Non-Arc Welding Processes
Non Arc Welding Processes
Resistance Weld
High Energy Density
Friction Welding
Brazing & Soldering
Plastics Joining
1998/1998/MJ1/MatJoin4/1
Non-Arc Welding Processes (Part 1)
Lesson Objectives
When you finish this lesson you will
understand:
• Resistance Weldability and Various
Resistance Welding Processes
• Oxy-fuel welding and cutting principles
• Solid state welding processes and
comparisons between them
• Advantages and disadvantages of each
process
Learning Activities
1. Read Handbook
pp 16-30
2. Look Up
Keywords
3. View Slides;
4. Read Notes,
5. Listen to lecture
6. View Video
7. Do on-line
workbook
8. Do Homework
Keywords:
Resistance Spot Welding, Seam Welding, Spot Weldability Lobe,
Oxy-Acetylene Torch, Friction Welding, Diffusion Welding,
Ultrasonic Welding, Explosive Welding
Non-Arc Welding Processes
Introduction
Non-Arc Welding Processes

Resistive heating, chemical reactions, focused light and
electrons, sound waves, and friction can also be used to
join materials







Resistance welding
Oxy-Fuel Welding
Friction welding (&Solid State)
Laser and electron beam welding
Brazing and soldering
Plastics joining
Adhesive bonding
1998/1998/MJ1/MatJoin4/3
Non-Arc Welding Processes
Resistance Welding
Resistance Welding


The resistance of metal to
the localized flow of current
produces heat
Process variables




Current
Time
Force
Spot and seam welding
Spot welding
1998/1998/MJ1/MatJoin4/4
Non-Arc Welding Processes
electrode
electrode
Spot Weld
1998/1998/MJ1/MatJoin4/5
Non-Arc Welding Processes
Resistance Welding
Electrodes
Truncated cone



Dome
Pointed
Electrode tips wear during service, causing nugget size
to decrease
Zinc-coating on steel alloys with copper electrodes to
form brass
Copper base materials, divided into classes
1998/1998/MJ1/MatJoin4/6
Non-Arc Welding Processes
Resistance Welding
Time (cycles of current)
Operating Window - Lobe Curve
Constant electrode
force
Nugget
too small
Acceptable
nugget
size
Expulsion
Current (1000’s of amperes)
1998/1998/MJ1/MatJoin4/7
Non-Arc Welding Processes
1998/1998/MJ1/MatJoin4/8
Non-Arc Welding Processes
Roll spot weld
Overlapping seam weld
Continuous seam weld
1998/1998/MJ1/MatJoin4/9
Non-Arc Welding Processes
Resistance Welding Advantages
• High speed, < 0.1 seconds
in automotive spot welds
• Excellent for sheet metal
applications, < ¼-inch
• No filler metal
1998/1998/MJ1/MatJoin4/10
Non-Arc Welding Processes
Resistance Welding
Process Disadvantages and Limitations







Higher equipment costs
than arc welding
Power line demands
Nondestructive testing
Low tensile and fatigue
strength
Not portable
Electrode wear
Lap joint requires
additional metal
1998/1998/MJ1/MatJoin4/11
Non-Arc Welding Processes
Link to the “Resistance Welding
Videos from the Video Page on the
WE300 Webpage
1998/1998/MJ1/MatJoin4/12
Non-Arc Welding Processes
Turn to the person sitting next to you and discuss (1 min.):
• If the Lobe Curve represents the welding parameter
combinations which produce good welds, why do so many of
the automotive spot welds have expulsion?
Turn to the person sitting next to you and discuss (1 min.):
• When spot welds are place too close to one another, some of
the current from the second weld shunts thru the first. Why
then can overlap seam welds work when the welds are so
close that they overlap?
1998/1998/MJ1/MatJoin4/13
Non-Arc Welding Processes
Introduction
Non-Arc Welding Processes

Resistive heating, chemical reactions, focused light and
electrons, sound waves, and friction can also be used to
join materials







