Manufacturing Processes /Unit - II/ Joining Processes

UNIT II
JOINING PROCESSES
Operating principle, basic equipment, merits and applications of Fusion
welding processes: Gas welding - Types Flame characteristics; Manual metal
arc welding- Gas Tungsten arc welding- Gas metal arc welding- Submerged
are welding- Electro slag welding: Operating principle and applications of:
Resistance welding - Plasma are welding – Thermit welding- Electron beam
welding, Friction welding and Friction Stir Welding: Brazing and soldering;
Weld defects: types, causes and cure. Case studies on welding in marine.

Introduction
 Welding is the process of joining two or more metals by application of heat. Welding is
used for making permanent joints. In order to join two or more pieces of metal together
by welding process the most essential requirement is Heat. Pressure may also be
employed. It is used in the manufacture of automobile bodies, aircraft frames, railway
wagons, machine frames, structural works, tanks, furniture, boilers, general repair work
and ship building
two groups of welding processes according to the state of the base material during the welding
process:
 Fusion welding or Non pressure welding
(Liquid-state welding)
 Pressure welding or plastic welding
(Solid-state welding)
In the Fusion welding, the material at the joint is heated to a molten state and allowed to
solidify. Since no pressure is applied in this process, it is also known as Non pressure welding.
Addition of filler material may be required for fusion welding. This Includes Gas welding, Arc
welding, Thermit welding, etc.

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 Manufacturing Processes /Unit - II/ Joining Processes
In the pressure welding, the pieces of metal to be joined are heated to a plastic state and then
forced together by external pressure. In this welding, two parts are jointed together under
pressure or a combination of pressure and heat. If heat is applied, the contact temperature is
below the melting point of the base metal. No filler material is required in pressure welding.
 Ex: Resistance welding – Butt welding, Spot welding, Seam welding, Projection welding falls
under this category.
Electric Arc Welding

The main parts

Welding Machine (Power Supply):
 Electric or Power is supplying from Direct Board to Welding Machine to Electrode cable
to Electrode Holder.
Cable
 The main function is to deliver the current to the electrode holder from the machine.
Holder
 The function is to hold the Electrode.
Electrode
 This electrode creates a spark when contacting the work.
Hand Gloves
 While performing welding operation safety comes first so for the hand we use here Hand
gloves.

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Goggles
 As the welding operation temperature is too high we can see the operation with the naked
eye but after some time the eye gets damaged. The eye can not sustain with high
temperature therefore here we use Goggles.
Aprons
 Aprons are like clothes. We wear this for safety purposes.
Chipping Hammers
 This instrument is for holding the work piece whenever required.
Wire Brush
 To remove unwanted material from the welded work piece that is slag we use a wire
brush.
Arc Welding Working Principle
The process of electric arc welding is based on the principle that, when electric current is passed
through an air gap from one electric conductor to another, then an electric arc is produced which
generates a very intense and concentrated heat.
Working
 First of all, metal pieces to be weld are thoroughly cleaned to remove the dust, dirt, grease,
oil, etc. Then the work piece should be firmly held in suitable fixtures. Insert a suitable
electrode in the electrode holder at an angle of 60 to 80° with the work piece.
 Select the proper current and polarity. The spot are marked by the arc at the places where
welding is to be done. The welding is done by making contact of the electrode with the work
and then separating the electrode to a proper distance to produce an arc.
 When the arc is obtained, intense heat so produced, melts the work below the arc, and
forming a molten metal pool. A small depression is formed in the work and the molten metal
is deposited around the edge of this depression. Then the joint has cooled. After welding is
over, the electrode holder should be taken out quickly to break the arc and the supply of
current is switched off.
Arc Welding Advantages
 The process gives high deposition rates.
 Welding speed is high.
 Wire consumption is low.

