Product Realization Through Manufacturing

Course Number: MCP101

For academic purpose only. Contents of the slides are meant
for MCP101 course only at IITD

Revision Session

Course Coordinator:
Dr. Prithviraj Mukhopadhyay
Dr. Binayak Sen
Department of Mechanical Engineering
Indian Institute of Technology Delhi
Hauz Khas – 110 016
 Joining Processes
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The term joining is generally used for welding, brazing which forms a permanent joint between the parts: Joints
that cannot be easily be separated.

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 Overview of Joining Processes
• An assembly process where two or more components are joined to
• For academic purpose only. Contents of the slides are

obtain desired part/configuration

• For example, a typical automotive body assembly consists of 200 - 250 sheet
metal parts assembled at 60 -100 assembly stations
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• On the Eiffel Tower, 2.5 million rivets hold together 12,000 metallic pieces
• Joining is inclusive of processes such as welding, brazing, soldering,
adhesive bonding, and mechanical fastening
✓Welding+ brazing + soldering → two or more parts are fused together by
means of heat, pressure or both forming a join as the parts cool
✓Adhesive bonding → by employing synthetic glue such as epoxy resins
✓Mechanical fastening → nut and bolt, screws and rivets

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 Overview of Welding
• Welding is a joining process in which two or more parts are coalesced at their contacting surfaces by a suitable
application of heat and/or pressure (joining of materials as AWS)
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• In some welding processes, a filler material is added to facilitate coalescence

• The assemblage of parts that are produced by welding is called a weldment
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• As per AWS, joining of materials where metallurgical continuity and coalescence of materials are observed

Advantages of welding Limitations of welding

• provides a permanent joint
• welded joint strength can be more than parent
metal
• economical in terms of material usage and
fabrication cost
• can be accomplished in the field as well
• manual and expensive in terms of labour cost
• involve high energy sources and dangerous
/hazardous
• welding joint defects substantially reduce strength
• it does not allow convenient disassembly

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 Types of Welding Processes
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Fusion Welding Solid-state welding

Process process

In this process heat is used to melt the base

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It refers to joining processes in which coalescence

materials. In some of the fusion welding process,
results from application of pressure alone or a
filler is added to the molten pool to facilitate the
combination of heat and pressure. If heat is used,
process and provide bulk and strength to the
the temperature is below the melting point of the
welded joint.
metals being welded.

Welding is considered to be a joining process in which two or more parts are

coalesced at their contacting surfaces by a suitable application of heat and/or
The fusion welding process in which no pressure.
filler material is required is referred to as
In some welding processes, a filler material is added to facilitate coalescence.
“autogenous welding process”
The assemblage of parts that are produced by welding is called a weldment.

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 Widely used Welding Processes Categorized
Under Fusion Welding Operation
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Electron beam
Arc Welding
welding and laser
Process (AW)
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beam welding
Resistance Oxyfuel gas
Welding (RW) welding (OFW)

Widely used Welding Processes Categorized

Under Solid State Welding Operation

Diffusion Welding Friction Welding Ultrasonic Welding

(DFW) (FRW) (USW)

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 Types of Welded Joints
There are five basic types of joints bringing two parts together for joining
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Power Density: To accomplish the fusion, a source of high-density heat energy is supplied to the faying
surfaces and the resulting temperatures are sufficient to cause localised melting of the
base metals. 𝑃𝑜𝑤𝑒𝑟 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟𝑟𝑒𝑑 𝑡𝑜 𝑡ℎ𝑒 𝑤𝑜𝑟𝑘
𝑃𝑜𝑤𝑒𝑟 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 =
𝑆𝑢𝑟𝑓𝑎𝑐𝑒 𝐴𝑟𝑒𝑎

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 Power Densities of Major Fusion Welding Processes
Power Density
12000

10000
10000
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9000

8000

6000

4000
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2000
1000
10 50
0
Oxyfuel Arc Welding Resistance Laser Beam Electron Beam
Welding Welding Welding Welding

The issue is more complicated than indicated by the previous expression. During welding process, the arc
produced in many welding processes move that results in preheating ahead of the operation and post
heating behind it.

