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CH 29
CH 29
CH 29
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 29-1
Fusion Weld Zone
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 29-2
Grain Structure in Shallow and Deep Welds
(a) (b)
Figure 29.2 Grain structure in (a) a deep weld (b) a shallow weld. Note
that the grains in the solidified weld metal are perpendicular to the surface
of the base metal. In a good weld, the solidification line at the center in the
deep weld shown in (a) has grain migration, which develops uniform
strength in the weld bead.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 29-3
Weld Beads
(b)
(a)
Figure 29.3 (a) Weld bead (on a cold-rolled nickel strip) produced by a laser beam. (b)
Microhardness profile across the weld bead. Note the lower hardness of the weld bead
compared to the base metal. Source: IIT Research Institute.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 29-4
Regions in a Fusion Weld Zone
Figure 29.4 Schematic
illustration of various regions
in a fusion weld zone (and
the corresponding phase
diagram) for 0.30% carbon
steel. Source: American
Welding Society.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 29-5
Corrosion
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 29-6
Incomplete Fusion
Figure 29.6 Low-quality weld beads, the result of incomplete fusion. Source: American Welding
Society.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 29-7
Discontinuities in Fusion Welds
Figure 29.7 Schematic illustration of various discontinuities in fusion welds. Source: American Welding
Society.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 29-8
Cracks in Welded Joints
Figure 29.8
Types of cracks
(in welded
joints) caused
by thermal
stresses that
develop during
solidification
and contraction
of the weld bead
and the
surrounding
structure. (a)
Crater cracks.
(b) Various
types of cracks
in butt and T
joints.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 29-9
Crack in a Weld Bead
Figure 29.9 Crack in a weld bead, due
to the fact that the two components were
not allowed to contract after the weld
was completed. Source: S. L. Meiley,
Packer Engineering Associates, Inc.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 29-10
Distortion After Welding
Figure 29.10 Distortion of parts after welding: (a) butt joints; (b) fillet welds. Distortion is caused
by differential thermal expansion and contraction of different parts of the welded assembly.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 29-11
Residual Stresses Developed During Welding
Figure 29.11 Residual stresses developed during welding of a butt joint. Source: American
Welding Society.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 29-12
Overview of Commercial Joining Processes
TABLE 29.1 Overview of Commercial Joining Processes*
Joining Process
S G F G Brazing
M S M C T P E E O D F E L I D
Thick- A A A A A A S G R F F F R B B T F I R D R F
Material ness W W W W W W W W W W W W W W W B B B B B B B
Carbon steel S x x x x x x x x x x x x x x x x
I x x x x x x x x x x x x x x x x x
M x x x x x x x x x x x x x x
T x x x x x x x x x x x x
Low-alloy S x x x x x x x x x x x x x x x x x
steel I x x x x x x x x x x x x x x x
M x x x x x x x x x x x x x
T x x x x x x x x x x x
Stainless S x x x x x x x x x x x x x x x x x x
steel I x x x x x x x x x x x x x x x x
M x x x x x x x x x x x x x x x
T x x x x x x x x x x x
Cast iron I x x x x x x
M x x x x x x x x x
T x x x x x x x
Nickel and S x x x x x x x x x x x x x x x x
alloys I x x x x x x x x x x x x x x
M x x x x x x x x x x x
T x x x x x x x x
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 29-13
Overview of Commercial Joining Processes
(cont.)
TABLE 29.1 (continued)
Joining Process
S G F G Brazing
M S M C T P E E O D F E L I D
Thick- A A A A A A S G R F F F R B B T F I R D R F
Material ness W W W W W W W W W W W W W W W B B B B B B B S
Aliminum S x x x x x x x x x x x x x x x x x x x
and alloys I x x x x x x x x x x x x x x
M x x x x x x x x x x
T x x x x x x x x
Titanium S x x x x x x x x x x x x
and alloys I x x x x x x x x x x
M x x x x x x x x x x
T x x x x x x x
Copper and S x x x x x x x x x x x
alloys I x x x x x x x x x x
M x x x x x x x
T x x x x x
Magnesium S x x x x x x x x x
and alloys I x x x x x x x x x x x
M x x x x x x x
T x x x
Refractory S x x x x x x x x x x x x
alloys I x x x x x x x
M x x
T
*This table is presented as a general survey only. In selecting processes to be used with specific alloys, the reader
should refer to other
appropriate sources of information.
Source: Courtesy of the American Welding Society.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 29-14
Overview of Commercial Joining Processes
(cont.)
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 29-15
Destructive Techniques
Figure 29.12 Two types of specimens for tension-shear
testing of welded joints.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 29-16
Testing of Spot Welds
Figure 29.14 (a) Tension-
shear test for spot welds.
(b) Cross-tension test. (c)
Twist test. (d) Peel test;
see also Fig. 30.8.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 29-17
Welding Design Guidelines
Figure 29.15 Design guidelines for welding. Source: J. G. Bralla (ed.), Handbook of Product Design for
Manufacturing. Copyright ©1986, McGraw-Hill Publishing Company. Used with permission.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 29-18
Standard Identification and Symbols for Welds
Figure 29.16
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 29-19
Weld Design Selection
Figure 29.17
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 29-20