Kupdf Welding

Weld Joints
(a) Butt joint (b) Corner joint (c) T joint (d) Lap joint (e) Edge joint
FIGURE 12.1 Examples of welded joints.
e
c
y n
t
i a n
l
i n i
o
e t
t
b n c
a
i s s i e
r t t a p
a r r s s
h V a a e
c y
t M I
n
t P P n i
l f l
g n l a
e r i o a
n g
i l g l b
i e u t
e s a r e l s s s
r
t e m a o e a i o
Method S D S L T R E V C
Arc welding 1 2 3 1 3 1 2 2 2
Resistance welding 1 2 1 1 3 3 3 3 1
Brazing 1 1 1 1 3 1 3 2 3
Bolts and nuts 1 2 3 1 2 1 1 1 3
Riveting 1 2 3 1 1 1 3 1 2
Fasteners 2 3 3 1 2 2 2 1 3
Seaming, crimping 2 2 1 3 3 1 3 1 1
TABLE 12.1 Comparison of various joining
Adhesive bonding 3 1 1 2 3 2 3 3 2 methods.
Note: 1, very good; 2, good; 3, poor.
Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid
© 2008, Pearson Education
General Summary
Joining Skill Level Welding Current Distor- Cost of

Process Operation Advantage Required Position Type tion
∗
Equipment
Shielded Manual Portable High All ac, dc 1 to 2 Low
Lo
metal arc and flexible
Submerged Auto
Autom
mat
atic
ic Hig
igh
h de
depo
possi- Low to Flat and ac, dc 1 to 2 Medium
arc tion medium horizontal
Gas metal Semiautomatic Works with Low to All dc 2 to 3 Meedium to
M
arc or automatic most metals high high
Gas tung- Manual or Works with Low to All ac, dc 2 to 3 Medium
sten arc automatic most metals high
Flux-cored Semiautomatic High deposi- Low to All dc 1 to 3 Medium
arc or automatic tion high
Oxyfuel Manual Portable High All – 2 to 4 Low
and flexible
Electron Semiautomatic Works with Medium to All – 3 to 5 High
beam,, las
beam laser
er or automatic most metals high
beam
∗
1, highest; 5, lowest
TABLE 12.2 General characteristics of joining processes.

processes.

Oxyfuel Gas Welding
2100 C
° 1260 C
°
Outer envelope Acetylene
(3800 F)
° (2300 F)
°
(small and narrow) feather
Inner cone Outer Inner cone Bright luminous Blue

3040 to 3300 C ° envelope (pointed) inner cone envelope
(5500 to 6000 F) °
(a) Neutral flame (b) Oxidizing flame (c) Carburizing (reducing) flame
Gas mixture
Filler rod Welding torch

Molten
Flame
weld metal
Solidified
Base metal weld metal
(d)
FIGURE 12.2 Three basic types of oxyacetylene flames used in oxyfuel gas welding and cutting
operations: (a) neutral flame; (b) oxidizing flame; (c) carburizing, or reducing, flame. (d) The principle of
the oxyfuel gas welding operation.

Pressure
Pressu re Gas Weldi
elding
ng
C2H2 + O2 mixture
Torch
withdrawn
Torch
Flame heating
of surfaces
Upsetting
force
Clamp
(a) (b)
FIGURE 12.3 Schematic illustration of the pressure gas welding

welding process; (a) before, and
(b) after.
after. Note
Note the formation of a flash at the joint, which can later be trimmed off.

Heatt Tran
Hea Transfer
sfer in Weld
Welding
ing
Specific Energy, u
Material J/mm3 BTU/in3
Aluminum and its alloys 2.9 41
Cast irons 7.8 112
Copper 6.1 87 Heat input
Bronze (90Cu-10Sn) 4.2 59 H V I
Magnesium 2.9 42 = e
Nickel 9.8 142 l v
Steels 9.1-10.3 128-146
Stainless steels 9.3-9.6 133-137
Titanium 14.3 204
Welding speed
TABLE 12.3 Approximate specific energy V I
required to melt a unit volume of commonly v = e
welded materials. uA

