Industrial Processes II INDUSTRIAL PROCESSES II INDUSTRIAL PROCESSES II INDEN 3313 INDEN 3313 Lecture 6 – Case Study Lecture 6 – Case Study Fusion Welding -- Oxyfuel and Fusion Welding -- Oxyfuel and Electric (Arc) Welding Electric (Arc) Welding Processes Processes
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Industrial Processes II INDUSTRIAL PROCESSES II INDEN 3313 Lecture 6 – Case Study Fusion Welding -- Oxyfuel and Electric (Arc) Welding Processes.
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Industrial Processes II
INDUSTRIAL PROCESSES IIINDUSTRIAL PROCESSES II
INDEN 3313INDEN 3313
Lecture 6 – Case StudyLecture 6 – Case Study
Fusion Welding -- Oxyfuel and Fusion Welding -- Oxyfuel and Electric (Arc) Welding Electric (Arc) Welding
ProcessesProcesses
Industrial Processes II
OVERVIEWOVERVIEW
• Case Study Case Study – Overview and Phases
• Fusion WeldingFusion Welding– Oxyfuel
– Arc
– Resistance
Industrial Processes II
QUESTIONSQUESTIONSTO START ??TO START ??
Industrial Processes II
CASE STUDYCASE STUDY• Goal to Study the Design and Goal to Study the Design and
Manufacture of ToolingManufacture of Tooling– Phase I (15%)
• Identify Possible Parts for Case Study• Each Student to Identify Three (3) Parts for
Case Study– One part => Cast– One Part => Machined– One Part => Other Than Cast/Machined that
will require tooling for its Production (Forging Dies, Stamping/Bending Dies, …)
• Form/Format on Web– Part (Name, Function, Sketch)
• Due Next Thursday– Hard Copy and Electronic Submission (e-mail)
Industrial Processes II
CASE STUDYCASE STUDY– Phase II (15%) – Part Processing Concepts
• Following Part Submission (Phase I) Instructor will select/modify Parts and Assign
• A processing sequence will be designed for the part and the tooling requirement(s) for its production via this sequence will be determined.
• Each student will execute this phase for one part concept.
• Due 2/22/00• Format on Web
Industrial Processes II
CASE STUDYCASE STUDY– Phase III (70%)
• Each Student will detail the design and manufacture (parameters, costs, …) of an assigned piece of tooling. For part concepts requiring more than one piece of tooling, one student will be assigned each piece and one report will be developed for each part.– 10% -- Schedule for Project (Due 3/8/00) and
THERMIT WELDINGTHERMIT WELDING• Basic Process DescriptionBasic Process Description
– Use of Heat Produced by Thermite Reaction to Superheat Fe and Use Superheated Fe to Effect Weld
• ReactionsReactions– 1. 3 Fe3O4 + 8 Al -> 9 Fe + 4 Al203 + Heat
– 2. 3 FeO + 2 Al -> 3 Fe + Al203 + Heat
– 3. Fe203 + 2 Al -> 2 Fe + Al203 + Heat
• Iron for Weld, Aluminum Oxide Slag Iron for Weld, Aluminum Oxide Slag (Protects Weld as It Cools)(Protects Weld as It Cools)
Industrial Processes II
THERMIT WELDINGTHERMIT WELDING• Sources/Causes of DefectsSources/Causes of Defects
– Inclusions– Large Grooves Required (Superheat of
Base)
• AdvantagesAdvantages– Large Amounts of Filler Metal Available
Quickly
Industrial Processes II
THERMIT WELDINGTHERMIT WELDING
[Amstead et al, Figure 8.26, p. 186]
Industrial Processes II
CONSUMABLE ELECTRIC ARC CONSUMABLE ELECTRIC ARC WELDINGWELDING
• Basic Process DescriptionBasic Process Description– Creation of an Electrical Potential and
Exceeding the Initiation Voltage to Produce an Electrical Arc, the Heat of Which (~55,000o F) Effects the Weld; the Electrode is Melted by the Arc and Supplies Filler Metal to the Weld
• ParametersParameters– Distance from Electrode to Work
CONSUMABLE ELECTRIC ARC CONSUMABLE ELECTRIC ARC WELDINGWELDING
• Provision of Non-Corrosive Provision of Non-Corrosive EnvironmentEnvironment– Electro-Gas Welding (EGW)
• Inert Gas Supplied
– Electroslag Welding (ESW)• Slag Used to Shield • Technically, Arc is Extinguished - Resistance
Used To Heat
Industrial Processes II
SHIELDED METAL ARC SHIELDED METAL ARC WELDINGWELDING
[Kalpakjian, Figure 27.4, p. 862]
Industrial Processes II
SUBMERGED METAL ARC SUBMERGED METAL ARC WELDINGWELDING
[Kalpakjian, Figure 27.7, p. 864]
Industrial Processes II
GAS METAL ARC WELDINGGAS METAL ARC WELDING
[Kalpakjian, Figure 27.8, p. 865]
Industrial Processes II
FLUX CORED ARC FLUX CORED ARC WELDINGWELDING
[Kalpakjian, Figure 27.10, p. 867]
Industrial Processes II
ELECTRO-GAS WELDINGELECTRO-GAS WELDING
[Kalpakjian, Figure 27.11, p. 868]
Industrial Processes II
ELECTROSLAG WELDINGELECTROSLAG WELDING
[Kalpakjian, Figure 27.12, p. 869]
Industrial Processes II
NON-CONSUMABLE ELECTRIC NON-CONSUMABLE ELECTRIC ARC WELDINGARC WELDING
• Basic Process DescriptionBasic Process Description– Creation of an Electrical Potential and
Exceeding the Initiation Voltage to Produce an Electrical Arc, the Heat of Which (~55,000o F) Effects the Weld; the Electrode is Not Melted by the Arc and a Separate Rod (Optional) Supplies Filler Metal to the Weld
• ParametersParameters– Distance from Electrode to Work