Welding Processes Flashcards
Joining includes _____, ______, ____, _________
Welding, Brazing, Soldering, Adhesive bonding of materials
What is welding?
Metal joining process in which two or more parts are joined or coalesced at their contacting surfaces by suitable application of heat or/and pressure.
Welding joint can be stronger than the parent materials if a proper __________ is used that has strength properties better than that of parent base material.
filler
Welding processes can be broadly classified into two categories.
Fusion welding and solid state welding
What is fusion-welding processes?
Heat is applied to melt the base metals. (A filler metal is added to the molten pool during welding to facilitate the process and provide strength to the welded joint.
When no filler metal is used, that fusion welding operation is referred to as ______ weld.
autogenous
What are the types of fusion welding process?
Arc, Resistance, Oxyfuel Gas, Electron Beam, Laser
In this operation, electric arc is used to produce heat energy and the base metal is headed. What am I?
Arc welding
In this operation, electric resistance is generated to the flow of current that generates heat energy
between two contacting surfaces that are held in pressure. What am I?
Resistance welding
Operation in which heat is
generated by a hot flame generated mixture gas of oxygen and acetylene. What am I?
Gas welding
In this operation, joining is done by coalescence resulting from application of pressure only or a combination of heat and pressure. Temperature is less than the melting point of the metals. No filler metal is utilized. What am I?
Solid State Welding
Two part surfaces are held together under pressure
at elevated temperature and the parts join by solid state diffusion. What am I?
Diffusion welding
Joining occurs by the heat of friction and plastic deformation between two surfaces. What am I?
Friction welding/Stir welding
: Moderate pressure is applied between the two
parts and an oscillating motion at ultrasonic frequencies is used in a
direction parallel to the contacting surfaces. What am I?
Ultrasonic welding
What are the 5 joint configurations?
Butt, corner, lap, tee, edge
It consists of a mixture of filler metal and base metal that have completely melted. What am I?
Fusion Zone
What are the 4 weld zones?
Fusion zone, weld interface, HAZ, and Unaffected base material.
The amount of heat required to melt a given volume of material depends on what?
heat energy, melting point, heat of fusion of material
Two important factors are defined for the losses. the are _______ and ________.
Heat transfer factor and melting factor.
A high power density combined with a low conductivity work material results in a _____.
A high melting factor
It is a fusion welding process in which the melting and joining of metals is done by the heat energy generated by the arc between the work and
electrode. What am I?
Arc Welding
What are the two types of electrodes?
Consumable and Non-consumable
What is straight polarity?
work piece is positive and electrode is negative. Suitable for shallow penetration and joints with wide gaps.
What is reverse polarity?
Work piece is negative and electrode is positive. Suitable for deeper welds.
What are the Arc Welding processes with consumable electrodes?
Shielded Metal Arc welding (SMAW), Gas Metal Arc Welding (GMAW), Flux Cored Arc Welding (FCAW), Submerged Arc Welding (SAW).
What are the Arc Welding processes with non-consumable electrodes?
Gas Tungsten Arc Welding (GTAW), Plasma Arc Welding, Resistance Welding, Resistance Spot Welding, Resistance Seam Welding.
In this process, various fuels are mixed with oxygen and burnt to perform welding. What am I?
Gas welding/ Oxy Fuel gas welding, and oxyacetylene welding
In this process, welding is carried out by highly focused, high intensity electron beam bombarding against the work piece. Generally carried out in vacuum, otherwise there will be disruption of electron beam by air molecules. What Am I?
Electron Beam Welding
Is a fusion welding process in which joining/coalescence is attained by the heat energy of a highly concentrated, coherent light beam focused on the joint to be welded. What am I?
Laser Beam Welding
A mixture of aluminum powder and iron oxide that produces an exothermic reaction when ignited. What Am I?
Thermit Welding
Joining of materials are performed with the help of heat and pressure or pressure alone. A metallurgical bond is created with little or no melting of the base metals. To metallurgically bond two similar or dissimilar metals, the two metals must be
brought into intimate contact so that their atomic forces attract each other. What am I?
Solid State Welding
Two or more sheets are kept one above the other and rolled to generate bonding between them. What am I?
Roll Welding or Bonding
Because of progressive explosion, high pressure zone propels
the flyer plate to collide with the backer metal progressively at high velocity, so that
an angular shape is generated as the explosion advances.
What Am I?
Explosive Welding
A non-consumable rotating tool with a specially designed pin and shoulder is
inserted into the abutting edges of sheets or plates to be joined and traversed along the line of joint.
The tool serves two primary functions: (a) heating of workpiece, and (b) movement of material to produce the joint.
What Am I?
Friction Stir Welding
Presence of small voids in the weld metal formed by gases entrapped during solidification. It usually results from inclusion of atmospheric
gases, sulfur in the weld metal, or contaminants on the surfaces. What am I?
Porosity
Cavities formed by shrinkage during solidification. Both of
the cavity type defects are similar to defects found in castings. What am I?
Shrinkage voids
These are nonmetallic solid particles (like flux in arc welding,
metallic oxides in welding Al) trapped inside the weld metal. What am I?
Solid inclusions
It is a weld bead in which fusion has not occurred
throughout the entire cross section of the joint. What am I?
Incomplete fusion
It is a joining process in which a filler metal is melted and
distributed by capillary action between the faying
(contact) surfaces of the metal parts being joined. What am I?
Brazing
Joining process in which a filler metal with melting point (liquidus) not exceeding 450°C is melted and distributed by capillary action between the faying surfaces of the metal parts being joined. What am I?
Soldering
A ________ is simply the type of electrode used in SMAW (stick) welding.
Welding rod
What is a carbon-arc electrode?
A carbon or graphite rod though which the current is conducted between the electrode holder and the arc.
What is metal-arc electrode?
Filler metal in the form of a wire or rod, whether bare or covered, which is conducted between the electrode holder and the arc.
Atomic electrode is what?
On of the two tungsten rods between the pints of which the arc is maintained.
What is filler metal?
Is the metal added to the joint when welding, brazing or soldering. This is colloquially known as an electrode in welding.
What process has a continuously fed tubular electrode?
FCAW
