METAL JOINING

Dr. N. RAMACHANDRAN, NITC 1


METAL JOINING• Even the simplest object is an assembly of

components• Complex ones - greater number of parts-

subassemblies joined to perform the function• METHODS-

WELDING, BRAZING, SOLDERING, ADHESIVE BONDING, MECHANICAL JOINING

NITC


WHY JOINING?

• IMPOSSIBLE TO MAKE AS ONE PIECE• EASINESS AND ECONOMY IN

MANUFACTURE• EASY IN REPAIRS AND MAINTENANCE• FUNCTIONAL PROPERTIES DIFFER- e.g.: Carbide tips of tools,corrosion resistant

parts, tungsten carbide tip of pens, brake shoes to metal backing etc…

• TRANSPORTING SITE/ CUSTOMER

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CLASSIFICATION

• According to the STATE of the materials being joined

• Extent of external heating- PRESSURE• Use of FILLER materials

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Joining Processes

RESISTANCE

MECH. JOINING

ARCCUTTINGCHEMICAL

CONSUMABLE NON CONSUMABLE

Oxy-fuelThermit

LIQUID

SOLID

LIQUID-SOLID

SpotSeam

ProjectionFlashStud

percussion

GTAWPAWEBWLBW

SMAWSAW

GMAWFCAWEGWESW

ForgeCold

UltrasonicFriction

ExplosionDiffusion

BrazingSolderingAdhesive Bonding

FasteningCrimpingSeamingStitching

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History of welding

And

American Welding Society


Vulcan – The Roman Fire God


Welding Heat Exchanger


Dr. N. RAMACHANDRAN, NITC 10• Thermite Welding Patent 729573


• The Bible mentions Tubal Cain, " forged all types of tools from bronze and iron." He may have been the first to join metals with the forging process. His flame was an open hearth into which he placed the metals to be heated to the forging temperature.

• In 1892 Morehead and Wilson accidentally discovered how to make acetylene. It was found that combining acetylene with oxygen produced the hottest flame temperature--5720 degrees F. Since this is well above the melting point of most metals the oxyacetylene welding process soon developed.

HISTORY OF WELDING


HISTORY OF WELDING3000 B.C.• It was around this time that the Sumerians joined

metals together in a “hard soldering” process to create swords for battle.

• In the tomb of Queen Pu-abi, several gold artifacts buried with her show signs of being brazed.

• Also around this time, the Egyptian culture used charcoal fires to turn iron ore into sponge iron.

• This was then beaten to weld the particles together, creating some of the first accounts of “pressure welding” (Sapp 2003)


• 1000 B.C.• The first forge welding came along around 1000

B.C. (Sapp 2003). This process involves heating the metals and then using pressure to bond the pieces together (Fogg 1997). An archeological dig found iron and bronze artifacts that had been forge welded and dated from this time.

• Four boxes made of gold were also found around this time in Ireland. These boxes showed evidence of being pressure welded on some of the joints. This was done through a hammering process that fused the pieces together (Sapp 2003).


• 60 A.D.• Around 60 A.D., an author named Pliny wrote

about some of the information that he knew about welding. He wrote about the brazing process for gold at this time and talked of the salts that were used for a flux mixture (Sapp 2003). Brazing is defined as, “a process intended to permanently join two or more metals/materials together to form a single assembly by heating them in the presence of a filler metal that begins to melt above 450° C (840° F)” (Kay 2003). Flux is a material used to melt and keep the metal from oxidizing (Fogg 1997). Pliny also goes on to describe a way to determine how easily a metal will braze by looking at the metals color after it oxidizes (Sapp 2003).


• 400 A.D.• The Iron Pillar in Delhi, India, is a monument to

welding technology itself. Created around 400 A.D. and weighing around six tons, this giant column is around 25 feet tall and 16 inches in diameter at the base. Formed from iron billets, this column was fused together by forge welds. This pillar is even more impressive when one realizes that the iron obtained for use at this time was harvested from meteors, and only in small quantities (Sapp 2003)


• 1776

• A scientist named Antoine Lavoisier discovered in 1776 that if an atmosphere were made entirely of oxygen, a metal could be burnt in that environment. This experiment with oxygen lead to a belief that oxygen could be used to cut metals. This left over metal oxide could also be melted at lower temperatures, showing a change in the state of the metal (Sapp 2003).


• 1801

Sir Humphrey Davy was also a leading scientist in the production of modern welding practices. In 1802, Sir Humphrey created the first human created electric arc. He used high voltage electricity and a pair of carbon rods and produced a change in one that jumped to the other. This is now the basis for what is now known as arc welding (Hoyle 2003).

• 1846• A British scientist named James

Nasmyth develops a uniform convex curve to the sides of metal pieces to be welded. By doing this, the adhesion between the two metals starts at the middle and works its way out. This helps in expelling the flux and other impurities out of the joint, instead of trapping them in which makes the joint weaker (Nasmyth 1997).

Sir Humphrey DavyBachman, Michal. (2003).

Davy, sir humphery. Retrieved December 1, 2003

fromhttp://www.jergym.hiedu.cz/~bachmanm/images/davy.jpg

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• 1800-1850s• Scientists are using the oxy-hydrogen blowpipe as a laboratory tool

to examine refractory metals to the extreme temperature of 4468°F. • 1800• Alessandra Volta discovers that two dissimilar metals connected by

a substance became a conductor when moistened, forming a 'Voltaic Cell'.

• 1801 • Sir Humphrey Davy (1778-1829) of London England, experimented

and demonstrated the arc between two carbon electrodes using a battery. This was the forerunner to electric-arc lighting.

• Vanadium was discovered in Mexico and was thought to be a form of chromium for the next three decades. In 1830, it was rediscovered by N.C. Sefstrom, and in 1887, H.E. Rosco isolated the element from its compounds, mainly vanadite and carnotite. It was named for the Scandinavian love goddess Vanadis.

• 1808 • Magnesium is discovered as a chemical element by Sir Humphrey

Davy. • Sir Humphrey Davy proved the existence of aluminum.


• 1818 • Robert Hare, a professor of Chemistry at the University of

Pennsylvania invents the hydrogen blowpipe. • 1820• Hans Christian Oersted established connection between electricity

and magnetism. • Andre-Marie Ampere pioneered the field of electromagnetism. • 1823• Charles Macintosh opens a rubber factory in Glasgow Scotland. • 1827 • Friedrich Wholer discovers aluminum in 1827 • 1828• Wallaston produced sponge platinum and welded it together by

cold-pressing, sintering and then hammering while the metal was hot.

• 1831• Michael Faraday invents the Dynamo creating electricity from

magnets


• 1835-1836 • English chemist Edmund Davy (1785-1857), a cousin of Sir Humphrey Davy described the

properties of acetylene, but was unable to give correct formula. • Frenchman Sainte Claire Deville invents the oxygen-hydrogen blowpipe. Used mainly as

laboratory equipment for melting platinum and producing enamel. • 1838• Charles Goodyear discovers the vulcanization of rubber, giving rise to the development of

rubber hoses for welding gases. • Eugene Desbassayrs de Richemont patents a process of fusion welding • 1839 • Michael Faraday discovers the homopolar device that generates voltage. • 1840 • Frenchman E. Desbassayns de Richemont invents the first air-hydrogen blowpipe. • de Richemont coins the phrase "soudure autogène", improperly translated into English as

"autogenous welding". Welding implies solid state whereas fusion welding implies a liquid state.

• 1841 • German H. Rossier used the air-hydrogen blowpipe for soldering lead. • 1846 • James Nasmyth, while investigating the proving of ship chain for the British Admiralty,

discovered and gave the reason for the convex forge welding "scarf". By preparing the surfaces to be welded with a slightly convex surface the flux and swarf are squeezed out of the joint. Otherwise they are trapped in the joint weakening it. This was the first improvement in the forge welding process in 3000 years. Prior to this time the shape of the joint was randomly flat concave or convex.


• 1856• James Joule begins to experiment with a relatively new form of power

called electricity. Through his experiments, James develops the first arc welding techniques in history (Roberge 2003).

