The process of joining metals

usually by heat or sometimes

with pressure and sometimes
with an intermediate or filter
material with high melting point.
1. BASIC INTERVALS
a. Squeeze Interval
b. Weld Interval
c. Hold Interval
d. Release
e. Standby Interval
2. POPULAR WELDING PROCESSES
a. Arc Welding
✓ TIG Welding
✓ MIG Welding
b. Solid State Welding
c. Resistance Welding
✓ Spot Welding
✓ Seam Welding
✓ Upset Welding
 BASIC INTERVALS

Welding electrode comes

forward and engage the
metal pressing against the
surface.
Typical squeeze time is 1
sec.
 BASIC INTERVALS

Welding transformer is
energized, current flows
and creates a weld.
On heat subinterval is a
condition when the
current is on.
On cool subinterval is
when the current is off
Typical duration (2-10
sec).
 BASIC INTERVALS

Weld interval is finished.

Electrode pressure is
maintained.

Welding electrode is retracted.

The time after release interval

to the next start sequence.
POPULAR WELDING PROCESSES

It is simply the use of

electric arc to provide heat.
Process of utilizing the
concentrated heat of an
electric arc to join metal by
fusion of the parent metal
and the addition of metal
to joint usually provided by
a consumable electrode.
POPULAR WELDING PROCESSES

Either direct or alternating

current may be used for the
arc, depending upon the
material to be welded and
the electrode used.
Various forms of arc welding
includes electroslag welding,
plasma arc welding, gas
metal arc welding,
submerged arc welding, gas
tungsten arc welding, etc.
ARC WELDING MACHINE
POPULAR WELDING PROCESSES

Gas tungsten arc welding

An arc is formed between a
non-consumable tungsten
electrode and the metal
being welded.
Some of its benefits includes
superior quality welds,
precise control of heat, free
of splatter and low distortion.
TIG WELDING
GTAW Weld Area
 POPULAR WELDING PROCESSES

Gas metal arc welding

Commonly used high deposition
rate welding process
Referred to as a semiautomatic
welding process
Benefits include all position
capability, long weld can be
made without start and stops
and minimal post weld cleaning
is required.
GAS METAL ARC WELDING
GMAW WELD AREA
1) Direction of Travel
2) Contact Tube
3) Electrode
4) Shielding Gas
5) Molten Weld Metal
6) Solidified Weld Metal
7) Workpiece
POPULAR WELDING PROCESSES

Group of welding processes

which produces coalescence
at temperatures essentially
below the melting point of
the base materials being
joined, without the addition
of brazing filler metal.
Pressure may or may not be
used.
POPULAR WELDING PROCESSES

Sometimes called solid state

bonding processes.
Includes cold welding,
diffusion welding, explosion
welding, forge welding,
friction welding, hot pressure
welding, roll welding, and
ultrasonic welding
SOLID STATE WELDING MACHINES
POPULAR WELDING PROCESSES

Uses the application of electric

current and mechanical pressure
to create a weld between two
pieces of metal.
Weld electrodes conduct the
electric current to the two pieces
of metal as they are forged
together.
Some of its benefits include high
speed, easily automated,
suitable for high rate production
and it is economical.
RESISTANCE WELDING
POPULAR WELDING PROCESSES

Resistance welding in which

the weld is produced by the
heat obtained at the
interface between the work
pieces.
SPOT WELDS
RESISTANCE SPOT WELDING
POPULAR WELDING PROCESSES

Spots are very closed

to each other that they
overlap and make a
continuous seam weld.
SEAM WELDING MACHINE
POPULAR WELDING PROCESSES

Resistance welding process

applicable to small welding
areas.
 UPSET WELDING MACHINE

UPSET MOTION
 CONTROL SYSTEM

Controlled directly by an input

signal.
It has no feedback and therefore
less accurate.
Usually requires an operator to
control the speed and direction
of movement of the output.
 CONTROL SYSTEM

Can respond and move loads

quickly.
With greater accuracy.
Has an automatic feedback
system that informs the input
the desired movement has
taken place.
Classified as closed-loop system

Normally made up of
electromechanical parts and
consists of a synchro control
system, servo amplifier and
feedback.
INPUT CONTROL AMP MOTOR LOAD

FEEDBACK
 BASIC SERVO SYSTEM

Control the position of the load.

In AC position servo, the
amplitude and phase of the AC
error signal determine the amount
and direction the load will be
driven.
In the DC position servo system,
the amplitude and polarity of the
DC error signal are used to
determine the amount and
direction of the load will be driven.
Potentiometer is one of the
simplest position sensor device
and is generally used because of
its small size, high accuracy and
output which can either be AC or
DC.
Balanced potentiometer in a
closed loop servo system is a
voltage divider that functions as
a position sensor and produces
the error voltage that is fed to
the servo amplifier.
LINEAR POSITION SERVO
 BASIC SERVO SYSTEM

Same principle of error signal

generation as position servo
except that the velocity is being
sensed rather than the position.
 BASIC SERVO SYSTEM

Similar to velocity and position

servos except that the
acceleration of the load is
being sensed rather than
position or velocity.
The tachometer of the velocity
loop is replaced with an
accelerometer.
HIGH ACCELERATION SERVO
Used to stabilize a system
to minimize or eliminate the
problem of overshot.
 DAMPING CONDITIONS

Provides instant response to an

error signal but results in the
load oscillating about the point of
synchronism.

Takes as excessive amount of

time to reach synchronization.
OVERDAMPED
UNDERDAMPED
Servo characteristics defined as
the time between the input of the
signal and the actual movement of
the load.
Undesirable and is reduce with the
use of high gain amplifiers.
Damping systems are added to
smoothen the operation.
 SERVO DEVICES

Used in servo systems that

move light loads.
 SERVO DEVICES

Control heavy loads and are

widely used in servo systems.
 SERVO DEVICES

Magnetic error detector that

can be used in systems limited
by large angular movements.

CROSSED E-TRANSFORMER
 SERVO DEVICES

Used to change a DC error

signal into an AC input error
signal for servo amplifiers.

Convert AC error signal to DC

error signal.
Drive a DC servo amplifier.
 SERVO DEVICES

Used when power from a

conventional servo amplifier is
too small to drive a large servo
motors.
 SERVO DEVICES

Tachometer
Used in the velocity servo loop.

PRECISION RATE GENERATOR

 SERVO DEVICES

Used in AC or DC servo system.

Must have a flat gain, minimum
phase shift and low noise level.

DIGITAL SERVO AMPLIFIER

Applied to any rapidly spinning
object.
A functional gyroscope is
constructed and mounted.
RATE GYROS are specially
mounted so they are free to
precess in only one direction
and are used to measure
angular rates.
GYROSCOPE
 PROPERTIES OF GYROS

Tendency of a spinning wheel

to remain in fixed position in
space.

Factors that Affect Rigidity

a. Weight
b. Shape
c. Speed of rotation of the rotor
PROPERTIES OF GYROS

Property of a gyro that causes

it to tilt in a direction
perpendicular to the direction
of any outside force.
The direction of precession in
a gyro is always 90° from the
direction of the applied force.