Shielded
Shield ed Metal Arc Welding
Welding machine AC or DC
power source and controls Solidified slag
Work Arc Electrode

cable holder Coating
Electrode Electrode
Shielding
Work gas
Base metal
Electrode
cable Weld metal Arc
FIGURE 12.4 (a) Schematic illustration of the shielded metal arc welding process. About one-half of all
large-scale industrial welding operations use this process. (b) Schematic illustration of the shielded
metal arc welding operation.
7
5 4
2
FIGURE 12.5 A weld zone showing
showing the build-up
6 3
sequence of individual weld beads in deep welds.
8

Submerg
Sub merged
ed Arc Weldi
Welding
ng
Electrode-wire reel
Flux hopper
Voltage and
current control
Unfused-flux
recovery tube
Wire-feed motor
Electrode cable
Contact tube
Workpiece Voltage-pickup
Weld backing leads (optional)
Ground
FIGURE 12.6 Schematic illustration of the submerged arc welding process

process and equipment. Unfused
flux is recovered and reused.

Gas Met
Metal
al Arc Weld
elding
ing
Solid wire electrode
Shielding gas
Current conductor
Travel
Nozzle
Wire guide and
Shielding gas contact tube
Arc
Solidified weld metal
Base metal Molten weld metal
(a)
Feed control
Control system Wire
Gas out
Gun control Gas in
Shielding-gas source
Gun
Workpiece
FIGURE 12.7 (a) Gas metal arc welding process,
Voltage control
formerly known as MIG welding (for metal inert
Wire-feed
drive motor Welding machine gas). (b) Basic equipment used in gas metal arc
welding operations.
Contactor control 110 V supply
(b)

Flux-C
Flu x-Cored
ored Arc Weld
Welding
ing
Current-carrying guide tube
Arc shield composed of Insulated extension tip

vaporized and slag-forming
compounds protects metal
transfer through arc
Powdered metal, vapor-or
gas-forming materials,
Solidified slag deoxidizers and scavengers
Molten slag
Arc
Solidified weld metal Base metal
Metal droplets covered with
thin slag coating forming
Molten molten puddle
weld metal
FIGURE 12.8 Schematic illustration of the flux-cored arc welding process. This
operation is similar to gas metal arc welding.

Electrogas & Electroslag Welding
Power source Control panel
Drive rolls
Electrode conduit Wire reel
Welding wire
Gas
Wire-feed drive
Oscillator
Electrode lead
Welding gun Oscillation (optional)
Water
Gas
Gas box Consumable
Gas guide tube
Water out Water out Molten slag
Welding wire Supplementary Work
shielding gas Molten weld pool
Water in Water in Workpiece
Fixed shoe Moveable shoe Retaining shoe
(ground) lead
Water in
Primary shielding gas
Water out
FIGURE 12.9 Schematic illustration of the

electrogas welding process. FIGURE 12.10 Equipment used for electroslag
welding operations.

Gas Tun
ungs
gste
tenn Arc
Arc Weld
Weldin
ingg
Travel
Electrical conductor
Tungsten electrode
Gas passage
Shielding gas
Filler wire Arc
Solidified weld metal

Molten weld metal
(a)
Inert-gas
ACor DC
Cooling-water supply
welder
supply
Torch
Filler rod
FIGURE 12.11 (a) Gas tungsten arc welding
Drain
Workpiece process, formerly known as TIG welding (for
tungsten inert gas). (b) Equipment for gas
Foot pedal (optional)
tungsten arc welding operations.
(b)

Plasma
Pla sma Arc Weldi
Welding
ng
Tungsten
electrode
– Plasma gas –
Shielding gas
Power Power
supply supply
+
(a) (b)
FIGURE 12.12 Two types of plasma arc welding processes: (a) transferred and (b)
nontransferred. Deep and narrow welds are made by this process at high welding
speeds.

Weld Bead Comparisons
Laser welds
(a) (b)
FIGURE 12.13 Comparison of the size of weld weld beads in (a) FIGURE 12.14 Gillette Sensor razor cartridge,
electron-beam or laser-beam welding with that in (b) with laser-beam welds.
conventional (tungsten arc) welding. Source: American Welding
Society, Welding Handbook, 8th ed., 1991.

