Assignment II

Department of Mechanical and Manufacturing Engineering

Faculty of Engineering

EMM5702
ADVANCED MANUFACTURING TECHNOLOGY
AND PROCESS
Lecturer: Professor Dr. Shamsuddin B. Sulaiman

Name:

INDIVIDUAL ASSIGNM

1) Mariyam Jameelah binti Bahari

2) Nor Suhada binti Abdullah

Matrik No.
GS36904
GS37775

A REVIEW OF ADVANCED WELDING TECHNOLOGY

Mariyam Jameelah 1,a, Nor Suhada2,b
1,2

Department of Mechanical and Manufacturing Engineering,

Faculty of Engineering, University Putra Malaysia
a
mariyam.jameelah84@gmail.com, b sueada6080@gmail.com,

1.

ABSTRACT

In this review we discussed on advanced welding technology used nowadays. The

discussion is tailored to the importance of welding, classification of welding process and
also selection of welding process. Process of fusion welding and pressure welding have
been discussed in this paper. Conventional welding process such as Gas Metal Arc
welding, Tungsten arc welding, Resistance welding and friction welding are briefly
explained. Advanced in welding technique also been justified such as plasma arc
welding, laser beam welding, electron beam welding and ultrasonic welding. Main
objective for welding process development were determined such as need to improve the
total cost effectiveness, concerning over the safety and welding environment and also
potential shortage of skilled technician and operators. Advantages and disadvantages of
advanced welding also been explained through others researcher paper and writing.

2.

INTRODUCTION

Welding and joining are importance for the manufacturer of a range of engineering
components, which involve in a very large structure from ships, bridges to a very
complex structure such as aircraft engines or miniature components until microelectronics applications. Joining is an all inclusive term covering processes welding such
as welding, brazing, soldering, adhesive bonding and mechanical fastening. These
processes are essential aspect of manufacturing and assembly operating for example, a
product such as cooking pot with a handle, is easier and more economical to
manufacturer as individual component, which are then assembled.
There are three major categories of joining processes. There are mechanical fastening,
adhesive bonding and welding. Mechanical fastening involves traditional methods of
using various fasteners, such as bolts nuts, and rivets. Meanwhile, adhesive bonding is a
unique application requiring strength, sealing, thermal and electrical insulating, vibration
damping, and resistance to corrosion between dissimilar metals. In welding, it consists of
fusion welding, brazing and soldering and also solid state [1].
The main objective for welding process development is the need to improve the total cost
effectiveness of joining operations in fabrications and manufacturing industry. Another
factor is concerning over the safety and welding environment. Potential shortage of

skilled technician and operators in many countries also influence the requirement for
research considerations,
According to John Norrish in his study, the cost of producing a welded joint is the sum of
costs associated with labor, material, and power and decreasing of capital plant. The total
cost of welding operation in western economies is largely covered by the cost of labor.
This can account up to 70% to 80% of the total [4]. Cost effectiveness of welding process
was totally depending on deposition rate. The higher the deposition rate, the shorter the
weld cycle time and the lower the labor cost. Deposition rate give a misleading indication
of cost effectiveness.
For safety issue, normally the operators are protective by a clothing, local screening and
ventilations. One of the main objectives of welding process development is to improve
the working environment or remove the operator from the hazardous. High levels of
operator skill also required in traditional welding process. This may involve costly
training program. Thus, the newer processes can offer some reduction in the skill
requirement by replacing more complex equipment. Therefore, the cost of training will be
recovered very quickly in productivity and quality improvement.

3.
3.1

BACKGROUND
Conventional welding processes

There are many different welding processes have been developed, to be simplified it be
classified in two group. There are fusion and pressure welding, refer Fig.1. Fusion
welding is defined as melting together and coalescing material by means of heat [1].
Filler metals were added to the weld area during welding.
Gas welding is grouped under fusion welding. The most important process in gas welding
is oxygen-acetylene welding. It can be used for joining a variety metals. The liquid air
boiled and when nitrogen and argon escape, pure liquid oxygen is left. The gas is
compressed in cylinder at pressure of 15MPa. It can be used with most ferrous and
nonferrous metals for almost any workpiece thickness.
Gas Metal Arc welding (GMAW) is a chosen process which is higher productivity and
good in quality. It been developed in mid-1800s that included heating, melting and
solidification of metals and filler material in restricted fusion zone by transient heat
source to form a joint between the parents metals [3]. Welding parameters influenced the
quality, productivity and cost welding joint. Welding parameter such as arc welding
current, arc voltage, welding speed, torch angle, free wire length, nozzle distance,
welding position, and direction should be conform to achieved a perfect arc.

Fig. 1: Welding processes [4].