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 Arc Welding

Consumable Electrodes Non-Consumable Electrodes

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 Arc welding
• It is a fusion welding process in which the
melting and joining of metals is done by
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the heat energy generated by the arc

between the work and electrode
• An electric arc is a discharge of electric
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current across a gap in a circuit; it is

sustained by the presence of a thermally
ionized column of gas through which
current flows
• An electric arc is generated when the
electrode contacts the work and then
quickly separated to maintain the gap Schematic of electric arc welding processes
• A temperature of 5500°C or higher is
generated by this arc • This temperature is sufficient to melt most of the metals. The molten
metal, consisting of base metal and filler, solidifies in the weld region
• In order to have seam weld, the power source moves along the weld line

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 Arc Shielding
At high temperatures in arc welding, the metals being joined are chemically reactive to
oxygen, nitrogen and hydrogen in the air.
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The arc shielding is accomplished by covering the electrode tip, arc, and molten weld pool with a
blanket of gas or flux, or both which inhibit the exposure of the weld metal to air.

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 Flux
During welding, the flux melts and become a liquid slag, covering the operation and
protecting the molten weld metal.
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The method of flux application differs for each process. The delivery technique includes:

• Pouring granular flux onto the welding operation

• Using tubular electrodes in which flux is contained in the core and released as the electrode is consumed
• Using a stick electrode coated with flux material in which the coating melts during welding to cover the
operation
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 Power source in arc welding
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• Both AC and DC can be used

• AC machine less expensive to purchase and operate but generally
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restricted to the welding of ferrous metals

• DC is advantageous as better arc control is possible
• Convection, conduction, radiation, and spatter account for losses that
reduce the amount of usable heat
• Power in arc welding is the product of the current I passing through
the arc and the voltage E across it

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 Power source in arc welding - Polarity
• Polarity (direction of current flow is important):
• Straight polarity (DCEN) in which workpiece is positive and electrode is
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negative is suitable for deeper welds

• Reverse polarity (DCEP) in which workpiece is negative and electrode is
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positive is suitable for wider and shallower penetration (like in sheets) and
joints with wide gaps
• AC current in which the arc pulsates rapidly. This method is suitable for
welding thick sections and for using large-diameter electrodes at maximum
currents

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students of IITD
 Power source in arc welding - Polarity
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Selection of appropriate
polarity is important for
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successful welding as it
affects:
1. distribution of heat
generated by welding arc
at anode and cathode,
2. stability of the arc and
3. cleanliness of weld

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 Resistance Welding (RW)
• Resistance welding (RW) is a group of fusion-
welding processes that use a combination of heat
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and pressure to accomplish coalescence, the heat

being generated by electrical resistance to current
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flow at the junction to be welded

• The operation results in a fused zone between the
two parts, called a weld nugget in spot welding
• RW uses no shielding gases, flux, or filler metal
• By comparison to arc welding, the electrodes are
non-consumable
• Electrodes in RSW: (i) Copper based, (ii) Refractory
metal (Cu, Tungsten combinations)
Resistance Spot Welding
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students of IITD
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Resistance Welding
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Resistance Welding
 Setup Used for Spot Welding
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Force, Current

(1) (2) (3) (4) (5)

Spot welding cycle For the academic purpose only. The contents are only for
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 Factors Governing Fusion Welding Process
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Schematic illustration of fusion welded joint

Important factors governing a fusion welding process are:

• The characteristics of the heat source

• The nature of deposition of the filler material in the fusion zone, know as the weld pool
• The heat flow characteristics in the joint
• The gas metal or slag metal reactions in the fusion zone
• The cooling of the fusion zone with associated contraction, residual stresses, and metallurgical changes

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