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 The consumption of electrical energy is low, as a maximum of 97 % of heat energy can
be utilized.
 Any length can be welded without any interruption.
 High-quality Welds are achieved with no fusion defects, no porosity and slag inclusions.
Arc Welding Disadvantages
 High skilled operator required to perform an operation.
 Arc is invisible, it can be controlled only by measuring arc voltage and current.
 It can be used only in the down hand welding position.
Arc Welding Application
 The application of Arc welding in the various department like:
 Industries Construction
 Shipbuilding
 Farm equipment
 Lawn and Garden
 Highway Equipment
 Institutional Equipment
 Railways Department
Tungsten Inert Gas Welding (TIG)
In this process a non-consumable tungsten electrode is used with an envelope of inert shielding
gas around it. The shielding gas protects the tungsten electrode and the molten metal weld pool
from the atmospheric contamination. The shielding gases generally used are argon, helium or
their mixtures. Typical tungsten inert gas welding setup is shown in Fig.
Components of Tungsten Inert Gas Welding
 Power Supply
 Inert Gas Supply
 Welding Torch/Holder
 Tungsten Electrode
 Shielding Gas
 Filler Rod

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Power Supply:
In TIG welding we need a constant power supply because if there was a fluctuation of current
then it is hard for the welder to weld the joints properly.
Inert Gas Supply:
In TIG Welding, we need an inert gas supply to provide the shielding to the weld area from the
atmospheric gas (For example, Oxygen, Nitrogen, and Hydrogen).
Welding Torch:
In TIG Welding the welding torch is designed to do either automatic and manual operations.
However, in terms of construction, both are the same, in the manual torch, they are provided with
a handle to hold, and in case of automatic, they are designed to mount on an automatic machine.
Torches are provided with a cooling system either by water or air.
Tungsten Electrode:
In TIG Welding we use a non-consumable electrode made of Tungsten or Tungsten Alloy. Due
to High-temperature resisting capacity (Melting Temp of Tungsten is 3,422 °C ) of tungsten
rather than any other metal, that’s why we use the tungsten electrode. The diameter of the
electrode is generally varies from 0.5 mm to 0.65 mm, and the length varies between 75 mm to
610 mm.
Shielding Gas:
Shielding gases are used to protect the welding pool from atmospheric gases like nitrogen,
oxygen otherwise these gases can damage the welding surface by creating porosity, blowhole,
etc.

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Filler Rod:
As we already know, in TIG Welding, we use a non-consumable electrode that is Tungsten, so in
some cases, we need separate material to fill up the gap between two joints. The material of the
filler rod can be anything, like carbon steel, aluminum, etc. It generally depends on the type of
joints, the work-piece material, thickness and also the properties of the work piece.
Working of Tungsten Inert Gas Welding:
When we switch on the machine the high-frequency generator provides an electric spark. The
electric spark is struck between the Workpiece and the Electrode either by touching electrode by
scrap material or by using a high-frequency unit. We need to do this operation (Touching with
the scrap material) at least 2-3 times to warm up the electrode before the actual operation started.
Due to this, we can save the breaking of the electrode tip.
In actual operation, the heat generated by the electric spark which fuses the metal from the joint
area and it produce a molten weld pool. The size of the pool depends on the size of the electrode
and the amount of the current supplied by the generator. The arc area is surrounded by an inert or
reducing gas shield to protect the weld pool and the non-consumable electrode. The process may
be operated autogenously, that means without filler material or filler material may be added by
feeding a consumable wire or rod into the established weld pool. Tungsten Inert Gas Welding
produces very high-quality welds across a wide range of materials with thicknesses up to about 8
or 10mm.
Advantages
 Superior quality welds
 Welds can be made with or without filler metal
 Precise control of welding variables (heat)
 Free of spatter
 Low distortion
Limitations
 Requires greater welder dexterity than MIG or stick welding
 Lower deposition rates
 More costly for welding thick sections

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Gas Metal Arc Welding (MIG Welding)
This process also known as Shielded Inert Gas Metal Arc (SIGMA) welding, Metal Inert Gas
(MIG) welding or Gas Metal Arc Welding (GMAW) uses a shielded arc struck between a bare
metal electrode and the work piece. The metal electrode is provided in the form of a wire reel.
The typical setup for GMAW or MIG welding process is shown in Fig. The consumable
electrode is in the form of a wire reel which is fed at a constant rate, through the feed rollers.
The welding torch is connected to the gas supply cylinder which provides the necessary inert gas.
The electrode and the work-piece are connected to the welding power supply. The power
supplies are always of the constant voltage type only. The current from the welding machine is
changed by the rate of feeding of the electrode wire. Normally DC arc welding machines are
used for GMAW with electrode positive (DCRP).

