Advanced Welding
Technology (ME60004)
Lecture 2- Introduction
(Part 2)
Siddharth Tamang
Assistant Professor,
MED,
IIT Kharagpur 1
Electroslag Welding
In electroslag welding, an electrode wire is fed
through an electrically conductive bath of
molten slag.
The resistance of the slag bath to the flow of
current produces heat, the bulk of which is
concentrated primarily in the slag area
immediately surrounding the tip of the
electrode.
In comparison to arc welding, the energy
density is low (typically 10 W/mm2 to 50
W/mm2) since the heat is transferred to the
base plates over a relatively large area.
Thermite welding
Thermite welding (TW)is a process that uses heat from exothermic reactions to produce
coalescence between metals. Reactions occurs between metal oxides and reducing
agents. Thermite mixtures consist of oxides with low heats of formation and metallic
reducing agents that have high heats of formation when oxidized.
If finely divided metal oxides and aluminum are blended and ignited by means of an
external heat source, the aluminothermic reaction will occur according to the following
chemical reaction:
Metal oxide + aluminum → aluminum oxide + metal + heat
3/4Fe3O4 + 2Al → 9/4Fe + Al2O3
The superheated products of a thermite reaction flow into the gap between the workpieces
with sufficient heat to melt both faces of the base metal. When the filler metal has cooled, all
unwanted excess metal is removed by oxygen cutting, machining, or grinding.
High Energy Beam Sources
Laser Beam Welding
Laser beam welding (LBW) produces coalescence with the heat from a laser beam impinging on
the joint. Filler metal occasionally may be used, but the process is primarily used autogenously.
Laser welding is an ideal process when high welding productivity, versatility in joint
configuration and automation is a priority .
the laser beam is focused by various
arrangements of lenses and mirrors.
Due to the small focal spot sizes that can be
obtained, high power densities can be produced.
The high power cause the intense evaporation of
metal and a keyhole in the workpiece through
which the beam can penetrate.
The molten metal flows from the front to the rear
of the keyhole, where it solidifies to form a weld
with a very high ratio of depth to width.
Electron beam welding
Electron beam welding (EBW) is similar to laser welding except that electrostatic and magnetic
lenses focus a beam of electrons.
In electron beam welding, energy is developed in the workpiece by bombarding it with a
focused beam of high-velocity electrons.
Electron beam welding is generally performed at voltages between 20 kV and 150 kV.
The depth of penetration of a focused beam is determined by the power density at the work
surface and the speed of welding.
Mainly three types
1. High vacuum EBW, the pioneering process that operates at a pressure of 0.1 pascal (Pa)
or lower;
2. Medium or soft vacuum EBW, which operates at pressures of 10.0 Pa; and
3. Nonvacuum EBW, which operates at l00 kilopascal (kPa).
high depth-to-width ratio; high strength; ability to weld thick sections in a single pass; low
distortion, and a narrow heat-affected zone.
Friction Welding
In friction welding (FRW), a
bond is created between
a stationary workpiece and a
rotating workpiece by
generating frictional heat
between them while they
are subjected to high
compressive forces on the
contacting surfaces.
Schematic Illustration
of Friction Welding Friction Stir Welding
Explosion Welding
• In explosion welding , the detonation of an
explosive is utilized to accelerate the flyer
plate to a high velocity as it collides with a
stationary component.
• At the moment of impact, the kinetic energy
of the flyer plate is released as a
compressive stress wave on the surfaces of
the two components.
• During explosive welding, the collision
progresses across the surface of the plates
being welded, forming an angle between the
two colliding components.
• The compressive interatomic and
intermolecular forces create a bond.
• The result of this process is a weld without a
heat-affected zone.
Ultrasonic Welding
• Ultrasonic welds are produced by introducing high-
frequency vibratory energy into the weld zone of the
metals to be joined.
• The workpieces are clamped together between two tips or
jaws, and the vibratory energy is transmitted through one
or both sonotrode tips that oscillate in a plane essentially
parallel to the weld interface.
• The elastic and plastic deformations induce a very localized,
transient temperature rise at the weld interface.
• Under the proper conditions of clamping force and
vibratory power, the temperatures reached are typically in
the range of 35% to 50% of the absolute melting point of
the metals being joined.
• A light clamping force applies pressure through the reed to
the sonotrode tip. The transducer is wedge-shaped where
it attaches to the reed. It produces a high-frequency power,
generally within the range of 15 000 Hz to 75 000 Hz.
Diffusion Welding