Fusion Welding Processes

Summary

This script delves into various welding processes, highlighting fusion and solid-state techniques. It explains the role of electrical arcs and chemical energy in fusion welding, detailing consumable and non-consumable electrodes. The script further discusses arc shielding methods, including gas and flux, and their importance in protecting the weld. It also covers specific welding processes like gas metal arc welding, TIG, and plasma arc welding, emphasizing their unique applications and advantages. Additionally, it touches on resistance welding and other unique fusion processes like electron beam and laser beam welding, noting their high precision and equipment requirements.

Takeaways

• 🔥 Welding processes are categorized into fusion welding and solid-state welding.
• 🌐 The arc welding process involves melting metals using heat from an electrical arc between an electrode and the workpiece.
• 🔩 Consumable electrodes are used up during welding and serve as a source of filler metal, while non-consumable electrodes are not consumed and require separate filler metal if needed.
• ⚡ The arc is a discharge of electrical current across a gap in the circuit, with ionized gas columns known as plasma through which the current flows.
• 🛡 Arc shielding is crucial to protect the weld from oxygen, nitrogen, and hydrogen in the air, and can be achieved with shielding gases or fluxes.
• 🌀 Shielding gases like argon, helium, and carbon dioxide are used in various arc welding processes to protect the weld.
• 🧱 Fluxes are substances that prevent the formation of oxides and other contaminants, providing a protective atmosphere for welding.
• 🔧 Gas Metal Arc Welding (GMAW) uses a consumable bare metal wire with gas shielding, offering better arc stability and higher deposition rates.
• 🌟 Tungsten Inert Gas (TIG) welding uses a non-consumable tungsten electrode and an inert gas for arc shielding, suitable for aluminum and stainless steel.
• 💥 Plasma Arc Welding is a specialized form of gas tungsten arc welding with a high-velocity stream of inert gas, capable of very high temperatures and excellent weld quality.

Q & A

What are the two main categories of welding processes mentioned in the script?

The two main categories of welding processes mentioned are fusion welding and solid-state welding.

What is the role of the electrical arc in fusion welding?

In fusion welding, the electrical arc provides the heat necessary to melt the metals, creating a molten pool that allows the metals to merge.

What is the temperature range that the arc can reach in fusion welding?

The arc can reach temperatures up to 10,000 Fahrenheit (5,500 Centigrade), which is sufficient to melt any metal.

What are the two types of electrodes used in arc welding?

The two types of electrodes used in arc welding are consumable and non-consumable. Consumable electrodes are used up during the welding process and serve as the filler metal, while non-consumable electrodes are not consumed and require separate filler metal if needed.

How does the shielding of the arc in welding protect the weld?

Shielding of the arc in welding protects the weld from the surrounding air, preventing oxidation and contamination by using shielding gases like argon, helium, or carbon dioxide, or by using fluxes that prevent the formation of oxides and other contaminants.

What is the difference between gas metal arc welding (GMAW) and shielded metal arc welding (SMAW)?

GMAW uses a continuous, consumable bare metal wire as an electrode with shielding provided by the gas, while SMAW uses a consumable electrode coated with flux material that melts during welding to cover the operation.

What are the advantages of Tungsten Inert Gas (TIG) welding?

TIG welding offers high-quality welds, minimal distortion, and no need for flux or shielding gases. It is suitable for welding aluminum and stainless steel, but it is generally slower and more costly than consumable electrode processes.

What is plasma arc welding and how does it differ from other arc welding processes?

Plasma arc welding is a specialized form of gas tungsten arc welding that uses a constricted arc and an inert gas to produce a high-velocity plasma jet. It offers better arc stability, excellent weld quality, and deeper penetration control compared to other arc welding processes.

What is resistance welding and how does it work?

Resistance welding is a group of welding processes that use heat and pressure to accomplish welding. The heat is generated by the electrical resistance as the current flows through the parts to be joined at the contact points.

What are some other fusion welding processes mentioned in the script that do not fall under arc or resistance welding?

Other fusion welding processes mentioned include electron beam welding, laser beam welding, electrostatic welding, and thermite welding. These processes use unique technologies to generate the heat required for melting and joining materials.

How does electron beam welding differ from other welding processes in terms of environment and equipment?

Electron beam welding requires a vacuum chamber to minimize disruptions to the electron beam by air molecules. It offers high-quality welds with deep and narrow profiles but has high equipment costs and requires precise joint preparation and alignment.

