ME477 Fall 2004

AW with Consumable Electrodes AW with non-consumable Electrodes

• Flux-cored Arc Welding (FCAW)
– Use a continuous consumable tube • Gas Tungsten Arc Welding (GTAW)
with flux and others such as deoxidizer – Tungsten (Wolfram) Inert Gas (TIG) Welding
and alloying elements – With or without a filler metal
– Two types – Tungsten melts at 3410°C
• Self-shielded – flux has an ingredient for – Shielding gas: argon, helium or a mixture
shielding
– All metals (commonly Al and Stainless steels)
• Gas-shielded – external gas in a wide range of thickness
– Produce high quality weld joint – Slow and costly but high quality weld for thin
• Electrogas Welding (EGW) sections
– Flux-cored or bare electrode with • Plasma Arc Welding (PAW) – a special form
external shield gas and water-cooled of GTAW but with a constricted plasma gas to
molding shoes. attain a higher temperature
– Used in shipbuilding • Carbon Arc Welding – Graphite is used as
• Submerged Arc welding (SAW) electrode
– Shielding is provided by the granular • Stud Welding – for cookware, heat radiation
flux fin.
– Large structures
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2. Resistance Welding Force Spot Welding Cycle

• RW – heat and pressure to + electrode
accomplish coalescence. Weld nugget
• Power source: heat generated: H = I 2 Rt
• Resistance Welding Processes - electrode
– Resistance spot welding (RSW)
• Electrodes – Cu-based or Force
refractory(Cu+W)
• Rocker-arm spot welders
(1) (2) (3) (4) (5)
– Resistance seam welding (RSEW)
– Resistance projection welding (RPW)
Force, Current

– Flash welding (FW) – Heating by Force

resistance
Current
• Upset welding – similar to FW but pressed
during heating and upsetting.
• Percussion welding – similar to FW but
shorter duration (1) (2) (3) (4) (5) time
– High-frequency (induction and resistance)
welding 15 16

3. Oxyfueld gas Welding 4. Other Fusion Welding

• Oxyfuel gas weldings (OFW) – Use • Electroslag Welding – similar to electrogas welding, no arc is
various fuels mixed with oxygen used
• Thermit (from Thermite™) Welding, dated 1900, is a fusion –
• Oxyacetylene welding – A mixture of welding process that uses a mixture of Al powder and iron
acetylene and oxygen oxide in 1:3 ratio for exothermic reaction (reaching 2500°C)
– Total heat: 55x106J/m3 – Used in railroad, repair cracks in ingot and large frame and shaft.
– Acetylene: odorless but commercial
acetylene has a garlic order.
– Unstable at 1atm thus dissolved in
acetone.
• Other gases
– MAPP (Dow), Hydrogen,
Propylene, Propane and Natural gas
Outer Envelope
(1260°C)
Acetylene feather
Inner cone (2090°C)
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(3480°C)

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