Explain the economics and application of non traditional process of welding.

Non-traditional welding processes are a group of welding processes that use energy sources other than
heat to join materials. These processes include :-

• Friction stir welding(FSW) :- In FSW, a rotating tool is plunged into the workpiece and then
moved along the joint line. The friction between the tool and the workpiece generates heat,
which melts the material and creates a weld.
• Laser welding :- In laser welding, a laser beam is used to melt the workpiece material. The laser
beam can be focused to a very small spot, which allows for very precise welding.
• Electron beam welding (EBW) :- In EBW, an electron beam is used to melt the workpiece
material. The electron beam is generated in a vacuum, which allows for very high welding
speeds and deep penetration.

The economics of non-traditional welding processes vary depending on the specific application, but in
general, they can lead to significant cost savings in large-scale production.

Here are some of the factors that can contribute to the cost savings of non-traditional welding
processes :- (Advantages)

• Faster welding speeds :- Non-traditional welding processes can often weld materials much
faster than traditional welding processes. This can lead to significant cost savings, especially
in large-scale production.
• Tighter tolerances :- Non-traditional welding processes can often produce welds with tighter
tolerances than traditional welding processes. This is important for applications where the
strength or appearance of the weld is critical.
• Less heat input :- Non-traditional welding processes typically produce less heat input than
traditional welding processes. This can help to reduce warpage and distortion in the workpiece.
• Improved weld quality :- Non-traditional welding processes can often produce welds with
superior quality than traditional welding processes. This is due to the fact that non-traditional
welding processes often produce a more uniform weld bead and a finer grain structure.

disadvantages

However, non-traditional welding processes also have some disadvantages including :-

• Higher equipment costs :- The equipment required for non-traditional welding processes is
often more expensive than the equipment required for traditional welding processes.
 • Specialized training :- Operators of non-traditional welding processes often require specialized
training. This can increase the cost of training and the time it takes to bring new employees up
to speed.
• Limited availability :- Non-traditional welding processes are not as widely available as
traditional welding processes. This can make it difficult to find qualified welders and to obtain
the necessary equipment.

Application :-

Non-traditional welding processes are becoming increasingly popular in a variety of industries,

including :-

• Aerospace :- Non-traditional welding processes are used to join lightweight materials such as
aluminum and titanium in the aerospace industry. This has led to significant weight savings,
which has in turn led to reduced fuel consumption and emissions.

• Automotive :- Non-traditional welding processes are used to join high-strength steels in the
automotive industry. This has led to improved strength and durability, which has in turn led to
increased safety and reliability.

• Medical :- Non-traditional welding processes are used to join medical implants and other
medical devices. This has led to improved quality and performance, which has in turn led to
improved patient outcomes.

• Energy :- Non-traditional welding processes are used to join pipes and other components in the
energy industry. This has led to improved efficiency and reliability, which has in turn led to
reduced costs.

As non-traditional welding processes become more popular, they are likely to continue to be used in a
variety of industries to improve the quality, performance, and efficiency of products.

frictional welding
Friction welding is a solid-state welding process that generates heat through mechanical friction
between two workpieces in relative motion to one another, with the addition of a lateral force called
"upset" to plastically displace and fuse the materials. Because no melting occurs, friction welding is
not a fusion welding process, but a solid-state welding technique more like forge welding. Friction
welding is used with metals and thermoplastics in a wide variety of aviation and automotive
applications.

There are three main types of friction welding:

• Rotary friction welding (RFW): In RFW, one workpiece is rotated while the other is held
stationary. The rotating workpiece is brought into contact with the stationary workpiece and
the two are held under pressure. The friction between the two workpieces generates heat,
which causes the materials to soften and flow. The rotating workpiece is then stopped and the
two workpieces are brought together under a compressive force. This force plastically deforms
the materials and creates a weld.
• Linear friction welding (LFW): In LFW, one workpiece is moved linearly while the other is held
stationary. The moving workpiece is brought into contact with the stationary workpiece and
the two are held under pressure. The friction between the two workpieces generates heat,
which causes the materials to soften and flow. The moving workpiece is then stopped and the
two workpieces are brought together under a compressive force. This force plastically deforms
the materials and creates a weld.
• Inertia friction welding (IFW): In IFW, one workpiece is spun up to a high speed and then
brought into contact with the other workpiece. The two workpieces are held under pressure
and the spinning workpiece is brought to a stop. The inertia of the spinning workpiece causes
it to impart a large amount of energy to the stationary workpiece, which generates heat and
causes the materials to soften and flow. The two workpieces are then brought together under
a compressive force. This force plastically deforms the materials and creates a weld.

Friction welding offers a number of advantages over other welding processes, including:

• High strength welds

• No filler material required
• No heat-affected zone
• Good surface finish
• Ability to weld dissimilar materials
• Repeatable process

Friction welding is used in a wide variety of applications, including:

• Aerospace
• Automotive
• Medical
• Energy
• Manufacturing
 • Construction

Friction welding is a versatile and reliable welding process that can be used to join a wide variety of
materials. It offers a number of advantages over other welding processes, making it a popular choice
for a variety of applications.