WELDING DEPARTMENT

The components are brought to this section after the cold forming process for welding operation. It can be said that there are mainly three sections in this department: light welding, heavy welding and robotic welding. It is a very important phase during the manufacturing process since there can be disformings on the component due to heat. And welding talence of the welder has a great importance. Thus welders should be well trained. And as I see this plant has experienced welders. Before my internship I never had chance to experience MI !MA welding. I only did electrod arc welding practice in the university. "o I was curious about practicing the MI !MA welding.

Light Welding Section

The reason this section is called as #$ %ight &elding "ection$$ is the si'e and weight of the components. Because in this section relatively smaller and lighter components are welded. (or example, holders and some small component of a flange is welded in this section, while the flange is welded to chassis in the heavy welding section. The welding machines in this section are MI !MA welding machines. )ence as inert gasses argon, helium and carbon dioxide are used.

as metal arc welding * MA&+, sometimes referred to by its subtypes metal inert gas *MI + welding or metal active gas *MA + welding, is a welding process in which an electric arc forms between a consumable wire electrode and the wor,piece metal*s+, which heats the wor,piece metal*s+, causing them to melt, and -oin. Along with the wire electrode, a shielding gas feed through the welding gun, which shields the process from contaminants in the air. The process can be semi.automatic or automatic. A constant voltage, direct current power source is most commonly used with MA&, but constant current systems, as well as alternating current, can be used. "hielding gases are necessary for gas metal arc welding to protect the welding area from atmospheric gases such as nitrogen and oxygen, which can cause fusion defects, porosity, and weld metal embrittlement if they come in contact with the electrode, the arc, or the welding metal. This problem is common to all arc welding processes/ for example, in the older "hielded.Metal Arc &elding process *"MA&+, the electrode is coated with a solid flux which evolves a protective cloud of carbon dioxide when melted by the arc. In MA&, however, the electrode wire does not have a flux coating, and a separate shielding gas is employed to protect the weld. . The choice of a shielding gas depends on several factors, most importantly the type of material being welded and the process variation being used. 0ure inert gases such as argon

and helium are only used for nonferrous welding. 0ure carbon dioxide, on the other hand, allows for deep penetration welds but encourages oxide formation, which adversely affect the mechanical properties of the weld. Its low cost ma,es it an attractive choice, but because of the reactivity of the arc plasma, spatter is unavoidable and welding thin materials is difficult. As a result, argon and carbon dioxide are fre1uently mixed in a 234!534 to 674!874 mixture. enerally, in short circuit MA&, higher carbon dioxide content increases the weld heat and energy when all other weld parameters *volts, current, electrode type and diameter+ are held the same. As the carbon dioxide content increases over 574, spray transfer MA& becomes increasingly problematic, especially with smaller electrode diameters. The welding machines in this section are e,a brand. And the electric current they wor, is between 577 and 377 ampers. The level of the current is ad-usted as the tic,ness of the material.

Heavy Welding Section

Synergic Welding
"ynergic MI !MA * MA&+ welding is a variant of pulsed MI !MA welding. A synergic welding set provides unit current pulses to detach identical molten droplets of predetermined volume from the electrode wire, combined with the other parametric relationships necessary for stable wire burn off. 9nit pulses are uni1ue to a given material and wire diameter and their details are programmed into a synergic welding set. Modern sets contain a variety of consumable and wire diameter combinations, including programmes for flux and metal.cored consumables. The three essential characteristics of synergic operation are: 8. 0ulse parameters are selected automatically. 5. 0ulse fre1uency or duration is directly related to wire feed rate. :. ;lectronic control of parameters ensures uniform penetration and weld bead profile. In practical terms, this allows an operator to pre.select wire material and diameter once for any welding operation, then ad-ust the one control that governs wire feed rate. The <one ,nob< operation synonymous with this type of power source is the principal advantage of such a system compared to conventional non.synergic sets, which re1uire that the pulse parameters

*pulse fre1uency, pea,!bac,ground current etc.+ be individually set for a given wire feed speed. Thus synergic welding sets offer the advantages associated with pulsed MI !MA welding, combined with a <welder friendly< control system. "ynergic control is also used in conventional MI !MA , in which the voltage is ad-usted in relation to the wire feed. It is now possible to buy a <synergic wire feeder< which performs this function in con-unction with a standard rectifier power source.

Robot Welding Section

=obot welding is the use of mechani'ed programmable tools *robots+, which completely automate a welding process by both performing the weld and handling the part. 0rocesses such as gas metal arc welding, while often automated, are not necessarily e1uivalent to robot welding, since a human operator sometimes prepares the materials to be welded. =obot welding is commonly used for resistance spot welding and arc welding in high production applications, such as the automotive industry. The robot may weld a pre.programmed position, be guided by machine vision, or by a combination of the two methods. The advantages to robot welding:

(aster welding cycle times >o brea,s in production Better 1uality weld product %ess wasted material ?onsistent weld seam =emoves wor,ers from ha'ardous wor, environments More precision, flexibility to reach hard.to.reach spots "aving money through speed, 1uality production and fewer labor costs