Metal Joining Process

METAL JOINING PROCESS

Manufacturing processes, in which single parts are combined to form an
assembly, are referred to as metal joining
• Mechanical assembly: Using various fastening methods to

mechanically attach two (or more) parts and/or subassemblies
together. This group includes processes for non-permanent or
permanent.
Permanent assembly: Two (or more) parts and/or subassemblies are

coalesced to form a permanent joint. Examples are welding, riveting,
brazing and soldering.
MECHANICAL ASSEMBLY
Non-permanent Assembly
Threaded fasteners
Components that have external or internal threads for

assembly of parts. The common threaded fastener types
are screws, bolts, studs and nuts.
• Bolt is an externally threaded fastener that is

inserted through holes in the parts and screwed into
a nut on the opposite side;
• Nut is an internally threaded fastener having

standard threads
• Screw is an externally threaded fastener that is

generally assembled into a blind threaded hole and
no nut is required;
• Stud is an externally threaded fastener, but without

the usual head possessed by a bolt. Studs can also
be used to assemble two parts using a nut. They are
available with threads on one end or both.
Permanent Mechanical Assembly
Riveting
• A rivet is an unthreaded, headed pin used to join two (or more) parts by
passing the pin through holes in the parts and then forming (upsetting) a
second head in the pin on the opposite side.
• The deforming operation can be performed hot or cold and by hammering or

steady pressing. Once the rivet has been deformed, it cannot be removed
except by breaking one of the heads.
Riveting
Welding
• Welding is a material joining process for permanently combining two

(or more) parts.
• Welding involves melting and subsequent solidification of the

material from two parts thus forming a strong joint between them. The
assemblage of parts is called a weldment.
• There are two groups of welding processes according to the state of

the base material during the welding process:
– Liquid-state welding (fusion welding)
– Solid-state welding.
Welding Types
• Fusion welding is by far the most important category. In fusion
welding, the base material is heated to melt. The most important
processes in this group fall in the following categories:
Oxy-fuel gas welding: an oxyfuel gas produces a flame to melt the base
material;
Arc welding: heating and melting of the material is accomplished by an

electric arc;
Resistance welding: the source of heat is the electrical resistance on the

interface between two parts held together under pressure.
Oxyfuel gas welding
• A group of fusion operations that burn various fuels mixed with oxygen
to perform welding or cutting.
• The most important oxyfuel gas welding process is oxyacetylene welding.
• Oxyacetylene welding (OAW) is a fusion welding process performed by a

high-temperature flame from combustion of acetylene and oxygen. The
flame is directed by a welding torch and a filler metal in the form of rod is
added if the process is applied to weld.
• Composition of the filler must be similar to that of the base metal.

Oxyacetylene welding
• oxyacetylene flame
• Very high temperature: 3200 0C
𝐶2 𝐻2 + 𝑂2 → 2 𝐶𝑂 + 𝐻2 (𝑊ℎ𝑖𝑡𝑒 𝑐𝑜𝑛𝑒)
4 𝐶𝑂 + 2𝐻2 + 3𝑂2 → 4𝐶𝑂2 + 2𝐻2 𝑂 (𝐵𝑙𝑢𝑒 𝑐𝑜𝑛𝑒)
Department of Mechanical Engineering 10

Oxyacetylene welding
Generic Arc Welding process
• Arc welding (AW) is a fusion welding process in which coalescence of

the metals is achieved by the heat from an electric arc between an
electrode and the work piece (base metal).
Gas Metal Arc Welding
• Gas Metal Arc Welding (GMAW) is an arc welding process in which the
electrode is a consumable bare metal wire and shielding is accomplished by
flooding the arc with a gas. The bare wire is fed continuously and
automatically from a spool through the welding gun
Arc welding with non-consumable electrodes
Gas Tungsten Arc Welding
– Gas Tungsten Arc Welding (GTAW) is an arc welding process that uses a
non-consumable tungsten electrode and an inert gas for arc
shielding.
– Shielding gases typically used include argon, helium or a mixture of these

gases. The GTAW process can be implemented with or without a filler
metal.
– When a filler metal is used, it is added to the weld pool from a separate rod
or wire.
Thermit Welding
• Heat obtained by an exothermal chemical reaction

• A Mould is kept around the part to be welded
• Preheating flame is used to bring the ends of workpiece to red heat
• A mixture of aluminium, iron oxide ignited

𝟖𝑨𝒍 + 𝟑𝑭𝒆𝟑 𝑶𝟒 → 𝟗𝑭𝒆 + 𝟒𝑨𝒍𝟐 𝑶𝟑
• Temperature of 3500 0C attained - reaction produces liquid iron and

molten slag - made to flow into the mould
• Molten iron is Used to weld heavy parts and for joining rails
Resistance Spot Welding
• Resistance spot welding (RSW) is a resistance welding process in

which fusion of the base metal is achieved at one location by
opposing electrodes.
Electric Resistance Welding
• Low voltage, High Current
• High resistance at point of contact

Spot Welding
Weld
Movable electrode Fixed electrode
Work piece
• Lap welds in thin sheets
• Rise in temperature at contact spot
• Welding by applying pressure using electrodes (Ferrous and Non-ferrous

alloys) Department of Mechanical Engineering 19
Friction welding
• Friction welding is a solid-state welding process in which
coalescence is achieved by frictional heat combined with
pressure.
• The heat is generated by the friction between the two components

surfaces, usually by rotation of one part relative to the other -
which softens the material without melting it.
• The parts are driven toward each other with sufficient force to
form a metallurgical bond.
• No filler metal, flux, or shielding gases are required.