Another fusion welding process is shielded metal-arc welding (SMAW) which is one of
the oldest, simplest, and most versatile joining processes. The electrical are generated by
touching the tip of a coated electrode against the workpiece and withdrawing it quickly to
a distance sufficient to maintain the arc. SMAW is commonly used in general
construction, shipbuilding, pipeline and maintenance work because of it portable fuelpowered generator that can easily be used in remote area.
Tungsten arc welding (TIG) is one of the processes that grouped under fusion welding.
Non-consumable tungsten rod is used as the electrode with inert gases shielding such as
argon or helium. Dissimilar metals also can be welded by TIG for highest quality welds.
TIG is popular for welding aluminum and stainless steel pipe. It is more precise because
of the arc heat and filler metal additions are controlled independently. However, the
process is slow [8].
Welding with pressure also been classified under solid-state welding process. These
include resistance welding, friction welding, diffusion bonding, cold pressure and many
more process. Resistance welding is a process in which the heat required for welding
produced by means of electrical resistance across the two components to be joined. The
advantage of resistance welding is high quality weld and can be produced quickly. It also
often applied using robots welding [9].
Friction welding also grouped under pressure welding. It can used to join a wide variety
of materials for example rotational symmetry of components. In friction welding, the heat
required for welding is generated through friction at the interface of the two components
being joined [10].

4.
4.1

ADVANCED WELDING TECHNIQUES

Principle and application of advanced welding techniques

Several of advanced welding techniques have been introduced to ease conventional

welding process. This section will briefly explained the principle application of advanced
welding technique such as plasma arc welding, laser beam welding, electron beam
welding and ultrasonic welding.
Plasma arc welding (PAW) is a process that is similar to TIG welding. PAW has been
developed to increase productivity by using TIG concept. It is closely resembles TIG
welding process by using non-consumable tungsten electrode and shielding gas as argon
[15]. PAW able to fast welding speed and high efficiency compared to GTAW. PAW
also increases electrode service life that last for entire production shift without needed to
be reground. PAW also offers a large tolerance to joints gaps.

Fig 2: Schematic of keyhole plasma arc welding [6].

Laser beam welding (LBW) has become widely used in industries because of it good
quality of welding produced with minimal shrinkage. By utilizing a high-power laser
beam heat to produce a fusion weld. Laser beam can be shaped, manipulated and focused
optically on the workpiece. The laser spot diameter can be as small as 0.2mm precisely.
Material such as aluminum, ferrous metals, copper, and titanium can be welded. Usage of
laser welding has eliminated the need of direct tool contact with workpiece due to narrow
straight line of sight free of obstruction [11]. Modern welding of the nickel super alloy
with fiber laser beam has been developed to improve efficiency and clean welding
compare to laser beam welding.
Compared to LBW, electron beam welding (EBW) can welded almost any metal and
workpiece thickness range from foil to plate. Capacities of electron beam guns range can
up to 100kW. Similar as LBW, EBW technique can also produced appropriate
penetration weld, low heat input, small weld and heat affected zone, improve efficiency
and clean welding [12]. Application of EBM includes welding of aircraft, nuclear,
electronic component also gear and shaft for automotive industry.

Fig 3: Parts of Fiber Laser Beam welding (FLBW), the ABB IRB 2400 6-axis
anthropomorphic robot as a positioning machine [12].
Another fasters and cost effective method of welding used today is ultrasonic welding.
Ultrasonic welding is a process by converting heat through friction that melts the plastic
or metal. It can be used to join thermoplastic, synthetic fabrics and films. Ultrasonic
welding is a green technology that can eliminate the usage of glues or any solvent. It was
first introduced in early 1950s as ultrasonic metal welding for wire bonding, tube sealing
and thin metal foils joining [13]. Ultrasonic has a capability in producing clean surface
oxides and contaminants welding. It is also able to weld large area using minimal energy
with low cost per weld.

Fig 4: Schematic diagram of an ultrasonic welding machine [14].

5.
5.1

ADVANTAGES IN WELDING TECHNIQUES

Vision system in welding process

Welding process is one of the famous joining methods. It used in various industries. One
of the welding methods used in pipe welding. A study on monitoring molten pool [15]
using the machine vision in pipe welding has been carried out. The aim is monitor the
molten pool image using machine vision as sensor during pipe welding. The vision
system captured image of the molten pool width and neural network used to simulate the
weld bead width. System of the machine vision as the sensor has reduced the welding
process complexity and also the processing time reduced. Effectiveness of the image
processing and simulation process are proven. Vision system use to obtain information on
what goes on in the environment and the process monitored at possible distances. Vision
system also can analyze the entire work environment [21]. The vision system has some
issues where the image obtain is 2D image and also the pixel resolutions of the images
obtain.

Fig 5: A robot following 3D weld joint.

Camera mounted on the robot hand [7]

Fig 6: torch for tandem welding [3]

5.2
Consumable Guide Enclosed Arc Welding (CGEAW)
New welding method has been developed by Paton Electric Welding Institute, National
Academy of Science, Ukraine. The new method called Consumable Guide Enclosed Arc
Welding (CGEAW) which use self-shielded flux cored wire that deliver through a
longitudinal slot in a specially prepared plated consumable electrode [16].
Formerly, rails joined by riveting method. As the new method introduced, it is suitable
for weld rails. An advantage of using CGEAW methods is the weld joints are extremely
high quality. Moreover, the parts joined are very stable. Other advantages are shielding
gases or fluxes are not required in this welding method and there is no preheating or heat
treatment welds. CGEAW equipments are easily adopted to weld rails in different sizes
and shapes. Joining rails using welding method has several disadvantages. Some of them
are expensive equipments of large dimension and quality of weld products depends on
the welders competence.