• 1860s • An Englishman named Wilde successfully used the theories of Volta and Davy

and the primitive electric sources of the time to make "Joins" and received a patent for the earliest form of the art now known as "electric welding".

• 1860 • French chemist Berthelot (1827-1907) accurately gave the correct formula of

C2H2 to acetylene. Also found it to be unstable (1863) under certain pressure and temperature.

• 1862 • A German, Friedrich Wohler (Woehler), produces acetylene gas from calcium

carbide. • 1863• The first successful oil pipeline was built by Samuel Van Sickel at Titusville,

Pennsylvania where 2-1/2 miles of 2 inch diameter cast Pipeline was laid for the transfer of 800 barrels of crude oil. The pipe was screw coupled and hammered since welding was not yet invented for pipe joining. The Dresser coupling, invented in 1891 was the first time a mechanical joint could be assembled without excessive leaking. This method was the standard for pipelining until the mid-1930s, when welding overtook the assembly process.


• 1865• John Motley Morehead, a graduate of North Carolina State

University in 1891, was working as a chemist for Willson Aluminum Company determined that when heating slacked lime mixed with coal tar and immersed in water would produce acetylene gas. Acetylene is formed when bicarburet of H2 and ground carbon produces a solid of calcium carbide when immersed in water. This was originally discovered 56 years earlier by Edmund Davy.

• 1876• Otto Bernz of Newark New Jersey founded the Otto Bernz Company

selling plumber's tools and the gasoline torch "Alway's Reliable". • 1877-1903 • Development of gas welding and cutting, carbon arc and metal arc

welding. • Elihu Thomson invents a low-pressure resistance welding machine

which was accomplished by causing internal resistance enough to reach the plastic stage of a metal. Later, it was referred to as Incandescent Welding.

• 1877• During a lecture at the Franklin Institute (Philia), E. Thomson

reversed the process of (...)


• 1881• A man named Augusta De Meritens used a form of arc

welding to adhere two lead plates together to made a battery. He worked along with another man named Nikolai N. Bendaros, who would later gain the patent for this welding process. Known as carbon arc welding, Bendaros and another Russian scientist, Stanislaus Olszewski, would obtain patents for this variation of arc welding in various countries, including America and Britain in the next few years. This type of welding would gain in popularity at the end of the 19th century and into the first years of the 20th century (Cary pg. 9).

• 1886• Bendaros receives a patent from Russia for a form of

carbon arc welding that actually could cut metal. The process was named "Electrohefest" after the Greek god of Fire and Blacksmithing, Hephaestus (Sapp 2003).

http://www.bsu.edu/web/cwjohnson2/welding.html#Carbon_Arc_Welding%23Carbon_Arc_Welding


• 1881 • Auguste DeMeritens working at an associated laboratory founded by the

periodical "l'Electricien" - Cabot Laboratory (Cabat), France was using arc heat to join lead plates for storage battery. French Patent Number 146010 was issued.

• 1885 • Nikolai N. Benardos (Bernados) and Stanislav Olszewaski (Olszewaski) secured a

British patent with carbon arc welding. Both men were working under the direction of A. DeMeritens with the arc lighting industry at the Cabot Laboratory (Cabat) in France. Carbon was oxidized at the carbon tip and created CO2 at the arc for shielding. Both men had to generate their electricity using a steam-engine (prime-mover) to turn the generator and produce electricity. The alternative was to use batteries which did not last long because of the short-circuiting involved. Patents applied for and received besides Britain: Belgium, Germany, Sweden, and France.

• 1886 • N. N. Benardos obtained Russian Patent (No. 11982) electric arc welding with

carbon electrode called ""Elecktrogefest" or "Electrohephaestus". The methods of cutting and welding metals by the arc was termed "Electrohefest" in memory(sic) of Hephaestus, the ancient Greek god of Fire and Blacksmith work. (The Romans renamed Hephaestus to Vulcan and which is shown on the title page, giving instruction to the craftsmen forging metal.)

• Benardos receives permission from the Russian Government to organize production in 1885 for "The production of this plant is based on welding and brazing by electricity and also producing devices for electrical illumination" (Note: emphasis mine)

• Electric furnace installed for production of aluminum alloys. An important step in early development of the Aluminum industry.


• 1887 • N.N. Benardos and S. Olszewaski secured an American Patent for

the welding apparatus. (U.S. Patent No. 363320, May 17) • The "blowpipe" or "torch", using the gases acetylene and liquefied

air or oxygen, was developed. • Thomas Fletcher develops blowpipe that could be used with either

hydrogen or coal gas and oxygen • An English shop began making tanks, casks, and iron garden

furniture with the electric arc process. • 1888• Benardos/Olczewski granted patent 12984 for Carbon Arc Welding. • 1889 • Hans Zerner is issued German Patent 53502.3.12.1889 for the Twin

Carbon Arc welding process?. • C. Coffin is issued patent 395878, 'Process of Electric Welding'. • The US Commissioner to the 1889 Paris Universal Exposition upon

seeing the arc welding process demonstrated wrote in a report "...As the metal is burnt and brittle where it is welded, the process is not a success."



• 1890• C.L. Coffin discovers a method of transferring metal from a metal electrode to

the joint to fill the gap in the joint. For his work, Coffin was able to patent his idea, which was the first to use a metal electrode (Cary pg. 9).

• C. L. Coffin in Detroit Michigan awarded first U.S. Patent (No. 419032, Jan 1) for metal electrodes. This was the first record of metal melted from an electrode and actually carried across the arc to deposit filler metal in the joint to make the weld. One electrode was carbon and the other electrode was filler material.

• Coffin also described the GTAW beginnings when a weld was made in non-oxidizing atmospheres.

• A bank robber in Great Britain used the newly developed "blowtorch" to gain access to bank vaults.

• 1892 • Canadien Thomas 'Carbide' Willson and American James Turner Moorhead begin to

commercially produce acetylene as a product from calcium carbide in Spray, North Carolina.

• Slavianoff suggests that a bare metallic electrode could be substituted for the carbon electrodes of the Benardos process.

• Concurrently, C. L. Coffin is also credited with introducing the bare metallic electrode in the US

• Baldwin Locomotive Works was using Carbon Arc Welding (CAW) for locomotive maintenance. The weld joints were hard and brittle because of the carbon flaking off into the weld puddle.

• 1886-1898 • Elihu Thompson of the Thompson Welding Co. invented Resistance Welding (RW).


• 1895 • The combustion of Oxygen and Acetylene was

discovered by Henri LeChatelier in his home country of France. Describes combustion of acetylene with equal volume of oxygen proceeds in two stages:

• Step 1: 4 CO + 2O2 = 4CO2

• Step 2: 2 H2 + O2 = 2H2O• Machine for liquid air generation placed in operation • Lord Reyleigh and Sir William Ramsey discover Argon

(Ar). • Konrad Roentgen (Bavaria) observed the effects of x-

radiation while passing electric current through a vacuum tube.


• 1895-1905 • During a 10 year period in the U.S. and at a rate of one

accident per day, boilers were exploding with the loss of life from the accidents at twice that rate.

• 1900• E. Fouch and F. Picard develops oxyacetylene torch in

France. • 1901 • Menne invented the Oxygen Lance in Germany. • Soon after Charles Picards invention of the oxyacetylene

blowpipe in Paris France, this invention was called upon to repair a cast iron part on an acetylene pump. Quite by accident, the filler metal had enough silicon present to prevent the formation of the excessively hard white iron.

• 1902 • President Teddy Roosevelt took over the Panama Canal

project from the French.


• 1903 • Hans Goldschmidt of Essen, Germany invented Thermit Welding (TW), an exothermic

reaction between aluminum powder and a metal oxide.. Used to weld railroad rails together.

• Oxyacetylene is applied commercially. • 1904 • Concentrated Acetylene Company invents the portable cylinder for the auto

headlights. • 1905 • L. W. Chubb of Westinghouse Electric & Manufacturing, East Pittsburg, PA,

experiments with electrolytic condensers and rectifiers and found that wires could be connected to aluminum plates. Also found that copper could be joined in a like manner. When the cells discharged, sparks were formed.

