COMPARISON OF FRICTION WELDING TECHNIQUE WITH CONVENTIONAL WELDING METHODS
Megavarnan.R
M.E Student, Mechanical Department, Bannari Amman Institute Of Technology,Sathyamangalam-638401, India, megavarnan7@gmail.com
Abstract
In general, any machine part can be produced by one of various manufacturing methods such as forging, machining, casting and welding. Determination of the manufacturing methods depends on production costs of the alternatives for individual parts. Friction welding which is an alternative welding method, is widely used in production of machine parts having different cross-section or diameter in order to decrease manufacturing costs and the main advantage of friction welding methods is to reduce defects existing during
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INTRODUCTION TO WELDING:
Welding is a fabrication process that joins materials, usually metals or thermoplastics, by causing coalescence. This is often done by melting the workpieces and adding a filler material to form a pool of molten material that cools to become a strong joint, with pressure sometimes used in conjunction with heat, or by itself, to produce the weld.
Welding may be defined as "the metallurgical joining of two metal pieces together to produce essentially a single piece of metal".
Classification of Welding and Allied
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In a weldment, internal stress is caused by thermal expansion and contraction as the weld metal cools and solidifies.
Incomplete Penetration:
A discontinuity characterized by an unpenetrated and unfused area in a joint that occurs when weld metal does not extend through the thickness of the joint. Incomplete penetration can result from insufficient welding heat, improper joint design, and improper lateral control of the welding arc.
Distortion:
A disfigurement that signals that a weld joint was not prepared properly.
Lack of Fusion:
Lack of fusion is the failure to fuse together either the base metal and weld metal or subsequent beads in multipass welding because of failure to raise the temperature of base metal or previously deposited weld layer to melting point during welding.
Shrinkage Cavity: the cavities which are formed due to shrinkage of weld metal during its solidification. The shrinkage cavity usually occurs during welding of thick plates in a single pass using submerged arc welding or electroslag welding processes. Friction welding:
The Friction Welding Process was formally defined by the AWS on Oct 15, 2008 in the Recommended Practices AWS C6.1 for the Welding
According to Pickwelder, “This type of welding is used in welding wide varieties of metals and alloys such as magnesium, steel, stainless steel, nickel, copper, aluminum, bronze and many other nonferrous metals” (James). MIG can be used with a number of different metals making it very diverse. This is a good quality as it can bond to any metal with the right settings and welding wire. According to JobsiteUS, “A range of material thicknesses can be welded from thin gauge sheet metal right up to heavier structural plates” (Peter Apalais). MIG welding can weld through all different metals and their thicknesses. This is good for production because this process can do both while some processes can only weld thin or thick metal. According to Coastal Media Brand, “Capable for a variety of applications, including – trailer hitches, auto body repair and restoration, farm/ranch equipment, household projects, repairing wheel barrows, bicycles, etc” (Coastalmedia843) The multivariate MIG has so many possibilities that can be used for nearly anything that involves repair work or production. It is good for commercial use and even for your home. This shows the extent that MIG welding can go up to, and the list goes on. All in all Gas Metal Arc Welding is the best process that can be used for an expansive amount of uses for anything consumer grade and
Welding started back in the medieval days. But there was only one welding process, and it was called forge welding. Forge welding is the use of heating metal, shaping it (by pounding it with a hammer), then cooling it. People back then had to go to their local black smith go get things fixed. Some tasks required black smiths to be extremely precise, and have an even level of thickness throughout the piece of metal that they are foraging.