5.3
Arc Welding
Conventional welding methods develop to meets the needs of rapid technology expand.
Innovations of welding method is one of the way to produce better products at lower cost
and it is a challenge to any company to gives a friendly environments to the workers [17].
Both TIG and MIG has been put innovation into them.
Tandem welding is one of welding method using two electrode wires initially apply in the
submerged arc welding. During Tandem method welding, two electrodes use which
called leading electrode and following electrode which there are placed one after another.
The leading electrode placed first and followed by the following electrode. Automation
and robotize Tandem welding method will increased the speed of weld parts. However,
the speed is depends on the thickness of the welded elements and joints. Another welding
method to improve the welding productivity is TIME (Transferred Ionized Molten
Energy) welding. TIME welding is one of new variant of metal active gas welding.
5.4
Pipeline Welding
The growth in pipeline industries has drive Cranfield Universitys Welding Engineering
Research Centre develop Tandem GMAW (Gas Metal Arc Welding) techniques which
use two tandem torches on a single carriage. This technique allows high welding speed
and reduction of welding time. In a comparison of Tandem GMAW with traditional
GMAW techniques, there is 25% saving in girth welding costs. The major advantage is
the weld bevel and profile similar to conventional techniques and it can use conventional
radiography and automated ultrasonic testing to detect defects [20].
5.5
Welding Technologies for Thermoplastic Composite
Welding joining method not only for metal but also used for thermoplastics composites
which widely used in aerospace applications. A recent study [18] has identified several
welding techniques for thermoplastics composite. Thermoplastic composite structure has
become important as it can replace metallic and thermoset composite. Ultrasonic welding
able to weld two or more components depends on the material physical properties,
frequency and amplitude of ultrasonic waves and joint design. Ultrasonic welding
techniques use in many industries such as electrical, aerospace, energy, medical and
packaging. These welding techniques applied in aerospace industry as it is compatible to
joint lightweight thermoplastic matrix composite materials.
Microwave welding also used to weld thermoplastic composite. The advantage of using
microwave welding for aerospace industry is the capability to irradiate the whole
components and it can produce three dimensional joints. Less than one minute needed to
weld. However, it comes with a drawback which the homogenous material heating only
possible for simple geometries.
On the other hand, there is one more popular welding method for thermoplastic
composite. It is the hot plate welding. Hot plate welding popular as it is simple, reliable
and economical to produce strong welds joints. IR welding is one of the new techniques
in welding but it gives several advantages such as able to fast heating and it allows high
productivity rates in automated system to produce strong joints. In addition, IR welding
has a great flexibility and capable to joint large flat and curved areas.

Welding techniques has used widely and also in aerospace industries. Aeronautical
industry nature of welding is characterized by low production, high unit cost, extreme
reliability and severe operation conditions [19]. Friction welding used to joints
components with simple cross section where in aeronautics they use friction welding to
joint aluminium landing gear components. Friction Stir Welding (FSW) use to replace
others welding techniques such as plasma arc welding and electron beam welding in
special application of aluminium and titanium.
Boeing has invested in the usage of FSW to weld the booster core tanks. Flash welding
used in aeronautics as it produces strong welds as the base material and flash welding can
joint section with complicated cross section. Major used in aeronautics industries is the
Diffusion Welding because it has proven useful when combined with super plastic
forming (SPF) of titanium alloys. Application of diffusion welding reduces the original
riveted aluminium design with total cost savings around 30%

Fig 7: Schematic diagram for hot plate

welding [4]

Fig 8: Wing access panel for the airbus

A310/A320 made of titanium SPF/DFW
[5]

5.6
Issues of Intelligentized Welding Technology
Intelligence welding manufacturing technology related to the key intelligent technical
elements such as sensing welding process for imitating welders sense organ function,
knowledge extraction and modeling of welding process for imitating welders experience
reasoning function, and intelligent control of welding process for imitating welders
decision-making operation function.

Fig 9: The Key scientific and technical problem in Intelligence Welding Manufacturing
Technology [8]

6.0
CONCLUSION
Welding techniques has developed in several ways to increase productivity of the process
and also the main focus is to reduce cost. In addition welding techniques nowadays is not
limited for metal materials only but also can be used to weld thermoplastic composite.
Start from the simple welding techniques until up to the complicated techniques, it is
widely used and utilize to obtain maximum benefits. In future, welding techniques will
develop to meets the industries needs like aeronautic industries which preferred welding
techniques than the riveting techniques. The same concept can be seen in pipeline
industries which some techniques developed to meet the requirements such as curved
parts and complex joints.

8.

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