Original Fusion zone Heat-affected
structure (weld metal) zone
Fusion
Fusio n Weld Charact
Characteristi
eristics
cs
Base metal
Molten weld metal
e
r
u
t Melting point of base metal
a
r
e
p Temperature at which the (a) (b)
m base-metal microstructure
e
T is affected
Original FIGURE 12.16

12.16 Grain structure
structure in (a) a deep
temperature weld and (b) a shallow weld. Note that the grains
of base metal
in the solidified weld metal are perpendicular to
FIGURE 12.15 Characteristics of a typical fusion their interface with the base metal.
weld zone in oxyfuel gas welding and arc welding
processes. 1 mm
0.1 mm 145 Melt zone

155
0.43 mm 260
330 Heat-affected
zone
355
Hardness (HV)
(a) (b)
FIGURE 12.17 (a) Weld bead on a cold-rolled nickel strip strip

produced by a laser beam. (b) Microhardness profile across the
Manufacturing Processes for Engineering Materials, 5th ed. weld bead. Note the lower hardness of the weld bead as
compared with the base metal. Source: IIT Research Institute.
Fusion Defects
FIGURE 12.18 Intergranular corrosion

corrosion of a weld
joint in ferritic stainless-steel welded tube, after
exposure to a caustic solution. The weld line
li ne is at
the center of the photograph. Source: Courtesy
of Allegheny
Allegheny Ludlum Corp.
Weld Weld
Weld
FIGURE 12.19 Examples
of various incomplete Base
B
fusion in welds. metal
Incomplete fusion from oxide Incomplete fusion in a
or dross at the center of a joint, groove weld
Incomplete fusion in fillet welds. especially in aluminum
B is often termed bridging
! "
(a) (b) (c)

Defects in Welded Joints
Underfill Crack
Inclusions Base metal
Incomplete
penetration
(a)
FIGURE 12.19
12.19 Examples of various incomplete
Good weld
fusion in welds.
Overlap Undercut
Porosity
Lack of
penetration
(b) (c)
Weld
Toe crack
Transverse
crack
Longitudinal
Crater crack Base metal
cracks
Underbead
crack
FIGURE 12.20 Examples of various defects in

Weld
fusion welds.
Weld
Transverse
crack
Longitudinal
crack Base
metal
Base
metal Toe crack
(a) (b)
Weld Cra
Crack
ck
FIGURE 12.22 Crack in a weld bead, due to the fact that the two components
components
were not allowed to contract after the weld was completed. Source: Courtesy of
Packer Engineering.

Distortion
Distor tion in Welds
Weld FIGURE 12.23 Distortion and
Weld
warping of parts after welding,
caused by differential thermal
Transverse shrinkage Weld Weld
expansion and contraction of
Neutral axis
different regions of the welded
assembly. Warping can be reduced
Angular distortion
Longitudinal or eliminated by proper weld
shrinkage design and fixturing prior to
(a) (b) (c) (d)
welding.
Residual stress
Comp
Compre
ress
ssiv
ive
e Ten
ensi
sile
le
Base
metal FIGURE 12.24 Residual stresses developed in a
straight butt joint. Source: Courtesy of the
American Welding Society.
Weld
(a) (b)

Distortion
Distor tion of Welded Struct
Structures
ures
Rigid frame Hot zone (expanded) Contraction
Internal
Melt
(residual)
(pushed
tensile
out)
stress
No shape Distortion
change
( a) (b) (c)
FIGURE 12.25 Distortion of a welded structure. (a) Before welding;

welding; (b) during welding, with
weld bead placed in joint; (c) after welding, showing distortion in the structure. Source: After
J.A. Schey.
Schey.

Tens
ensio
ion-S
n-Shea
hearr Test
estin
ingg
Root bend
Longitudinal
tension-shear
Clamp
Roller Face bend
Weld
Transverse Side bend

tension-shear
(a) (b) (c)
FIGURE 12.26 (a) Types of specimens for tension-shear testing of welds. (b) Wraparound bend test method.
(c) Three-point bending of welded specimens. (See also Fig. 2.21.)

Tens
ensio
ion-
n-Sh
Shear
ear Tes
Testt of Sp
Spot
ot Wel
elds
ds
(a)
1.
Raised nugget
(b) 2.
Hole left in part
Button diameter
indicates quality
3.
(c) (d)
FIGURE 12.27 (a) Tension-shear test for spot welds; (b) cross-tension
cross-tension test; (c) twist
test; (d) peel test.

