Advanced welding techniques : holistic view with design perspectives

This book provides an insight into the welding techniques with a cross-disciplinary treatment to address the shortcomings of contemporary learning of welding terminology. Various topics covered include introduction to welding processes, design requirements, prominence of design, case studies presenting structural defacements due to inappropriate design, comprehensive surveys on welding processes selected from various process categories, design calculations to be adopted for specific applications and sample calculations. This book is useful for researchers, engineers and professionals working on welding equipment and technologies. Preface 5 Contents 7 About the Authors 11 List of Figures 12 List of Tables 17 1 Welding: An Overview 18 1.1 Welding Techniques—Classification 18 1.2 Resistance Welding 19 1.2.1 Process Variations 19 1.2.2 Preferred Materials for RSW 21 1.2.3 Design Considerations 22 1.2.4 Typical Applications of Resistance Weld Variants 22 1.3 Solid-State Welding 22 1.3.1 Process Variations 23 1.3.2 Preferred Materials for Solid-State Welding 24 1.3.3 Design Considerations 25 1.3.4 Typical Applications 25 1.4 Arc Welding 25 1.4.1 Process Variations 26 1.4.2 Preferred Materials for Arc Welding 27 1.4.3 Design Considerations 27 1.4.4 Typical Applications 28 1.5 High-Energy Density Welding 28 1.5.1 Process Variations 28 1.5.2 Preferred Materials for Laser Beam Welding 30 1.5.3 Design Considerations 30 1.5.4 Typical Applications 31 1.6 Conspectus of Welding Techniques 31 References 32 2 Decision Making in Welding Design 33 Abstract 33 2.1 Introduction 33 2.2 Standards and Specifications 34 2.3 Factors Affecting Design 34 2.4 Expected Weld Characteristics 35 2.4.1 Example: Design Requirements—For Spot Welding 36 2.5 Effects of Design on Welding Procedure Selection 38 2.6 Weld Distortion and Defects 38 2.6.1 Weld Distortion 38 2.6.2 Weld Defects 39 2.7 Design Methodologies 41 2.7.1 Energy-Based Model 41 2.7.2 Energy Density and Line Energy Estimation 41 2.7.3 Full Factorial Design and Response Surface Methodology Used as a Design of Experiments Approach 42 2.8 Design Failures—Case Study 42 2.8.1 Case History 1: Magnetic Pulse Welding Failure 43 2.8.2 Case History 2: Friction Stir Welding Failure 43 2.8.3 Case History 3: Laser Welding Failure 43 2.8.4 Case History 4: TIG Welding Failure 44 2.8.5 Case History 5: Bridge Failure 44 2.8.6 Case History 6: Chernobyl Reactor Accident 45 2.8.7 Case History 8: Aircraft Engine Failure 46 2.9 Conspectus of Weld Design Studies 46 References 49 3 Resistance Spot Welding and Design 50 Abstract 50 3.1 Introduction 50 3.2 Process Applications 54 3.3 Compatible Materials 54 3.4 Fundamentals of Resistance Spot Weld Process 54 3.5 Resistance Spot Welding Machine Details 57 3.6 Literature Review 61 3.7 Sample Design Data, Process Parameters and Design Calculations 70 3.7.1 Case Study for Design Calculations 70 3.7.1.1 Design Calculations—Based on Material Properties 70 3.7.2 Sample Data for a Particular Application 74 3.8 Conspectus of Design Studies in Resistance Spot Welding 75 References 75 4 Tungsten Inert Gas Welding and Design 77 Abstract 77 4.1 Introduction 77 4.2 Process Applications 78 4.3 Compatible Materials 79 4.4 Fundamentals of Tungsten Inert Gas Weld Process 80 4.5 Tungsten Inert Gas Welding Machine Details 82 4.5.1 Power Source 83 4.5.2 Torch 84 4.5.3 Electrodes for Welding 85 4.5.4 Shielding Gases 86 4.6 Literature Survey 87 4.7 Sample Design Data, Process Parameters, and Design Calculations 91 4.7.1 Welding Amperage Selection 93 4.7.2 Sample Design Calculations 94 4.7.2.1 Case I 94 4.7.2.2 Case II 96 4.7.3 Sample Data for Various Materials and Applications 99 4.7.3.1 Set I 99 4.7.3.2 Set II 100 4.7.3.3 Set III 100 4.8 Conspectus of Design in Tungsten Inert Gas Welding 101 References 101 5 Laser Beam Welding and Design 103 Abstract 103 5.1 Introduction 103 5.2 Process Applications 106 5.3 Compatible Materials 106 5.4 Fundamentals of Laser Beam Weld Process 108 5.5 Laser Welding Machine Details 108 5.6 Literature Survey 111 5.7 Sample Design Data, Process Parameters, and Design Calculations 116 5.7.1 Design Sequence in Welding 117 5.7.2 Approach I: Heat Affected Zone Considerations 118 5.7.3 Approach II: Thermal Gradients with Varying Thickness 120 5.7.4 Approach III: Use of Energy-Based Model for Weld Depth Determination 123 5.7.5 Approach IV: Use of Process Optimization Techniques 127 5.7.6 Sample Parameter Values 129 5.7.6.1 Set I [17] 129 5.7.6.2 SETII 131 5.7.6.3 SETII 131 5.7.7 Case Study for Selection of Laser Source 133 5.7.8 Laser Welding Parameters 136 5.7.9 Power Supply for Laser Machine 139 5.7.9.1 Charging of Capacitor 141 5.7.9.2 Overvoltage Circuit 141 5.7.9.3 Control of Pulse Shape 142 5.8 Conspectus of Design Studies in Laser Beam Welding 143 References 144 6 Friction Stir Welding and Design 146 Abstract 146 6.1 Introduction 146 6.2 Process Applications 150 6.3 Compatible Materials 151 6.4 Fundamentals of Friction Stir Weld Process 151 6.4.1 Heat Generation Analysis 152 6.5 Friction Stir Welding Machine Details 155 6.6 Literature Survey 160 6.7 Sample Design Data, Process Parameters & Design Calculations 166 6.7.1 Sample Data I 167 6.7.2 Design Calculations- Case Study 170 6.8 Conspectus of Design Studies in Friction Stir Welding 177 References 177 7 Magnetic Pulse Welding and Design 179 Abstract 179 7.1 Introduction 179 7.2 Process Applications 182 7.3 Compatible Materials 182 7.4 Fundamentals of Magnetic Pulse Weld Process 182 7.5 Magnetic Pulse Welding Machine Details 185 7.6 Literature Survey 187 7.7 Sample Design Data, Process Parameters, and Design Calculations 192 7.7.1 Design Calculations I 193 7.7.2 Design Calculations II 197 7.7.3 Design Case Study III 199 7.7.4 Design Case Study IV 201 7.7.5 Design Calculations—Weldability Curve 203 7.7.6 MPW: Electrical Model 205 7.8 Conspectus of Design Studies in Magnetic Pulse Welding 208 References 208