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WovkshoP Joining Mos Tngatase| Unit — &.() a What is the diffesence between Welding and Joining 2 Ans => Welding. doining (1) A pesmanent joining process Whese two ox mose matesials ase fused together by heat ) Pyessuse 10% both with ox Without filles matestal , (i) A genesal team weftss t0 ConnecHng two 0x Move Paste together by mes hanical . adhesive ow thesmal methods - (li) Ze is Pesmanent - Wi) Zt may be peymanet by tempsoaay . di) ZA involves melting oy Plashe defasmaton at the interface OF Posts. (iil) Te incudes medhods like. bolting i Biveling Soldecing boaxing s adhesives and Welding ibselt. (iv) His used in Stouctusal Fabsicahon , Pipelines) pac - Ssuse Vessels , audymabrje Gnd qexospace {ndustyres. (Iv) Te is Used in machinery Gssembly electsonics u Sheet metal . disteusz Shou hises and Sidya~ Kons whese dis assem dy 16 wequised. § (vy) &-g- — welding of the is0n Od - l (Vv) €-g.—bolted Ox SCxewed Jointr Can be dism~ Gn ed > % w 2) What is ‘the. diffexence Tempox aay 2 ( Joining ) Ans => between. Pesmanent and. > a aaag Tampioary Joining 1) A type OF Joint wheye the Pasts axe Connected in Such a way that! they Cannot the components . be sepaxoted- without dorniging i (i) A type of Yoint wheae the pasts aze Connected but can be easily Sepaxated Without damage to the Comp Onents - (1) 3 is mekallusgical bond, locking . Chemical bond ox mechanical |: ui) Pusely mechanical fas— Fening (thseads , pins , bolts’ (ii) Te is Usually Stoung and dusadle soften as Staong | as the base mateaial. (ill) Stvengi\ depends on Fastener size , mokatal and tighlening = generally less Shsong than Pesm~ Gnent Jinar. - (iv) Tk is not possible widhour byeaking ds damaging the joint - (¥) Possible anytime without ‘clamuaging the font py Pasts - \V) exampler . Welding ; Soldesing , beazing *iveting « adhesive bonding elt V) examples Boltin t Scuewing ) Cottey joints, Pin Joint — nut and bolt Cem ecrons Classification of Resistance i> Flash Bubs Welding —> (Ry + Reststang > Spot Welding > Prgjection Welding > Seam Welding | | (1) Solid Liguid ( Heteve genous) i, @ Base metal — Solid @ Filles metal — lie -—> difference Composition than base metal. “Two Types - 0) Brazing (1}) Soidesting Oy What is the Patnciple of . Gras Welding 2 Ans => The paincple of gas Welding is based on © Combustion oF a fuel gas With Dxy¥gen 40 produce high tempesatuse flame thak melts Ghd joins metals togeth ew . P10 a fOr -o.cetylene) \\ f f Hoase Pire | red, | } i Torch | | \ [Aftey | f _inozzle Jit ig ignited | $ heab and (pes eek Ve OF Chemical A Coo Cylinder [45mPa] ( ceky) ene) > Coz amount of Oxygen ty inde (4s Mpa) Oxygen cons UMphan is loss © Heat gas is Mose. XK Two Types o€ Reaction fn (I) Primasy Reaction — [Suppliga o make seach fasiey] CoHe2 + 02 ——> 20609 +he + Aha Gas Welding — At exit of Nozzle tip- (Fsom cylindes) [ contaotled} e “Tempevatus e — Avxound 3200°C- (hottest flame) 8 Chayacherishcs - —> No excess Oxygen ov Caabon. —> Ives not oxidize oy Cadburize the metal. * Applications — —> Used tov welding mild Steel, skar— ness Steely cast 1¥on,; alum num 7 ete. * Diagsam — _~ Dukes flame ey, . (1275°C ) “ Innes Cone (8200° c) Caxbusizing (I) Goring | Flame = & oe Gias Bato — Oxygen : Acetylene {itt (excess Acetylene) ¢ Innes Cone — Bluish- white ® Feather — Long whittsh Poston & Outes envelope — Longer, bluish flame, ® Chavactesishcs - —> Flame js vich in Caabon « —> Tends + add casbon + the Weld metal . © Applications — —p Suitable foy Ske ess 1 * Diageam — (I) Dxidi sing Flame I ®© Gas Dotip — Oxygen Welding high~ coabon too] Steels, etc, : Acetylene >A [€x C56 Oxygen ) ° Innes cone — Small ® Outer envelope —Sh ° ‘Tempesatuse — Slig heltzal flame © Charackeyistcg — —_> Excess OX OF the 1 Shayp bluish - 033 WYht pusple. bey highey than lup to -3500°C) . ygen Causes Oxidation weld metal. o) vp Waite down the pzinciple of Ac Welding 2 e Ans =» 7p, B Principle o£ dyc welding 16 based on the Production of heat by Gn electyc Gye Steck between On electrode and the Wosk piece. Bb . . e When Gn electric, cuxsent padses thavugh & y Small gap between the electyode and the Wosk piece the Gis in the gap gets ionized , Gnd an ave fe > fosmed- ) To : © This dac parduces intense heat , which melts: ; the base metal and the clectsode. y ® Th . @ molten metal fom the Clectxode fills the Y Joint gop and on Cooling it Solidifies +p fxm a Stzong : weld Oink. ‘ Y [| Powes Supp ly eo _ Fectys Qs wn Discuss ditfexen’ ty pes Of welding deres de fects axe. _ Vins > Different bypes Of Welding (I) Gras Pososity — * (nas bubbles’ Eaapped In the weld metal. : olds sOpEY * Causes 2 Contaminated Shielding gas! Imnpsope Welding Lechnique 1 Oy moidtuxe. {Ir} Slag Inclusions — o Slag poaticles taapped in the weld metal- * Couses ! Impzopes Slag vemoval ; Incoxvect Welding technique % poos joink pxepardtion. (II) Weld Spattex — @ Mose amount of liquid meta) is these > heat input is moze- « Remedies — Select Optimum Welding Speed = aac pply force Splaching + (Y) Weld. Cracks e Featuses in the weld metal 0% heat affected ZAone- © Causes : Theamal Stoesses , hydvogen tmb— YikHemenk ox matestad defects . 13) Ditfesence bebween electrode and filles aod- Ans=» (7) Electyode — © Consumable : Electaodes Axe Consumed the Welding padcess . : Flux Goated : Mang electyodes have a flux Coating that paotects the ac and mo)ten metal. © Cussent Qwsying : Electsodes caszy electyjal Cussent to sustain the axe. © Sheilded Metal Ayc Welding (SMAW) ¢ Electzodes doe Commonly Used (nh SMAW ox "Stick” welding . | ) Filles Rod — © Won Consumable ‘ Filles xodgs can be Consumed og hon— Consumable clepending on Lhe welding pxocess @ Mo Flux Coating . Filles sods typically dont have q flux Coating instead Shidding gos es aye Used - oo’ bd Ndded to the Weld pool - Filey @tds ase, meted Cind added to the Weld P00) to fill gaps oY joimtr. © Vavious Welding Puocesses : Filles vods axe used in poocesses like Gas Metal Rac Welding (Grav) Gyas Tungsien Agc Welding (ATAW) and oxy -fual Welding , (it) Compose the pyocess oF Soldesing Gnd Baazing. Ans=>(T) Soldesing -— ® Metal joining process Using Filler mm etal that méitr below 450°. ® low Tempescture (150° - 450°) c © oot Source iS Soldesing (30h , Clectote fron, Small qey Alama » © Filles metal 1S Tin-lead Hr Sflyer, Lin Copp ex alloys” . + “Soint sroergth is Weaken. o Effect on base metal is very Nite themed — diéteston- ° Easy Tey ulxes , less Skil * Suitable for light duty Sone , ¢ Applicatone : Electronics , PCR, werign “Chper — esutpments . 