Roll Bonding & Ultras
Ultrasonic
onic Welding
Force
Mass
Cladding metal Transducer
Toolholder
Transducer DC
Base metal polarization Roller
Coupling
supply
system
Rolls Workpiece
Tip AC
Direction of power
Workpiece vibration supply
Anvil
FIGURE 12.28 Schematic illustration

of the roll-bonding, or cladding, (a) (b)
process.
FIGURE 12.29 (a) Components of an ultrasonic welding machine for

lap welds. (b) Ultrasonic seam welding using a roller.

Friction
Frict ion Welding
FIGURE 12.30 Sequence of operations in the
friction welding process. (1) The part on the left
Beginning of flash
Force is rotated at high speed. (2) The part on the right
r ight
1.
2.
Force
is brought into contact under an axial force. (3)
Speed increased The axial force is increased, and the part on the
h
t
g 3. left stops rotating; flash begins to form. (4) After
n
e
l
t
a specified upset length or distance is achieved,
e Flash
s
p the weld is completed. The upset length is the
U
,
e
distance the two pieces move inward during
c
r
o
Force 4. welding after their initial contact; thus, the total
F
,
d
e
length after welding is less than the sum of the
e
p Total upset length lengths of the two pieces. If necessary,
necessary, the flash
S e n g t h
U p se t l le
h
can be removed by secondary operations, such
Time
as machining or grinding.
FIGURE 12.31
12.31 Shapes of the fusion zone in
friction welding as a function of the force applied
(a) High pressure (b) Low pressure (c) Optimum
and the rotational speed.
or low speed or high speed

Friction
Frict ion Stir Welding
Shouldered
non-consumable
tool
Probe
Weld
FIGURE 12.32 The principle of the friction stir welding process. Aluminum-alloy plates
up to 75 mm (3 in.) thick have been welded by this process. Source: TWI, Cambridge,
United Kingdom.

Resistance
Resist ance Spot Welding
Electrodes
Weld nugget
Lap joint
1. Pressure 2. Current 3. Current off, 4. Pressure released

applied on pressure on
(a)
Electrodes
Electrode
Electrode tip
Indentation
Sheet
Weld nugget separation
Workpiece Workpiece
(a) (b)
Heat-affected zone
Electrode
(b)
FIGURE 12.34 Two types of electrode
electrode designs
for easy access in spot welding operations for
complex shapes.
FIGURE 12.33
12.33 (a) Sequence in the resistance
spot welding operation. (b) Cross-section of a
spot weld, showing weld nugget and light
indentation by the electrode on sheet surfaces.

Seam & Resist
Resistance
ance Projection Welding
Electrode wheels
Electrode wheels
Weld nuggets
Weld Weld
Sheet
(a) (b) (c) (d)
FIGURE 12.35 (a) Illustration of the seam

welding process, with rolls acting as electrodes.
(b) Overlapping spots in a seam weld. (c) Cross-
section of a roll spot weld. (d) Mash seam Force
welding.
Flat electrodes Weld
nuggets
Sheet
Product
FIGURE 12.36 Schematic illustration of
Workpiece
resistance projection welding: (a) before and (b)
after. The projections on sheet metal are Projections
produced by embossing operations, as described Force
in Section 7.5.2.
(a) (b)
Flash & Stud Welding
Arc
FIGURE 12.37 Flash welding process for

for end-to-
end welding of solid rods or tubular parts. (a)
Before and (b) after.
(a) (b)
Push Pull Push
FIGURE 12.38 Sequence

of operations in stud arc
Stud
welding, used for welding Molten
bars, threaded rods, and Ceramic weld
ferrule Arc Weld
various fasteners on metal
Workpiece
metal plates. (base metal)
1. 2. 3. 4.

