Joining Flashcards

1
Q

Reasons for joining

A

Uneconomical/impossible to manufacture in one piece
Less cost to join together, including transportation of parts
Product may need to be taken apart for maintenance etc

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2
Q

Oxyfuel gas welding

A

Flame produced using fuel gas and oxygen
Filler used to provide extra material at weld zone
Flux generates gas shield around weld zone to prevent oxidation

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3
Q

Thermite welding

A

Metal melted by an oxidation reaction (usually iron power reacting with aluminum oxide)

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4
Q

Friction welding

A

Workpieces joined through inertial, linear, or stir friction

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5
Q

Arc welding

A

Heat generated by electrode arcing to workpiece

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6
Q

Shielded metal arc welding (SMAW/stick welding)

A

Oldest and simplest welding method
Flux-coated electrode hand-fed towards piece
Good for remote work and thicker materials

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7
Q

Gas metal arc welding (GMAW/MIG)

A

External source of gas shields weld to prevent oxidation (no flux)
Can be automated, electrode fed via “glue gun”

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8
Q

Flux-core arc welding

A

Similar to MIG but electrode is flux rod coated in filler metal

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9
Q

Gas tungsten arc welding (GTAW/TIG)

A

Gas is fed around reusable tungsten electrode
Filler metal is hand-fed towards weld area
Good for precise welds on thin materials

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10
Q

What is the weakest point of a weld?

A

The area right next to the weld zone, also called the heat-affected area

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11
Q

Plasma arc welding (PAW)

A

Plasma is concentrated at weld area
Filler is hand-fed like TIG
Good for precise welds

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12
Q

Electron beam welding (EBW)

A

Fast, concentrated beam of electrons used as heat source
Must be done in near vacuum

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13
Q

Laser beam welding (LBW)

A

Laser is used as heat source

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14
Q

What kinds of welding are used in space?

A

Induction and laser welding

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15
Q

Induction welding

A

Heat generated through resistance created on conductive, magnetic workpiece

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16
Q

Resistance welding

A

Heat is supplied by electrical resistance between two members
No electrodes, shielding gas, or flux

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17
Q

Zones of a fusion welded joint

A

Base metal
Heat-affected zone
Fusion zone

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18
Q

Weld defects

A

Porosity
Slag inclusions
Incomplete fusion
Incomplete penetration
Weld profile
Underfilling
Undercutting
Overlap
Cracks
Distortion

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19
Q

Cold welding

A

Dies/rolls apply pressure to mating interfaces
Uses plastic deformation to join surfaces

20
Q

Ultrasonic welding

A

Static force and oscillating shears applied to mating surfaces

21
Q

Diffusion bonding welding

A

Creates strong joints that maintain the properties of the base material

22
Q

Explosion welding

A

Layered explosives create high-pressure
Causes mechanical interlocking of the surfaces
Useful for large plates of dissimilar metals

23
Q

Brazing

A

Filler metal is melted between mating surfaces but the surfaces themselves remain solid

24
Q

Soldering

A

Similar to brazing but at lower temperatures
Results in weaker joints
Filler/flux can be in paste form

25
Adhesive advantages
Load distribution is even, no localized stresses Thin/fragile components and porous materials w/ different sizes/properties can be bonded Does not reach very high temps
26
Adhesive disadvantages
Can be time-consuming Surface preparation is critical Hard to test nondestructively, reliability can be a concern
27
Riveting
Permanent/semipermanent joint created by deforming rivet into hole
28
Stapling/Clinching/Stitching
Very fast Good for thin materials
29
Seaming
Two thin pieces folded together
30
Crimping
Done with tubular/flat parts Squishes things into place
31
Snap-in fasteners
Cheap Easy Good for rapid assembly and disassembly
32
Advantages of mechanical fastening
Easy disassembly Can allow for movable/adjustable joints Cheaper
33
To create a brazed joint of the same strength as a similar welded joint a larger ____ is required.
weld area
34
Welding techniques for dissimilar materials
TIG MIG
35
Filler rod characteristics for dissimilar materials
Strength of weaker metal Melting point between materials
36
Don't weld these material combinations
Titanium and steel Aluminum and copper Aluminum and stainless steel
37
Aluminum welding processes
TIG MIG
38
Cast iron welding processes
Stick Note: must pretreat before welding
39
Copper, brass, and alloys welding processes
TIG
40
Stainless steel welding processes
TIG MIG Stick
41
Steel welding processes
Any
42
Nickel welding processes
TIG
43
Titanium welding processes
TIG Laser
44
Magnesium welding processes
Laser Friction stir Resistance spot
45
Thermoplastic welding processes
Hot gas Ultrasonic