Free Essay

Welding Techniques

In: Other Topics

Submitted By mattthesack
Words 622
Pages 3
Matthew Laine
Unit 6 Lab 1: Case Problem
Materials and Processes in Design
DT1410
Chapter 15 Case Problem 1: Welding Thin Materials I have to disagree with both, the experienced welder and the production supervisor. Arc welding is not the ideal process for thin metals. It takes many years for a welder to acquire the skills to arc weld thin metal and ever the most experienced welders mess up and ruin product. TIG welding would work with the thin metal but will take a lot longer and cost a lot more. It also takes the longest to master. Gas MIG (GMAW) is the process I recommend for the thin metal. I will explain the three processes in the following paragraphs. Arc Welding is one of the oldest welding processes around. It can be the cheapest to start with as there is not a lot of equipment needed. It is also very versatile as there are a lot of specialized electrodes available. These specialized electrodes are used for different types of preferences which include: hardening, high-strength, stainless, mixed, cast iron and other meter alloys. This process requires a flux coating to shield the weld and the flux will have to be cleaned from the weld. This process is very difficult to accomplish of thin metals of all types. Therefore, takes a considerable amount of training and practice to master. Also this process requires no gas or wire feeder which allows this process to be portable. This process works of AC (used on aluminum) or DC (used on ferrous metals (steels)). TIG welding is also very versatile and produces the highest quality welds. It also takes a considerable amount of practice and is the least productive of the different types of welding. TIG uses a torch with a tungsten electrode. To protect the weld and tungsten, argon must be used as a shielding gas. In this process an arc is struck between the tungsten and the work piece and a short gap is maintained. As the weld progresses, filler wire is dipped in the weld pool. In this process a constant current (AC or DC depending on the metal used) must be maintained. This is a physically complicated process because you must, control the torch, feed the wire, move at the right speed and also use the correct current. This process is much easier for bench work. TIG can weld just about any metal with AC and DC power sources. Gas MIG welding is also called GMAW (Gas, Metal Arc Welding). It uses a thin wire as an electrode and is filler fed by a wire feeder to the gun. This process requires a power source that has a constant voltage (CV) DC. This process produces very clean weld with no slag or spatter. You must use argon/CO2 or straight CO2 as a shielding gas. The filler wire used in this process is less expensive than the wire used in TIG. This process is great for thin metals of all types. MIG is the easiest process to learn but requires gas and a wire feeder so it is not as portable. This is my conclusion: Arc welding is the most difficult on thin metals. Gas MIG welding is the easiest on thin metals and has the cleanest welds. TIG is the most expensive process, easiest to control and is great for aluminum. In the circumstance of this case problem, I recommend Gas MIG welding to produce the patio furniture frames. It will cost a bit more than the Arch welding but will cost less than TIG welding. It will require a wire feeder, gun, gas bottle and regulator. This process is easy to learn and is great for large quantity production.

Similar Documents

Free Essay

Plastics

...please click for enlargement Variations of Joint Designs or Energy Directors For the design of plastic parts for assembly with ultrasonic energy, many recommendations exist to save time, energy and tooling modifications. The first step for a designer is to determine the most suitable joining technique. The following variations are possible: Ultrasonic Welding Ultrasonic Swaging, Staking, Spot-Welding Ultrasonic Insertion Ultrasonic Welding The molten material builds at the contact area of the energy director between the to be welded parts. The ultrasonic waves are transferred through the part to the joint area. Common "standard" joint designs include: Basic 90 Degree Energy Director 90 Degree Energy Director Step Joint 90 Degree Energy Director Tongue & Groove Herrmann Ultrasonics Mash Joint Double V-Point Tongue & Groove The recommended process examples listed above can be varied with inserted gaskets or in-molded 2K injection molded gaskets. Ultrasonic Swaging, Staking, Spot-Welding please click for enlargement In addition to conventional types of joint design for bonding injection molded plastic parts, ultrasonic welding can be used in a verity of forms to accomplish a mechanical bond when only one part is of thermoplastic material. Common applications include: Swaging, for deforming or bending an area of a plastic piece to trap the other part (of different plastic or other materials). Through......