Friction welding
• Rotary Friction Welding
Friction welding
• Linear Friction Welding
Friction welding
• Friction Stir Welding
Brazing/Soldering
• Brazing and soldering are very similar methods of joining metals and
other materials by applying heat and a filler metal.
• When heat is applied, the metal flows by capillary action into the gap
between the base metals or materials and join them by creating a
metallurgical bond between them at the molecular level.
• Brazing differs from soldering in that the filler metal is of greater

strength with a higher melting point. Soldering is used in electronics
industry extensively.
Brazing
• Joining of two metal pieces by using a filler metal whose melting temperature is
above 450oC but lower than the melting point of base metal: Liquid – Solid
• Unlike welding, here only the filler metal is melted.
• Filler material (Brazing solder or spelter) is melted and allowed to flow between
metals to be joined – fills in by capillary action.
TORCH Brazing
• A flux is applied to the surfaces to be brazed.
• A torch is use to direct a flame towards the workpiece and joint.
• Once the joint area reaches suitable temperature, filler wire is added – filler wire
melts
• Base metal should have high temperature tolerance.
• Mostly performed manually – skill of worker is important

FURNACE Brazing
• A furnace is used to supply the required temperature for brazing
• Suitable for mass production
• Parts and the brazing metal are loaded into the furnace and heated to brazing
temperature
• Workpiece cooled and removed

Soldering
• Form of joining metals by another metal or alloy heated to its melting point
– solder or filler alloy
• Melting temperature lower than 450 oC.
• Soldering iron is used to heat the solder
• Heated metal: Solder, flows between the metals to be joined and solidifies
• Mechanical and physical properties of solder should be near to those of

base metals
• Easily separable and are useful for semi permanent work


Metal Joining Process - 6 Nov 24

Uploaded by

Copyright:

Available Formats

Metal Joining Process - 6 Nov 24

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Metal Joining Process - 6 Nov 24

Uploaded by

Copyright:

Available Formats

METAL JOINING PROCESS

• Mechanical assembly: Using various fastening methods to

Permanent assembly: Two (or more) parts and/or subassemblies are

Components that have external or internal threads for

• Bolt is an externally threaded fastener that is

• Nut is an internally threaded fastener having

• Screw is an externally threaded fastener that is

• Stud is an externally threaded fastener, but without

• The deforming operation can be performed hot or cold and by hammering or

• Welding is a material joining process for permanently combining two

• Welding involves melting and subsequent solidification of the

• There are two groups of welding processes according to the state of

Arc welding: heating and melting of the material is accomplished by an

Resistance welding: the source of heat is the electrical resistance on the

• The most important oxyfuel gas welding process is oxyacetylene welding.

• Oxyacetylene welding (OAW) is a fusion welding process performed by a

• Composition of the filler must be similar to that of the base metal.

• Very high temperature: 3200 0C

Department of Mechanical Engineering 10

• Arc welding (AW) is a fusion welding process in which coalescence of

– Shielding gases typically used include argon, helium or a mixture of these

• Heat obtained by an exothermal chemical reaction

• Preheating flame is used to bring the ends of workpiece to red heat

• A mixture of aluminium, iron oxide ignited

• Temperature of 3500 0C attained - reaction produces liquid iron and

• Resistance spot welding (RSW) is a resistance welding process in

• Low voltage, High Current

• High resistance at point of contact

Movable electrode Fixed electrode

• Lap welds in thin sheets

• Rise in temperature at contact spot

• Welding by applying pressure using electrodes (Ferrous and Non-ferrous

• The heat is generated by the friction between the two components

• No filler metal, flux, or shielding gases are required.

• Brazing differs from soldering in that the filler metal is of greater

• Unlike welding, here only the filler metal is melted.

• A torch is use to direct a flame towards the workpiece and joint.

• Base metal should have high temperature tolerance.

• Mostly performed manually – skill of worker is important

• Suitable for mass production

• Workpiece cooled and removed

• Melting temperature lower than 450 oC.

• Soldering iron is used to heat the solder

• Mechanical and physical properties of solder should be near to those of

• Easily separable and are useful for semi permanent work

You might also like

Pfad - The Proxy pFad of © 2024 Garber Painting. All rights reserved.