Even though welding has been around for a long time, most of the best inventors were around during the 19th century and have changed the way thing are done today. During the 20th century, many technological advancements developed and have made welding easier because of the different types of welding that have been developed. Welding impacted the world during World War l, because during the war armaments that were going to be utilized were ordered in tremendous amounts. Therefore, welding has been around since the Iron Age and has let people build strong steel and powerful armament such as Weapons, tanks, and planes. Finally, welding has had many advancements, and will continue to do so in the future, because the world needs
A welder fabricates, assembles, and deconstructs metal structures such as windmills, buildings, boats,etc. There are various types of equipment used in this profession that deconstruct and fabricates marvelous structures. Welders, welding rods, grinders, plasma cutters, shapers, and measuring tools all play a huge part in this hardworking profession. There are also multiple types of welding,(Arc welding, Electroslag welding, Flux-cored welding, Gas Metal Arc welding, Gas Tungsten-Arc welding, MIG welding, Plasma Arc welding, Shielded-Metal Arc welding, Submerged Arc welding, and TIG welding). Due to the certain type of work that welders do they the strength and skills to manage welding equipment. They also must be able to read and interpret
Tomorrows Welders Thomas Jefferson said, “I find that the harder I work, the less I call it work”. I have often found myself in situations where I needed to fix something but could not because it is metal. I believe this might be why I began to show interest in welding. There is great satisfaction in being able to create or fix a metal object on your own.
Welders can use hand held welders or even robotic welders to produce welds. Both equally requiring a incredible amount of knowledge. They can also fill holes, produce structures and build custom parts for automotive race shops. Welders often work fulltime on shipyards, oil rigs, and pipelines or anywhere else where a specific job is needed. Welders are often required to interpret blueprints or sketches and weld accordingly to fulfill job duties. Arc welding is the most common type of welding today and is what most welders use. (bls) There are over 100 different welding processes that a welder can learn how to use however, Stick, Tig and Mig are the 3 most common used in the industry. These are used most to maintain equipment
When most people think about welding they think of it as a blue-collar, low-intelligence job, but they could not be more wrong. Welding is, admittedly, much more dirty than working in a cubicle for eight hours, but involves a huge amount of science that many don’t think about past college. The link between science and welding may sometimes be hidden by a thick layer of metal dust and spatter, but it can easily be seen if one knows where to look. Without advancements in science, there is no way that welding could be what it is today, have had the same improvements, or even be a very survivable process.
"Welding Processes, Welding Faults, Defects & Discontinuities For NDT Technicians Part 3." Hera.org. Hera, n.d. Web. 15 Mar. 2014. .
What is welding some may ask. “Welding is the use of brazing or soldering to join together or split apart pieces of metal.” Says miller electric inc. The First recorded forms of welding was from the bronze age when metal boxes were made by “pressure welding lap joints together.” In medieval times welding was used by hammer to forge weapons of different types. “It was actually not until the late 1800’s that traditional welding
In doing so, they weld metal parts, fill holes, and can even repair cracks in a brace. Because of its heavy duty strength, welds can be used to repair cars, ships, and even airplanes. Also, welds are used in the construction of buildings and bridges. Various tools are needed to perform proper welding techniques, for example, a person may need clamps, welding rods, a chipping hammer, a torch, glasses, a welding helmet, an apron or non flammable clothing to properly weld metal. In addition, a person may also need a specific type of welder for a certain occasions.
Welding is a very important tool used in our daily lives. Welding is the process of joining two metal pieces together by applying heat. A filler helps to make the joint. Everything we use from trucks to houses have some type of welding in them. There are many types of welding careers to choose from. There is a great demand for welders today. My project was to build a table and candelabra out of metal. Most of the metal I gathered came from junk yards and had to be cleaned of rust.
Welding can be traced back to the ancient times. One of the earliest methods of welding is bronze age. when ancient people back then had small gold circular were made by pressured welding lap joined together. Then in the Iron Age the Egyptians and people in the eastern area learned to weld pieces of iron together. In the middle age blacksmithing was developed. Blacksmithing is when you weld a piece of metal and hammering it but it was in the 19 century that welding was invented as they know it today.
Welding is an art, science, and high paying career all in one. Welding is the most effective way to join two pieces of metal, it is the only way to join them so they act as one. Numerous things in our daily lives has been welded from coffeepots to skyscrapers. Welding can be done almost anywhere outdoors, indoors, underwater, and even space (“Welding Basics”). It is practically
Sasaki, Tomoaki. "Study for TIG-MIG Hybrid Welding Process - Springer." Linked.springer.com. Springer, 01 Jan. 2014. Web. 28 Apr. 2014.
?Automation Reduces Weld Spatter? Welding Design & Fabrication (Jun. 2001): 37 EBSCOhost. Online. Nov. 2002 .