SPECIAL WELDING PROCESSES

Habib Ibnu jabar (11/15238)

Adyan Rizkya Akbar (11/14763)
 High Energy Density Processes

ELECTRON BEAM WELDING (EBW)

Electron beam welding(EBW) is
a fusion welding process in
which a beam of high-velocity
electronsis applied to the
materials being join.The
workpieces meltas the kinetic
energy of the electronsis
transformed into heat upon
impact.
 Advantages :
 Deepest single pass weld
penetration of the fusion processes
 14-inch-thick steel

 Fast travel speeds

 Low heat input welds produce low
distortion
 High Energy Density Processes

LIMITATIONS
 High initial start-up cost
 Not portable

 Part size limited by size of vacuum chamber

 Produces x-rays

 Part fit-up is critical

 High cooling rates may lead to materials

problems
VACUUM

 Produce high-quality welds

 Used in electron beam welding

 Nuclear/special metal applications

 Zr, Hf, Ti
 Reduces impurities by a factor of 20 versus
other methods
 Expensive and time-consuming
LASER-BEAM WELDING

 Laser-beam welding
(LBW) utilizes a laser
beam as the heat source.
 - Beam can be focused onto small area,
it than has high energy for deep
 - penetrating capability.
 - Power level up to 100kW.
- Welding speed up to 250ft/min
- Can weld foil up to 1’’ plate
ADVANTAGES
– No vacuum required;
– Laser beam can be shaped, manipulated and focused.
 Easily automated;
– Do no generate X-rays;
– Better quality weld. Less tendency for incomplete fusion,
spatter, porosity ans distortion.
ELECTROGAS WELDING (EGW)
 Uses a continuous consumable
electrode, either flux-cored wire or
bareWire with externallysupplied
shielding gases, and molding
shoes tocontain molten metal
 When flux-cored electrode wire is
used and noexternal gases are
supplied, then special caseof self-
shielded FCAW
 When a bare electrode wire used
with shielding gases from external
source, then special caseof
GMAW
PLASMA ARC WELDING

• Developed in the 1960’s

• Temperatures exceeding 60,000F
• Ionized hot gas containing equal shares of electrons and ions
• Highly Concentrated
• Filler fed into the arc, like GTAW
• Shielding gas like Argon, Helium, etc
• Transferred Arc, Nontransferred methods
• Deep, Narrow Welds
• Great stability
• Low thermal distortion
(a) front view with molding shoe removed for
clarity, and (b)side view showing molding shoes
on both sides.
ULTRASONIC WELDING
ADVANTAGES & LIMITATIONS

 Advantages
 Fast

 Can spot or seam weld

 Limitations
 Equipment complex, many
variables
 Only use on small parts

 Cannot weld all plastics

0.1.1.2.5.T25.95.12
INERTIA WELDING

 Inertia Welding provides the increased benefits

of repeatability and consistent upset length
(overall length) over standard direct drive
friction welding systems. This is extremely
important when welding is required on both
ends of the work piece as in the manufacturing
of fuser and pressure rollers for the
Photocopier Business.
PROCESS ADVANTAGES

 Ability to weld dissimilar materials (weld-able materials):

process allows the joining of dissimilar metals that traditional
welding does not.
 Lead times reduced: process is at least twice (and up to 100
times) as fast as other welding techniques.
 Cut raw material costs with bi-metal applications: use
expensive materials only where they are necessary.
 Reduces machining labor: which in turn increases capacity and
reduces perishable tooling costs.
 Wide range of part shapes: Friction welders are versatile
enough to join a wide range of part shapes, materials and
sizes.
 Forged quality: with a 100% butt joint weld through the contact
area.
 Solidification defects do not occur: e.g. gas porosity,
segregation or slag inclusions.
 Powder metal components: can be welded to other powder
metals, forgings, castings or wrought material.
 Eliminates human error: with the machine-controlled process
the weld quality is independent of operator skill or aptitude.
 Low Power requirements: are as much as 20% of that required
of conventional welding processes.
 Superior strength in critical areas: with full surface welds.
 High production runs can be accomplished.
 Minimal set-up for prototype and short runs.
EXPLOSION WELDING

 Explosion welding is a solid-state process that

produces a high velocity interaction of
dissimilar metals by a controlled detonation
 Oxides found on material surfaces must be
removed by effacement or dispersion
 Surface atoms of two joining metals must come
into intimate contact to achieve metallic bond
PRINCIPLE OF EXPLOSION

 Cladder metal can be placed parallel or

inclined to the base plate
 Explosive material is distributed over top of
cladder metal
 Upon detonation, cladder plate collides with
base plate to form weld
PLACEMENT OF CLADDER METAL-PARALLEL

 Standoff distance predetermined

and unique to material
combination
 Achieved by placing shims
between plates
 Shims designed to be
consumed by explosion wave
and do not affect weld
 Usually ranges between 0.5-2
times the thickness of cladder
plate
 Cladder must reach critical
velocity before impact
ADVANTAGES

 No heat-affected zone (HAZ)

 Only minor melting

 Material melting temperatures and coefficients

of thermal expansion differences do not affect
the final product
 The shock front compresses and heats the
explosive material which exceeds the sonic
velocity of undetonated explosives
THERMIT WELDING
 Thermit welding provides a
fast and economical method
of joining the rails at site. It
enables high speeds, more
safety and longer life of
rails and the rolling stock. It
also improves the quality of
the weld joint due to a
reduced Heat Affected Zone
(HAZ).
THERMIT REACTION

 Aluminium + Iron(111) oxide ---->Aluminium oxide + Iron

 Due to very high temperatures (up to 2400°C,

reaction enthalpy: 852 kJ/mol) the reaction of iron
oxide with aluminium forms elemental iron, which
seeps in liquid form out of the flower pot drainage
hole.
THANK YOU VERY MUCH