MIG welding procedure

Step 1: Setup the MIG welding machine
Step 2: Setup the gas tanks
Step 3: Setup the welding gun and feed wire
Step 4: Attach the group clamp
Step 5: Clean the weld surface
Step 6: Wear safety equipment

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Step 7: Turn on the gas cylinders
Step 8:Setup the welding parameters as per recommendation
Step 9: Turn on welder
Step 10: Set the speed of feed wire and check the wire in welding gun
Step 11: Start welding the work piece
Step 12: Close the valve of gas cylinder
Step 13: Turn off welder after welding is completed
Advantages
 All position capability
 Higher deposition
 Less operator skill required
 Long welds can be made without starts and stops
 Minimal post weld cleaning is required
 The MIG arc is relatively longer and less stable than TIG arc.
Disadvantages
 Heavily oxidized weld deposit
 Irregular wire feed
 Unstable arc
 Difficult arc starting
Submerged Arc Welding

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The main parts of Submerged Arc Welding:
 Consumable Electrode
 Power Sources
 Granular Flux
 Base Metal
 Electrode Holder
1. Consumable Electrode:
The consumable electrode is the electrode which is having current on it and when it’s touching to
the workpiece it gets melt there.
2. Power source:
For the operation of welding Power required, to generate a good amount of heat so that
workpiece and electrode can melt easily (Spark produces between them)
3. Granular Flux:
The main function of Granular flux is to avoid the exceeding heat, which is generated when
electrodes touch to the workpiece.
4. Base Metal:
The base metal is metal on which have to weld it might be:
 Carbon steels (structural and vessel construction)
 Low alloy steels
 Stainless steels
 Nickel-based alloys
5. Electrode Holder:
The main works of this are to hold the electrode. This device is a non-conductor device.
Working of Submerged Arc Welding
The base metal is connected to -ve energy sources whereas the electrode is connected with the
positive sources. In some device, the granular flux is fixed with the electrode holder or it might
not be. Now, Power is on, so we will bring the electrode near the base metals where have to start
the welding with the help electrode holder. When it touches to the base metal the spark produces
between them and the same time granular is also provided. When the operation is finished we
remove the electrode holder and also we remove that granular flux So, That the welding
operation which is done will be seen from the naked eye.

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Advantages:
 Smooth welds of high strength and ductility with low H2 and N2 content.
 Because of high current, high metal deposition, high welding speeds and good
penetration are achieved.
 Due to high speeds less distortion will occur.
 Elimination of fumes and spatter.
 Absence of visible arc and ease of penetration.
Limitations
 During welding process arc is not visible, judging the welding progress is difficult and so
tools like jigs, fixtures and guides are required.
 Pre-placing of flux may not always possible.
 This welding process is limited to flat position.
 Flux is subjected to contamination that may cause weld porosity.
 Chlorine, Aluminium, Magnesium, Lead, Zinc cannot be welded
Electro slag Welding

Electro slag Welding is a welding process, in which the heat is generated by an electric current
passing between the consumable electrode (filler metal) and the work piece through a molten
slag covering the weld surface. Prior to welding the gap between the two work pieces is filled
with a welding flux.
Electro slag Welding is initiated by an arc between the electrode and the work piece (or starting
plate). Heat, generated by the arc, melts the fluxing powder and forms molten slag. The slag,