Words: 360 - Pages: 2

Free Essay

Welding Safety

...your First project Welding technology offer's society many beneficial ability's in enginering, construction, architecture, and also creates varied safety Concern's for the individual tradesmen' "tradeswomen"and their environment's. Welding Cover's a temperature range from 1500 F - 3000 ººF (800 ºC - 1635 ºC) and poses certain inevitable inherent risk's. As a skilled worker in this industry, one must proactively plan, prepare for any and all possible problem's, determine solution's and prepare preventative measures to use in case they arrive. Many welders reflecting on thier welding shop experience can admit they have acquired scars, acknowledge the dangers, and admit the necessity of demonstrating a professional respect for proper personal safety equipment and techniques. it has been said “If you play with fire you get burned” There are three main different risk's associated with welding including , heat, inhaling toxic fumes and electrical shock that are the most hazardous to your health, other various danger's include Gas leak, fire's and explosion's. In addition the extreme heat welding creates can burn you in many ways if not properly protected. There is ultraviolet light generated by the welding arc “electrical connection between welder and workpiece” that can cause severe radient heat, sunburns and increase your risk of skin cancer. Sparks can burn right through your gloves, boots and multiple layers of clothing even specialized welding coats! Using personal......

Words: 659 - Pages: 3

Free Essay

Prediction and Optimisation of Fsw

...aluminium (AA5083). Firstly, data-driven modelling techniques such as Artificial Neural – Fuzzy networks and regressive analysis are used and by making the effective use of experimental data, FIS membership function parameters are trained. At the core, mathematical model that functionally relates tool rotational speed and forward movement per revolution to that of Yield strength, Ultimate strength and Weld quality are obtained. Also, simulations are performed, and the actual values are compared with the predicted values. Finally, multi-objective optimization of mechanical properties fuselage aluminium was undertaken using Genetic Algorithm to improve the performance of the tools industrially. AIMS AND OBJECTIVES Objectives of the dissertation include  Understanding the basic principles of operation of Friction Stir Welding (FSW).  Gaining experience in modelling and regressive analysis.  Gaining expertise in MATLAB programming.  Identifying the best strategy to achieve the yield strength, Ultimate Tensile strength and Weld quality of Friction Stir Welding.  Performing optimization of mechanical properties of FSW using Genetic Algorithm. I  To draw conclusions on prediction of mechanical properties of FSW optimization of aircraft fuselage aluminium. ACHIEVEMENTS  The basic principles of friction welding of the welding operations are well studied and understood.  The theoretical concepts of modelling techniques are familiarised.  Gained expertise in MATLAB......

Words: 9686 - Pages: 39

Premium Essay

Lgal Doc

...PREPARING TO WELD 17 17 17 18 18 2 3 COMPRESSED GASSES AND EQUIPMENT HAZARDS ................................... 3 ADDITIONAL SAFETY INFORMATION ......... 4 PREPARING A SAFE WELDING WORK AREA.. PREPARING THE WORK PIECE ............. ALUMINUM WELDING PREPARATION ........ CONNECT WELDER GROUND .............. PRODUCT DESCRIPTION 5 5 5 5 5 OPERATION GETTING TO KNOW YOUR NEW WELDER .... SETTING THE CONTROLS ................. HOLDING THE GUN ....................... Position of the Gun to the Work Piece ......... Distance from the Work Piece ............... LAYING A BEAD .......................... CLEANING THE WELD BEAD ............... 19 19 19 20 20 21 21 21 SPECIFICATIONS ......................... WELDER CONTROLS AND THEIR FUNCTIONS. DUTY CYCLE ............................. INTERNAL THERMAL PROTECTION .......... ASSEMBLY AND INSTALLATION 6 6 6 7 7 7 8 8 8 9 UNPACKING YOUR WELDER ................ INSTALL THE GROUND CLAMP .............. INSTALL WELDING GUN ASSEMBLY .......... PROVIDE REQUIRED POWER ............... Power Requirements ....................... Connect Welder to Power Source ............. Extension Cord Use ........................ INSTALL TANK TRAY AND BRACKET .......... SELECT SHIELDING GAS ................... WELDING TECHNIQUES...

