Chapter 33: Other Welding Processes, Brazing and Soldering · ME-215 Engineering Materials and Processes Veljko Samardzic Electroslag Welding FIGURE 33-1 (a) Arrangement of equipment

Veljko SamardzicME-215 Engineering Materials and Processes

Chapter 33:

Other Welding Processes,

Brazing and Soldering


33.1 Introduction


33.2 Other Welding and Cutting

Processes


Electroslag Welding

FIGURE 33-1 (a) Arrangement of equipment and workpieces for making a vertical weld by the

electroslag process. (b) Cross section of an electroslag weld, looking through the water-cooled

copper slide.


Electron Beam Welding

FIGURE 33-2 Schematic diagram

of the electron-beam welding

process


Examples of Electron Beam

Welding

FIGURE 33-3 (Left to

right) Electronbeam

welds in 19-mm-thick

7079 aluminum and 102-

mm-thick stainless

steel. (Courtesy of

Hamilton Standard

Division of United

Technologies

Corporation, Hartford,

CT.)


Process Summary of EBW


Examples of Laser Welding

FIGURE 33-4 Laser butt weld

of 3-mm (0.125-in.) stainless

steel, made at 1.5 m/min with a

1250-watt laser. (Courtesy of

Coherent, Inc., Santa Clara, CA.)


Process Summary of LBW


Comparison of Power Densities

FIGURE 33-5 Comparison of the power densities of various welding processes. The high power

densities of the electronbeam and laser-beam welding processes enable the production of deep,

narrow welds with small heat-affected zones. Welds can be made quickly and at high travel speeds.


Schematic of Laser Beam Cutting

FIGURE 33-6 Schematic of

laser-beam cutting. The laser

provides the heat, and the flow

of assist gas propels the molten

droplets from the cut.


Cutting Surface

FIGURE 33-7 Surface of

6-mm-thick carbon steel cut

with a 1250-watt laser at 1.8

m/min. (Courtesy of Coherent,

Inc., Santa Clara, CA.)


Schematic of Flash Welding

FIGURE 33-8 Schematic

diagram of the flash-welding

process. (a) Equipment and

setup; (b) completed weld.


33.3 Surface Modification by Welding

Related Processes


Schematic of a Metal Spray Gun

FIGURE 33-9 Schematic diagram of an oxyacetylene

metal-spraying gun. (Courtesy of Sulzer Metco,

Winterthur, Switzerland.)


Plasma Arc Spray Gun

FIGURE 33-10 Diagram of a

plasma-arc spray gun. (Courtesy

of Sulzer Metco, Winterthur,

Switzerland.)


Comparison of Thermal Spray

Deposition


33.4 Brazing


Joint Strength

FIGURE 33-11 Typical variation of tensile strength with

clearance in a butt-joint braze. (Courtesy of Handy & Harman, Rye, NY.)


Joint Clearance in Brazing

FIGURE 33-12 When brazing dissimilar metals, the initial joint clearance should be adjusted for

the different thermal expansions (here brass expands more than steel). Proper brazing

clearances should exist at the temperature where the filler metal flows.


Common Joint Design

FIGURE 33-13 The two most common

types of braze joints are butt and lap. Butt

offers uniform thickness across the joint,

whereas lap offers greater bonding area and

higher strength


Variations of Butt Joints

FIGURE 33-14 Variations of

the butt and lap configurations

include the butt-lap and scarf.

The four types are shown for

both flat and tubular parts.


Common Joint Designs for

Brazing

FIGURE 33-15 Some common

joint designs for assembling

parts by brazing


Compatibility of Brazing

Materials


Brazing Material Families


Furnace Assembly

FIGURE 33-16 Two

views of an array of

furnace-brazed

assemblies.

(www.franklinbrazing.com


Schematic of Braze-Welding

Process

FIGURE 33-17 Schematic of the

braze-welding process


33.5 Soldering


Solder Joints

FIGURE 33-18 Some common

designs for soldered joints.


Compatibility of Soldering


Common Solder


Wave Soldering

FIGURE 33-19 Schematic of wave

soldering

Documents

Chapter 33: Other Welding Processes, Brazing and Soldering · ME-215 Engineering Materials and Processes Veljko Samardzic Electroslag Welding FIGURE 33-1 (a) Arrangement of equipment