manufacturing - joining

Question 1

Name some Assembly Operations

Answer 1

1. Welding
2. Brazing
3. Soldering
4. Adhesive
5. Fasteners
6. Press Fitting

Question 2

What is Welding?
Name the types.

Answer 2

Fabrication process that joins two similar materials at high temp.

MIG
TIG
ELECTRICAL / STICK

Question 3

What is MIG welding?
Name some pros and cons.

Answer 3

Metal Inert Gas
- uses continuous wire through a gun feed to join metals, uses a shielding gas
Pros:
1. versatile
2. fast
3. beginner friendly
4. consistent welds
Cons:
1. high set up cost
2. not suitable outside
3. prone to ‘burn throughs’
4. equipment requires regular maintenance
5. can warp thin materials

Question 4

What is TIG welding?
Name some pros and cons.

Answer 4

Gas Tungsten Welding
- uses non-consumable electrode in a gun and a stick of filler rod to deliver current to weld two materials together
Pros
1. precision
2. clean process - uses inert gas
3. can be operated in any position
Cons:
1. slower process
2. highly skilled work
3. special ppe - high intensity light
4. high initial start up costs

Question 5

What is ARC welding?
Name some pros and cons.

Answer 5

stick, electrical welding
-uses consumable electrode (metal surrounded by flux) to arc and fuse metals together.
- both the metal and the electrode are bonded and when they touch it arcs - causing a weld.
Pros:
1. high efficiency & speed
2. strong bonds
3. good welds
Cons:
1. highly skilled
2. intense heat - requires PPE.

Question 6

What is Brazing?

Answer 6

heating material and using filler wire to joining together.
done at a lower temp than melting point of parent material.
more similar to soldering than welding.

Question 7

What is Soldering?

Answer 7

Process of joining two metal surfaces together using filler metal (solder).
-Commonly used in electronics (PCB’s)

Question 8

Pros and cons of: Brazing

Answer 8

Pros:
1. can be used on dissimilar materials
2. fast - good for mass production
3. cleaner joints than welding
4. base metals don’t melt - preserves shape and mech properties)
5. good for delicate applications
6. can be done with handheld torch and filler
Cons:
1. limited metals (low melting point)
2. surface prep required
3. weaker joints if done wrong

Question 9

Pros and cons of: Soldering

Answer 9

Pros:
1. low temp operation
2. quick
3.simple
Cons:
1. weak joints
2. not suitable for high temp joints
3. ineffective for long-length welds.
4. not suitable for heavy metals.

Question 10

Pros and Cons of: Bolts / Fasteners.

Answer 10

Pros:
1. Easy
2. cost effective
3.revesible - good for repairs or modifications
Cons:
1. less rigid
2. not permeant (can be pro and con)

Question 11

Pros and Cons of Rivets

Answer 11

Pros:
1. durable
2. fast and simple
3. interference fit
4. cheap
5. non-permanent
Cons:
1. labour
2. failure mode is normally a chain reaction
3.