lecture 1 las-lasan
TRANSCRIPT
8/20/2019 Lecture 1 Las-lasan
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BK20A0401 Modern Welding Technology 1
Responsibles Persons: Dr. Paul Kah and Lic. Raimo Suoranta
Theoretical work load is 182 hours.
• Lectures (1stperiod) – 24 h
• Lectures ( 2nd Period)-24 h
• Laboratory tutorials (1st &2ndperiod) – 14 h
o Obligatory
• Term paper, with presentation (1st period 1st&2ndperiod)- 16 h
o Obligatory
• Evaluation
o Exam 80%- term paper with presentation 20%
28 September2014 BK20A0401 ModernWeldingTechno logy
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• Slides
• Your own notes
• Literatures
-ModernWeldingTechnology, SixthEdition: Howard B. Cary &Scott c. Helzer
-WeldingScience & Technology, Ninth Edition, Volume 1, AWS
• Internet
8 S eptember 2 014 BK 20A0401 Modern Wel di ng Technology
• Welding is the only way of joining material to formuniformconnection and the mostcommon way of joining
• Welding isvery efficient way to join materials
• Welding is vital to economy
• Welding ranks high among
industrial processes andinvolves more sciences andvariables than those involved inany other industrial process
• It is often said that over 50 –70% of the gross nationalproduct is related to welding inone way or another
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BK20A0401 Modern Welding Technology 2
• The most common joining method on mechanicalengineering
• Parts are joint together or gladded utilizing heatand/or pressure so that the parts make up uniformconnection
• Filler material may be used
o Melting point about same as parent material
• Weldingprocessesaredividedin twogroups:
o Fusion welding
o Pressure welding
• Solid state welding
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Some of the advantages of welding are:
• lowest cost,
• permanent joining method.
• lighter weight through better use of materials
• It joints all commercial metals
• It can be used anywhere
• It provides design flexibility
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Welding has limitations. Some of this limitations are:
• Requires suitable procedures .
• Manual weldingis humanfactor dependent.
• Required suitable inspections to assure quality.
These limitations can be overcome bymeans of:
• Nondestructive test,
• Good supervision,• Qualified procedures,
• Qualified personals,
• Mechanized welding methods.
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• Weldingis expectedtogrowdue toitseconomic advantage:
o Intelligently designed weldments will be always lessexpensive than similarapplications than products madebyothermanufacturingmethods.
• Welding will continue to dominate the materials joiningindustry because the productivity of welding is being
increased. This is due to reduce of overall cost as aconsequenceof:
o Improvedfiller metalswithhigherdepositionrate
o Increaseusedof computercontrolledweldingequipmentandprocesses.
8 September2014 BK20A0401 ModernWeldingTechno logy
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BK20A0401 Modern Welding Technology 3
5500 B.C. Egyptians recognize “forge welding” forcopper and gold
800 “Damascus Sword”-steel forge weldedto high strength
1877 Electric resistance welding possibility
1905 Concept of coated electrodes
1910 Oxyacetylene cutting and weldingtechniques
1932 Gas shielded welding
1960 Laser and electron beam welding,friction welding
1990 Robotics
2000-> Hybrid processes
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• Fumes
• UV-radiation
• Noise
•Ergonomcs
•…
Work
env ronment
•Processes
•Equipment
• Mechan zation/Automaton
/ Robotization
Welding
• Base materals
• Fil ler materials
• Assi stant materials
•Weld
Metalurgy • Strengh calcuations
• Fat igue design
• DFM
Design
• Qualitysystems
• Qualified welders
• Testing
• …
Quality
BK20A0401 ModernWelding Technology
• Processes
• Metallurgy
• Automation
• Productivity
• Quality
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• MIG/MAG
• TIG
• PAW
• SAW
• Beam processes
• Hybrid welding processes
• Friction
• EGW/ESW
• SMAW
• Cutting
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BK20A0401 Modern Welding Technology 4
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The industries where welding is either a primary product or a critical enablingtechnology:
o Miningandoil andgasextraction.
o Heavyconstruction,i.e.cross-countrypipingandotherpipelines.
o Primarymetalmanufacturing,weldingis mostlyusedfor maintenancepurposes.
o Fabricated metal products (e.g. pressure vessels, tanks, machine bases, prefabricatedmetalbuildings).
o Machinery manufacturing (e.g. agricultural, mining, metal working machine, cranes,bulldozers).
o Welding andsoldering equipment, (e.g.manufacturingof welding equipment, machines a
robots).
o Electricalequipment
o Transportation-motorvehicle
o Transportation-railroadrollingstock
o Transportation-shipandboatbuilding
o Repair andmaintenance
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A number of safety and health problems areassociated with welding. These hazards are:
• Electrical shock• Arc radiation• Air contamination• Fire and explosion
• Compressed gases• Welding cleaning• Other hazards related to specific welding
processes or occupations.