Outlines

00:00

🔥 Fusion and Arc Welding Techniques

This paragraph introduces two main categories of welding: fusion welding and solid-state welding. It focuses on fusion welding, specifically arc welding, where metals are joined by heat generated from an electrical arc. The paragraph explains the role of the arc in producing high temperatures, the use of consumable and non-consumable electrodes, and the importance of shielding the arc from air to prevent oxidation and contamination. It also discusses various shielding methods, including the use of gases like argon, helium, and carbon dioxide, and fluxes that protect the weld area. The paragraph concludes with an overview of different arc welding processes, such as shielded metal arc welding (SMAW), gas metal arc welding (GMAW), and their variations like self-shielded and gas-shielded flux-cored arc welding.

05:02

🛠️ Advanced Arc Welding Processes

The second paragraph delves into more advanced arc welding processes, including submerged arc welding (SAW) and tungsten inert gas (TIG) welding. It describes SAW as a process where a continuous consumable electrode is used with arc shielding provided by a granular flux. The paragraph also explains TIG welding, which uses a non-consumable tungsten electrode and an inert gas for arc shielding. The advantages of TIG welding, such as high-quality welds and minimal post-weld cleaning, are highlighted. Additionally, the paragraph touches on plasma arc welding, which uses a concentrated plasma arc for welding and offers excellent penetration control and weld quality. The disadvantages, such as high equipment cost and limited access to certain joints, are also mentioned.

10:06

🔩 Resistance and Other Fusion Welding Methods

The third paragraph discusses resistance welding, a group of processes that use heat and pressure to join materials. It details the resistance spot welding process, which occurs at small contact points defined by part design. The paragraph also covers other fusion welding processes that do not fit into the arc or resistance categories, such as electron beam welding, laser beam welding, electrostatic welding, and thermite welding. Electron beam welding is described as a high-intensity process that can produce deep, narrow welds with minimal heat effect. However, it requires precise joint preparation, alignment, and can be costly due to the need for a vacuum chamber. Laser beam welding is also mentioned, which uses a concentrated light beam and does not require a vacuum chamber or emit X-rays.

15:07

🌐 Laser Beam Welding and Its Applications

The final paragraph focuses on laser beam welding, a process that uses a high-concentration, coherent light beam for joining materials. It mentions that this process is typically performed with shielding gases to prevent oxidation and does not usually require filler metal. The paragraph highlights the high power density and precision of laser beam welding, making it suitable for small parts. It also notes that no vacuum chamber is required for laser welding, and there are no X-rays emitted during the process. The ability to focus and direct the laser beam using optical lenses and mirrors is also discussed, allowing for deep penetration and high depth-to-width ratios in welds.

Keywords

💡Fusion Welding

Fusion welding is a process where metals are joined by melting their surfaces and allowing them to cool and solidify together. This method is crucial for creating strong, permanent bonds between metal pieces. In the video, fusion welding is mentioned as one of the two main categories of welding processes, highlighting its importance in the field.

💡Electrical Arc

An electrical arc is a discharge of electrical current through a medium, such as air or a gas, that can conduct electricity. In welding, the heat generated by the arc is used to melt the base metal and the filler material. The script describes how the arc's chemical energy can reach extremely high temperatures, making it capable of melting any metal.

💡Plasma

Plasma, often referred to as the fourth state of matter, is an ionized gas that conducts electricity. In welding, plasma is used to create a stable and focused stream of high-temperature gas that can melt metals. The video mentions that the arc is a discharge of electrical current across a gap in the circuit, creating plasma that facilitates the welding process.

💡Consumable Electrodes

Consumable electrodes are those that are used up during the welding process and also serve as the source of filler metal. They are essential in fusion welding processes to add material to the weld pool. The script explains that consumable electrodes are consumed during welding and come in forms like welding rods or wires.

💡Non-consumable Electrodes

Non-consumable electrodes do not get used up during the welding process. They are typically made of materials like tungsten that have a high melting point. The video script specifies that non-consumable electrodes are not consumed but may gradually become infused with the metal at high temperatures during the welding process.

💡Shielding Gases

Shielding gases are used in welding to protect the weld area from atmospheric contaminants like oxygen, nitrogen, and hydrogen, which can affect the quality of the weld. The script mentions the use of gases like argon, helium, and carbon dioxide to shield the arc and the molten metal from the surrounding air.

💡Flux

Flux is a substance used in welding to remove impurities and create a protective atmosphere around the weld. It helps to stabilize the arc and reduce spatter. The video describes various flux application methods, such as applying flux to the welding operation or using a stick electrode coated with flux material.

💡Gas Metal Arc Welding (GMAW)

GMAW, also known as Metal Inert Gas (MIG) welding, uses a continuous, consumable bare metal wire as an electrode with shielding provided by a flow of gas from the welding gun. The video script highlights that GMAW has a better arc stability and higher deposition rate compared to other welding processes, making it suitable for automation.

