld seam
electrodes
45
2l
a
l
2a
V=la
2
V=2la
2

dec. 2005 20 / 27 Traian CICONE
WELDING-Design recommendations
3. Design simplicity can save much
welding and assembly time
11
dec. 2005 21 / 27 Traian CICONE
WELDING-Design recommendations
4. Design sections for circular or straight
seams to permit automatic welding
5. For better flow force - taper zone near
the seam is recommended
dec. 2005 22 / 27 Traian CICONE
WELDING-Design recommendations
6. Accurate machining should be always done after the welding and
eventually a stress release thermo-mechanical treatment
7. Do not design weld seams where other stress concentrators already exist
Reduce the length of weld seams
12
dec. 2005 23 / 27 Traian CICONE
8. Avoid the intersection of the seams
1
2
4
5 3
6 7
8 9
1
2
3 4 5
6 7
8 9
10 11 11 10
WELDING-Design recommendations
dec. 2005 24 / 27 Traian CICONE
BRAZING & SOLDERING
Temperatures are always below the melting point of the base materials
FILLER (braze or solder) differs completely from the base material
Soldering is similar to brazing except that the filler metal has a melting
temperature below 450C and has relatively low strength.
Brazing is a group of processes in which materials are joined by
heating to a suitable temperature and by using a filler metal with
a melting point above 450C, but below that of the base metal.
brazing alloys are based on tin, lead, silver, etc
tin-lead alloys
alloys including antimony, zinc and aluminum
13
dec. 2005 25 / 27 Traian CICONE
BRAZING & SOLDERING
Dissimilar metals, cast and wrought metals, can be joined
Assemblies can be joined (brazed or soldered) in a stress-free condition
Materials of different thicknesses can be joined
As temperature is lower, metallurgical properties of base materials are not seriously
disturbed
Joints require little or no finishing
Advantages
The joint may be less resistant to mechanical and heat loading than the base material
Filler materials are usually expensive
The need for initially clean surfaces
Shortcomings
dec. 2005 26 / 27 Traian CICONE
BRAZING & SOLDERING
14
dec. 2005 27 / 27 Traian CICONE
BRAZING & SOLDERING