Process Selection - From Design to Manufacture Part 9 pot

ease with which a material can be welded and the quality of the finished weld, i.e.. Material composition alloying elements, grain structure and impurities and physicalproperties thermal

completed assemblies from workstation to workstation is required In general, the various types ofstation/transfer system for flexible assembly are:

a variety of operations are performed Typically, greater than six components to be assembledrequires a multi-station arrangement

Economic considerations

Typical applications

casting machines and injection molding machines

Design aspects

geometry for feeding, handling, fitting and checking, and reduce overall assembly costs

Quality issues

down-time) are due to the incoming component quality

. Robot working envelope must be securely guarded.

safety is paramount, for example, hazardous or toxic environments, heavy component parts or ahigh repeatability requirement causing operator fatigue

6.3 Dedicated assembly

Process description

composing previously manufactured components and/or sub-assemblies into a complete product

of unit of a product Typically, a number of workstations comprising automatic part-feeders and fixedwork-heads are arranged on an automatically controlled transfer system to compose the productsequentially (see 6.3F)

Process variations

Orientation can be achieved by vibratory/centrifugal bowl feeders, by receiving partsalready orientated by the supplier in pallet, magazine or by escapement mechanisms for part-feeding

occur using fixed work-heads and/or pick and place units

e.g ‘peg in hole’, adhesive bonding, staking and screwing

detection of foreign bodies, part-failure and machine in-operation Common technologies includevision systems, tactile/pressure sensors, proximity sensors and ‘bed of nails’

usually built up on a work carrier, pallet or holder Therefore, a system for transferring the partly

6.3F Dedicated assembly process

completed assemblies from workstation to workstation is required In general, transfer systems fordedicated assembly are either:

in-line or rotary systems Can set up a buffer system using this configuration Typically, greaterthan ten components to be assembled requires a free-transfer arrangement

Economic considerations

variants are based on parts missing from original design

Typical applications

Design aspects

geometry for feeding, handling, fitting and checking, and reduce overall assembly costs

Quality issues

location stability problems

down-time) are due to the incoming component quality

. It is difficult and expensive to incorporate insensitivity to component variation and faults in assemblysystems to reduce this problem Sensing capabilities are limited in this capacity.

safety is paramount, for example, hazardous or toxic environments, heavy component parts or ahigh repeatability requirement, causing operator fatigue

7 Joining processes

7.1 Tungsten Inert-Gas Welding (TIG)

Process description

electrode at the joint line The parent metal is melted and the weld created with or without the

stable stream of inert gas, usually argon, to prevent oxidation and contamination (see 7.1F)

Materials

alloys, copper and stainless steel Carbon steels, low alloy steels, precious metals and refractoryalloys can also be welded Dissimilar metals are difficult to weld

Process variations

magnesium alloys

thermal conductivity, for example copper, or material thickness greater than 6 mm giving increasedweld rates and penetration

7.1F Tungsten inert-gas welding process

Economic considerations

argon cost and decreased production rate Helium/argon gas is expensive but may be viable due toincreased production rate

costs can be high for fabrications using automated welding

grinding back of the weld may be required

Typical applications

Design aspects

Configurations)

although TIG is suited to automated contour following

most welding positions

Quality issues

avoid porosity and inclusions

materials’ original physical properties

distortion on large fabrications

times

can cause an unstable arc

oxidation

by automation however, it does reduce distortion, improve reproduction and produces fewer weldingdefects

ease with which a material can be welded and the quality of the finished weld, i.e porosity andcracking Material composition (alloying elements, grain structure and impurities) and physicalproperties (thermal conductivity, specific heat and thermal expansion) are some important attributeswhich determine weldability

7.2 Metal Inert-Gas Welding (MIG)

Process description

joint line The parent metal is melted and the weld created with the continuous feed of the wire which

oxidation and contamination (see 7.2F)

Materials

aluminum, nickel, magnesium and titanium alloys and copper Refractory alloys and cast iron canalso be welded Dissimilar metals are difficult to weld

Process variations

welding (vertical, overhead) and thin sheet; spray transfer uses high currents for thick sheet andhigh deposition rates, typically for horizontal welding

mix of argon/helium, also used for nickel alloys and copper Pure argon is used for aluminum alloys

self-shielding, although flux-cored wire is preferred with additional shielding gas for certain ditions Limited to carbon steels and lower welding rates

con-7.2F Metal inert-gas welding process

Economic considerations

back of the weld may be required

overhead welding (see Appendix B – Weld Joint Configurations)

wherever possible

good for welds inaccessible by other methods

Quality issues

avoid porosity and inclusions

. Shielding gas chosen to suit parent metal, i.e it must not react when welding.

used for site work (windy conditions where the shielding gas may be gusted or positional welding)and large fillet welds

materials original physical properties

distortion on large fabrications

the use of dedicated tooling does reduce distortion, improve reproduction and produces fewerwelding defects

ease with which a material can be welded and the quality of the finished weld, i.e porosity andcracking Material composition (alloying elements, grain structure and impurities) and physicalproperties (thermal conductivity, specific heat and thermal expansion) are some important attributeswhich determine weldability