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having low electric conductivity, is maintained in liquid state due to heat produced by the electric
current. The slag reaches a temperature of about 3500°F (1930°C). This temperature is sufficient
for melting the consumable electrode and work piece edges. Metal droplets fall to the weld pool
and join the work pieces.
Construction of Electro slag Welding Process
The construction of electro slag welding is not very complex. The base plate acts as a positive
electrode and the filler wire acts as a negative electrode. Two work pieces to be joined are kept
on the base plate. The filler wire is inserted in the cavity from the top and is perpendicular to the
base plate. Flux is also fed into the cavity using a hopper. A guide tube is used to guide the filler
wire to the correct position.
Step-by-step working
 Initially, the flux is fed inside the cavity then the power supply is started.
 When the filler wire touches the base plate through the flux, an arc is generated due to a
short circuit between the filler electrode and the base plate.
 This arc produces heat which is sufficient to melt the flux. This is the principle of arc
welding used in electro slag welding.
 After the arc is produced and the flux is melted the weld progresses in the upward
direction.
 More flux is added from the top, now the heat generation takes place due to the resistance
offered by the molten flux and the process looks like resistance welding.
 This helps in fusing the walls of the work piece and the consumable wire. Hence a weld
is formed between the two work pieces.
 The weld formed is due to the molten filler wire, molten flux as well as fusing of the
walls of the work piece.
Advantages of Electro slag Welding
 High deposition rate - up to 45 lbs/h (20 kg/h)
 Low slag consumption (about 5% of the deposited metal weight)
 Low distortion
 Unlimited thickness of work piece.
Disadvantages
 Very high heat applied to the base metals

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 Proper cooling is needed for high temperature applied
 Only vertical position can be welded
 Offers low toughness to the weld
Gas Welding

Gas welding is a fusion welding process in which the heat for welding is obtained by the
combustion of oxygen and fuel gas. The fuel gas may be acetylene, hydrogen, propane or butane.
An intense gas flame is thus produced which melts the edges of the parts to be welded. The
molten metal is allowed to flow to Solidify together and continuous joint is obtained.
Gas Welding Equipments
1. Gas cylinders
2. Regulators
3. Pressure gauges
4. Rubber hoses
5. Welding torch
6. Safety goggles
7. Gloves
8. Spark lighter
9. Wire brush
1. Gas Cylinders
Oxygen and acetylene gases are stored in separate cylinders and used for gas welding. The
colour of oxygen cylinder is black and the acetylene gas is stored in maroon cylinders. Oxygen is

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stored at a pressure of 125Kg/cm2. Acetylene gas is stored at a pressure of 16 Kg/cm2 in the
cylinder.
2. Regulators
Separate regulators are fitted on both the cylinders. A regulator is used to control the working
pressure of the gases. The working pressure of oxygen is 1Kg/cm2 and acetylene is 0.15Kg/cm2.
Working pressure of these gases is altered according to the thickness of the metal parts of the
joint.
3. Pressure Gauges
Two pressure gauges are fitted each on the oxygen cylinder and on the acetylene cylinder. One
of the pressure gauges indicates the pressure of the cylinder and the other gauge indicates the
working pressure of the specific gas.
4. Hoses
Separate hoses are used to connect the two cylinders with the welding torch through regulators.
The colour of the hose from the oxygen cylinder is black and the one from the acetylene cylinder
is red. These hoses carry the gases to the welding torch.
5. Welding Torch
Oxygen and acetylene reach the welding torch through the passages of hoses from the respective
cylinders. These gases are mixed in the mixing chamber of the welding torch. Flame is produced
at the tip of the torch when the gases are ignited.
There are two control valves present in the torch to control the quantity of oxygen and acetylene.
By this control, the grade of the flame can be altered. The size of the flame is altered to suit the
thickness of the metal parts.
6. Welding Gloves
Protective hand gloves are used by the operator to prevent possible damages that may be caused
by high temperatures and metal splashes during welding.
7. Spark Lighter
Spark lighter is used to ignite the oxy-acetylene gas at the tip of the welding torch.
8. Wire Brush
Wire brushes are useful in cleaning the weld before and after the welding process
Flame characteristics
1. Neutral Welding Flame

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A neutral flame results when approximately equal volumes of oxygen and acetylene are mixed in
the welding torch and burnt at the torch tip. The temperature of the neutral flame is of the order
of about 5900°F (3260°C). It has a clear, well defined inner cone, indicating that the combustion
is complete. The inner cone is light blue in color. It is surrounded by an outer flame envelope,
produced by the combination of oxygen in the air and superheated carbon monoxide and
hydrogen gases from the inner cone

This envelope is Usually a much darker blue than the inner cone. A neutral flame is named so
because it affects no chemical change on the molten metal and, therefore will not oxidize or
carburize the metal. The neutral flame is commonly used for the welding of mild steel, stainless
steel, cast Iron, copper, and aluminum
2. carburizing or reducing flame
 The carburizing or reducing flame has excess of acetylene and can be recognized by
acetylene feather, which exists between the inner cone and the outer envelope. The outer
flame envelope is longer than that of the neutral flame and is usually much brighter in
color. A reducing flame may be distinguished from carburizing flame by the fact that a
carburizing flame contains more acetylene than a reducing flame.