Resistance welding
Oxy-Fuel Welding
Friction welding (&Solid State)
Laser and electron beam welding
Brazing and soldering
Plastics joining
Adhesive bonding
1998/1998/MJ1/MatJoin4/14
Non-Arc Welding Processes
2C2H2 + 2O2  4CO + 2H2
( Oxygen from torch)
4CO + 2H2 + 3O2  4CO2 + 2H2O
(Oxygen from Air)
Linnert, Welding Metallurgy,1998/1998/MJ1/MatJoin4/15
AWS, 1994
Non-Arc Welding Processes
Thermite Welding
Power
Fe2O3 + 2Al > 2Fe + Al2O3 + heat
Base Metal
Liquid
1998/1998/MJ1/MatJoin4/16
Non-Arc Welding Processes
Turn to the person sitting next to you and discuss (1 min.):
• The oxy-fuel and that thermit welding are both chemical
burning reactions. In the first oxygen is supplied by oxygen
gas, in the thermit welding, it is supplied by the iron oxide.
Why does this aluminum “burning” in the thermit welding
work?
1998/1998/MJ1/MatJoin4/17
Non-Arc Welding Processes
Introduction
Non-Arc Welding Processes

Resistive heating, chemical reactions, focused light and
electrons, sound waves, and friction can also be used to
join materials







Resistance welding
Oxy-Fuel Welding
Friction welding (&Solid State)
Laser and electron beam welding
Brazing and soldering
Plastics joining
Adhesive bonding
1998/1998/MJ1/MatJoin4/18
Non-Arc Welding Processes
Solid-State Welding

Processes that produce a weld through the application of
pressure at a temperature below the melting temperature
of the base material; no filler metal is used




Friction welding
Diffusion welding
Ultrasonic welding
Explosion welding
0.1.1.2.2.T9.95.12
1998/1998/MJ1/MatJoin4/19
Non-Arc Welding Processes
Friction Welding (FRW)
0.1.1.2.2.T10.95.12
1998/1998/MJ1/MatJoin4/20
Non-Arc Welding Processes
Friction Welding
Friction Welding - Advantages


For correct part geometry,
friction welding is faster
than most other
processes
Can join dissimilar
materials together



Copper to steel or
aluminum
Easily automated for high
volume production
Can join plastics
1998/1998/MJ1/MatJoin4/21
Non-Arc Welding Processes
Friction Welding
Limitations of Friction Welding




Start-up cost is high
Parts must be able
to rotate about an
axis of symmetry
Free machining
alloys are difficult to
weld
Non-forgeable
materials cannot be
friction welded
1998/1998/MJ1/MatJoin4/22
Non-Arc Welding Processes
Diffusion Welding Working Principles

1st stage


1st stage deformation
and interfacial boundary
formation
2nd stage


deformation forming interfacial
boundary.
asperities come
into contact.
Grain boundary migration and
pore elimination.
3rd stage

Volume diffusion and pore
elimination.
2nd stage grain
boundary migration
and pore elimination
3rd stage volume
diffusion pore
elimination
1998/1998/MJ1/MatJoin4/23
Non-Arc Welding Processes
1998/1998/MJ1/MatJoin4/24
Non-Arc Welding Processes
1998/1998/MJ1/MatJoin4/25
Non-Arc Welding Processes
1998/1998/MJ1/MatJoin4/26
Non-Arc Welding Processes
AWS Welding Handbook
1998/1998/MJ1/MatJoin4/27
Non-Arc Welding Processes
Ultrasonic Welding

Advantages



Fast
Can spot or seam weld
Limitations



Equipment complex, many
variables
Only use on small parts
More on this below for
plastics
1998/1998/MJ1/MatJoin4/28
Non-Arc Welding Processes
Principles of Explosion Welding
Detonator





Explosive
Welding arrangement
consists of three
components Base component
Prime component
Explosive.
Base component remains
stationary, supported by
anvil.
prime
component
Base
component
Component arrangement
for explosion welding
1998/1998/MJ1/MatJoin4/29
Non-Arc Welding Processes
Principles of Explosion Welding



Prime component is placed
either parallel or at an
angle to the base.
Explosive is distributed
over top surface of prime
component.
Upon detonation, prime
component collides with
base component to
complete welding.
Detonation
Weld
Prime
component
Jet
Base
component
Action between components
during explosion welding.
1998/1998/MJ1/MatJoin4/30
Linnert, Welding Metallurgy,
AWS, 1994
Non-Arc Welding Processes
1998/1998/MJ1/MatJoin4/31
Non-Arc Welding Processes
Turn to the person sitting next to you and discuss (1 min.):
• In friction welding, the outer part of the bar is moving
faster and will therefore have more heating than the exact
center of the bar. What might you do to “even out” the
heating across the entire interface?
1998/1998/MJ1/MatJoin4/32
Non-Arc Welding Processes
Do Special Project Homework on Solid State Welding
1998/1998/MJ1/MatJoin4/33