MFE201final exam12-07

MFE201final exam12-07 - Welding • Process Capability –...

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Unformatted text preview: Welding • Process Capability – Excellent capability – Almost on all materials – 3 to 1 max. thickness ratio – Sufficient overlap & edge distance Resistance Welding • Process Advantages – Low skilled operator – Fast operation – Inexpensive – Low heat input to part – Less distortion than TIG • Process Disadvantages – Poor Fatigue Life – Requires coupons to simulate part Resistance Welding • Important parameters of Process – Pressure, current amplitude, cycle time, sequence time, hold time, cool time (seam), Coupons, Electrodes, Time, Water, Calibration of amp and voltage Vacuum & Furnace Brazing • Process Capability – Excellent capability – Multiple joints can be done simultaneously complex irregular shapes – All positions of joints can be brazed (horizontal, vertical, around corners) – Manually inaccessible areas can be joined – Part is limited by furnace Vacuum & Furnace Brazing • Process Advantages – Base metal does not melt – Thick and thin materials can be joined – No finishing is required – Parts can be • Process Disadvantages – Some braze alloys are extremely brittle – High cost of braze alloys Vacuum & Furnace Brazing • Important Parameters of Process – Good Control of Temperature – Good control of Alloy prepping – Powder Ratio – Control of Tack welding Vacuum & Furnace Brazing • Factors Influencing Process Cost – Equipment • Handling (equipment cost) • Cleaning • Vacuum Furnace expensive up to ($500 K) – Consumables • Mostly Furnace elements • High Maintenance • Cost of some brazing alloys Tungsten Inert Gas Manual Welding (TIG) • Process Capability – Excellent High Stress hardware – Excellent to weld parts with excessive gaps and mismatch (No limit) – Weld all positions – Requires inert gas for all (backing gas may be optional limited only by accessibility immovability of torch and operator skill Tungsten Inert Gas Manual Welding • Process Advantages – Able to weld complex contours – Build light weight hardware – Non – symmetrical joints – Fixture flexibility • Process Disadvantage – Parts subject to contamination due to poor gas backing – Shrinkage or distorting from excessive heat Tungsten Inert Gas Manual Welding • Important Parameters of Process – Control of amperage range – Know Materials to be welded – Proper filler wire – Non – leaking torched Electron Beam Welding • Process Capability: – Able to join thin / thick materials with minimum distortion – Weld in a vacuum – Good control of weld parameters – Good repeatability – Weld Prices PPG Electron Beam Welding • Process Advantages: – Good Welding atmosphere – Good uniformity of weld – Able to control weld depths • Process Disadvantages: – Expensive installation – Restricted to accessibility to some materials – High Maintenance Electron Beam Welding • Important parameters of Process – Speed of rotary table or gun....
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This note was uploaded on 04/04/2008 for the course MFE 201 taught by Professor Okhuysen during the Fall '07 term at Cal Poly Pomona.

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MFE201final exam12-07 - Welding • Process Capability –...

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