A reducing flame has an approximate temperature of 3038°C. A carburizing-flame is used in the

welding of lead and for carburizing (surface hardening) purpose. A reducing flame, on the other

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hand, does not carburize the metal; rather it ensures the absence of the oxidizing condition. It is
used for welding with low alloy steel rods and for welding those metals,
[Link] flame
The oxidizing flame has an excess of oxygen over the acetylene. An oxidizing flame can be
recognized by the small cone, which is shorter, much bluer in color and more pointed than that of
the neutral flame. The outer flame envelope is much shorter and tends to fan out at the end. Such
a flame makes a loud roaring sound. It is the hottest flame (temperature as high as 6300°F)
produced by any oxy-fuel gas source.

Advantages of Gas Welding

 Applied for different classes of work
 Welding temperature is controlled easily
 The quantity of filler metal added in the joint can easily be controlled
 The cost of the welding unit is less
 The cost of maintenance is less
 Both welding and cutting can be done
Limitations of Gas Welding
 Intended for welding thin work pieces only
 The process of welding is slow
 The time taken by the gas flame to heat the metal is more when compared with electric
arc
 The strength of the joint is less
 Great care should be taken in handling and storing gas cylinders

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Resistance Welding
Resistance Welding is a welding process, in which work pieces are welded due to a combination
of a pressure applied to them and a localized heat generated by a high electric current flowing
through the contact area of the weld.

construction of Resistance Welding

 Power Supply
 Initiating Switch
 Timer
 Contractor Point
 Step Down Transformer
 Primary and Secondary winding
 Moveable and Fixed Electrode
 Air valve and
 Pneumatic cylinder
Power Supply
In this system a welding transformer is attached and in that the various switch are there for
controlling the power supply further to the welding system. The AC power is supplied in this
welding system because of the ease and convenience.
Step Down Transformer
It converts the high voltage & low current from the primary side of the transformer to the low
voltage & high current value on the secondary side of the transformer. In the primary winding
the voltage is more because it the primary winding is connected to the power supply. And here

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the input receives as high power but using step down transformer we reduce it and than sends to
the send to the electrode through secondary windings.
Moveable and Fixed Electrode
In this welding process, two electrodes are used. The upper electrode is a moveable electrode and
downward is a fixed electrode connected to the fixed frame. In the electrode, the current is
passing which will further help to join the work piece.
Air valve
It is connected to the pneumatic cylinder and air valve is used to send the pressure from one
point to another point. The air valve is made up of cast iron, steel, ductile iron, and so on.
Pneumatic cylinder
The pneumatic cylinder is also known as an air cylinder. It is a mechanical device that uses
compressed gas to produce a force in a reciprocating linear motion.
Working
Resistance welding is a pressure welding process. The work piece which will be welded is placed
in between electrodes. Here two electrodes are used one is fixed and another is moveable. Now
we switch on the power supply. Here the low voltage and high current are passed through the
work piece. In between the work piece, The work piece offers resistance to the flow of current.
Therefore the temperature here rises and the temperature will further rise to the fusion point of
the work piece. We control the power supply because of low and high-temperature generation.
At the same time, the pressure is applied to the work piece. Now in between the work piece, a
circular nugget is created and The nugget size depends on the size of the electrode.
Advantages of Resistance Welding
 Fast rate of production.
 No filler rod is needed.
 Semi automatic equipments.
 Less skilled workers can do the job.
 Both similar and dissimilar metals can be welded.
 High reliability and reproducibility are obtained.
 More general elimination of warping or distortion of parts.
Disadvantages of Resistance Welding
 The initial cost of equipment is high.

