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437 Welding Assignments Example

The document discusses various advanced welding processes including TIG, MIG/MAG, laser beam welding, electron beam welding, plasma arc welding, and friction stir welding, detailing their mechanisms, applications, and differences. It also covers the factors affecting weld quality such as weld bead configuration, microstructural characteristics, and weld composition. Additionally, it addresses failure modes of welded joints, emphasizing the importance of material condition and mechanical analysis in diagnosing failures.

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31 views19 pages

437 Welding Assignments Example

The document discusses various advanced welding processes including TIG, MIG/MAG, laser beam welding, electron beam welding, plasma arc welding, and friction stir welding, detailing their mechanisms, applications, and differences. It also covers the factors affecting weld quality such as weld bead configuration, microstructural characteristics, and weld composition. Additionally, it addresses failure modes of welded joints, emphasizing the importance of material condition and mechanical analysis in diagnosing failures.

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eaglecatcher.nmt
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Unit 437 Welding technology and practi Task1 Advanced Welding Process LIE ¢ TIG/TAG welding s TIG comes. from USA and is an abbreviation of Tungsten inert gas. Tungsten also called \wolfram - is a metal with fusion point of more than 3300 C, which means more than double the fasion point of the metals which are usually welded. Inert pas is the same thing as inactive ga which means a type of gas will not to combine with other elements Figure 1.1 TIG welding of TIG Wi TIG welding is an electric arc welding process in which the fusion energy is produced by ‘an electric are buming between the work piece and the tungsten electrode, During the welding process the electrode , the are and the weld pool are protected against the damaping effects of the atmospheric air by an inert shielding gas, By mean of a gas nozzle the shielding gas is lead to the ‘welding zone where it replaces the atmospheric air. TIG welding differ from the other arc welding process by the fact that the electrodes in other processes such as MIG/MAG and MMA Fhe HG are ‘As mentioned before the fusion energy in TIG welding is produced in the arc burning: between the tungsten electrode and the workpiece. The wire feeding can be done manually or mechanically. In DC TIG electrode is usually connected to negative polarity and the workpiece to positive polarity. According to the theory of clectrons the negatively charged electrons and positively ions will migrate when the arc is ignited The oe i atomnaaive 10 positive pole while the ions will travel in the ‘opposite direction. Inthe are there will therefore be a collision between the electron and the ions ghd this collision produces heat energy. The flow of electrons from the point of the electrode takes place at a very high speed and when it hits the workpiece a substantial amount of heat nergy is produced. When the flow of ions hits the point of the electrode there is not produced a similar amount of hear energy. The total produced heat energy is distributed by approx. 30% to the point of the electrode that is connected to the negative pole and approx. 70% to the workpiece connected to the positive pole ns MIG/MA‘ in Pass)correctly explained the MIG/MAG welding process, transfer, Juding modes of metal MIG/MAG welding process Metal inert Gas (MIG) and Metal Active Gas (MAG)welding are gas metal are welding process that use heat created from a DC electric are between a consumable metal eleetrode and workpiece which melt together to create a weld pool that fuses to form a join MIG and MAG welding are known as gas metal arc welding process in the USA. MIG/MAG is similar to MMA in that heat for welding is produced by forming an are between a consumable metal electrode and the workpiece; the electrode melts to form the weld bead. The main difference is that the metal electrode is a small diameter wire fed through the contact tip from a wire feeding spool gun , while a shielding gas is fed through the welding torch. As the wore is continuously fed, the manual process is sometimes referred to as semi-automatic welding “MIG and MAG welding both use gas bottles to provide the shielding gas and compatible filler ‘materials for example , to weld aluminium ,an aluminium wire should be used , whereas steel ‘MIG welding would require an appropriate stee! filler wire. ‘The different between MIG and MAG MIG(Metal Inert Gas ) welding is a welding process in which an electric are forms between a consumable wire electrode and the work piece. This process uses inert gases or g3s taixtures as the shielding gas . Argon and helium are typically used for the MIG welding of non ferrous metals such as aluminium. MAG@Metal Active Gas) welding is an are welding process where an eldectroc ate ios created between a consumable wire electrode and the material to be joined. MAG welding uses ieldia ses, primarily for the welding of steels. These shielding gases are mixture of transfers from the filler wire to the weld pool largely ess, there are three principal metal transfer modes: ‘© Short circuiting, (dip transfer) + Spray transfer © Pulsed transfer siting and pulsed metal transfer are used for low current operation, while sfer, the Short spray transfer is only used with high welding ot ts. In short circuiting, or dip tr sears meth forming on the tip ofthe wire is ranofered by the wire dipping into the wek! pool and the inductance in relation this achieved by setting a low voltage. Care in setting the voltagt to the wire feed speed is essential to minimize spatter, Inductance is used to control the surge in current which occurs when the wire dips into the weld pool For spray transfer, much higher wire is necessary to ensure that wire does not make contact. re: chor-circuit, with the weld pool. The molten metal atthe tip ofthe wire transfers 10 the weld pool in the form of a spray of small droplets (less than diameter ofthe wire) however» there is a minimum current level or threshold, below which droplets are not forcibly projected crows the are fan open arc technique is attempted much below the threshold curent level» the jent to prevent large droplets forming at the tip of the wire. These s transfer erratically across the are under normal gravitational force . the plused mode was low are forces are insuffi

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