PPT: Joining Processes | Manufacturing Engineering - Mechanical Engineering PDF Download

 Page 1


Unit No. 3 (Metal Joining Processes)
?Principle of welding, soldering, Brazing and adhesive bonding. 
?Classification of welding and allied processes
?Capabilities and applications
?welding parameters
?general concepts of weldability
?welding metallurgy and weldament design
?Gas welding and gas cutting
?Arc welding
?Power sources and consumables
?Resistance welding
?Spot, Projection and seam welding process
?Atomic hydrogen
?Ultrasonic
?Plasma and laser beam welding
?Electron beam welding
?special welding processes 
e.g. TIG, MIG, friction and explosive welding, welding of C.I. and Al. 
?Defects of welding and remedial actions
?Numerical Calculation of Different process parameters of welding.
Teaching Hours – 12 and Percentage Weightage 25% (18 Marks)
Page 2


Unit No. 3 (Metal Joining Processes)
?Principle of welding, soldering, Brazing and adhesive bonding. 
?Classification of welding and allied processes
?Capabilities and applications
?welding parameters
?general concepts of weldability
?welding metallurgy and weldament design
?Gas welding and gas cutting
?Arc welding
?Power sources and consumables
?Resistance welding
?Spot, Projection and seam welding process
?Atomic hydrogen
?Ultrasonic
?Plasma and laser beam welding
?Electron beam welding
?special welding processes 
e.g. TIG, MIG, friction and explosive welding, welding of C.I. and Al. 
?Defects of welding and remedial actions
?Numerical Calculation of Different process parameters of welding.
Teaching Hours – 12 and Percentage Weightage 25% (18 Marks)
Welding
Welding is a process in which localized coalescence
(Permanent Joint) is produced by heating the material upto
suitable temperature with or without application of filler
material.
If filler material is different from base material it is
heterogenous welding.
Advantages:-
? Different Material can also be welded.
? Welding can be done anywhere.
Disadvantages:-
? In the heat affected zone properties of base material is also
affected.
? To dismantle, we have to break the weld
? Initial investment is more
? Highly skilled operator is required
Page 3


Unit No. 3 (Metal Joining Processes)
?Principle of welding, soldering, Brazing and adhesive bonding. 
?Classification of welding and allied processes
?Capabilities and applications
?welding parameters
?general concepts of weldability
?welding metallurgy and weldament design
?Gas welding and gas cutting
?Arc welding
?Power sources and consumables
?Resistance welding
?Spot, Projection and seam welding process
?Atomic hydrogen
?Ultrasonic
?Plasma and laser beam welding
?Electron beam welding
?special welding processes 
e.g. TIG, MIG, friction and explosive welding, welding of C.I. and Al. 
?Defects of welding and remedial actions
?Numerical Calculation of Different process parameters of welding.
Teaching Hours – 12 and Percentage Weightage 25% (18 Marks)
Welding
Welding is a process in which localized coalescence
(Permanent Joint) is produced by heating the material upto
suitable temperature with or without application of filler
material.
If filler material is different from base material it is
heterogenous welding.
Advantages:-
? Different Material can also be welded.
? Welding can be done anywhere.
Disadvantages:-
? In the heat affected zone properties of base material is also
affected.
? To dismantle, we have to break the weld
? Initial investment is more
? Highly skilled operator is required
Soldering
? The melting point temperature of filler material is less than 450°C
and it is also less than melting point temperature of base material.
? Filler material is an alloy of lead and tin is known as solder.
? The flux used in soldering is zinc chloride (ZnCl2) and HCI.
? The strength of joint is less when compared to brazing.
? Used in electronic industry.
Brazing
?The melting point temperature of filler material is more than 450°C 
but less than the melting point temperature of base material.
?Filler material is an alloy of copper and zinc, copper and silver, 
copper and aluminium. This is known as spelter.
?The flux used is borax and boric acids.
?Strength is more.
?Used in pipe fitting where leak proof joints are required for intricate 
light weight components.
Page 4


Unit No. 3 (Metal Joining Processes)
?Principle of welding, soldering, Brazing and adhesive bonding. 
?Classification of welding and allied processes
?Capabilities and applications
?welding parameters
?general concepts of weldability
?welding metallurgy and weldament design
?Gas welding and gas cutting
?Arc welding
?Power sources and consumables
?Resistance welding
?Spot, Projection and seam welding process
?Atomic hydrogen
?Ultrasonic
?Plasma and laser beam welding
?Electron beam welding
?special welding processes 
e.g. TIG, MIG, friction and explosive welding, welding of C.I. and Al. 
?Defects of welding and remedial actions
?Numerical Calculation of Different process parameters of welding.
Teaching Hours – 12 and Percentage Weightage 25% (18 Marks)
Welding
Welding is a process in which localized coalescence
(Permanent Joint) is produced by heating the material upto
suitable temperature with or without application of filler
material.
If filler material is different from base material it is
heterogenous welding.
Advantages:-
? Different Material can also be welded.
? Welding can be done anywhere.
Disadvantages:-
? In the heat affected zone properties of base material is also
affected.
? To dismantle, we have to break the weld
? Initial investment is more
? Highly skilled operator is required
Soldering
? The melting point temperature of filler material is less than 450°C
and it is also less than melting point temperature of base material.
? Filler material is an alloy of lead and tin is known as solder.
? The flux used in soldering is zinc chloride (ZnCl2) and HCI.
? The strength of joint is less when compared to brazing.
? Used in electronic industry.
Brazing
?The melting point temperature of filler material is more than 450°C 
but less than the melting point temperature of base material.
?Filler material is an alloy of copper and zinc, copper and silver, 
copper and aluminium. This is known as spelter.
?The flux used is borax and boric acids.
?Strength is more.
?Used in pipe fitting where leak proof joints are required for intricate 
light weight components.
Page 5


Unit No. 3 (Metal Joining Processes)
?Principle of welding, soldering, Brazing and adhesive bonding. 
?Classification of welding and allied processes
?Capabilities and applications
?welding parameters
?general concepts of weldability
?welding metallurgy and weldament design
?Gas welding and gas cutting
?Arc welding
?Power sources and consumables
?Resistance welding
?Spot, Projection and seam welding process
?Atomic hydrogen
?Ultrasonic
?Plasma and laser beam welding
?Electron beam welding
?special welding processes 
e.g. TIG, MIG, friction and explosive welding, welding of C.I. and Al. 
?Defects of welding and remedial actions
?Numerical Calculation of Different process parameters of welding.
Teaching Hours – 12 and Percentage Weightage 25% (18 Marks)
Welding
Welding is a process in which localized coalescence
(Permanent Joint) is produced by heating the material upto
suitable temperature with or without application of filler
material.
If filler material is different from base material it is
heterogenous welding.
Advantages:-
? Different Material can also be welded.
? Welding can be done anywhere.
Disadvantages:-
? In the heat affected zone properties of base material is also
affected.
? To dismantle, we have to break the weld
? Initial investment is more
? Highly skilled operator is required
Soldering
? The melting point temperature of filler material is less than 450°C
and it is also less than melting point temperature of base material.
? Filler material is an alloy of lead and tin is known as solder.
? The flux used in soldering is zinc chloride (ZnCl2) and HCI.
? The strength of joint is less when compared to brazing.
? Used in electronic industry.
Brazing
?The melting point temperature of filler material is more than 450°C 
but less than the melting point temperature of base material.
?Filler material is an alloy of copper and zinc, copper and silver, 
copper and aluminium. This is known as spelter.
?The flux used is borax and boric acids.
?Strength is more.
?Used in pipe fitting where leak proof joints are required for intricate 
light weight components.