• 1907 • Two German welders came to the U.S. and formed Siemund-Wienzell Electric

Welding Co. and patented a metal arc welding method. Another German formed company, Enderlein Electric Welding Co. also started up. This was the beginning of the arc welding industry in the U.S.

• Lincoln Electric Company of Cleveland Ohio began by manufacturing electric motors in 1895. By 1907, Lincoln Electric were manufacturing the first variable voltage DC welding machine.

• 1907-1914 • Oscar Kjellberg (pronounced 'Shellberg') of Sweden and the ESAB (Elektriska

Svetsnings-AtkieBolaget) Company invented the covered or coated electrode by dipping bare iron wire in thick mixtures of carbonates and silicates. The purpose of the coating was to protect the molten metal from oxygen and nitrogen. His pioneering of covered electrode development paved the road during the next twenty years in the research of reliable flux coated electrodes.


• 1908 • Oscar Kjellberg received Patent No. 231733 for the coated welding

electrode. • N. N. Benardos develops electroslag welding process. • 1909 • Strohmenger developed the Quasi-arc electrode which was wrapped in

asbestos yarn. • The keel of the H.M.S. TITANIC was laid on March 31 at Harland and

Wolff shipyard. • Schonner, a physicist with BASF (Badischen Anilen und SodaFabrik)

invents the plasma arc system using a gas vortex stabilized arc. • First industrial application of plasma at BASF (Badische Anilin und

Sodafabrik) by a physicist manufacturing nitrogen dioxide (NO2). • 1910• Charles Hyde of Great Britain is issued a patent for brazing steel tubes. By

clamping two pieces into position, copper is placed in the joints as metallic strips, plating or powder mixed in a paste. Heated in a hydrogen furnace (oxygen-free atmosphere) and by capillary attraction flows copper into the joint

• 1911 • H.M.S. TITANIC is launched on May 31. • First attempt to lay 11 miles of pipeline using oxy-acetylene welding near

Philadelphia, Pennsylvania. • American physicist (Matters) developed a plasma arc torch for heating a

metal fusing furnace.


• 1912 • Lincoln Electric Co. introduced the first welding machines after

experimentation started in 1907. • E. G. Budd Spot Welds (SW) the first automobile body in Philadelphia,

Pennsylvania. • Langmuir gives the "plasma" to a gas or gas mixture brought to such a

high temperature that all diatomic molecules are dissociated and the atoms partially ionized and where all monotomic gases are fully ionized.

• Firecracker welding technique, a version of shielded metal arc welding is patented in Germany.

• Strohmenger introduced coated metal electrodes in Great Britain. The electrodes had a thin wash coating of lime or clay resulting in a stable arc.

• Strohmenger obtained US patent covering an electrode coated with a blue asbestos with a binder of Sodium Silicate (NAXX). This was the first electrode which produced weld metal free of impurities.

• 1913 • Avery and Fisher develop the acetylene cylinder in Indianapolis, Indiana. • 1914 • A 34 mile pipeline was laid near Enid, Oklahoma using oxy-aceylene

welding for the oil industry.


• 1915-1916• Underwater cutting was carried out but interest did not come about until 1926. • 1916• Companies licensed resistance welding equipment, mostly spot welding was the

intended use. • 1917 • Because of a gas shortage in England during World War I, the use electric arc

welding to manufacture bombs, mines, and torpedoes became the primary fabrication method.

• 1918 • Admiralty testing of metal-arc welding on Barge Ac 1320 leads Lloyd's Register to

permit metal-arc welding in main structures on an experimental basis. • 1917-1920 • During World War I, a Dutchman, Anthony Fokker, began using welding in the

production of Fuselages in German fighter planes. • HMS Fulagar (Fullagar) was first all welded hull vessel - Great Britain. • The repair of sabotaged German ships in New York Harbor highlighted the first

important use welding because the German merchant marines tried to destroy the ships boilers on 109 ships. A team of engineers from a railroad company (possibly the Rock Island Line) was tasked to the repair. Later, 500,000 troops were delivered to the European War in France using these repaired ships. The success of the weld repairs catapulted welding to the arena for manufacturing and repair and dashed it sordid past as a controversial operation.


• 1919 • President Woodrow Wilson established The United States Wartime Welding

Committee of the Emergency Fleet Corporation under the leadership of Dr. Comfort Avery Adams.

• Dr. Comfort Avery Adams, held a meeting on January 3rd to form the "American Welding Society ". The Constitution of this meeting was approved on March 27.

• C. J. Holslag used Alternating Current (AC) for welding, but this was not popular until 1930.

• The AWS Constitution of the January meeting was approved on March 27. • Reuben Smith developed and patented the paper-coated electrode. The weld did not

leave a slag and produced an acceptable weld. • 1920s • Various welding electrodes were developed:

– Mild steels electrodes for welding steels of less than 0.20% carbon; – Higher carbon and alloy electrodes; and – Copper alloy rods.

• Researchers found that Oxygen (O2) and Nitrogen (N2) when in contact with molten metal caused brittle and porous welds.

• Alexandre and Langmuir, from General Electric Co., used Hydrogen in chambers to weld. Began with two carbon electrodes and later switched to Tungsten.

• Bundy-Weld of Bundy Company, Detroit Michigan uses sheetmetal coated with a copper paste and is rolled tightly around itself and placed in a furnace. The brazed joint is formed into one piece tubing.

• The automotive industry began using Automatic Welding with a bare wire fed to the workpiece to the production of differential housings.

• Poughkeepsie Socony (1235 tons), the first all-welded tanker was launched in the USA.


• 1920 • P.O. Nobel of General Electric Company developed automatic welding,

using Direct Current (DC) using the arc voltage to regulate feed rate. Primary use was to repair worn motor shafts and crane wheels.

• The British ship "Fulagar" was constructed by the Cammell-Lairds and launched. In 1924, the ship grounded. A report in the British "Journal of Commerce" (July 17, 1924) reported that she held steadfast and if rivets were used in the construction, the ship would surely have opened up and not be able to get off the bank.

• After WW I, the Treaty of Versailles limited the Germans from designing and building ships in excess of 10, 000 tons for armored ships and cruisers not to exceed 6,000 tons. Welding was an experimental production option before WW I but the Germans used it to develop the next stage of warships by saving weight whereby the ship could then carry more armament or armor plating in selected areas.

• Torch brazing is in full swing using silver and gold filler metals and mineral fluxes as protective cover.

• Electrification of Russia begins utilizing hydroelectric power sources. • 1921• Leslie Hancock pioneered flame cutting machine where the burner followed

the path of a magnetized stylus tracking around the contour of a metal template. The stylus is propelled by a gramophone motor.


• 1922 • "No longer in the tones of a Walt Whitmanesque muscular America, the

skyscraper celebrated the technology that was bringing the world together." • The first issue of the "Proceedings of the American Welding Society" was

published in January (Vol. 1, No. 1). The name was changed in February, the next month, to "Journal of American Welding Society ".

• The Prairie Pipeline Company weld an 8 inch diameter pipeline 140 miles long to carry crude oil from Mexico to Jacksboro, Texas. The advantage of welding over fittings saved the project 35 percent and the cost of weld, labor and material was $2.00 per welded joint.

• 1923 • Institute of Welding Engineers was formed and headquartered in New York

City. • Naval Research Laboratory (NRL) was formed by the US Government

which was motivated by Thomas Edison's belief that history demonstrates a relationship between technological innovation and national security.

• 1924 • 1st all-welded steel buildings constructed in U.S. by General Boiler Co. "to

the exclusion of rivets". • Resistance, gas and metallic arc welding in the manufacturing of all steel

automobile bodies at the E.G. Budd Manufacturing Company. • Mechanical flash welder used for joining rails together. • First recognition of welding design was presented in papers written by: J. C.

Lincoln, S. W. Miller, C. J. Holslag, H. A. Woofter, and J. H. Deppler.