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• Aircraft and Airspace
all connections are done bywelding
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Welding assembly of an airplane chassis
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• Aircraft and Airspace
all connections are done bywelding
BK20A0401 ModernWelding Technology
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BK20A0401 Modern Welding Technology 5
• Aircraft and Airspace
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• Shipbuilding and offshore
SAW welding, MIG/MAG welding
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• Shipbuilding and offshore
Hybrid and laser welding
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• Shipbuilding and offshore
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BK20A0401 Modern Welding Technology 6
• Automotive and land transport
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Welding assembly of a
truck chassis
Automotive robotic welding
assembly of a car body
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Parts of an automobile
assembly which arewelded
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• Automotive
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Automotive production use alot of welding for cars
aluminium frames
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• Automotive
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BK20A0401 Modern Welding Technology 7
• Automotive
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Welding of dissimilarmaterials
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• Trains and railroad
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• Thermite welding
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• Bicycles
MIG and MAG, TIG
welding
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BK20A0401 Modern Welding Technology 8
• Bicycles
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• Bicycles
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• Oil industry and pipelines
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Welding pipeline in severeenvironment conditions
GMAW welding of a pipe in afactory
Winter welding shelter
BK20A0401 ModernWelding Technology
• Oil storage tanks
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Welding for oilrelatedapplicationsshould be goneaccording to
strict regulations,as even smallamount ofdefects in a weldcan cause afailure
BK20A0401 ModernWelding Technology
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BK20A0401 Modern Welding Technology 9
• Nuclear reactors
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• Household appliances
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• Furniture
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• Bridges and structures
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BK20A0401 Modern Welding Technology 10
• Buildings
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Nowadays welding isused in constructionmoreand moreoften
BK20A0401 ModernWelding Technology
• Leisure structures
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• Jewelry ndustry
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• Jewelry ndustry
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BK20A0401 Modern Welding Technology 11
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• Artand sculptures
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• Repairwelding
TIG welding
1
2
3
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• Repairwelding
BK20A0401 ModernWelding Technology
• Underwaterwelding
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Underwater weldingmask
BK20A0401 ModernWelding Technology
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BK20A0401 Modern Welding Technology 12
• Underwaterwelding
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UnderwaterweldingchamberUnderwater inspectingand weldingrobot
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• Etc…
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Butt Tee
Lap Corner
Edge
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BK20A0401 Modern Welding Technology 13
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Tounderstandweldingitisnecessarytobefamiliarwiththebasictermsusedbyindustry.
•Weldng: is a joiningprocessthatproducescoalescence a ofmaterialsbyheatingthemtotheweldingtemperature,with or withoutapplication ofpressureor bythe applicationof pressurealone,andwithor withouttheuseof fillermetal.
•Weldment:is anassemblywhosecomponentpartsarejoinedbywelding.
• Joint: is thejunction of members orthe edge ofmembers that areto bejoinedor havebeenjoined.
•Weld: it is veryimportantto distinguishbetween jointand weld. Thereare differenttypesofweldandtheyarebestdescribedbytheirshapewhenshownincross-section.
•Fillermetal:is ametaloralloytobe addedinmakingwelded,brazed,orsolderedjoint.
a. Coalescenceis defineda s thegrowingtogetheror growthinto onebodyof thematerials beingwelded.
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• Groove weld
Used to weld members aligned in the same plane
• Fillet weld
Typically members are perpendicular situated
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• Butt weld
o Between mating members
o High weld preparation cost
• accuracy
o “Difficult” to weld
• Fillet weld
o
Easypreparationo Asymmetric loads, lower design loads
• Plug & slot welds
o Modified fillet welds in lap joints,using holes through one member
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• Simple & cheap to assemble &weld
• Stress concentrations at toes &root
• Notch at root (fatigue, toughness)
• Critical dimension is throatthickness
• Root gap affects throat thickness• Radiography & ultrasonic testing is
of limited use
• Large fillets use a lot of weld metal& therefore are uneconomic
Lap joint
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BK20A0401 Modern Welding Technology 14
Single vee
can be s ingle
or double welded
Single bevel
Double vee
Backing permanent or temporary)
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Flat Horizontal
VerticalUp or Down
Overhead
Horizontal vertical
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Axis vertical Axis horizontal Axis inclined 45°
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Land
Root radius“U” preparation
Double “U” butt
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Joint root is “ that portion of a joint
to be welded where the membersare closest to each other”
The joint roots are shown as shaded
areas in (A)-(D) and lines in (E) (F)
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Groove face is “ that surface of a
member included in the groove”Root face (land) is “that portion ofthe groove face within the joint
root”
Root edge is a root face of zero
width
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Fusion face
Root face
Rootgap
Included angle
Bevel angle
Root run Toe
Toe
Reinforcement
Groove
Weld
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• Root opening isthe separationbetween thework pieces atthe joint root
• Bevel is anangular edgepreparation
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BK20A0401 Modern Welding Technology 16
Weld face
Root
Toe
Toe
Base
metal
Base
metal
Weld
metal
Weldmetal
Throatthickness Throat
thickness8 September 2014 BK20A0401 Modern Welding Technology 61
Root penetration
Total throat
thickness
Effective
penetration
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• Proper groove is one of the things that ensure good quality
• Proper groove is essential also in relation to welding costs
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Groove angle
Shape
Size
Cleanliness
Root face
Fusion face
Root edge
Edge angle
Bevel angle
Root face
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• Welding process
• Welding position
• Material
• Mechanization
• Possible root support
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• I-groove =>2 mm, mechanized welding =>4 mm
– Air gap ~material thickness
– Mechanized welding – no air gap
• V – groove 5-15 mm material thickness, groove angle 60o
• Thicker materials – narrow gap or U-groove
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• Thin materials – lap joint
• I – groove 1-4 mm
• Against support ->8 mm
• V-groove >5mm (>50o)
o Air gap 1-3 mm
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• I – groove
o =>8 mm, single side
o =>16 mm, single sided against backing
o =>20 mm, double sided
• Y -groove
o =>25 mm, double sided
• X – groove
o 16 - 35 mm, two runs
o Root face 2-8 mm
• Narrow gap
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• Typically always I – groove
o =>8 mm (12 mm)
o Zero air gap
• Typically always I – groove
o =>8 mm (20 mm)/ =>300 mm
o Zero air gap
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• If the fluidity of molten material is low, the groove anglemust be wider
• The groove must be very clean when welding Ti, Cu, Ni
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• Natural groove from the joint
• Thick plates -bevel
o Over 12 mm
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