What is manufacturing Science
Converting the raw material into useful finish products with
definite dimensions by adding some values.
Nature and standard of values will decide the quality of the
products.
A. Digital manufacturing.
B. Virtual manufacturing.
Value addiction can be performed with different technique and
processes.
1. Welding
2. Casting
3. Forming
4. Machining
5. Additive manufacturing
6. Powder metallurgy
Manufacturing processes to bring about
change in shape
1. Welding: Due to Addition of Material
2. Casting: Due to changes of state of material
3. Forming: Due to change in the shape of material by applying
forces and stresses.
4. Machining: Due to removal of material
5. Additive manufacturing: Due to layer by layer additions
6. Powder metallurgy: Due to be pressing and sintering of the
power formed material.
Manufacturing Processes
Raw Finished
Material Product
Welding Technique
Fusion welding Processes:
• Gas welding
• Arc Welding
• Laser beam welding
• Electron beam welding
Solid state welding processes:
• Friction stir welding
• Friction Welding
• Resistance welding
• Ultrasonic Welding
• Explosive Welding
Oxy Acetylene Gas Welding
Comparison of different Arc welding
processes
1.)- 2.4 mm 0.7 mm -2.4 mm 1mm -6 mm
2.)- 3.4 mm
3.)- 4.0 mm
4.)- 4.7 mm
Affected zone of MMAW Affected zone of GMAW Affected zone of GTAW
Friction stir welding
Variable Parameter
1. Pin Length
2. Pin Diameter
3. Shoulder Diameter
4. RPM of Tool
5. Welding Speed
6. Tool Tilt Angle
Terminology of FSW
Variable Parameter
1. Pin Length
2. Pin Diameter
3. Shoulder Diameter
4. RPM of Tool
5. Welding Speed
6. Tool Tilt Angle
Comparison of different Arc welding processes
8000°C
6000°C
M
M
A G
W M
A G
W T
4000°C A
W
3000°C
1200°C
1000°C F
S
W
500°C
Room Temperature
Heat Affected Zone (HAZ)
MMAW
GMAW
GMAW
GTAW
GTAW
GTAW
GAS WELDING
Types of Flame
Types of Flame
Oxyacetylene Welding
Figure 31.21 A typical oxyacetylene welding operation (OAW).
Acetylene (C2H2)
• Most popular fuel among OFW group because
it is capable of higher temperatures than any
other ‑ up to 3480C (6300F)
• Two stage chemical reaction of acetylene and
oxygen:
– First stage reaction (inner cone of flame):
C2H2 + O2 2CO + H2 + heat
– Second stage reaction (outer envelope):
2CO + H2 + 1.5O2 2CO2 + H2O + heat
Oxyacetylene Torch
• Maximum temperature reached at tip of
inner cone, while outer envelope spreads out
and shields work surfaces from atmosphere
Figure 31.22 The neutral flame from an oxyacetylene torch
indicating temperatures achieved.
Alternative Gases for OFW
• Methylacetylene‑Propadiene (MAPP)
• Hydrogen
• Propylene
• Propane
• Natural Gas
Heat affected zone
HAZ of Fusion welding
TMAZ Weld Nugget HAZ
HAZ of Friction Stir Welding
Types of Welding Polarity/ Current in SMAW, GTAW, FCAW & GMAW
The three different types of current or polarity used for welding are:
[Link] current (AC),
[Link]-current electrode negative (DCEN) is also called straight Polarity.
[Link] current electrode positive is also called DCEP and Reverse Polarity.
DCEN or also known as Straight Polarity works with the electrode connected to
the negative, and the work is connected to the positive terminal.
The electrons flow from the Cathode (Welding electrode) to the Anode
(workpiece). This gives around 1/3 of the welding heat on the welding rod and 2/3
on the base material being welded. Straight polarity due to the above reason
results in high welding rod melting.
DCEN is used in GTAW/ TIG welding as well as some limited applications in Shielded
metal arc welding (Stick Welding).
DCEP heats the electrode much more than DCEN in TIG welding; thus, DCEP is
rarely used in the TIG Welding process.