7.3 Manual Metal Arc Welding (MMA)

Process description

parent metal is melted and the weld created with the manual feed of the electrode along the weldand downwards as the electrode is being consumed Simultaneously, a flux on the outside of theelectrode melts covering the weld pool and generates a gas shielding it from the atmosphere andpreventing oxidation (see 7.3F)

Materials

metals is not recommended, but occasionally performed Dissimilar metals are difficult to weld.Process variations

and properties required Core sizes are between 11.6 and 19.5 mm and the electrode length isusually 460 mm

operations Uses the pin or stud as a consumable electrode to join to the workpiece at one end.Portable semi-automatic or static automated equipment available

Economic considerations

7.3F Manual metal arc welding process

. Manually performed typically, although some automation possible.

required in setting up

be removed during runs and some grinding back of the weld, may be required Weld spatter oftencovers the surface which may need cleaning

B – Weld Joint Configurations)

wherever possible

excellent for welds inaccessible by other methods

Quality issues

rate

. Access for weld inspection important, e.g NDT.

avoid porosity and inclusions after each pass

materials original physical properties

distortion on large fabrications

times

deoxi-dants in the flux minimizes carbon loss, which reduces weld strength

hydrogen cracking

work-piece may need demagnetizing or the return cable repositioned

ease with which a material can be welded and the quality of the finished weld, i.e porosity andcracking Material composition (alloying elements, grain structure and impurities) and physicalproperties (thermal conductivity, specific heat and thermal expansion) are some important attributeswhich determine weldability

7.4 Submerged Arc Welding (SAW)

Process description

electrode wire and the workpiece at the joint line The arc melts the parent metal and the wirecreates the weld as it is automatically fed downwards and traversed along the weld, or the work ismoved under welding head The flux shields the weld pool from the atmosphere preventing oxida-tion Any flux that is not used is recycled (see 7.4F)

Materials

Process variations

deck plates for example), self-propelled traversing unit on a gantry or moving head type (forshorter weld lengths) and fixed head where the work rotates under the welding unit (for pressurevessels)

additional alloying elements Wire sizes range from 10.8 to 19.5 mm

hardfacing parts subject to wear (bulk materials handling chute)

7.4F Submerged arc welding process

. Fluxes available in powdered or granulated form, either neutral or basic Neutral fluxes used for lowcarbon steel and basic fluxes for higher carbon steels.

increase deposition rates

Economic considerations

align-ment

Joint Configurations)

retain flux and mold the weld pool

Quality issues

formed giving inferior weld toughness

. Access for weld inspection important, e.g NDT.

when using high currents

avoid porosity and inclusions on each pass

materials original physical properties

length through varying the wire feed rate, and thereby improving weld quality

steels

ease with which a material can be welded and the quality of the finished weld, i.e porosity andcracking Material composition (alloying elements, grain structure and impurities) and physicalproperties (thermal conductivity, specific heat and thermal expansion) are some important attributeswhich determine weldability

7.5 Electron Beam Welding (EBW)

Process description

(anode) by an electron gun (cathode), where fusion of the base material takes place The operationtakes place in a vacuum, and the work is traversed under the electron beam typically (see 7.5F)

Materials

aluminum, titanium, copper, refractory and precious metals

Process variations

available, depending on type of work, size and location

a vacuum using suction cups

along the joint using magnetic coils, rather than the work under the beam on a traversing system

fusion

using the same equipment by varying process parameters

7.5F Electron beam welding process

Economic considerations

important consideration

Typical applications

Config-urations) Horizontal welding position is the most suitable

height of work in a chamber is 1.2 m typically

Quality issues

reduced to less than 40 mm for out-of-vacuum

hardened steels

method Joints gaps less than 0.1 mm required Therefore, abutment faces should be machined toclose tolerances

7.6 Laser Beam Welding (LBW)

Process description

commonly known as a laser Focusing of the laser is performed by mirrors or lenses (see 7.6F)

Materials

than chemical composition, electrical conductivity or hardness

Process variations

continuous wave modes are used

drilling, blanking, engraving and trimming, by varying the power density

Economic considerations

7.6F Laser beam welding process

. Lead times can be short, typically weeks.

Typical applications

Design aspects

2-dimensions Horizontal welding position is the most suitable

Configura-tions)

precisely

attach-ment can be used

metal pool surrounding the weld area

. The reflectivity of the workpiece surface important Dull and unpolished surfaces are preferred andcleaning prior to welding is recommended.

method

7.7 Plasma Arc Welding (PAW)

Process description

electrode, which provides the electrical current for the arc The plasma provides the energy formelting and fusion of the base materials and filler rod (when used) (see 7.7F)

Materials

Process variations

key-holing mode of operation

7.7F Plasma arc welding process