• 1925 • ASME Boiler Code Construction Code Section VIII is issued for unfired pressure

vessels. • AWS Board of Directors approves "Standardization of Hose Connections for Welding,

and Cutting Torches and Regulators" • AWS held First Welding Show with the National Fall Meeting, 21-23 October, in Boston. • A.O. Smith fabricates a single-piece heavy walled pressure vessel entirely by welding

and was PUBLICLY tested then placed in an oil cracking service. • 1926 • H.M. Hobart and P.K. Devers used atmospheres of Helium and Argon for welding with a

bare rod inside the atmosphere. Due to the impurities of the inert gases and the corresponding high cost along with a lack of knowledge about current density, commercial applications were not realized at this time.

• UNA-METHOD - Trade name for the rail joint welding process, arc welding apparatus, electrodes and supplies. UNA Welding & Bonding Co. Cleveland Ohio.

• FUSARC - (need info)...? • Irving Langmuir, a noted chemist with General Electric Co. developed the Atomic

Hydrogen Welding (AHW) Process. Co-authored with R. A. Weinman the paper was "Atomic Hydrogen Arc Welding"

• Naval Research Laboratory (NRL) employee, P. W. Swain authored a paper "X-ray tests of weld " which was to have an impact with the welding industry much longer than the introduction of Atomic Hydrogen Arc Welding. The technique used a gamma-ray radiation as a shadow method to detect flaws in cast or welded steels. The techniques was used to detect flaws on the US Navy 9000 tonne heavy cruisers. The process was later identified as a Nondestructive test method and contributed to the success of developing improved steel castings for the U.S. Navy.

• Landstroth and Wunder of A. O. Smith Co. solid extruded heavy coatings for metal-arc welding electrodes.


• 1927 • Lindberg's Ryan monoplane fuselage was manufactured with welded steel

alloy tubing. • Soviet Union production of Resistance Welding machines at Elektrik Works

called the "AT-8" and the "ATN-8: apparatus's for spot-welding and the "AS-1" and the "AS-25-1" for buttwelding.

• John J. Chyle of A. O. Smith Corp. invented and patented the first extruded, all-position, cellulosic, titanium dioxide later classified as E6010 type welding electrode.

• 1928 • In East Pittsburgh, Pennsylvania, on the Turtle Creek, America's First All-

Welded Railroad Bridge was erected by Westinghouse Electric and Manufacturing Company. Westinghouse used the bridge to transport the large generators from facilities to the rest of the country by way of the railways. Weighing in at 20,000 pounds and at 62 foot long, the bridge was manufactured without the use of rivets, a common method of bridge construction of those days. The testing of the bridge was completed by driving a locomotive on the bridge. (Information Courtesy of Mr. LaFave)

• Code for Fusion Welding and Gas Cutting in Building Construction (predecessor of AWS D1.1) was issued by the American Welding Society.


• 1929 • Lincoln Electric Co. started production of heavy coated electrodes

(Fleetweld 5) and sold the electrodes to the public. Sues A.O. Smith and wins.

• 1st European All-Welded bridge in Lowicza, Poland. Designed in 1927 by Professor Stefana Bryly and spanning the Sludwie River this bridge was still in use as late as 1977, whereby it was being replaced with a newer highway and bridge which is designed for wider traffic. The Polish Government planned to move the bridge 80 meters up stream and establish the bridge as a historical monument. In 1995, AWS President ED Bohnart presented to the Government of Poland, the AWS Historic Welded Structure Award.

• Welding symbols are established by the American Welding Society

• General Electric experiments with "Controlled-Atmosphere brazing", using hydrogen gas for copper to steel brazes.

• Welding conferences are held on the campuses of Lehigh and Syracuse


• 1930-1940s • Atomic hydrogen arc welding process developed. Found that hydrogen

was liberated releasing heat, which was 1/2 of the BTU of acetylene. Used primarily for tools steels. Development included an automatic version of the process.

• 1930 • Specifications for welding electrodes were beginning to be written. • H. M. Hobart issued Patent Number 1746081, for "Arc Welding" and P. K.

Devers was issued Patent Number 1746191 for "Arc Welding" on Feb 4 for using a concentric nozzle with a wire feed. This became known later as Gas Metal Arc Welding (GMAW). Work was based on various atmospheres in 1926.

• Germany started development work to find a suitable substitute for their dwindling supply of critical alloys. Experiments in the U.S. and Germany found that Thermoplastics when heated could be pressed together and obtain a permanent bond. In 1938 this principle was incorporated into "Hot Gas" welding technique. Thermoplastic rod and sheet were heated simultaneously by a stream of hot air while the rod was pressed into the sheet causing a bond. World War II forced Germany to further develop and use welded Thermoplastic as a corrosion resistant structural material.


• 1930 continued….• Stud Welding (SW) was developed by the New

York Navy Yard to fasten wood to steel. • Submerged arc welding developed by National

Tube Co. in McKeesport, PA by Robinoff. Later sold rights to Linde Air Products and renamed UNION-MELT. Used in late 30s and early 40s in shipyards and ordnance factories.

• 1st all-welded merchant ship was built in Charleston, South Carolina.

• Advancements in protective atmospheres that dissociate chromium oxide from the surface of stainless steel are performed in furnaces without the mineral flux and were found in laboratories with no commercial equivalence


• 1931 • E. G. Budd Manufacturing Company of Philadelphia spot welded stainless steel

(18-8) and built the Privateer. The spot-welding was a process called "shotwelding" a proprietary process developed by E.G. Budd.

• Combustion Engineering shipped the first commercial land boiler fabricated by ASME welding code to Fisher Body Div. of General Motors Corporation.

• 1932 • Submerged Arc Welding (SAW) developed by National Tube Co. in McKeesport,

PA by Robinoff. Later sold rights to Linde Air Products and renamed UNION-MELT. Used in late 30s and early 40s in shipyards and ordnance factories.

• British Corporation Register and Lloyd's introduce revised rules and approvals for the use of welding on ships.

• 1933 • Lincoln Electric Co. published 1st edition of "Procedure Handbook of Arc Welding

Design and Fabrication" with the purpose to have its customers use arc welding efficiently. As a full service company, this book provided the customers a knowledge of welding education and training.

• English Antiquarian, H. A. P. Littledale patents the "Littledale Process (British Patent No. 415,181)", following the same approach that Pliny and Theophilus wrote about from the past two millenniums. Mixing copper salts with seccotine glue ultimately would produce the following reaction {CuO+C -> Cu + CO} which is where brazing would theoretically be reached. The temperature the reaction takes place: 850C.


• A major innovation was described in a patent (US Patent number 2,043,960) that defines the Submerged Arc Process invented by Jones, Kennedy and Rothermund. This patent was filed in October 1935 and assigned to Union Carbide Corporation. The Specification states, Page 4, Column 2, Lines 4 through 7 that the application was in part a continuation of applications Serial Numbers 657,836 and 705,893 filed in February 1933 and January 1934.

http://www.netwelding.com/History_Submerged_Arc%202.htm#Kennedy

http://www.netwelding.com/History_Submerged_Arc%202.htm#Kennedy


• 1934 • 1st All-welded Excavator - HARNISCHFAGER Corp. • 1st All-welded British bridge - Middlesborough, England • Lloyd's Rules for pressure vessels permits inspection

using X-Ray technology. In Scotland, welding was beginning to be recognized as a separate crafts trade and the Trade Unions were opposed to this recognition. The General Secretary of the Boilermaker's Union argued that it was unfair to condemn any young man to a lifetime of welding. (Scotland). The Shipbuilding Employers insisted on the separate recognition.

• Westinghouse introduces the "Ignitron" which would become the basis for resistance welding timing controllers.

• American Welding Society presents John C. Lincoln the Samuel Wylie Miller Medal for "Meritorious Achievement". The award cited him for his work on the variable voltage machine, the ductility and strength of welds, the carbon arc automation process, and his efforts to expand the use of welding in many industries.


• 1935 • Granulated flux developed in 1932 and a continuous bare wire feed became

known as "Submerged Arc Welding (SAW)" and saw major applications in shipbuilding and pipe fabrication (see 1932 for a different account).

• Solid extruded electrodes are introduce in Britain and subsequently the first British welding electrode standard written.

• Welding has "Arrived" when London, England hosts 900 attendees at the "Great Symposium" on the "Welding of Iron and Steel"

• Solar Aircraft Company of San Diego California develops a flux to combat welding problems with stainless steel manifolds for the U.S. Navy and was regarded as a closely-guarded military secret. Where flux is applied to the front of the weld, this was placed on the backside of weld, protecting from oxide formation. Later, the product was developed further to accommodate the Heliarc process.

