Promanu II Welding

PROSES MANUFAKTUR II
JOINING, Welding, Brazing, Soldering

Literature:
Material and Processes in Manufacturing 6th Ed.
By E. Paul DeGarmo, J. Temple Black, Ronald A.Kohser
Prof. Dr.-Ing. Ir. Suhardjono, MSc.

Joining (Penyambungan)
• Joining (penyambungan) adalah proses yang
digunakan untuk menggabungkan beberapa
single component menjadi satu komponen
yang lebih kompleks
• Lebih luas disebut perakitan (Assembly)
Joining Classification
Welding Classification
Mechanical Joining
Upsetting Hollow rivet

Stapling
Thin sheets
Cold Cold
Solid-state Joining
means at room temperature
Solid-state bonding: Interatomic bonds may be established by bringing atoms
of two surfaces in close enough proximity to assure adhesion
Cold weld
Hot Solid-state Joining
Sandwich : Silver
or cooper core Press together axially
with gold face
sheets heated in
furnace for
prolonged time, a
permanent bond butt
is obtained
-Steinless steel to mild

steel for corrosion
protection,
-Nickel to copper core to
Poor joint quality
provide the required
magnetic properties
Liquid-state Welding
• In the great majority of applications, the
interatomic bond is established by melting.
• When the workpiece materials and filler (if
used at all) have similar compositions and
melting points, the process is referred to as
WELDING
Oxyacetylene Welding (OAW)/Oxyfuel Gas
Welding(OFW)
• Heat is produced by combustion of acetylene

(C2H2) with oxygen (O2), flame temperature 3700 oK
• Primary combustion takes place in the inner zone
and generates 2/3 of the heat by the reaction
2C2H2 +2O2  4CO +2H2
• Complete combustion takes place in the outer
envelope: 4CO +2O2 4CO2
2H2 + O2  2H2O
Oxyacetylene Welding (OAW) or
Oxyfuel Gas Weding (OFW)
Friction or Inertia Welding
Friction Welding
Jika Temperatur naik akibat dari putaran dan tekanan axial dan sudah
terlihat flash keluar (tanda pelelehan), maka putaran harus segera
dihentikan dan tekanan dinaikkan 2x lipat.
Friction (inertia) Welding Machine
Single-phase Material
Two-phase material
HAZ VS Fe-C diagram
Distortion during welding
Weldability (mampu las)
Resistance Welding
Electric circuit for RW
Heat
H=I2RT
H is Heat,
I the current,
R the electrical Resistance,
T the time or duration of the
current flow.
Temperature distribution
Welding Cycle RW
Spot Welding
Tear Test
Spot-welding machine
Spot welder for automobile
underbody
Hand spot-welding guns
Metal to be spot welded
Resistance Seam Welding (RSEW)
Seam Welder
Making seam-weld pipe
Fabricating of I-beam
Projection Welding
Advantages and disadvantages of RW
Application of Thermit Welding
Flash-Welding
Flash Weld
Consumable-electrode Welding
Gas-shielded arc-welding
Gas Metal Arc Welding (GMAW) or
Metal Inert Gas (MIG)
Gas Metal Arc Welding (GMAW)
GTAW
Welding torch for GTAW
Comparison of the metal deposition
rates with hot and cold filler wire in
GTAW
Gas Tungsten arc spot welding
SMAW
Basic mode of metal transfer during arc
welding
Arc-Welding Electrode Designation
Example: E7016 is a low-alloy steel electrode that will provide a deposit having
a minimum tensile strength of 70.000 psi in the non-stress-relieved condition;
it can be used in all positions, with either alternating current or reverse-polarity
direct current, and it has a low-hydrogen-type coating.
Functions of the coating of electrode
Flux-cored Arc Welding (FCAW)
Submerged Arc Welding (SAW)
Application of SAW
Electroslag Welding
Stud Welding (SW)
Applications of Stud Welding
AC Welding Machine
Type of Weld
Type of Weld-joint
Type of joint
Type of Joint
Weld procedures
Welding of large structures
Liquid-solid-state Bonding
• Workpiece and filler metal have substantially
different melting point.
• The joint is established without the workpiece
material being melted.
Brazing
• A common feature of all brazing processes is the very small
gap between the parts to be joined, which is then filled out
by capillary action.
• Surface cleanliness and adhesion can be assured simply by
a suitable furnace atmosphere in the brazing of steel with
copper at around 2000oF (1200oC)
• In all other processes a flux is necessary to provide
cleansing action and thus assure wetting and adhesion of
the surfaces.
• The most common filler material for steel is 60/40 Cu-Zn
brass or a variant of it (brazing Temp. 1800oF or 1000oC) or
Silver-base alloys (silver brazing, around 1400 oF or 800oC)
Brazing
Soldering
• Filler metals of even lower melting point (usually
tin-lead alloys) are used in soldering; thus the
joint is of much lesser strength, but parts can be
joined without exposing them to excessive heat.
• Fluxing is again essential, usually with a zinc
chloride solution for general work, or with
organic rosins for electrical connections where
corrosion could create a severe conductivity
drop.

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PROSES MANUFAKTUR II

JOINING, Welding, Brazing, Soldering

Prof. Dr.-Ing. Ir. Suhardjono, MSc.

Upsetting Hollow rivet

-Steinless steel to mild

• Heat is produced by combustion of acetylene

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