Words: 14464 - Pages: 58

Free Essay

Training

...information on how to achieve good sound weld by familiarizing the imperfections, joint configuration, types of joints and welds and the enhancement of the welders’ skill/technique. 2. PURPOSE The purpose of this training module is to equip the welder with the ability to conduct visual inspection, familiarization with weld imperfection and to enhance welders ability make a weld free of any imperfection/defect inside the weld metal and weld surface. 3. REFERENCE 3.1 CSWIP Book 2008 3.2 TWI Course Reference WIS7 3.3 ASME I 3.4 ASME V 3.5 ASME IX 4 TRAINING PROGRAM Welder’s training would help to enhance the skill of each welder. It takes a lot of practice in order to be acquire a very good welding skill specially in boilers which has limited distance between weld joints and are quite restricted which gives a welder a hard time to perform. Before Welding • Ensure that all operations are carried out in complete compliance with local, company, or National safety legislation (i.e. permits to work are in place) etc. • Welding Machine, grinder, quiver, electrode holder, ground clamp and other tools they will use must be check if in good condition. • Proper PPE (i.e. welding mask, arm sleeve, respirator, welding cloves, welding apron, etc.) must be prepared. • Materials must be confirmed for the proper welding consumable issuance. • Analysis on the joint must be done to determine if need rectification in fit-up. • Working area must be checked if there are......

Words: 272 - Pages: 2

Free Essay

Double Lumen

...FLEXIBLY DIVIDED DOUBLE LUMEN ENDOTRACHEAL TUBE Viren Sunil Kalsekar, Joy Lee, Jenny Qiu, Nicholas Ragosta, Javier Ramos, David Taylor Massachusetts Institute of Technology Cambridge, MA, USA ABSTRACT Endotracheal tubes (ETT), are used to maintain patient airway access during surgical procedures. The design presented here addresses a current need of the gold standard ETT by allowing for the passage of a larger bronchoscope through the inner lumen of the ETT while keeping outer dimensions constant. This design incorporates a flexible membrane with a wavy geometry to ensure a return to the neutral axis, thus allowing for even ventilation of both lungs. Flow tests simulating surgical ventilation conditions were conducted. These results confirmed that adequate air flow could be obtained independent of any pressure differences across the membrane. Tests of the prototype also confirmed that maximum instrumentation diameter was increased through this design when compared to a commercially available ETT with identical outer dimensions (35 Fr). Finite element analysis was conducted to determine the necessary thickness of the membrane for a safe design. One key design feature of the membrane is that its state of maximum deflection (2.1mm) does not significantly hinder airflow through the smaller lumen. Tests to further evaluate the functional requirements of safety and ease of use are currently under way. Methods of manufacturing this design are also under investigation.......

Words: 6040 - Pages: 25

Free Essay

Norne Paper

...pipeline was selected by Statoil for transport of the multiphase well stream from the two oil reservoirs. The Norne field is located at 66° North and subjected to strict environmental requirements. Therefore a Carbon steel pipeline, built with a corrosive resistant alloy layer ( CRA ), had been selected for the resistance against the corrosive fluid without the use of chemicals. An implication of this construction method is that the pipeline girth welds have to be made with an austenitic welding consumable (typically Inconel), which is very difficult to inspect using ultrasonic testing method. Furthermore the reeling process used for the pipeline installation require severe weld flaw detection capabilities. An extensive AUT-CRA qualification program has been utilized by Technip and Statoil to confirm that the proposed CRA inspection method meet the quality standards and requirements of DNV OS F101 Appendix E. Throughout the qualification process it has been verified that the CRA inspection technique adequately detects and qualitatively sizes the weld defects that also have been observed in destructive, microscopic evaluation. The so called Primary & Coincidence CRA inspection method* has been demonstrated to be very versatile in comparison with...

Words: 6161 - Pages: 25

Free Essay

Manufacturing Process Gold Chain

...in the industry, I arrived at the conclusion that the history of chain making is either a well kept secret or just not of much interest to anyone. Precious metal chain for jewelry has been around for a long time. Basically when man first began working extensively with gold back in Neolithic times he found that certain metals, most notably pure gold, were extremely ductile and could be hammered and stretched to a great degree. With the invention of wire, man could now take something rigid like metal and turn it into something flexible like chain. Chain making has always been, up until the middle of the 18th century, a labor-intensive time consuming hand operation. It was a well-versed art and most books on jewelry will demonstrate basic techniques on making chain by hand. Before automated wire drawing machines, the craftsman had to hammer down and pull metal through succeeding smaller dies to form thin wire. Once the wire was pulled down to the needed diameter, it was wound around a mandrel forming loops. Then, the craftsman would make a cut through the looped wire down the length of the mandrel forming individual offset loops. The craftsman would then interlock the loops, bend each link closed, and then solder each link. Tedious indeed, if you considered making an 1132 chain (.011" wire at 32 links per inch) by hand, it would contain 512 links for a...