Explosion
Explosi on Welding
Deto
Detona
nato
torr Expl
Explos
osiv
ive
e
Deto
Detona
nato
torr Expl
Explos
osiv
ive
e Clad me
Clad meta
tall Buffer
(flyer) Clad metal FIGURE 12.39 Schematic
Constant- Angular-interface illustration of the explosion
interface A
clearance gap
clearance
welding process: (a) constant
gap interface clearance gap and (b)
Base plate Base plate angular interface clearance gap.
(a) (b)
FIGURE 12.40 Cross-sections of explosion

welded joints: (a) titanium (top) on low-carbon
steel (bottom) and (b) Incoloy 800 (iron-nickel-
base alloy) on low-carbon steel. The wavy
interfaces shown improve the shear strength of
the joint. Some combinations of metals, such as
tantalum and vanadium, produce a much less
wavy interface. If the two metals have little
metallurgical compatibility, an interlayer may be
added that has compatibility with both metals. (a) (b)
{\it Source:} Courtesy
Cour tesy of DuPont Company.
Company.

Diffusion Bonding
Stop off Bonding pressure
1. Core sheet 2. Diffusion bonding
Gas
Die
pressure
for forming
Die
3. Superplastic forming 4. Final structure
FIGURE 12.41 Sequence of operations in diffusion bonding and

superplastic forming of a structure with three flat sheets. See also Fig. 7.46.
Source: After D. Stephen and S.J. Swadling.

ISBN No. 0-13-227271-7
Brazing
Brazi ng & Braze Welding
T
e
n
Torch Brass filler metal h
s
t i
l
Base Base metal g
e
s
n
metal e
t
r
r S e
t h n
g t
Flux s e a h
t r s
n t r e n
i t h
gt
g
o
Filler J
metal
(a) (b) Joint clearance
FIGURE 12.43 The effect of joint clearance on

FIGURE 12.42 (a) Brazing and (b) braze welding
welding operations. tensile and shear strength of brazed joints. Note
that unlike tensile strength, shear strength
continually decreases as clearance increases.
Base Metal Filler Metal Brazing Temperature ( C) ◦
Aluminum and its alloys Aluminum-silicon 570-620

Magnesium alloys Magnesium-aluminum 580-625
Copper and its alloys Copper-phosphorus 700-925
TABLE 12.4 Typical filler metals for
for brazing Ferro
errous
us and
and nonf
nonfer
erro
rous
us allo
alloys
ys (exc
(excep
eptt Silv
Silver
er and
and coppe
copperr allo
alloys
ys,, 62
620-
0-11
1150
50
various metals and alloys. alum
alumin
inum
um and
and magn
magnesesiu
ium)
m) copp
copper
er-p
-pho
hosp
spho
horu
russ
Iron-, nickel-, and cobalt-base alloys Gold 900-1100
Stainless steels, nickel- and cobalt- Nickel-silver 925-1200
base alloys

Furnace Brazing & Brazed Joints
Filler FIGURE 12.44 An application

application of
Filler-metal
metal furnace brazing: (a) before and
wire
(b) after. Note that the filler
metal is a shaped wire.
(a) (b)
FIGURE 12.45
12.45 Joint designs
designs commonly used in
brazing operations.

Solder Joints
(a) Flanged T (b) Fl

Flush la
lap (c) Fl
Flanged co
corner (d) Line contact
Bolt
or rivet
FIGURE 12.46 Joint designs commonly used

used for
soldering.
(e) Flat lock seam (f) Flanged bottom (g) Gull wing
Crimp
PC board Wire
(h) Through hole (i) Crimped (j) Twisted
Solder Typical Application

Tin-lead General purp osose
Tin-zinc Aluminum
Lead
Lead-s
-sil
ilve
verr Stre
Streng
ngth
th at high
higher
er than
than room
room tempe
tempera
ratu
ture
re
TABLE 12.5 Types of solders
solder s and their Cadmium-sil
Cadmium-silver ver Strength
Strength at high
high temperatures
temperatures
applications. Zinc-alumin
Zinc-aluminum um Aluminum
Aluminum;; corrosion
corrosion resistance
resistance
Tin-
in-silve
lver Electronics
Tin-
Tin-bi
bism
smut
uth h Elec
Electr
tron
onic
icss

Soldering for Circuit Boards
Squeegee
Tensioned screen Screen material

Paste
FIGURE 12.47 Screening solder pastepaste onto
onto a
printed circuit board in reflow soldering. Source:
After V.
V. Solberg.
Solb erg.
Paste deposited Emulsion Contact ar

area
on contact area
Copper land
Copper land Wetted solder

Plating or coat
coating Oil or air
Flux
FIGURE 12.48 (a) Schematic
Residues
illustration of the wave soldering
process. (b) SEM image of a wave Turbulent zone
(oil prevents dross)
soldered joint on a surface-mount
device. See also Section 13.13. Oil mixed in
Turbulent zone
(dross formed
in air)
(a) (b)