• 1936 • 1st All-welded Box Girder Crane by HARNISCHFAGER Corp., Milwaukee WI. • 1st All-welded Gear were fabricated by HARNISCHFAGER Corp. Milwaukee WI. • First Specification for Design, Construction, Alteration and Repair of Highway

and Railway Bridges by Fusion Welding was issued by the American Welding Society.

• Tentative Rules for the Qualification of Welding Processes and Testing of Welding Operators was submitted by AWS.

• The Soviet Union at the Electrik Works started using the electronic control gears as the first valve timer with a thyristor contactor (RVE-1) for resistance welding.

• Japan Welding Society stipulates the rules of qualification testing in "The Standard of Qualification for Arc Welding Operator".


• 1937 • BS 538: Metal arc welding in mild steel, was issued, legitimizing arc

welding structural applications. • Norman Cole and Walter Edmonds, metallurgists from California are

granted a patent for their product named "Colmonoy". Derived from COLe and edMONds and allOY.

• 1938 • The Welding Handbook, First Edition was printed and edited by

William Sparagen and D. S. Jacobus. • Pressure vessel industry began implementing the high production

value of Automatic Welding. • The German Shipbuilding Industry uses welding extensively to

reduce the weight of warships and increase the overall size of the ship. This restriction was put in place after World War I.

• K. K. Madsen of Denmark describes Gravity Welding as a specialized electrode holder and the mechanism which will maintain a covered electrode in contact with the workpiece.

• A.F. Wall purchases Colmonoy and renames to Wall-Colmonoy (Detroit).


• 1939 • Floyd C. Kelly of General Electric publishes "Properties of Brazed 12% Chrome Steel" as an

early investigation of the strength of brazed joints.4Aluminum Spot Welding saw application in the Aviation Industry. He describes:

– Single lap tensile specimens – 45 degree vee-type tensile specimen – Butt brazed tensile specimens.

• Aluminum Spot Welding saw application in the Aviation Industry. • Ultrasonic Fluxless soldering patented in Germany. Process is conceived in 1936. • Air Arc Gouging is developed (USA). • Stud Welding (Nelson Stud Welding Co.) used by the US Navy to reduce time installing studs

during fabrication of ships and aircraft carriers. • 1940s • With World War II GTAW was found to be useful for welding magnesium in fighter planes, and

later found it could weld stainless steel and aluminum. • Canadian Welding Society (CWS) formed. • Exchequer, first all-welded ship built at Ingalls Shipyard in Mississippi. • J. Dearden and H. O'Neill (UK) discuss "Weldability" in terms of carbon equivalencies. • Sun Shipbuilding Company builds the world's largest ocean-going tanker, I. Van Dyck (11650

DWT). This was the first large scale use of automatic welding applied in shipyard work. • First mass soldering technique, Dip Soldering, is used for Printed Wiring Boards (PWB) to

keep up with the development of electronic equipment such as, Television, radios, etc. • Little advancement was made in brazing and there were no dry-hydrogen facilities, except for

laboratories, for brazing Stainless steel and there were no vacuum furnaces. • Germany was using 85Ag-15Mn brazing alloys as the best high temperature filler metal

available. Used for brazing hollow sheet metal blades used in the turbine engines and stators.


• 1940• Gas shielded metal arc welding developed by Hobart

and Devers at Battelle Memorial Institute. • 1941 • Engineers at Northrup Aircraft Co. and Dow Chemical

Co. developed the GMAW process for welding magnesium, and later licensed it to Linde Co. with a water cooled, small diameter electrode wires using CV power. Because of the high cost of inert gas, the cost savings were not recognized until much later.

• PLUTO - PipeLine Under The Ocean was created using the Flash Weld (FW) process for 1000 miles of 3 inch diameter pipe, to assist in the invasion of Normandy Beach, France. Once in place, the pipeline began pumping 1 million gallons of petrol per day directly to depots deep in the French country side.

• Friction Surfacing. H. Klopstock and A. R. Neelands "An Improved Method of Joining and Welding Metals" British Patent 572789, October 1941.


• 1942 • Chief of Research, V. H. Pavlecka, and engineer Russ Meredith of Northrup Aircraft Inc.

designed the Gas Tungsten Arc Welding (GTAW) process to weld magnesium and stainless steel. Alternate names are TIG (tungsten inert gas) and Argonarc and Heliarc. Heliarc is the term originally applied to the GTAW process. (Patent Number 2274631, 24 February 1942).

• The invention of GTAW was probably the most significant welding process developed specifically for the aircraft industry and remained so until recently, with the Friction Sir Weld process of the 1990's. Mr. Northrup of Northrup Aircraft Inc. was a visionary who wanted an all-welded aircraft (i.e., manufacturing costs, and lightweightness of the aircraft). Meredith was working from research of Devers and Hobart at General Electric (1920s) who had experimented with tungsten arcs in non-oxidizing atmospheres. The high reactivity of magnesium (Northrup's dream metal) would cause problems with more conventional processes, so, Meredith to began developing a torch with better handling characteristics and would use inert gas enshrouding tungsten. Thus, the Heli-arc process.

• From the Dec 1942 Welding Journal: "The full importance of arc welding on the future of magnesium alloys cannot be fully appreciated at this time but the fabrication of these strong light alloys has opened the possibilities that were not considered even a year ago. For the man in industry, this method of joining offers simplicity of structure, ease and speed of fabrication and over-all economy."

• US Patent 2269369, Jan 6, 1942 issued to George Hafergut for Firecracker Welding. • Traveling 285 miles north of Edmonton Canada and barging 1100 miles north to the

Norman Well refinery a base camp was setup to build the Canadian Oil (CANOL) project. Working for 20 months, 1800 miles of pipeline was laid along side of 2000 miles of road. The last weld was laid on 1 February 1944. On 1 April 1945 the wells were shut down.

• Second Edition of the Welding Handbook was printed and issued. • SAW proves it worthiness during World War II with the building of the Liberty Ships. • G.L. Hopkins of Woolrich Arsenal defines the problem of cracking in alloy steels and

hydrogen in welding electrodes.


• 1943 • Union-Melt is now commonly referred to as Submerged Arc Welding

(SAW). The process used rods rather than wire filler metal and could weld work pieces up to 2 -1/2 inches thick.

• Sciaky (USA) markets the three-phase resistance welder. • 1944 • 1st Low-hydrogen electrodes used in fabrication of alloy armor tanks

vehicles by the Heil Corp in response to the chrome and nickel shortages from World War II for the U.S. Army.

• The Bureau of Navy Aeronautics designed and E. G. Budd Mfg. built the "Conestoga", a stainless steel aircraft. Despite the success of the aircraft, aluminum and rivets became the influencing factor in aircraft design.

• 1945• After World War II, the Allies brought from Germany the alloy

combination, 85Ag-15Mn which has a 1760°F brazing temperature. • ElectoBrazing is used for manufacturing shafts to gears.


• 1946 • Sprayweld Process (US Patent 2361962) issued to Wall-Colmonoy uses

an alloy powder spray which produces a smooth, welded deposits. • General Electric Co. Ltd (UK) invents the Cold Pressure Welding

Process. • High Frequency (HF) stabilized AC tungsten-arc welding is used for

aluminum alloys. • 1947 • The Final Report of a Board of Investigation, ordered by the Secretary of

the Navy, "To Inquire Into The Design and Methods of Construction of Welded Steel Merchant Vessels, 15 July 1946" was issued.

• Canadian Welding Bureau was created as a division of the Canadian Standards Association

• The Austrian Welding Society is formed and publishes a monthly magazine "Scheisstechnik"

• Nicrobraz, developed by Robert Peaslee of Wall-Colmonoy, is a 2500°F nickel alloy braze filler metal used in hydrogen furnaces. Used for stainless steel fuel supply connecting injectors to injector pumps for 18 cylinder reciprocating engines. The fledgling aircraft engine industry needed something else for engines to experience a hot shutdown without blowing the silver braze filler metal out from the brazed joints. Typical alloy was 85Ag-15Mn (BAg-23).


