1.4 Metal addition processes

Question 1

What are the 7 metal addition processes

Answer 1

TIG, MIG, Oxy acetylene, Laser beam welding, brazing, soldering, electrical soldering

Question 2

What are the 4 welding types

Answer 2

TIG, MIG, Oxy acetylene, Laser beam

Question 3

What volume of production is MIG and TIG

Answer 3

One off to mass production

Question 3

What does MIG and TIG stand for

Answer 3

Metal inert gas and tungsten inert gas

Question 4

What metals are MIG used for

Answer 4

Sheet steel and Al

Question 5

What metals are TIG used for

Answer 5

Stainless steel and non ferrous metals

Question 6

What are the steps for TIG

Answer 6

1. The inert gas creates a shielding area around the weld
2. An electric arc melts the join area and a separate filler rod is also melted to fill the gap(Tungsten rod is not melted)

Question 7

What are the steps for MIG

Answer 7

1. The inert gas creates a shielding area around the weld
2. An electric arc melts the join area and a wire electrode(same metal as the metal being joined) is also melted to fill the gap

3.The electrode wire is fed through the “gun” as the triggers is pressed and a swirling action is used to form a continuous bead of weld

Question 8

What metals are oxy acetylene used for

Answer 8

low carbon steel

Question 9

What is the adv of TIG over MIG

Answer 9

TIG welding offers greater control and precision and offers neater welds with little finishing required

Question 10

What is the adv of oxy acetylene over TIG and MIG

Answer 10

No electricity required

Question 11

What are the 5 adv of laser beam welding

Answer 11

Wide range of metals, Dissimilar metals, Minimize heat distortion due to narrow beam, Smooth weld, Isolated and clean work environment

Question 11

What are the steps for oxy acetylene

Answer 11

1. Separately stored gases, oxygen and acetylene, are combined into a blow torch
2. The flame can be adjusted by changing the oxygen and acetylene mixture using valves, to allow the flame to weld or even cut metal
3. The joint area is heated till a melt pool is created and a steel filler rod is introduced to the area being heated(but not melted by the flame)
4. The flame is used to bring the melt pool along the joint as the filler rod is continuously added

Question 12

What is the disadv of laser beam welding

Answer 12

High capital cost

Question 13

What is the disadv of brazing over other welds

Answer 13

The process works at a lower temperature than welding, so it is suitable for joining thinner sheet metal but the resulting joint is not as strong as a welded one

Question 13

What metals are brazing used on

Answer 13

Ferrous and non ferrous metals

Question 14

What are the steps for brazing

Answer 14

1. Metal surface are cleaned/degreased and clamped together
2. A flux is applied to prevent the joint from oxidising.
3. The joint is heated, using a flame, till the metal glows
4. A brazing rod/filler rod* is applied to the joint and the melted rod flows along the joint by capillary action

Question 15

What is the diff between brazing and soldering

Answer 15

Similar process but for lightweight thin sheet metal. Lower temperature than brazing so weaker joint

Question 16

What filler rods are used in brazing

Answer 16

Copper, nickel or aluminum based

Question 17

What filler rods are used in soldering

Answer 17

Generally tin

Question 18

What are the 2 diff between electrical soldering and regular soldering and brazing

Answer 18

The solder wire is tin based and contains a flux, A heat sink can help protect electrical components from being damaged from heat