Podcast
Questions and Answers
What is the primary function of the rotating probe in Friction-stir Welding?
What is the primary function of the rotating probe in Friction-stir Welding?
- To apply high pressure
- To generate frictional heat (correct)
- To inject filler material
- To generate ultrasonic waves
Friction-stir Welding involves melting of the material.
Friction-stir Welding involves melting of the material.
False (B)
What happens to the softened material in Friction-stir Welding?
What happens to the softened material in Friction-stir Welding?
The softened material coalesces and is swept to the back.
What is the purpose of the welding tool in Stir Welding?
What is the purpose of the welding tool in Stir Welding?
Match the following welding processes with their characteristics:
Match the following welding processes with their characteristics:
Roll Welding involves the use of a rotating probe.
Roll Welding involves the use of a rotating probe.
What is shown in Figure 32-19(a) of the Stir Welding example?
What is shown in Figure 32-19(a) of the Stir Welding example?
What is the main advantage of Resistance Welding?
What is the main advantage of Resistance Welding?
Forge Welding is a modern welding process.
Forge Welding is a modern welding process.
What is the name of the process that uses conical welding bell or welding rolls to join pipes?
What is the name of the process that uses conical welding bell or welding rolls to join pipes?
Cold Welding is a variation of ______________ welding.
Cold Welding is a variation of ______________ welding.
What is the main difference between Forge Welding and Cold Welding?
What is the main difference between Forge Welding and Cold Welding?
Match the following welding processes with their descriptions:
Match the following welding processes with their descriptions:
Inertia Welding is a type of Solid-State Welding process.
Inertia Welding is a type of Solid-State Welding process.
What is the name of the welding process that uses high localized pressure to achieve coalescence?
What is the name of the welding process that uses high localized pressure to achieve coalescence?
What is the simplest and most widely used form of resistance welding?
What is the simplest and most widely used form of resistance welding?
A spot-weld nugget formed between two sheets of aluminum alloy is always symmetrical.
A spot-weld nugget formed between two sheets of aluminum alloy is always symmetrical.
What should happen to a weld during a tear test?
What should happen to a weld during a tear test?
A single-phase, air-operated, press-type resistance welder is controlled by a _______________.
A single-phase, air-operated, press-type resistance welder is controlled by a _______________.
What is the primary purpose of electrodes in resistance spot welding?
What is the primary purpose of electrodes in resistance spot welding?
Match the following welding processes with their characteristics:
Match the following welding processes with their characteristics:
Resistance welding involves forging and postheating operations.
Resistance welding involves forging and postheating operations.
What is the name of the device shown in the figure, which is a type of resistive welder?
What is the name of the device shown in the figure, which is a type of resistive welder?
What is the primary mechanism used in Friction Welding?
What is the primary mechanism used in Friction Welding?
Friction Welding can only be used for steel bars with a diameter of less than 1 inch.
Friction Welding can only be used for steel bars with a diameter of less than 1 inch.
What is the main advantage of Inertia Welding?
What is the main advantage of Inertia Welding?
Inertia Welding is a modification of _______________ welding.
Inertia Welding is a modification of _______________ welding.
What is the requirement for surfaces to be joined in Friction Welding?
What is the requirement for surfaces to be joined in Friction Welding?
Match the following welding processes with their characteristics:
Match the following welding processes with their characteristics:
What is the advantage of Inertia Welding in terms of speed?
What is the advantage of Inertia Welding in terms of speed?
What is a disadvantage of Friction-stir Welding?
What is a disadvantage of Friction-stir Welding?
Ultrasonic Welding can be used to weld thick sheets.
Ultrasonic Welding can be used to weld thick sheets.
What is the frequency range used in Ultrasonic Welding?
What is the frequency range used in Ultrasonic Welding?
In Ultrasonic Welding, the temperature rarely exceeds half of the __________ point.
In Ultrasonic Welding, the temperature rarely exceeds half of the __________ point.
What is an advantage of Ultrasonic Welding?
What is an advantage of Ultrasonic Welding?
Match the following welding processes with their characteristics:
Match the following welding processes with their characteristics:
Friction-stir Welding has a high flexibility.
Friction-stir Welding has a high flexibility.
What is the limitation of Explosive Welding?
What is the limitation of Explosive Welding?
Study Notes
Friction Welding (FRW)
- Utilizes friction-generated heat
- Surfaces to be joined must have square-cut, smooth surface
- Can be used for steel bars up to 8 inches in diameter or dissimilar metals
Inertia Welding
- Modification of friction welding
- Utilizes a flywheel
- Consistent weld quality since energy stored by the flywheel can be directly controlled for subsequent operations
- Fast and efficient
Friction-Stir Welding (FSW)
- Uses a rotating probe to generate frictional heat
- Material is softened without melting and stirred
- Softened material coalesces and swept to the back
- Features:
- Generates frictional heat
- Provides additional friction heating and prevents expulsion of softened material from the joint
- Applications:
- Example of Stir Welding: friction-stir weld joining 1.5- and 1.65-mm-thick aluminum sheets
Solid-State Welding Processes
- Types:
- Forge welding
- Forge-seam welding
- Cold welding
- Roll welding/ roll bonding
- Friction welding
- Inertia welding
- Friction Stir-Welding
- Ultrasonic Welding
- Diffusion Welding
- Explosive Welding
Forge Welding (FOW)
- Most ancient of welding processes
- Utilized by blacksmiths
- Equipment needed:
- Charcoal forge
- Hammer
- Anvil
- Borax flux
- Procedure:
- Joint preparation → Flux application → Welding
- Pieces to be joined are heated then hammered together until coalescence is achieved
- Results are highly variable
Forge Seam Welding
- Commonly used for pipes
- Uses conical welding bell or welding rolls
- Edges are joined in a lap or butt configuration
Cold Welding
- Variation of forge welding
- Done at room temperature
- Coalescence is achieved by the application of high localized pressure
- Used for soft, ductile materials
Roll Welding/ Roll Bonding (ROW)
- Sheets or plates of metal are passed through a rolling mill
- Can be done hot or cold
- Can be used to join similar or dissimilar metals
Ultrasonic Welding
- Uses high frequency (10kHz-200kHz)
- Temperature rarely exceeds half of melting point
- Restricted to welding thin sheets
- Advantages:
- Very fast
- Clean surface
- Equipment is simple to use
- Disadvantage:
- Limited to welding thin sheets
Diffusion Welding
- Uses high pressure and temperature to bond materials
Explosive Welding
- Accelerates one of the components through the use of explosives
- Limited geometry
Resistance Welding
- Processes:
- Resistance Spot Welding
- Resistance Seam Welding
- Projection Welding
- Advantages:
- Rapid
- Can be fully automated
- Skilled operators not required
- No filler metal, shielding gas, and flux required
- Minimal distortion of the parts being joined
- Dissimilar metal can be joined easily
- High degree of reliability and reproducibility can be achieved
- Limitations:
- High initial cost
- There are limitations to the thickness of material that can be joined
- Lap joints tend to add weight and material
- Access to both sides is usually required
- For some materials, surfaces need special preparation prior to welding
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