Words: 1991 - Pages: 8

Premium Essay

High Performance Steel for Highway Bridges.Pdf

...2003 ECI Conference on Advanced Materials for Construction of Bridges, Buildings, and Other Structures III % FILE: /main/production/doc/data/journals/services.bepress.com/advanced materials/assets/location.inc Switzerland% FILE: (cont) /main/production/doc/data/journals/services.bepress.com/eci/assets/proceedings/pdftitlepage.te Editors: % FILE: /main/production/doc/data/journals/services.bepress.com/advanced materials/assets/editors.incV Mistry, P.E., Office of Bridge Technology, Federal Highway Administration, USA Dr. Atorod Azizinamini, Ph.D., P.E., Civil Engineering Department, University of Nebraska, USA John M. Hooks, P.E., Office of Infrastructure Research & Development, Federal Highway Administration, USA % FILE: /main/production/doc/data/journals/services.bepress.com/eci/assets/proceedings/defines.tmpl (cont) Year  Paper  High Performance Steel For Highway Bridges Vasant C. Mistry ∗ ∗ Federal Highway Administration High Performance Steel For Highway Bridges Abstract All steels possess a combination of properties that determines how well steel performs. Strength, weldability, toughness, ductility, corrosion resistance, and formability are all important to determine how well steel performs. High-performance steel (HPS) can be defined as having an optimized balance of these properties to give maximum performance in bridge structures while remaining cost-effective. http://services.bepress.com/eci/advanced materials/1 Copyright c 2005 by......

Words: 3237 - Pages: 13

Free Essay

Studies on Friction Stir Welded Aa 7075

...21 April 2004 ; in revised form 28 June 2004) ABSTRACT Friction stir welding is a promising solid state joining process and is widely being considered for aluminum alloys. In this work, the microstructural and corrosion properties of friction stir welded 7075 Al alloy were studied. The microstructures of the base metal, bore metal, thermo-mechanically affected zone (TMAZ) and weld region were characterized by optical microscopy and transmission electron microscopy. Micro-hardness profile was obtained across the weld. The pitting corrosion properties of the weldments were studied in 3.5% NaCl solution. Friction stir welding of this alloy resulted in fine recrystallized grains in weld nugget which has been attributed to frictional heating and plastic flow. The process also produced a softened region in the weld nugget, which may be due to the dissolution and growth of possible precipitates, identified as Mg32(Al,Zn)49. Corrosion resistance of weld metal has been found to be better than that of TMAZ and base metal. 1. INTRODUCTION High strength precipitation hardening 7XXX series aluminum alloys, such as 7075 are used extensively in aerospace industry. These alloys are difficult to join by conventional fusion welding techniques. Hence realizing a fusion-welded joint in such alloys without impairing the mechanical properties is a difficult task for the welding engineer. Consequently the welding engineer has to rely on rivets and fasteners with substantial increase in...

Words: 2022 - Pages: 9

Premium Essay

Mem Sop

...Fabfurnish Following my under graduation, to tap the taste of start ups and ever growing interest in marketing – I started working ……<framing this> The front end marketing analytics, where direct cum indirect interaction with the customers and their reaction pushed us how to increase the conversion rate and engagement with audiences. <need to frame this> Customer Insights – based on that taking further actions Launching the new campaigns on facebook and optimizing them on the key metrics like CTR(Cost to revenue Ratio),CPC(Cost per Click),CPV(Cost per Visit)– lowering the CRR (Cost to Revenue Ratio – inverse of ROI) bought down by 70%. Optimization was done on the basis of reports in which number are stacked up from Google Analytics and FB Power Editor to check the bounce rate and Conversion Rate Good with reports and reports making Engaging in Mobile as this was the time in India (late 2014) where mobile grew as a major player in the advertising industry and various different inventory of FB like MPA (multiple ads) and doing the category wise segmentation & performing the strategic group analysis which help in growth of 40% mobile revenue. - - -> key insight ran ads of those products which have low basket value (<1000 INR) since audience have more interaction for these products on mobile platform and thus increasing the funds in this segment and generating a 14 lac transaction in a single day through optimized reports * To show interest......