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 Skilled persons are needed for the maintenance of equipment and its controls.
 In some materials, special surface preparation is required.
 Bigger job thicknesses cannot be welded.
Applications of Resistance Welding
Resistance welding is used for
 Joining sheets, bars, rods and tubes.
 Making tubes and metal furniture.
 Welding aircraft and automobile parts.
 Making cutting tools.
 Making fuel tanks of cars, tractors etc.
 Making wire fabric, grids, grills, mash weld, containers etc.

Electron beam welding

Construction
The schematic arrangement of Electron Beam Machining (EBM) is shown in Fig. It consists of
electron gun, diaphragm, focusing lens, deflector coil, work table, etc. In order to avoid collision
of accelerated electrons with air molecules, vacuum is required. So, the entire EBM setup is
enclosed in a vacuum chamber, which carries vacuum of the order 10-5 to 10-6 mm of
mercury. This chamber carries a door, through which the work piece is placed over the table. The
door is then closed and sealed.
The electron gun is responsible for the emission of electrons, which consists of the following
three main parts.
1. Tungsten Filament — which is connected to the negative terminal of the DC power
supply and acts as cathode.
2. Grid cup — which is negatively based with respect to the filament.
3. Anode — which is connected to positive terminal of the DC power supply.
The focusing lens is used to focus the electrons at a point and reduces the electron beam up to the
cross sectional area of 0.01 to 0.02 mm diameter.
The electromagnetic deflector coil is used to deflect the electron beam to different spot on the
work piece.

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Working
When the high voltage DC source is given to the electron gun, tungsten filament wire gets heated
and the temperature raises upto 2500°C. Due to this high temperature, electrons are emitted from
tungsten filament. These electrons are directed by grid cup to travel towards downwards and they
are attracted by anode. The electrons passing through the anode are accelerated to achieve high
velocity as half the velocity of light (i.e., 1.6 x 108 m/s) by applying 50 to 200 kV at the anode.
The high velocity of these electrons are maintained till they strike the work piece. It becomes
possible because the electrons travel through the vacuum.
This high velocity electron beam, after leaving the anode passes through the tungsten diaphragm
and then through the electromagnetic focusing lens. Focusing lens are used to focus the electron
beam on the desired spot of the work piece. When the electron beam impacts on the work piece
surface, the kinetic energy of high velocity electrons is immediately converted into the heat
energy. This high intensity heat melts and vaporises the work material at the spot of beam
impact.

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Plasma are welding
when a gas is heated to a sufficiently high temperature in the order of 11,000°C to 28,000°C, it
becomes partially ionized. The gas in this stage is termed plasma. These hot ionized
gases(plasma) used to heat the work plates, and the joint is created due to fusion.

 Initially, the work pieces are cleaned thoroughly.

 The power source supplies the power that produces an arc between the tungsten electrode
and nozzle, or the tungsten electrode and the work piece.
 The tungsten electrode gives a high-intensity arc used for ionization of gas particles and
converts orifice gases into plasma.
 This hot ionized gas is provided to the welding plates by a small hole. Shielding gases
such as argon etc are supplied through pressure valve and regulating valves to the
external nozzle of the welding torch.
 These gases form a shield around the welding area which protects it from atmospheric
gases such as oxygen, nitrogen, etc.
 The plasma collides to the welding plates and turns it into one piece.
 The next welding is carried in the direction of welding. If this welding process requires
filler material, it is fed manually by the welder.

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Advantages of PAW:
 Welding speed is higher.
 Penetration is more.
 Higher arc stability.
 The distance between torch and work piece does not affect heat concentration on the
work up to some extent.
 Addition of filler material is easier than that of TIG welding process.
 Thicker job can be welded.
 Higher depth to width ratio is obtained resulting in less distortion.
Disadvantages of PAW:
 Higher radiations.
 Noise during welding.
 Process is complicated and requires skilled manpower.
 Gas consumption is high.
 Higher equipment and running cost.
 Higher open circuit voltage requiring higher safety measures to take.
Thermit Welding

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Principle of Thermit Welding