💡Tungsten Inert Gas (TIG) Welding

TIG welding is a type of arc welding that uses a non-consumable tungsten electrode and an inert gas to shield the weld area. It is often used for welding aluminum and stainless steel due to its ability to produce high-quality welds. The script mentions that TIG welding does not require filler metal through the arc, resulting in little or no post-weld cleaning.

💡Plasma Arc Welding

Plasma arc welding is a high-temperature process that uses a plasma torch to create a concentrated heat source for welding. The video script explains that the plasma arc can reach extremely high temperatures, providing excellent weld quality and penetration control. However, it also notes the high equipment cost and larger torch size as potential disadvantages.

💡Resistance Welding

Resistance welding is a group of welding processes that use heat and pressure to join metals. The heat is generated by the electrical resistance at the contact points where the metals are to be joined. The video script describes resistance spot welding and resistance projection welding as examples of this process, which is particularly useful for joining sheet metal and fasteners.

Highlights

There are two main categories of welding: fusion welding and solid-state welding.

Fusion welding involves melting metals with heat from an electrical arc between an electrode and the workpiece.

The temperature in fusion welding can reach up to 10,000 Fahrenheit (5,500 Centigrade).

Addition of filler metal is used to increase the volume and strength of the weld joint.

The arc in welding is a discharge of electrical current across the gap in the circuit.

Electrodes in welding can be classified as consumable or non-consumable.

Consumable electrodes are consumed during welding and serve as the source of filler metal.

Non-consumable electrodes are made of materials like tungsten, which do not melt during the process.

Arc shielding is necessary to protect the weld from oxygen, nitrogen, and hydrogen in the air.

Shielding gases like argon, helium, or carbon dioxide are used for arc shielding.

Fluxes are substances that prevent the formation of oxides and other contaminants in welding.

Gas Metal Arc Welding (GMAW) uses a consumable bare metal wire as an electrode with gas shielding.

GMAW offers better arc stability and higher deposition rates compared to Shielded Metal Arc Welding (SMAW).

Flux-Cored Arc Welding (FCAW) is a type of GMAW that uses a self-shielded or gas-shielded flux-cored wire.

Submerged Arc Welding (SAW) uses a continuous consumable bare wire electrode with arc shielding by a granular flux.

Tungsten Inert Gas (TIG) welding uses a non-consumable tungsten electrode and an inert gas for arc shielding.

Plasma Arc Welding is a specialized form of gas tungsten arc welding with a highly concentrated arc.

Resistance welding uses heat and pressure to accomplish welding, with processes like spot welding and projection welding.

Other fusion welding processes include electron beam welding, laser beam welding, and thermite welding.

Electron beam welding provides high-quality welds with deep and narrow profiles and minimal heat-affected zones.

Laser beam welding uses a high concentrated coherent light beam for coalescence, often performed with shielding gases.

