UNIT-II

Metal Joining
Processes
and Equipment
 Metal joining
Joining is an all-inclusive term covering processes
such as welding, brazing, soldering, adhesive
bonding, and mechanical fastening.
Welding is a materials joining process which
produces coalescence of materials by heating
them to suitable temperatures with or without the
application of pressure or by the application of
pressure alone, and with or without the use of filler
material
 Classification of welding processes:
(i). Arc welding
Carbon arc (iv)Thermit Welding
Metal arc (v)Solid State Welding
Metal inert gas Friction
Tungsten inert gas Ultrasonic
Plasma arc Diffusion
Submerged arc Explosive
Electro-slag (vi)Newer Welding
(ii). Gas Welding Electron-beam
Oxy-acetylene Laser
Air-acetylene (vii)Related Process
Oxy-hydrogen Oxy-acetylene cutting
(iii). Resistance Welding Arc cutting
Butt Hard facing
Brazing
Spot
Soldering
Seam
Projection
Percussion
 Fusion-Welding
Processes
Fusion welding is defined as melting together and
coalescing materials by means of heat. Filler metals,
which are metals added to the weld area during
welding, also may be used.
Fusion welds made without the use of filler metals
are known as autogenous welds
 Oxyfuel-gas Welding
Oxyfuel-gas welding (OFW) is a general term used
to describe any welding process that uses a fuel
gas combined with oxygen to produce a flame.
The flame is the source of the heat that is used to
melt the metals at the joint.
The most common gas welding process uses
acetylene; the process is known as oxyacetylene-
gas welding.
Used for structural metal fabrication and repair
work.
 GAS WELDING EQUIPMENT...
1. Gas Cylinders
Pressure
Oxygen 125 kg/cm2
Acetylene 16 kg/cm2
2. Regulators
Working pressure of oxygen 1 kg/cm2
Working pressure of acetylene 0.15 kg/cm2
Working pressure varies depends upon the thickness of
the work pieces welded.
3. Pressure Gauges
4. Hoses
5. Welding torch
6. Check valve
7. Non return valve
Oxy-Acetylene welding
 Generation of Heat
The primary combustion process, which occurs in the inner
core of the flame involves the following reaction:
C2H2 + o2 -> 2co + H2 + Heat.

This reaction dissociates the acetylene into carbon monoxide

and hydrogen and produces about one-third of the total heat
generated in the flame.

The secondary combustion process is

2co + H2 + 1.502 -> 2co2 + H2O + Heat.
This reaction consists of the further burning of both the
hydrogen and the carbon monoxide and produces about
two-thirds of the total heat.
Note that the reaction also produces water vapor. The
temperatures developed in the flame can reach 3300C.
Types of Flames
 Types of Flames
The proportion of gas mixture is an important factor.

At a acetylene and oxygen in ratio of 1:1 (i.e., when there is no

excess oxygen), the flame is considered to be neutral .

With a greater oxygen supply, the flame can be harmful

(especially for steels), because it oxidizes the metal.

Only suitable for welding of copper and copper-based alloys.

If the oxygen is insufficient for full combustion, the flame is

known as a reducing, or carburizing, flame (a flame having
excess acetylene.

The temperature of a reducing flame is lower; hence, such a

flame is suitable for applications requiring low heat, such as
brazing, soldering, and flame-hardening operations.
 Types of Flames
Other fuel gases (such as hydrogen and
methylacetylene propadiene) also can be used in
oxyfuel-gas welding.

Hence, they are used for welding (a) metals with

low melting points (such as lead) and (b) parts that
are thin and small.

The flame with pure hydrogen gas is colorless;

therefore, it is difficult to adjust the flame by
eyesight
Advantages of gas welding
1. There is no need sophisticated and expensive equipment and
an additional source of electricity.

2. It can be very widely varied power flame welding metals with

different melting points.

3. Iron, copper, lead and brass better than welded using gas
welding.

4. With the right choice of the brand of the filler wire, the power
and the type of fire, produce high-quality welds.

5. Slow heating and cooling of the welded surfaces.

6. Welder can easily vary the temperature of the flame.

7. The strength obtained when gas welding seams may be

greater than in arc welding using low-quality electrodes.

8. Gas welding allows welding, cutting and tempering metals.

 Disadvantages of gas welding
1. Large heating zone.
2. With a thickness falling productivity. Welding thickness greater
than 5 mm is disadvantageous. In these cases, apply arc welding.
3. When connecting overlapping metal thickness greater than 3
mm to apply gas welding are not recommended because there
is tension in the metal, which can lead to deformation and
destruction of adhesions.
4. When gas welding are fairly dangerous substances with
atmospheric oxygen yielding explosive mixture (hydrogen,
acetylene, etc.) Gas cylinders used in welding should be
removed as much as possible from organic substances (fats, oils,
hydrocarbons). Ignoring the safety instructions can lead to fires
and explosions.
5. Slow heating and cooling of the welded surfaces.
6. Almost defies mechanization, unlike arc welding.
7. When gas welding it is impossible to dope the deposited metal.
At the same time, the quality of welds produced arc welding is
very dependent on the applied electrodes and a special wash.
8. High carbon steel is not recommended to be welded using gas
welding.
 Arc welding
Equipments:
A welding generator (D.C.) or Transformer (A.C.)
Two cables- one for work and one for electrode
Electrode holder
Electrode
Protective shield
Gloves
Wire brush
Chipping hammer
Goggles
Arc Welding Equipments
Metal arc welding
 ADVANTAGES
1) Higher welding speeds
2) Greater affidavit rates
3) Less post welding cleaning
4) Better weld pool perceivability
5) No stub end misfortunes or squandered worker
hours brought on by changing terminals
6) Positional welding offers no issues when
contrasted with different procedures.
7) The procedure is effortlessly robotized
8) No fluxes required by and large
9) Ultra low hydrogen process
 DISADVANTAGES
1) Higher introductory setup cost
2) Higher upkeep costs because of additional
electronic parts
3) The setting of plant variables requires a high
aptitude level
4) Less productive where high obligation cycle
prerequisites are vital
5) Radiation impacts are more extreme