Words: 1776 - Pages: 8

Free Essay

Steps to Build a Soybean Oil Press Machine

...and two 8-inch pieces of angle iron. The bar will serve as the top crossbar in your frame while the angle irons will join the frame to a wooden base. 3• Stand all three tubes on their ends, with the long tubes 5.5 inches apart. Place the short tube in between them and use an arc welder to weld the steel crossbar at their top ends, and the angle iron pieces on both sides of their bottom ends. This will make a rectangular metal frame with the short pipe in the middle of one short side. • 4 File or grind any rough edges from your frame, then paint it. The paint will dampen down any shavings. Once painted, it can be attached to a wooden base by passing screws through the holes in the angle iron piece. • 5 Make the press canister by welding a circular piece cut from your plate steel onto one end of a wide steel tube. Drill holes through the outside of the canister and file down any rough edges. • 6 Form the press piston by cutting another circle of plate steel just small enough to fit inside the press canister. On one side of the disk, weld a short length of pipe with a diameter big enough to fit snugly over the end of the short pipe in the press's frame. • 7 Chop off the bottom third of a round plastic jug and cut a hole in the center of it big enough for the middle pipe in your frame. This will collect the oil as it drips...

Words: 519 - Pages: 3

Free Essay

All the Pews on One Arrow

...preheat holes or in a two-piece tip the cutting tip will overheat and explode. a. True b. False 4. A cutting torch is used for cutting, welding, and heating. a. True b. False 5. Most hand torches can cut metal up to seven inches thick. a. True b. False 6. It is possible to cut steel that is four feet thick. a. True b. False 7. Acetylene should be used in a two-piece cutting tip. a. True b. False 8. Acetylene cutting tips should be one piece with 1 to 6 preheat holes. a. True b. False 9. The chance of a flashback is less with low pressure regulator settings that with high pressure settings. a. True b. False 10. The oxyfuel gas cutting torch works as a result of the metal being rapidly melted. a. True b. False 11. Hard slag is easier than soft slag to remove. a. True b. False 12. Distortion is not a problem if the correct fuel gas is used. a. True b. False 13. By looking at the drag lines in a cut, you can determine whether the cut was made correctly or incorrectly. a. True b. False 14. The two major methods for controlling distortion while make a cut is making two parallel cuts at the same time and speed and making a short cut and skipping a strip to keep the plate from separating. a. True b. False 15. The advantaged of a combination welding and cutting...

Words: 527 - Pages: 3

Premium Essay

Essay On Sand Molds

...Molding Methods Molding process is used to create intricate metal components. The mold material used to make these “molds” could be either temporary or permanent. Temporary molds are made up of refractory sands and resins. The temporary mold has to be broken to retrieve the cast. Permanent molds are made of ferrous materials and are normally employed for casting low melting point materials but this process is too costly. Because of this conundrum, most of the foundry industry has its castings produced using temporary mold materials. Compared to permanent molds, the temporary sand molds can cast high melting point materials and larger parts, while permanent molds can produce small castings of better quality and dimensional accuracy. Sand casting uses temporary sand molds to form complex metal components that can be made of almost any alloy. Sand casting has a relatively lower production rate as each time the part solidifies, the mold has to be broken to retrieve the part. The sand casting process makes use of a furnace, metal, pattern, and sand mold. The metal is melted in the furnace, ladled, and then poured into the cavity of the refractory sand molds. The sand mold is separated using “parting sad” and the solidified cast can be removed. Its relatively cheap and can even be used for steel foundry use. Apart from sand, a bonding agent such as clay is generally used. Water or some other moisturising agent is added to this mixture to develop strength and plasticity of the......

Words: 1218 - Pages: 5

Premium Essay

Lincoln Electric

...2006, Stropki looked back on his company’s more than 100 years in the welding equipment and consumables industry with pride, wondering whether a strong push into India should be the next step in his company’s globalization. An India expansion had been considered for several years, but thus far the company had focused on growing its operations in China and elsewhere around the globe. If Stropki were to approve a significant allocation of resources toward an India expansion, he wondered what would be the best way to enter. He had a wealth of company lessons and experiences to apply to the India investment decision, as his company had had international operations since the 1940s, had struggled internationally in the late 1980s and early 1990s, and had gone on to regain its global competitive advantage in the late 1990s and early 2000s. During Stropki’s tenure as CEO since 2004, the company had further expanded globally and by 2006 owned manufacturing operations in 19 countries across five continents. Most recently, the company had enjoyed increasing success in China as a result of its aggressive expansion through both a joint venture and set of majority-owned plants. As Stropki opened the Cleveland newspaper to check the previous Sunday’s Cleveland Browns score, he wondered how he could apply the lessons of the Chinese experience in particular, to India. Welding Industry Welding is a technique for joining pieces of metal by fusion through the application......

Words: 10250 - Pages: 41