Adhesive Bonding
Single taper Single

Simple Simple
Beveled Beveled Double taper Double
Radiused Radiused Increased thickness Beveled

(a) (b) (c) (d)
FIGURE 12.49 Various configurations

configurations for adhesively bonded joints: (a) single lap, (b)
double lap, (c) scarf, and (d) strap.
Peeling
force
FIGURE 12.50 Characteristic behavior of (a)

brittle and (b) tough and ductile adhesives in a
peeling test. This test is similar to peeling
adhesive tape from a solid surface.
(a) (b)

Properties
Properties of Adhesive
Adhesivess
Epoxy
Epox y Pol
olyu
yure
reth
than
anee Modi
Modifie
fiedd Ac
Acry
ryli
licc Cyan
Cyanoc
ocry
ryla
late
te Anae
Anaero
robi
bicc
Impact resistance Po or Excellent Go o d Po or Fair
Tension-shear 15-22 12-20 20-30 18.9 17.5
strength, MPa (2.2-3.2) (1.7-2.9) (2.9-4.3) (2.7) (2.5)
(103 psi)
Peel strength , N/m
∗
< 523 (3) 14,000 (80) 5250 (30) < 525 (3) 1750 (10)
(lb/in.)
Substrates b on
onded Most Most smooth, Most smo ot
oth, Most non- Metals, glass,
nonpo
porrous nonpo
porrous porous metals
por thermosets
or plastics
Service temperature -55 to 120 -40 to 90 -70 to 120 -55 to 80 -55 to 150
range, C ( F)
◦ ◦
(-70 to 250) (-250 to 175) (-100 to 250) (-70 to 175) (-70 to 300)
Heat cure or mixing Yes Yes No No No
required
Solvent resistance Excellent Go o d Go o d Go o d Excellent
Moisture resistance Go od-Excellent Fair Go o d Po or Go o d
Gap limitation, mm None None 0.5 (0.02) 0.25 (0.01) 0.60 (0.025)
(in.)
Odor Mild Mild Strong Mo derate Mild
Toxicity Mo derate Mo derate Moderate Low Low
Flammability Low Low High Low Low
Note: Peel strength varies widely depending on surface preparation and quality.
TABLE 12.6 Typical properties and characteristics

characteristics of chemically reactive
reactive structural
adhesives.

Rivets and Stapling
Standard loop Flat clinch

(a) (b)
Nonmetal
Metal channel
(c) (d)
(a) (b) (c) (d)
FIGURE 12.52 Examples of various fastening

FIGURE 12.51 Examples of rivets: (a) (a) solid, (b) tubular,
tubular, (c)
methods. (a) Standard loop staple; (b) flat clinch
split, or bifurcated, and (d) compression.
staple; (c) channel strap; (d) pin strap.

Seams & Crimping
FIGURE 12.53 Stages in forming a double-

lock seam. See also Fig. 7.23.
1. 2. 3. 4.
FIGURE 12.54 Two examples

exampl es of mechanical
mechani cal
joining by crimping.
(a) (b)

Snap Fasteners
Spring clip
Nut
Rod-end attachment Push-on

to sheet-metal part fastener
(a) (b) (c)
Deflected Rigid
Sheet-metal cover Sheet-metal cover Integrated snap fasteners
(d) (e) (f) (g)
FIGURE 12.55 Examples of spring and snap-in fasteners

fasteners to facilitate assembly.
assembly.

Design Guideli
Guidelines
nes for Welding
Poor Good Poor Good
Load
Load
(a) (b)
Cut not Deburred

square Burr edge
90°
(c) (d)
Surface to be machined
(e) (f)
FIGURE 12.56 Design guidelines for welding. Source: Bralla, J.G. (ed.)
Handbook of Product Design for Manufacturing , 2d ed. McGraw-Hill, 1999.

Weld Designs
Poor Go o d
FIGURE 12.57 Design guidelines for flash

welding.
Moment, M 3M
Continuous Intermittent
weld welds
Welds
(a) (b)
Wel
eld
d Ba
Base
se me
meta
tall
FIGURE 12.58 Weld designs for Example 12.7.

