VEMANA INSTITUTE OF TECHNOLOGY
Subject: Elements of Mechanical Engineering
Sub Code: EME 14/24
Module 4
Engineering Materials and Joining
process
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Elements of Mechanical Engineering
Introduction
• Joining process is where two or more pieces of parts are joined
together to produce a single product of required shape and size.
• The joining process can be classified as :
1. Permanent joining process
2. Semi – permanent or temporary joining process
• Fusing the metal together is a permanent joining process.
• Examples are welding, soldering and brazing.
• Temporary joining process is where the metal is not heated and carried
out at room temperature.
• Examples are nuts, bolts, screws and adhesives.
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Soldering
• Definition “A joining process wherein coalescence is produced by heating to
a suitable temperature and by using a filler metal having a melting point not
exceeding 427oC and below the solidification temperature of the base
metals”
• Uses fusible alloys to join metals known as solder
• Fluxes are used with solder in soldering process
• Fluxes are defined as any solid, liquid or gaseous materials, which, when
heated accelerate the wetting of metal with the solder
• Generally used in soldering are Rosin, Zinc Chloride and Aluminum Chloride.
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Different types of solder
• Hard solders are called spelter and hard soldering process is
called silver solder brazing
• Constituents: lead and silver
• Melting point is in the range of 350oC and above
• Gives greater strength and withstand more heat than soft solder.
• Soft solder is used for joining most common metals with an alloy
that melts at a temperature below that of the base metal, and
always below 4270C
• Constituents: Tin and Lead
• Melting point - 150 to 2000C
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Advantages:
1. The process is done at low temperatures hence, no metallurgical
damage to the base metal.
2. Simple heating of the solder can dismantle the soldering joint.
3. It is cost effective
Disadvantages:
4. The strength of the joint is not good compared to welding.
5. Flux material has to be cleaned after soldering, as most of the
fluxes are corrosive in nature.
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Application of soldering
Assembling electronic components to printed circuit boards.
Making connection between copper pipes in plumbing system
Used in joining sheet metal objects like food cans and metal containers
Used as a semi-permanent patch for a leak in container
Examples of solder Application
Tin-lead general purpose
Tin-zinc joining aluminum
Lead-silver Strength at temp. Higher than room
temp.
Zinc-aluminum corrosion resistance
Tin-silver, tin-bismuth electronic applications
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Brazing
“A joining process, which produces coalescence of materials by
heating to a suitable temperature and using a filler metal having a
melting temperature above 427°C and below the solidification
temperature of the base metals being joined”
Brazing is distinguished from soldering in that soldering employs a
filler metal having a melting point below 427°C.
The fluxes used in brazing are borax, boric acid, borates, chlorides
and fluorides.
Filler metal alloys used for brazing are Aluminum – Silicon,
magnesium, copper and copper zinc etc.,
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Types of Brazing
1. Torch Brazing
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2. Furnace Brazing
3. Dip Brazing
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4. Resistance Brazing 5. Induction Brazing
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Advantages:
1. It can be used to join dissimilar metals.
2. It provides good pressure tight joints.
3. Different cross sectional thickness material can be brazed.
4. Brazing avoids metallurgical damage to the metal.
Disadvantages:
5. Size limitations of the parts to be brazed - as the outer area has to be
elevated to the higher temperature, in large sections increasing the
temperature is difficult.
6. Tight mating parts are necessary for capillary action.
7. Fluxes are corrosive in nature, they have to be cleaned properly after
brazing.
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Welding
Simple definition of welding
“Joining metals through heating them to a molten state and fusing
them together.“
Technical definition of Welding
“A localized coalescence of metals, wherein coalescence is obtained
by heating to suitable temperature, with or without the application of
pressure and with or without the use of filler material. This filler material
has the melting point same as the base material.”
It is also know as a metallurgical joining process of two metal pieces,
to produce a single piece of product. .
In general definition of welding
“The joining of metals and plastics without the use of fasteners.“
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Welding Terminologies
• Base Metal – Work pieces that are needed to be joined
• Weld Bead - A weld bead is a weld deposit produced by a
single pass of the welding processes. It is also known as
bead
• Puddle – The molten base metal at the joint during the
welding operation
• Weld pass – Movement of weld torch from one end of the
joint to the other end.
• Tack Weld – it is the temporary joint done before welding to
keep the work pieces to be welded in place during welding.
The joints are done at the ends of the work piece.
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Classification of Welding Process
The welding process can be classified based on the source of
energy to heat the metal and the state of metal at the joint.
– Pressure Welding
– Fusion Welding
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Pressure Welding
• The surfaces of the joint to be welded is heated to a plastic state and
forced together with external pressure to finish the joint.
• Depends on the application of pressures and temperature
• ISO – 857 defines “Welding in which sufficient outer force is applied to
cause more or less plastic deformation of both the facing surfaces,
generally without the addition of filler metal. Usually, but not
necessarily, the facing surfaces are heated in order to permit or to
facilitate bonding”
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Fusion Welding
• Heating in to molten state and allowed to solidify to form
joint with or without the addition of filler material.
• The process is carried out with out the application of
pressure.
• ISO – 857 defines “Welding without application of outer
force in which the facing surface must be melted. Usually,
but not necessarily, molten filler metal is added”.
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• Arc welding is one of several
fusion welding processes for
joining metals.
• By applying intense heat
through a electric arc, metal at
the joint is melted and caused to
intermix - directly, or with an
intermediate molten filler metal.