• 1948 The Ohio State University Board of Trustees established the

Department of Welding Engineering on January 1 as the first of its kind for a Welding Engineering cirriculum at a University. OSU pioneered the Welding Engineering through an emphasis in the Industrial Engineering Department the previous nine years. The advantages of this engineering degree is 1) Enable satisfactory administration of problems relating to education and research in the welding field. 2) Recognition is given to the Welding Engineer as an entity among applied sciences. 3) A degree is authorized which is descriptive of a particular discipline imposed in training for professional work in the field.

Air Reduction Company develops the Inert-Gas Metal-Arc (MIG) process.


SIGMA Welding (Shielded Inert Gas Metal Arc) was developed to weld plate greater than1/8 inch instead of the "Heli-Arc" welding process. The arc is maintained in a shield of argon gas between the filler metal electrode and the workpiece. No flux is used. Licensed by Linde Air Products Co.

•1948-1949

Curtiss-Wright Corporation looks at brazing as a strong, lightweight process for durable assemblies.

•1949

American Westinghouse introduces and markets welding machines using Selenium Rectifiers.

US Navy uses inert-gas metal arc welding for aluminum hulls of 100 feet in length.

•1950

The Kurpflaz Bridge in Germany was built as the first welded orthotropic deck.


•1950s

Electron Beam (EB) welding process developed in France by J. A. Stohr of the French Atomic Energy Commission. First Public disclosure was 1957.

Wave soldering is introduced to keep up with the demand of Printed Wiring Boards used in the electronics age.

Research on testing of brazed joint begins as serious endeavor for the next ten years.

•1950

Electroslag Welding (ESW) is developed at the E. O. Paton Welding Institute, Ukraine USSR.

Third Edition of the Welding Handbook is printed by AWS.

Flash Butt Welding is the standard for welding rail line construction.


•1951

Russia use Electroslag Welding (ESW) process in production.

The Philip Roden Co. of Milwaukee Wisconsin announces the DryRod electrode oven. This oven is intended to provide a controlled moisture environment of 0.2% moisture standard set forth by the government. This oven provides adjustable temperature control of 200-550 F, vented and holding 350 pounds of electrodes.

•1953

Modifying the Gas Metal Arc Welding (GMAW) process, Lyubavskii and Novoshilov used CO2 with consumable electrodes. Resulted in hotter arc, uses higher current, and larger diameter electrodes.

The Ohio State University established a Welding Engineering College curriculum out of the Industrial Engineering Department.

•

http://www.weldinghistory.org/htmlhistory/link_osu_we.html


•1957 Flux Cored-Arc Welding (FCAW) patented and reintroduced by National Cylinder Gas Co. Plasma Arc Welding (PAW) Process developed by Robert M. Gage Russia, Britain, and USA independently develop a short-circuiting transfer for low-current low-voltage welding in a carbon dioxide atmosphere. Braze repair process for cracks in jet engine combustion chambers and transition ducts. 1958 The Soviet Union introduced the Electroslag Welding (ESW) Process at the Brussels World Fair in Belgium. This welding process had been used since 1951 in the USSR which was based on the concept and work of an American, R. K. Hopkins. Perfected at the Paton Institute Laboratory in Kiev, Ukraine, USSR and the Welding Research Laboratory in Braitislava, Czechoslovakia. AWS Committee on Brazing and Soldering is formed to develop a test for evaluating strength of brazed joints. Robert Peaslee proposes a test in the Welding Journal.


• 1959

Electroslag welding process was first used at the Electromotive Division of General Motors in Chicago and was called the "Electro-Molding Process".

Development of Inside-Outside Electrode which did not require an external gas shielding - Innershield from Lincoln Electric Co.

• 1958-1959

Short Arc (Micro-wire Short Arc) developed from refined power supplies and smaller diameter wires.

• 1960s

Pulsed Arc Welding...(more to follow)

Space Program is underway...(more to follow)

Difficult to stabilize GTAW at below 15 amps, Microplasma is developed to overcome the limitation.


1960 Development of a cold wall vacuum furnace. First laser beam produced using a ruby crystal for the Light Amplification Stimulated Emission Radiation (LASER). Explosive welding is developed in USA. Hughes Aircraft Company (Mainar) develops the first ruby laser (springtime). Bell Telephone Laboratories (Ali Javan) developed and presented the first gas laser using neon and helium (fall time) 1962 The Mercury Space Capsule is formed using inner and outer titanium shell, seam welded together using a three-phase resistance welder by Sciaky. 1963 U.S.S. Thresher sinks off the coast of New Hampshire and by December, the U.S. Navy charters the Submarine Safety Program (SUBSAFE) to control the fabrication, inspection and quality control of submarine construction. The presumed failure was with a silver-brazed piping joint, but after the investigation, the whole welding and brazing program was suspect. Included was the material properties of the welding and brazing filler metals.


• 1965-1967

CO2 lasers are developed for cutting and welding.

• 1967

H. J. Clarke makes the following Predictions during the AWS Plummer Lecture in Houston as he ties the current state of technology of welding to the future of progress:

World's Population would be greater than 5 Billion.

Large scale farming of the ocean and fabrication of synthetic protein.

Controlled thermonuclear power as a source of energy.

General immunization against bacteria and virile infections, perfected and available.

Primitive forms of life will created in the lab.

Automation will have advance for performance of menial chores and complicated functions.

Housewives would be ordering groceries and everyday items from central stores linked to the home electronically. (!!!)


• Children will be receiving education at home - "either by television or with personal teaching machines and programmed instructions"

Moon - mining and manufacture of propellant and on Mars, permanent unmanned research stations.

Weather manipulation by the military.

Effective anti-ballistic missile defense in the form of air-launched missiles and directed energy beams.

Libraries will be "computer-run"

Gravity welding is introduced in Britain after its initial discovery by Japan.

• 1969

The Russian Welding Program in Space began by producing Electron Beam welds on SOYUZ-6. Welding an AMG6 and DM-20 aluminum alloys with the Vulkan process. Sponsored by the E. O. Paton Welding Institute Academy of Science.


• 1970

As miniaturization developed from the pressure to increase component densities, Surface Mount Technology is developed. This required new ways to make soldered joints, including the development of vapor phase, infrared, hot gas and other re-flow technologies.

First AWS International Brazing Conference including 24 papers presented created much interest in the brazing process.

BP discovers oil off the coast of Scotland.

• 1971

British Welding Institute (Houldcroft) adds oxidizing gas jet around laser beam to develop laser cutting.


• 1973

The American Astronauts used Electron Beam welding process in June 1973 welding Aluminum Alloy 2219-T87, Stainless 304 and Pure Tantalum.

Welding equipment manufacturers concentrate on equipment refinement instead of new processes.

Two Supertankers, Globtik Tokyo and Globtik London (476025 DWT) were built for carrying 153 million gallons (3 million barrels) of crude oil


• 1976

First automotive production application of lasers weld begins with General Motors Corporation, Dayton Ohio using two 1.25 kW CO2 lasers. for welding valve assemblies for emission control systems.

• 1977

The US Federal Highway Administration issues a moratorium of Electroslag Welding (ESW) when cracks are discovered during an inspection of a bridge in Pittsburgh, Pennsylvania on an interstate highway. Failure analysis was conducted by Lehigh University on Interstate 79.

• 1980

The Fort McHenry tunnel contract, for 750 Million Dollars, is awarded to begin construction, completing Intestate 95 through Baltimore, Maryland. This is the largest tunnel of its kind, 180 feet at the bottom with two separate four lane immersed tunnels removing 3.5 million cubic yards of dredge.


• 1983

Homopolar pulse welding variation of the upset welding process research begins at the University of Texas at Austin at the Center for Electromechanics.

• 1987

Laser research begins a unique method for depositing complex metal alloys (Laser Powder Fusion).

• 1991

TWI of Cambridge England develops the Friction Stir Weld (FSW) process in its laboratory. This process differs from conventional rotary technology whereby a hard, non consumable, cylindrical tool causes friction, plasticizing two metals into a Solid-State Bond. No shielding gas or filler metal is required. Metals joined successfully include, the 2XXX, 6XXX and 7XXX series aluminum. NASA is the first US venture which welded the massive fuel tank for the Space Shuttle.

