Research on Different Types of Welding

1. Submerged Arc Welding (SAW):

SAW employs a granular flux that becomes submerged during welding. The arc forms beneath this flux layer, preventing visibility and offering a slag-free weld. This method is favored in sectors requiring meticulous weld quality.

Gas Tungsten Arc Welding (GTAW) or Tungsten Inert Gas (TIG) Welding:

GTAW or TIG utilizes a non-consumable tungsten electrode to form the weld. This technique is known for its precision, shielded by inert gases, and is common in welding thin sections of stainless steel and non-ferrous metals.

Plasma Arc Welding (PAW):

PAW is a method wherein an electric arc is formed between an electrode and the workpiece, constricted by a fine-bore copper nozzle, resulting in a concentrated plasma arc. This is essential in aerospace and electronic components due to its exactitude.

Real-World Applications

?

• SAW: Given its ability to produce high-quality welds, it's often used in shipbuilding and constructing large steel structures.
• GTAW/TIG: This method is popular in aerospace and automotive industries due to its precision and ability to weld different metals.
• PAW: Given its precision, it's used in industries where small, intricate welds are required, such as in the aerospace or electronics sectors.

?

Engineering Safety Precautions

?

SAW:?

• Ensure the workspace is well-ventilated to prevent the inhalation of fumes.
• Use protective gear, including a welding helmet and gloves.
• Ensure the filler material is compatible with the base material to prevent weak welds or corrosion.

?

GTAW/TIG:?

• Always use the correct shielding gas, and ensure the workspace is free from drafts that could disperse it.
• Wear a welding helmet with the appropriate shade for TIG welding to protect your eyes from intense light.
• Ensure a consistent flow rate of the shielding gas.

?

PAW:?

• Ensure that the workspace is well-ventilated. The intense heat can produce harmful fumes.
• Always wear a welding helmet and protective clothing.
• The choice of plasma gas (argon, helium, or a mixture) can influence arc characteristics and weld quality.

In all welding operations, regular equipment inspection is crucial. Proper operator training is essential, and always ensure that first aid and fire safety equipment is readily available.

?

Friction Stir Welding (FSW): FSW is a unique solid-state joining process, employing a non-consumable tool to join facing workpieces without melting them. This process has found significant applications in industries like automotive and aerospace, where the strength and reliability of the welds are paramount.

Real-World Applications for Friction Stir Welding:

Tesla Model Y's Octovalve Coolant System:

Tesla has employed FSW for the Model Y's thermal management system, specifically the Octovalve coolant system. This system controls and maintains temperatures in various vehicle parts, including the motor, battery, and cabin. The advantage of using FSW in this context is its ability to maintain the strength of aluminum parts while ensuring a reliable bond. The process allows the aluminum to reach a temperature that facilitates a strong bond between two metal pieces without turning the metal into liquid. This ensures that only the outer edges of the metal are exposed to heat, preserving the integrity of the rest of the assembly.

SpaceX's Falcon 9:

SpaceX uses Friction Stir Welding in the construction of its Falcon 9 rockets. Given the extreme conditions in space and the need for reliable and durable construction, FSW provides a method that ensures strong bonds without compromising the structural integrity of the materials. The aerospace industry, where materials often face extreme temperatures and conditions, benefits significantly from the reliability and strength offered by FSW.

Engineering Safety Precautions for Friction Stir Welding:

• Ensure the FSW tool is in good condition and appropriate for joining materials.
• Monitor the process to ensure consistent temperature and pressure, preventing defects in the weld.
• Regularly inspect the welds for any signs of weakness or defects.
• Ensure operators are trained specifically in FSW, given its unique nature compared to traditional welding methods.

Soldering:

Soldering is a process wherein two or more items are joined together by melting and putting a filler metal (solder) into the joint. The filler metal has a lower melting point than the adjoining metal. Unlike welding, soldering does not involve melting the workpieces. The primary purpose of soldering is to form a durable connection between two workpieces.

?

Real-World Applications:

• Electronics: Soldering is extensively used in electronics to connect components to printed circuit boards. This ensures that electrical components like transistors, capacitors, and resistors remain firmly attached and maintain a consistent electrical connection.
• Plumbing: Soldering is used to join copper pipes. The solder helps seal the joint, preventing leaks.
• Jewelry Making: Artisans use soldering to join jewelry pieces, especially when working with precious metals like gold or silver.
• Metalwork: In various crafts and hobbies, soldering can join thin pieces of metal together.

?

Engineering Safety Precautions:

Soldering:

• ?Always work in a well-ventilated area to prevent the inhalation of fumes produced during soldering.
• ?Use a soldering stand to hold the soldering iron when not in use.
• ?Wear safety glasses to protect your eyes from molten solder or flux splashes.
• ?Use lead-free solder, especially in electronics, to avoid potential health risks.
• ?Always clean the soldering iron tip after use to prolong its life and ensure efficient heat transfer.
• ?Keep flammable materials away from the soldering area.
• ?Ensure that the soldering iron is switched off and cooled down before storing.

References:

theweldingpro, A. (2021, November 10). 7 types of welding processes and their uses. The Welding Pro.

?https://theweldingpro.com/types-of-welding-processes/Links to an external site.???

?

Pfaller, A. (2022, October 11). Guide to tig welding basics. Miller Electric.?

https://www.millerwelds.com/resources/article-library/guide-to-tig-welding-basicsLinks to an external site.??

?

What is plasma welding?. TWI. (n.d.). https://www.twi-global.com/technical-knowledge/faqs/faq-what-is-plasma-weldingLinks to an external site.??

?

Austin, R. (2023, February 2). Welding Safety Tips and guide for beginners - welding judge. Welding Perfection.?

https://weldingperfection.com/blog/welding-safety/Links to an external site.????

?

Sharma, R. (2021, October 20). Submerged arc welding (SAW): Working process, equipment, parts, and its applications. cruxweld.?

https://www.cruxweld.com/blog/submerged-arc-welding/Links to an external site.??

?

fpm3.com, client. cityhosting. ca. (2021, June 28). Gas tungsten arc welding services: Veriform - metal fabrication done right. VeriForm Metal Fabrication.?

https://veriform.ca/welding/gtaw-welding/Links to an external site.??

Klender, J. (2020, April 22). Tesla leverages spacex welding technique in model Y components. TESLARATI.

https://www.teslarati.com/tesla-model-y-spacex-welding-technique-analysis-video/#:~:text=SpaceX%20uses%20friction%20stir%20welding%20for%20its%20rockets%2C,barrel%20sections%20of%20the%20Falcon%209%E2%80%99s%20second%20stageLinks to an external site.

?What is soldering? A full guide (meaning, definition and types). TWI. (n.d.).

https://www.twi-global.com/technical-knowledge/faqs/what-is-solderingLinks to an external site.??

exchange, C. R. (n.d.). Ford introduces new remanufacturing technique – plasma transferred wire arc welding. Ford Introduces New Remanufacturing Technique – Plasma Transferred Wire Arc Welding - Capital Reman Exchange. https://www.capitalremanexchange.com/plasma-transferred-wire-arc-welding-technology/Links to an external site.???