Thermit Welding is a welding process in which heat produced during an exothermic reaction is
used to weld two metal pieces (conductors) together. In this type of welding, a mixture of
aluminum and iron oxide is used in ratio 1:3 by weight. This mixture chemically reacts. This
reaction gives aluminum oxide and iron and also liberate a huge amount of heat which coverts
this mixture into molten state. Because the molten iron have higher density compare to
aluminum oxide so it remains bottom of the crucible. There is an opening at bottom of the
crucible from where, this molten iron poured at the required plates where we want to create joint.
Working thermit welding
 First both the work pieces which are needed to be weld, are cleaned.
 Now a wax pattern is created around the weld cavity.
 A moulding flask is fixed around the joint with the help of mold handle clamp. This wax
pattern is situated at the middle of the flask.
 Now the molding sand rammed around the wax pattern to create mold in which the
molten metal will pour. This mold involves all necessary parts like runner, riser, pouring
basin, gating system, opening for wax pattern etc. same as involves in casting.
 Now this mold is heated to remove wax pattern. The wax is melted and run off from the
wax pattern outlet prepared at bottom of the sand mold.
 Now the thermit mixture is taken into the refectory crucible. The ignite powder is placed
over the mixture. This mixture is ignited by a magnesium ribbon.
 This will start the thermit reaction which liberates a huge amount of heat. This reaction
form molten state of iron which flows from crucible to sand mould.
 This molten metal fills the weld cavity and fuses the parent metal to make a permanent
joint. This will allow to cool down. After proper cooling, flask is removed from the joint.

Panimalar Engineering College/Department of Mechanical Engineering

 Manufacturing Processes /Unit - II/ Joining Processes
 After removing the flask, machining is done to remove the welding burr or other extra
metal.
Advantages:
 Intended for finish welding of strengthens bars to be use in concrete construction.
 For welding new necks to rolling mill rolls with pinions.
 Used for welding large broken crankshafts
 For welding busted frames of machines
 For restore broken teeth on big gears
Disadvantages:
 Low deposition rate with operating factor
 Its cannot weld low melting point
 It has slag inclusion
 It is high skill factor
 Extremely high level of fumes
Friction Welding
Principle
Friction welding works on basic principle of friction. In this welding process, the friction is used
to generate heat at the interference surface. This heat is further used to join two work pieces by
applying external pressure at the surface of work piece. In this welding process, the friction is
applied until the plastic forming temperature is [Link] is normally 900-1300 degree
centigrade for steel. After this heating phase, a uniformly increasing pressure force applied until
the both metal work pieces makes a permanent joint.

Panimalar Engineering College/Department of Mechanical Engineering

 Manufacturing Processes /Unit - II/ Joining Processes
Working
First both the work pieces are prepared for smooth square surface. One of them is mounted on a
rotor driven chuck and other one remains stationary. The rotor allows rotating at high speed thus
it makes rotate mounted work piece. A little pressure force is applied on the stationary work
piece which permits cleaning the surface by burnishing action.
Now a high pressure force applied to the stationary work piece which forces it toward rotating
work piece and generates a high friction force. This friction generates heat at the contact surface.
It is applied until the plastic forming temperature is achieved. When the temperature is reached
the desire limit, the rotor is stopped and the pressure force is applied increasingly until the whole
weld is formed.
Advantages
 No filler metal, flux or shielded gases are needed
 It is an environment-friendly process with generation of smoke, fumes or gases.
 No material is melted so the process is in solid state with narrow HAZ
 Oxides can be removed after the welding process.
 The process is very efficient and comparatively very rapid welds are made.
 The weld is strength is stronger than the weaker of the two materials being joined
Disadvantages
 The process is restricted to joining round bars or tubes of same diameter
 Dry bearing and non-forgeable materials cannot be welded. (i.e. one of the material must
be ductile)
 Preparation and alignment of the work piece may be critical for developing uniform
rubbing and heating
 Equipment and tooling cost are high
 Free machining alloys are difficult to weld
Friction stir welding
Friction stir welding works on same principle of friction welding. In this process, friction is used
to generate heat at interface surface.
basic principle of friction welding
This heat starts diffusion process at the mating surface. A high pressure force applied at these
mating surfaces which accelerates metal diffusion process and form a metal to metal joint.