• Upon cooling and solidification,
a metallurgical bond is created.
• The final weldment potentially
has the same strength properties
as the metal of the parts
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• Welding arc can be defined as a “Sustained electrical
discharge through an ionized gas”.
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• Welding arc can be defined as a “Sustained electrical
discharge through an ionized gas”.
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Electrodes
• Consumable Electrode – it melts and supplies filler metal to the weld
• Non – Consumable Electrode - it does not melt but separate filler metal is to be
added to the weld.
• Consumable Electrode
It is a made of low melting point metal or alloy.
When arc is struck electrode starts to melt and transfer to the work piece in the
form of droplets.. The thermal efficiency of consumable electrode 85 % when
compared to non – consumable electrode of 55 %.
Bare electrodes which consist of metal or alloy wire without any flux coating.
Flux covered electrodes
which have flux covering the metal or alloy.
The flux acts as a shield to protect the arc and also to protect the weld pool.
Non – Consumable Electrodes
These electrodes are made up of high melting point metals like carbon, pure
tungsten etc.
These electrodes do not melt during welding process.
They generate arc, which melts the work piece.
Generally these metals do undergo vaporization and oxidation during welding
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Gas Welding
• This is fusion method of welding
• Strong gas flame is used to raise the temperature of w/p
• Filler material is used to fill the joint
• Heat is generated by the combustion of combustible gas
with oxygen
• This process of welding is generally known as Oxygen –
Fuel Gas welding (OFT )
• The commercial gas that is used for welding is acetylene,
hydrogen, propane, butane and commercial LPG.
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Oxy – Acetylene Gas welding
• This is a common gas welding process.
• Acetylene produces high heat content in the range of
3200 C than other fuel gases.
• Acetylene gas has more available carbon (92.3 %) and
hydrogen (7.7 %) by weight.
• Releases high amount of heat
C2H2+O2 = 2CO+H2+Heat
• Depending up on the gas pressure required for welding or
cutting oxy acetylene welding is classified into two
Low pressure System and (range of 0.5 to 3.5 bars )
High-pressure system (exceeds 1.5MPa.)
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Gas welding equipment
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Types of Flames
• One volume of Acetylene gas requires 2.5 times the volume of
oxygen for its complete combustion.
• Depending up on the ratio of oxygen supplied for combustion we
can classify flames into 3 types.
• This ratio is known as gas ratio.
• These flame types have a great effect on the melt pool chemically.
• There are 3 types of flames and they are-
– Neutral Flame,
– Carburising flame, and
– Oxidizing Flame.
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Neutral Flame
• Neutral flame is the one that is
used the most. This flame is
obtained by supplying equal
volumes of oxygen and acetylene.
• The flame can be distinguished by
its zones of combustion.
• The innermost zone, the cone, is
white in color and extends a short
distance from the tip of the torch.
• Acetylene burns in this zone to
form carbon monoxide and
hydrogen. The approximate
temperature of the inner cone is
3200 C.
• The outer cone or envelope is
faintly luminous and bluish is
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Carburizing Flame
• In this flame acetylene proportion is
increased in the gas ratio of 0.95 to 1.0.
• The flame has three zones a) inner
white zone b) intermediate whitish
cone and c) bluish outer envelope. The
inner zone which is sharply defined and
white in color.
• In this zone there is insufficient oxygen
to burn surplus acetylene. Cone
temperature is approximately about
3100 C.
• The remaining acetylene continues to
the second zone known as the
intermediate cone of whitish color.
• This intermediate zone extends in
length depending up on the amount of
acetylene present in the gas. The inner
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Oxidizing Flame
• In this flame there is excess of
oxygen.
• The flame has a small inner
cone and outer envelope.
• The inner cone is not sharply
defined as in neutral flame and
carburizing flame.
• The inner cone is purplish is
color. The temperature of the
inner cone is approximate of
3350 – 3400 C.
Elements of Mechanical Engineering
Difference between Soldering and Brazing
Brazing Soldering
Filler metals melting point is above Filler metals melting point is below
4270C 4270C
Brazed joints are stronger Solder joints are less stronger
Brazed joints can be used for service Solder joints can not be used in
in elevated temperature elevated temperature
Brazed joint resist corrosion to some The joints do not resist corrosion
extent
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Difference between Soldering Brazing and Welding:
Sl No.
Welding Soldering Brazing
1. It is a high temperature process where It is a low temperature process The base metals are not melted
the base metals are heated above their where the base metals are not but broadly heated to a suitable
melting temperature. melted. temperature.
2. The filler material used is made of same Filler material used is not the same Filler material used is not the
material as that of the base metal. as that of the base metal. same as that of the base metal
3. Joint is formed by the solidification of Joint is obtained by means of Joint is obtained by means of
the molten filler metal with the molten diffusion of the filler metal into the diffusion of the filler metal into
base metal base metal. the base metal associated with
surface alloying.
4. Strength of the joint obtained in Strength of the joint obtained in Strength of the joint lies in
welding is much stronger than the soldering is very low when between that of welded and
parent metal compared to that of brazed and soldered joints.
welded joints.
5. Requires certain finishing operations Joints can be used as it is without Surface finish is good. In some
like grinding, filling etc. any finishing operations. cases, finishing operations are
required.
6. Welding produces stronger joints. Since the joint obtained is not much Finds applications in arts, jewelry
Hence this process is used for strong, this process is mostly used works and also in industries.
fabrication and structural applications. for joining thin sheet metals, pipes,
wires etc.
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THANK YOU
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