Transcripts

there are two categories of the welding

processes the fusion building and the

solar state welding

the art holding process is a fusion

welding process in which the merging of

the metals is achieved by the heat from

an electrical arc between the electrode

and the work

the chemical energy from the arc

produces a temperature up to ten

thousand fahrenheit or five thousand

five hundred centigrade which is hot

enough to melt any metal

add filler metal to increase the volume

and the strength of the world joint

the critical arc is a discharge of the

electrical current across the gap in the

circuit

the ionized columns of the gas

is known as the plasma through which the

current is the flow

the unfolding electrodes can be

classified into consumable

and non-consumable

the consumable is going to be consumed

during the welding process

and is the source of the filler metal

and the art welding

the forms of the consumable equatorials

are going to be in the form of the

welding roads

or the worldwide

non-consumable is not consumed during

the welding process

the film metal must be added separately

if it's seeded and needed

it's made of tungsten which resists the

melting

but it's going to be gradually

infibulated during the welding a process

at high temperature in the arc building

the metal is chemically reactive to the

oxygen nitrogen and hydrogen in the air

to protect the operation

the ark must be shielded from the

surrounding air and arc loading

processes

the arc shielding is accomplished by

either using the shielding gases like

the argon on the helium or the

carbon dioxide

or by using the flux

the fluxes substance that prevent the

formation of the oxides and other

contaminates in the welding

all dissolves them

and fascinates the removal

the flux provides a protective

atmosphere for the welding

stabilizes the arc

and reduces battery

the various flux application methods are

the point of the groundwater flux onto

the welding operation

or the stick electrode coated with the

flux material that smelled during the

building to cover the operation

or using the tabular egg controls in

which your flux is going to be contained

in the core

and released as the equatorial is

consumed

the gas metal arc building uses a

consumable bare metal wire as an escape

road with a shielding by floating of the

arc with the gas

the shielding gases include the argon

and the helium for the aluminium welding

and the co2 for the steel bolting

the gas metal arc welding has a better

arc time because of the continuous

wireless control treating

and has a better use of the controlled

film metals than the smw

the higher deposition rate and eliminate

the problem of the stack removal

and can be really automated

the flash called arc welding is the

adoption of the shielded metal arc

welding to overcome the limitation of

the stick that controls

when has two versions

the first one is a self-shielded

flux called arc building for the core it

includes the compounds that produce

shielding assets

second type is the gas shielded

flux called art building by using

externally applied shielding assets

this controls is a continuous

concealable tubing

containing a flux and other ingredients

in its core

presence or absence of extreme

externally supply shielding gases

distinguish first a self-shielded core

provide the ingredients for the

shielding or the gas shielded towards

use the external shielding assets

submerged eye building uses a continuous

consumable bare wire electrode with arc

shielding by a cover of a granule flux

this crystal wire is split automatically

from a coil

flux is introduced to the joint slightly

ahead of the arc by gravity from mahuba

completely submerged operation

preventing the sparks splatter and

radiation

the casting is an arc building

or known as a tig

using a non-consumable thing is an

electrode

and another gas for the arc shielding

this can be used with or without

ethylene metal

when developmental use

it is added to build a pool from a

separate rod or wire

the main applications are for the

aluminum and census still mostly

the advantage of the tig is the high

quality worlds for the suitable

applications

lost patterns

because no filler metal through the arc

little or no post-world cleaning because

of no flux

its sad magnitude is is generally slower

and more costly than the consumable

controlled eyeballing processes

the plasma arc building is a special

form of the gas stingers and arc welding

in which a constructed plasma arc is

directed at the world area

the english electrode is contained in

nozzle

that focuses a high velocity stream of

the inert gas

into the arc region to form a high

viscosity

intensity hold plasma upstream

the temperature and the plasma arc

building can reach 28 000 degree

the advantage of the plasma arc building

are the good arc stability and the

excellent world quality

it has better penetration control than

the other arc welding processes

high treble speed

and can be used to world almost any

metals

the disadvantages are the high equipment

cost

and also the large torch size other than

the other arc holding processes

and this will tend to restrict the

access to some joints

the resistance welding

is a group of fusion molding processes

that uses a combination of the heat and

the pressure to accomplish the

cholesterols

the heat generated by the electrical

resistance the current flow at the

junctions to be welded

the principal resistance welding process

is the resistance sport building

a resistance projection molding the

resistant building process in which the

coal sense occurs

at one or more small contact points

on the parts

the contact point is defined by the

design of the parts to be joined

other reasons in projection buildings

operations are dividing all the

fasteners on the sheet metal

and the cross wire rolling

[Music]

other fusion molding processes

are a fusion molding process that cannot

be classified as an arc resistance or

those fuel weldings

they use a unique technologies

to develop the heat for the melting

the applications are typically unique

the processes include the equatron beam

molding the laser beam molding

electrostatic weldings and the thermal

molding

the alkytron molding is a fusion molding

process in which the heat for the

welding is provided by a highly focused

highly intensity stream of the

equidrones striking the work surface

the equitable molding gun operates as a

high voltage to accelerate the electrons

the beam currents are low

and the power in the electron beam

welding is not exceptional but the power

intensity is very high

when first developed the equitable

molding had to be carried out in a

vacuum chamber to minimize the

disruptions of the electrons beam by the

air molecules

the pump downtime

can take as long as one hour

accordingly there are three vacuum

levels in the elkatron beam buildings

they have vacuum moldings

medium vacuum molding and the non-vacuum

modeling

the electron beam molding can provide a

high quality welds

deep and narrow profiles

with limited heat effective zone

and low thermal distortion

no flux or shield gases are needed

however the disadvantage of the fkh1pm

is the high equipment cost

the appreciates joints preparations and

the alignments required

and the vacuum chamber required

the most important

disadvantage is the safety concern

as if control opinion buildings

the x-rays

laser beam molding is a fusion molding

process in which the coalescence is

going to be achieved by the energy of

the high concentrated

coherent light beam focus on joint

laser beam molding is normally performed

with a shielding gases to prevent the

oxidization

the film metal not usually added

high power density in a small area

so the laser pin molding often used for

small parts

no vacuum chamber is required for the

laser few moldings no x-ray emitted in

laser beam moldings and the lesson beam

can be focused and directed by optical

lenses and mirrors

these have been more things not capable

of a deep builds and high depth to earth

ratios

available in the control view moldings

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