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CH 27
CH 27
Fusion-Welding Processes
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 27-1
General Characteristics of Fusion Welding
Processes
TABLE 27.1
Skill level Welding Current Cost of
*
Joining process Operation Advantage required position type Distortion equipment
Shielded metal-arc Manual Portable and High All ac, dc 1 to 2 Low
flexible
Submerged arc Automatic High Low to Flat and ac, dc 1 to 2 Medium
deposition medium horizontal
Gas metal-arc Semiautomatic Most metals Low to All dc 2 to 3 Medium to
or automatic high high
Gas tungsten-arc Manual or Most metals Low to All ac, dc 2 to 3 Medium
automatic high
Flux-cored arc Semiautomatic High Low to All dc 1 to 3 Medium
or automatic deposition high
Oxyfuel Manual Portable and High All — 2 to 4 Low
flexible
Electron-beam, Semiautomatic Most metals Medium All — 3 to 5 High
Laser-beam or automatic to high
* 1, highest; 5, lowest.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 27-2
Oxyacetylene Flames Used in Welding
Figure 27.1 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. The gas
mixture in (a) is basically equal volumes of oxygen and acetylene.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 27-3
Torch Used in Oxyacetylene Welding
Figure 27.2 (a) General view of and
(b) cross-section of a torch used in
oxyacetylene welding. The acetylene
valve is opened first; the gas is lit
with a spark lighter or a pilot light;
then the oxygen valve is opened and
the flame adjusted. (c) Basic
equipment used in oxyfuel-gas
welding. To ensure correct
connections, all threads on acetylene
fittings are left-handed, whereas those
for oxygen are right-handed. Oxygen
regulators are usually painted green,
acetylene regulators red.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 27-4
Pressure-Gas Welding
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 27-5
Shielded Metal-Arc Welding
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 27-6
Multiple Pass Deep Weld
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 27-7
Submerged-Arc Welding
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 27-8
Gas Metal-Arc Welding
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 27-9
Equipment Used in Gas Metal-Arc Welding
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 27-10
Flux-Cored Arc-Welding
Figure 27.10 Schematic illustration of the flux-cored arc-welding process. This operation
is similar to gas metal-arc welding, showing in Fig. 27.8.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 27-11
Electrogas Welding
Figure 27.11 Schematic illustration of the
electrogas welding process. Source: American
Welding Society.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 27-12
Equipment for Electroslag Welding
Figure 27.12 Equipment used for
electroslag welding operations.
Source: American Welding Society.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 27-13
Designations for Mild Steel Coated Electrodes
TABLE 27.2
The prefix “E” designates arc welding electrode.
The first two digits of four-digit numbers and the first three digits of five-digit numbers
indicate minimum tensile strength:
E60XX 60,000 psi minimum tensile strength
E70XX 70,000 psi minimum tensile strength
E110XX 110,000 psi minimum tensile strength
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 27-14
Gas Tungsten-Arc Welding
Figure 27.13 The gas tungsten-arc welding process,
formerly known as TIG (for tungsten inert gas) welding.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 27-16
Comparison of Laser-Beam and Tungsten-Arc
Welding
Figure 27.16
Comparison of the
size of weld beads in
(a) electron-beam or
laser-beam welding to
that in (b)
conventional
(tungsten-arc)
welding. Source:
American Welding
Society, Welding
Handbook (8th ed.),
1991.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 27-17
Example of Laser Welding
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 27-18
Flame Cutting and Drag Lines
Figure 27.18 (a) Flame cutting of steel plate with an oxyacetylene torch, and a cross-
section of the torch nozzle. (b) Cross-section of a flame-cut plate showing drag lines.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 27-19