Brazing Handbook (Fourth Edition) shows the data of the filler metal/base metal failure transitions between 1T and 2T overlap and is the key for the design data (factor of safety).


1996 Over 7,00,000 brazements are produced for the aircraft industry in the US and Canada. Over 132,010,00 units of brazed automotive parts are produce. 1999 The Edison Welding Institute develops a solution to obtaining deeper penetration of a GTA weld by introducing FLUX onto the surface of the weld. This FLUX helps drive the welding arc heat deeper into the weld joint and permits 300 percent more penetration. 2000 Magnetic Pulse Welding (MPW) is introduced by Pulsar Ltd. of Israel using capacitive power as a solid state welding process. Discharging 2 Million amps in less than 100 microseconds this process can create a metallurgical, a non-metallurgical or a mechanical lock, depending on the substrate involved. No heat affected zone (HAZ) is created since only a rise of 30oC occurs. Tailored welded blanks of aluminum are used where spot welding was once performed.


2000Researchers from Argonne National Laboratory use the energy of the x-ray to weld metal-matrix composite (Ti or Al / Al2O3 or SiC) materials. Diode laser welding, once limited to compact disks, laser printers, and laser pointers, are now making their way to the manufacturing floor. Welding Type 304 Stainless steel (0.024 inch), Titanium foil (0.005 inch thick) and laser brazing with a silicon-bronze brazing wire. Conductive heat resistance seam welding (CHRSEW) is developed. The process uses steel cover sheets placed on top of aluminum butted together. Using conventional seam welding, the heat generated from the steel forms a molten interface on the aluminum and fusion is made at the butt joint. The steel covers are then removed.


• 2001 AWS D17.1, "Specification for Fusion Welding for Aerospace Applications" is published in March. The efforts of approximately 50 individuals from a cross-section of the Aviation Industry and government produces the first commercial aviation welding specification. Flame brazing 5XXX aluminum alloys using non-corrosive flux. Sulzar Elbar introduces laser powder welding technology. Permits rebuilding of substrate material (High Creep Resistance) and reproduction of the single crystal structure.

• 2002 From Linde Gas in Germany, a Diode laser using process gases and "active-gas components" is investigated to enhance the "key-holing" effects for laser welding. The process gas, Argon-CO2, increases the welding speed and in the case of a diode laser, will support the transition of heat conductivity welding to a deep welding, i.e., 'key-holing'. Adding active gas changes the direction of the metal flow within a weld pool and produces narrower, high-quality weld. CO2 Lasers are used to weld polymers. The Edison Welding Institute is using through-transmission lasers in the 230-980 nm range to readily form welded joints. Using silicon carbides embedded in the surfaces of the polymer, the laser is capable of melting the material leaving a near invisible joint line. 2003 2004 2005 Future developments.


ABOUT AWS The American Welding Society (AWS) was founded in 1919 as a multifaceted, nonprofit organization with a goal to advance the

science, technology and application of welding and related joining disciplines

• The Engineering Societies Building (left) in New York City was the home of AWS until 1961 when the Society moved to the United Engineering Center, also in New York City.


From factory floor to high-rise construction, from military weaponry to home products, AWS continues to lead the way in supporting welding education and technology development to ensure a strong, competitive and exciting way of life for all Americans.

• The Society moved its headquarters to Miami in 1971 (left).


• The American Welding Society, in conjunction with the Department of Energy, has put together a vision that will carry the welding industry through 2020.


• Technical Publications

• AWS offers over 300 books, charts, videos, replicas, proceedings, and software. 160 AWS-developed codes, recommended practices, and guides are produced under strict American National Standards Institute (ANSI) procedures, including one of the most consulted codes in the world, D1.1 Structural Welding Code - Steel.


Foundation

• Founded in 1989, to support research and education in welding and related technologies. It is committed to annually awarding fellowships to deserving graduate students for important research in areas important to the requirements of industry. Accordingly, each year the AWS Foundation administers six $20,000 grants - matched in kind by the participating universities. The award of scholarships to vocational and undergraduate college students is also a high priority and a student loan program has also been developed to prepare students for welding related careers.

http://www.aws.org/foundation/


• The Professional Program

The AWS Professional Program offers a broad spectrum of Technical Papers describing the latest findings in welding research, processes and applications. Special sessions and gatherings exploring the boundaries of industry issues are also significant features of the convention. Subjects cover an entire range of industry concerns from the joining of space age materials to production management techniques, testing, quality assurance and more.


Which welding process(es) will see an increase in use and which will see a decrease in use during the next decade?

• There was much speculation, but almost unanimously the process chosen for decline was shielded metal arc welding (SMAW). A very few speculated a decline in the use of gas metal arc (GMAW) and gas tungsten arc welding (GTAW). A significant group felt the continuous wire processes (FCAW, GMAW) would experience the most use. The GTAW process was the next most mentioned. One of the reasons stated for its increase was "the need for high-quality work on thin materials."


Welding Forges into the Future

Where do you see the use of welding automation heading in your industry?


• In what areas of welding do we need more knowledge? • Safety and Health. The industry needs more knowledge and

awareness regarding the hazards of welding, according to the respondents.

Welding of the newer grades of high-strength steels, high- alloy steels and heat treatable steels.

• We need to "keep up the 'how to weld' information with the increase in 'new' alloys, which are becoming more difficult to weld."

Automation. A variety of topics relating to automation. These included training in computerization and automation; information on short-run automation; and the need to create standard platforms for welding equipment, robot controllers, sensing devices and other automation peripherals.

The basics While universities and institutions are doing basic research, they cannot tell you the best process and fastest speed for a 1Ž4-in. fillet weld."


• What are the strengths of the welding industry? What are its weaknesses?

• What business improvements during the next ten years would be in your company's best interests?

• What has to be done in the future to keep the welding industry healthy?

More than 50% of the respondents believe improving the image of welding so top students

will be drawn to the industry and bettering training methods for welders and welding engineers are the

keys to welding's future.


• Are you optimistic or pessimistic about the future of your particular industry?

92% of respondents indicated they are at least optimistic about the future.

One respondent summed up his reasons this way:

Metallics will be around for a long time and they will need to be joined.


• Since time machines still exist only in the stories of H. G. Wells and other works of science fiction, no one can tell us exactly how welding will fare in the 21st century. However, the people who responded to the Welding Journal survey represent a cross section of fabricators of welded products and producers of welding equipment and related products. Together they offer a wide range of experience and knowledge. Answering the questions separately, in their respective cities, they still formed a consensus. They agree the future looks promising for welding. It remains and will continue to be a productive, cost-effective manufacturing method. However, steps must be taken to bring more skilled personnel into the industry, or changes must be made to accommodate for the lack of skilled personnel (e.g., welding automation). They also indicated the welding industry must embrace all of the modern-day technological tools to keep pace with the rest of the world. .


LIQUID STATE PROCESSES

• Partial melting and fusion of joint• Physical and mechanical changes taking place• Can be with application of pressure or by addition

of filler material

• Prior to joining, PREPARATION TO BE DONE

STANDARDS- AWS; ASTM-

TYPES OF GROOVES, JOINTS

NITC


Types of welds and symbols

• FILLET, SQUARE BUTT, SINGLE V, • DOUBLE V, SINGLE U, DOUBLE U, • SINGLE BEVEL BUTT, DOUBLE BEVEL BUTT, • SINGLE J BUTT, DOUBLE J BUTT, • STUD, BEAD(EDGE OR SEAL), PLUG, • SPOT, SEAM, MASHED SEAM, • STITCH, PROJECTION, • FLASH, UPSET etc. (REFER sketches supplied)

NITC


Standard location of elements of weld symbol

L PS

Specification process.

