Joining and Assembling Flashcards
___________ is putting two or more parts together
Joining
___________ is the sequence of multiple joining operations to make a product
Assembling
Joining and Assembly (J&A) can account for up to ________ of a
products total manufacturing cost and __________ of its total
manufacturing time
30%, 50%
_____________are often the points where products fail
Joints
What are the 5 types of joining processes?
Welding, Brazing, adhesive bonding, Mechanical, Joining using Form
What are the 6 most common joint geometries?
Butt, Lap, Sleeve, T, Edge, Corner
___________ welding involves heating material beyond its melting point
Fusion
__________________ welding heats the material until it is soft.
Solid-State
Welding can generally combine _________ material and can create local joints called __________ welds or continuous ones called ___________________ welds.
similar, spot, seam
When welding Stainless Steel and Aluminum, a good selection of _______ is important
Alloy
Welding is the most important joining process for _____________ steel which is generally __________________ steel,
Structural, Low carbon
Welding can undo __________________ or _________________ and can cause residual stress due to _____________________. It can also cause ____________ which degrades material properties.
Work hardening, Heat Treatments, Temperature Gradients, Oxidation
In ___________________________ welding , fuel acetylene is burned with oxygen to ___________ the metal
Oxy-acetylene gas welding, melt
What Welding method is best for thin sheets and tubes of aluminum, magnesium and titanium
TIG
What welding process is best for thin, low carbon steel products?
Oxy-acetylene gas welding
_______________ welding clamps sheet parts (usually low carbon steel) between ________________and discharging a large current
Resistance Spot welding, Copper Electrodes,
In Resistance Spot welding, no ______ is needed, it is fast and it can be automated, but ____________ welds are not very strong
Filler, spot
_____________ Welding uses a laser to provide heat to make spot or continuous welds and can weld _____material in a single pass. It has a high investment cost and is mostly used with ____________
Laser, thick, low carbon steel
___________________ is a relatively new welding method in
which heating is caused by the ___________ of a rapidly rotating
tool with a protruding probe.
Friction Stir Welding, friction
Friction stir welding (FSW) is a ___________ process where no filler is used and small welds can be made with ______________, but larger welds need dedicated equipment
Solid-state, CNC
Friction stir welding (FSW) was made for making long _______________ welds in _________________ extrusions but is also a common choice for titanium
continuous, aluminum
______________ is done by heating the plastic above its glass
temperature (amorphous plastic) or melting temperature
(_______________)
Plastic welding, crystalline plastic
Welding plastic is mainly done when you need ____________________ bonds
Strong airtight
What are the two main processes of plastic welding?
Ultrasonic and Hotplate
___________________ plastic welding uses a piezoelectric element to generate ultrasound that creates enough _________ to allow the interface to be joined
Ultrasonic, heat
________________ uses a hot metal plate that applies the heat
and then is removed before the parts are ____________
Hot Plate Welding, pressed together
Soldering is done below __________C and brazing is done at much
_____________ temperatures
450C, higher
Brazing is typically performed on _______ alloys such as _______
copper, brass
Brazing and soldering require much ________ heat than welding and therefore do not produce as much thermal distortion or ____________
less, residual stress
In brazing, lap and sleeve joints will be stronger than
__________ or ________ joints
tee, butt
what are the two brazing methods?
Torch brazing, Furnace brazing
_____________: common manual method of brazing in which a skilled worker manipulates a torch and a reel of filler material
Torch Brazing
_______________: Is when the parts are prepared, mounted in a jig with the filler material applied in the right places, and placed in a furnace where the filler material permeates the joint
Furnace Brazing
Soldering creates electrically _____________ joints and is used in electronics and _______________________
Heat Exchangers
Adhesives are slow but are the method of choice for combining _______________
composites
Adhesives should be loaded in ______________ only
Shear
Adhesives are weak in tension so _________ and ____________ joints work best
Lap, sleeve
What are the 4 types of adhesives?
Drying Adhesives, multi-component reactive adhesives, single-component reactive adhesives, hot melts
________________ use the dispersion of active adhesive in a solvent.
When the solvent evaporates, the adhesive hardens.
Drying adhesives
______________________________ Are mixtures of two different
compounds that when mixed set off a chemical reaction that will harden the mixture.
Multi-component reactive adhesives
_________________________________ are single compounds that
cause a chemical reaction when subject to an external trigger (e.g., UV light, heat, moisture). Epoxies are an example.
Single-component reactive adhesives
___________________ are thermoplastics that are heated until they
liquefy, applied to a surface and allowed to cool
o Allow for higher production speeds and do not require chemical reactions (so less fumes)
Hot Melts
Bolts can be used with a nut in a _______________ or by
themselves in a ___________________
through hole, blind hole
Bolts are most often made of ________________
Carbon Steel
Bolts are often forged by ________________
Cold Heading
Unlike bolts, screws do not have ______________ and transmit
force in shear
shanks
Screws are _____________, that is they form their own thread
when screwed into a hole
self-tapping
Rivets are permanent mechanical fasteners that start out as shanks about __________ thinner than the hole in the two parts needing to be joined
10%
___________ rivets require access to just one side of the joint, but are relatively _____________
pop, weak
Form closures can be divided into two categories based on whether they induce __________ or ______________ deformations
elastic, plastic
_____________is a form closure method where folding two metal sheets over each other like hooks to create a continuous seam
Seaming
______________, often known as press fits, rely on
compressive force and friction at the joint to hold it together
elastic plastic
Clamp Fits
_____________: Like seaming, but locally interlocks two pieces of metal together
Clinching