Single V groove Double V groove
(c)

Brazing Designs
Good Poor Comments
Too little joint

area in shear
Improved design
when fatigue
loading is a factor
to be considered
Insufficient
bonding
FIGURE 12.59 Examples of good and

and poor designs for brazing.

Design for Adhesive Bonding
Poor Good Very good
Adhesive
(a) (b) (c)
Adhesive A dhes i v e FIGURE 12.60 Various joint designs in adhesive

bonding. Note that good designs require large
contact areas for better joint strength.
Rivet S po t wel d
(d) Combination joints

Design for Riveting
Poor
Good
(a) (b) (c) (d)
FIGURE 12.61 Design guidelines for riveting. Source: Bralla, J.G. (ed.)
Handbook of Product Design for Manufacturing , 2nd ed. McGraw-Hill, 1999.

Case Study: Monost eel® Pistons
Monosteel
Oil gallery
Friction
welds
(a) (b)
Monosteel ® piston. (a) Cutaway view of the piston, showing the oil gallery
FIGURE 12.62 The Monosteel
and friction welded sections; (b) detail of the friction welds before the external flash is removed
by machining; note that this photo is a reverse of the one on the left.


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Weld Joints

FIGURE 12.1 Examples of welded joints.

Manufacturing Processes for Engineering Materials, 5th ed.

Joining Skill Level Welding Current Distor- Cost of

TABLE 12.2 General characteristics of joining processes.

Manufacturing Processes for Engineering Materials, 5th ed.

Inner cone Outer Inner cone Bright luminous Blue

Filler rod Welding torch

Manufacturing Processes for Engineering Materials, 5th ed.

FIGURE 12.3 Schematic illustration of the pressure gas welding

Manufacturing Processes for Engineering Materials, 5th ed.

Manufacturing Processes for Engineering Materials, 5th ed.

Work Arc Electrode

Manufacturing Processes for Engineering Materials, 5th ed.

FIGURE 12.6 Schematic illustration of the submerged arc welding process

Manufacturing Processes for Engineering Materials, 5th ed.

Manufacturing Processes for Engineering Materials, 5th ed.

Current-carrying guide tube

Arc shield composed of Insulated extension tip

Manufacturing Processes for Engineering Materials, 5th ed.

FIGURE 12.9 Schematic illustration of the

Manufacturing Processes for Engineering Materials, 5th ed.

Solidified weld metal

Manufacturing Processes for Engineering Materials, 5th ed.

Manufacturing Processes for Engineering Materials, 5th ed.

Manufacturing Processes for Engineering Materials, 5th ed.

Molten weld metal

Original FIGURE 12.16

0.1 mm 145 Melt zone

FIGURE 12.17 (a) Weld bead on a cold-rolled nickel strip strip

FIGURE 12.18 Intergranular corrosion

(a) (b) (c)

Manufacturing Processes for Engineering Materials, 5th ed.

Inclusions Base metal

FIGURE 12.20 Examples of various defects in

Manufacturing Processes for Engineering Materials, 5th ed.

Manufacturing Processes for Engineering Materials, 5th ed.

Rigid frame Hot zone (expanded) Contraction

FIGURE 12.25 Distortion of a welded structure. (a) Before welding;

Manufacturing Processes for Engineering Materials, 5th ed.

Transverse Side bend

Manufacturing Processes for Engineering Materials, 5th ed.

Hole left in part

Manufacturing Processes for Engineering Materials, 5th ed.

FIGURE 12.28 Schematic illustration

FIGURE 12.29 (a) Components of an ultrasonic welding machine for

Manufacturing Processes for Engineering Materials, 5th ed.

Manufacturing Processes for Engineering Materials, 5th ed.

Manufacturing Processes for Engineering Materials, 5th ed.

1. Pressure 2. Current 3. Current off, 4. Pressure released

Manufacturing Processes for Engineering Materials, 5th ed.

(a) (b) (c) (d)

FIGURE 12.35 (a) Illustration of the seam

FIGURE 12.37 Flash welding process for

Push Pull Push

FIGURE 12.38 Sequence

Manufacturing Processes for Engineering Materials, 5th ed.

FIGURE 12.40 Cross-sections of explosion