Panimalar Engineering College/Department of Mechanical Engineering

 Manufacturing Processes /Unit - II/ Joining Processes

Working
First both the work plates are clamped together same as in butt joint. These both plate’s weldable
surfaces are in contact with one another. Now a rotating tool pin is inserted into work pieces at
the interface surfaces until tool shoulder touched the work piece. This will deform the material
plastically due to heating by friction force.
This is state of the joining process in which, inter molecular diffusion will deform the material
plastically due to heating by friction force. Now the rotating tool is move forward along the joint
line. This will form a joint behind the tool. The tool continuously move unlit the whole weld is
form. After the joining process, tool is separated from the work piece. The hole created by tool
pin remains in the welding plates.
Advantages:
 Good mechanical properties in the as-welded condition
 Improved safety due to the absence of toxic fumes or the spatter of molten material.
 No consumables — no filler or gas shield is required for aluminium.
 Easily automated on simple milling machines — lower setup costs and less training.
 Can operate in all positions (horizontal, vertical, etc.), as there is no weld pool.
 Generally good weld appearance and minimal thickness under/over-matching, thus
reducing the need for expensive machining after welding.
 Can use thinner materials with same joint strength.
 Low environmental impact.
Disadvantages
 Exit hole left when tool is withdrawn.
 Large down forces required with heavy-duty clamping necessary to hold the plates
together.

Panimalar Engineering College/Department of Mechanical Engineering

 Manufacturing Processes /Unit - II/ Joining Processes
 Less flexible than manual and arc processes (difficulties with thickness variations and
non-linear welds).
 Often slower traverse rate than some fusion welding techniques, although this may be
offset if fewer welding passes are required.
Brazing
Brazing is a metal-joining process in which two or more metal items are joined together by
melting and flowing a filler metal into the joint. During the brazing process, the filler metal flows
into the gap between close-fitting parts by capillary action.

Use the wire brush or emery cloth to scuff the surface of the metal. Then clean the surfaces using
soapy water or a degreaser. Position the metal as desired. In most cases, an overlapped joint will
be stronger and braze together easier than a gapped joint. If needed, use clamps to secure the
pieces in position. Heat the joint where the two pieces of metal will meet until the joint glows.
Apply the brazing rod to the joint while continuing to heat the metal surfaces. For large areas,
heat portions of the joint to temperature and then move to the next adjacent area. After brazing,
use a wire brush to clean the brazed surface to remove any oxidation or residue
Advantages
 Low thermal distortions and residual stresses in the joint parts;
 Microstructure is not affected by heat;
 Easily automated process;
 Dissimilar materials and thin wall parts may be joined;
 High variety of materials may be joined;
 Moderate skill of the operator is required.
Disadvantages
 Careful removal of the flux residuals is required in order to prevent corrosion

Panimalar Engineering College/Department of Mechanical Engineering

 Manufacturing Processes /Unit - II/ Joining Processes
 No gas shielding may cause porosity of the joint
 Large sections cannot be joined
 Fluxes and filler materials may contain toxic components
 Relatively expensive filler materials.
Soldering
Soldering is a joining process used to join different types of metals together by melting solder.
Solder is a metal alloy usually made of tin and lead which is melted using a hot iron. The iron is
heated to temperatures above 600 degrees fahrenheit which then cools to create a strong
electrical bond

Advantages
 Low power is required
 Low process temperature
 No thermal distortions and residual stresses in the joint parts
 Microstructure is not affected by heat
 Easily automated process
 Dissimilar materials may be joined
 High variety of materials may be joined
 Thin wall parts may be joined
 Moderate skill of the operator is required.
Disadvantages
 Careful removal of the flux residuals is required in order to prevent corrosion
 Large sections cannot be joined
 Fluxes may contain toxic components
 Soldering joints cannot be used in high temperature applications
 Low strength of joints.

Panimalar Engineering College/Department of Mechanical Engineering

 Manufacturing Processes /Unit - II/ Joining Processes
Weld defects: types, causes and cure

Panimalar Engineering College/Department of Mechanical Engineering

 Manufacturing Processes /Unit - II/ Joining Processes

Panimalar Engineering College/Department of Mechanical Engineering