No tail- SMAW

Other side of arrow

Near side of Arrow

Field weld

Weld all around

Size

Length of weldUnwelded length

G- Grind C- Chip

F-File M-Machine

R- Rolling

Reference line

Finish symbol

Arrow connecting reference line to arrow side of joint /to edge prepared /member or both

NITC


ROOT

GROOVE ANGLE

Joint angle

Root Face

Groove face

NITC


WELD POSITIONS WELD MOVEMENTS

• FLAT

• HORIZONTAL

• VERTICAL

• OVERHEAD

• H

• O

• C

• J

• U

• ZIGZAG

NITC

Slide 2 of 18

WELDING TERMINOLOGY

http://www.staff.ncl.ac.uk/s.j.bull/mmm373/WELD/sld001.htm



http://www.staff.ncl.ac.uk/s.j.bull/mmm373/WELD/index.htm

http://www.staff.ncl.ac.uk/s.j.bull

http://www.staff.ncl.ac.uk/s.j.bull/mmm373/WELD/tsld002.htm



WELDING TECHNIQUES

FOREHAND BACKHAND

THIN

Same direction torch

Heat concentrated away from bead

Even flow, rippled design

THICK

Opposite direction torch

Heat concentrated on bead

Broad bead


WELD POSITIONS

• FLAT HORIZONTAL VERTICAL OVERHEAD

NITC


WELD MOVEMENTS

O ZIGZAGL

I STRAIGHT

Z


ASME P Material Numbers Explained

ASME has adopted their own designation for welding processes, which are very different from the ISO definitions adopted by EN24063.

DesignationDescription

OFW Oxyfuel Gas Welding

SMAW Shielded Metal Arc Welding (MMA)

SAW Submerged Arc Welding

GMAW Gas Metal Arc Welding (MIG/MAG)

FCAW Flux Cored Wire

GTAW Gas Tungsten Arc Welding (TIG)

PAW Plasma Arc Welding

Straight polarity = Electrode -ve Reverse polarity = Electrode +ve

http://www.gowelding.com/wp/pnumbers.htm


F Number General Description

1 Heavy rutile coated iron powder electrodes :- A5.1 : E7024

2 Most Rutile consumables such as :- A5.1 : E6013

3 Cellulosic electrodes such as :- A5.1 : E6011

4 Basic coated electrodes such as : A5.1 : E7016 and E7018

5 High alloy austenitic stainless steel and duplex :- A5.4 : E316L-16

6 Any steel solid or cored wire (with flux or metal)

2X Aluminium and its alloys

3X Copper and its alloys

4X Nickel alloys

5X Titanium

6X Zirconium

7X Hard Facing Overlay

ASME F Numbers

Note:- X represents any number 0 to 9


ASME A Numbers

These refer to the chemical analysis of the deposited weld and not the parent material. They only apply to welding procedures in steel materials.

A1Plain unalloyed carbon manganese steels.

A2 to A4 Low alloy steels containing Moly and Chrome Moly

A8 Austenitic stainless steels such as type 316.


ASME Welding Positions Note the welding progression, (vertically upwards or downwards),

must always be stated and it is an essential variable for both procedures and performance qualifications.

Welding Positions For Groove welds:-

Welding PositionTest Position ISO and EN

Flat 1G PA

Horizontal 2G PC

Vertical Upwards Progression 3G PF

Vertical Downwards Progression 3G PG

Overhead 4G PE

Pipe Fixed Horizontal 5G PF

Pipe Fixed @ 45 degrees Upwards 6G HL045

Pipe Fixed @ 45 degrees Downwards 6G JL045


TYPICAL WELDS




HORIZONTAL

VERTICAL UPWARDVERTICAL DOWNWARD


OVERHEAD


Multiple-pass layers. Weld layer sequence



G

for Groove Welds

F

for Fillet Welds



G

for Groove Welds

F

for Fillet Welds


Dr. N. RAMACHANDRAN, NITC 104PREPARATION FOR PIPE WELDING


Welding Positions For Fillet welds:-

Welding PositionTest Position ISO and EN

Flat (Weld flat joint at 45 degrees)

1F PA

Horizontal 2F PB

Horizontal Rotated 2FR PB

Vertical Upwards Progression

3F PF

Vertical Downwards Progression

3F PG

Overhead 4F PD

Pipe Fixed Horizontal 5F PF



Welding Positions QW431.1 and QW461.2

Basically there are three inclinations involved. Flat, which includes from 0 to 15 degrees inclination 15 - 80 degrees inclination Vertical, 80 - 90 degrees For each of these inclinations the weld can be rotated from the flat position to Horizontal to overhead.


WELD BEND TEST


Nick break test



Dr. N. RAMACHANDRAN, NITC 112PREPARATION FOR PIPE WELDING


Curved pipe heated


ELECTRODE IDENTIFICATION

Arc welding electrodes are identified using the A.W.S, (American Welding Society) numbering system and are made in sizes from 1/16 to 5/16 .

An example would be a welding rod identified as an 1/8" E6011 electrode.

The electrode is 1/8" in diameter

The "E" stands for arc welding electrode.


• Next will be either a 4 or 5 digit number stamped on the electrode. The first two numbers of a 4 digit number and the first 3 digits of a 5 digit number indicate the minimum tensile strength (in thousands of pounds per square inch) of the weld that the rod will produce, stress relieved. Examples would be as follows:

• E60xx would have a tensile strength of 60,000 psi E110XX would be 110,000 psi

• The next to last digit indicates the position the electrode can be used in.

• EXX1X is for use in all positions • EXX2X is for use in flat and horizontal positions • EXX3X is for flat welding


• The last two digits together, indicate the type of coating on the electrode and the welding current the electrode can be used with. Such as DC straight, (DC -) DC reverse (DC+) or A.C.Type of coatings of the various electrodes are explained elsewhere.

• Examples of the type current each will work with are as below.


• ELECTRODES AND CURRENTS USED• EXX10 DC+ (DC reverse or DCRP) electrode positive. • EXX11 AC or DC- (DC straight or DCSP) electrode

negative. • EXX12 AC or DC- • EXX13 AC, DC- or DC+ • EXX14 AC, DC- or DC+ • EXX15 DC+ • EXX16 AC or DC+ • EXX18 AC, DC- or DC+ • EXX20 AC ,DC- or DC+ • EXX24 AC, DC- or DC+ • EXX27 AC, DC- or DC+ • EXX28 AC or DC+


• CURRENT TYPES• SMAW is performed using either AC or

DCcurrent. Since DC current flows in one direction, DC current can be DC straight, (electrode negative) or DC reversed (electrode positive). With DC reversed,(DC+ OR DCRP) the weld penetration will be deep. DC straight (DC- OR DCSP) the weld will have a faster melt off and deposit rate. The weld will have medium penetration.Ac current changes it's polarity 120 times a second by it's self and can not be changed as can DC current.


ELECTRODE SIZE AND AMPS USEDElectrode Table

ELECTRODEDIAMETER

AMPRANGE

PLATE

1/16" 20 - 40 UP TO 3/16"

3/32" 40 - 125 UP TO 1/4"

1/8 75 - 185 OVER 1/8"

5/32" 105 - 250 OVER 1/4"

3/16" 140 - 305 OVER 3/8"

1/4" 210 - 430 OVER 3/8"

5/16" 275 - 450 OVER 1/2"

The table shown will serve as a basic guide of the amp range that can be used for different size electrodes. These ratings can be different between various electrode manufactures for the same size rod. The type coating on the electrode could effect the amperage range. Check manufacturer’s recommended amperage settings.

Note! The thicker the material to be welded, the higher the current needed and the larger the electrode needed


SOME ELECTRODE TYPES• E6010 : Used for all position welding using DCRP. It produces a deep

penetrating weld and works well on dirty,rusted, or painted metals

• E6011: Same characteristics as of the E6010, but can be used with AC

and DC currents.

• E6013: Used with AC and DC currents. It produces a medium penetrating

weld with a superior weld bead appearance.

• E7018: Known as a low hydrogen electrode and can be used with AC or

DC. The coating on the electrode has a low moisture content that reduces the introduction of hydrogen into the weld. The electrode can produce welds of x-ray quality with medium penetration.

(This electrode must be kept dry. If wet, it must be dried in a rod oven before use.)


Effects of expansion and contraction


CONTROLLING DISTORTION


HEAT AFFECTED ZONE


Documents

METAL JOINING