Vibration Welding
Vibration welding is a solid state welding process used to join to materials together. To achieve this goal, the parts must be moved very fast relative to one another horizontally under pressure, creating heat through surface friction that melts and welds the parts together. Vibration welding is being used for a wide range of automobile parts such as front and rear light assemblies, fuel filler doors, spoilers, instrument panels, fan surrounds and reservoirs for brake, power steering and vacuum systems. It can be applied to almost all thermoplastic materials, whether injection molded, extruded, blow-molded, thermoformed, foamed or stamped.
Process Steps of Vibration Welding
The vibration welding process consists of the following
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Because increasing the weld pressure can reduce the strength of the weld by forcing out all the molten plastic, resulting in a cold weld being formed. Hence, we must set the weld pressure at an optimum value so that we can complete the welding in least possible time as well as avoid the cold weld being formed.
Vibration welding equipment is either time controlled or depth controlled. If the equipment is depth controlled, then time is variable and vice-versa. Depth control is preferable. Weld penetration or displacement is crucial in determining the weld strength. As long as the threshold is reached, weld strengths are not very sensitive to welding frequency and amplitude; however, at a constant threshold value, weld strengths can decrease with increasing weld pressure. The maximum weld strength that can be achieved for parts made up of same material is approximately 75% of the strength of the original material. To achieve this high strength the parts should be designed such that the weld depth is in between 1.2 to 2.2 mm [21]. Figure 12: Material Strength of a welded joint (% parent material strength vs. weld depth for tensile test specimens of constant thickness).
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The testing not only enables us to achieve optimum process conditions but also gives scope for in process quality control. For this specific application the dynamic testing has more significance than the static testing. The Dynamic Burst Pressure Test is a suitable testing for this purpose. In this testing we send highly pressurized air into the air bag and check for the failure loads of the welded joint. The pressure rise time is typically, 5-15 milliseconds. [21] The burst strength of a vibration weld can be improved by 50% by proper control of welding process parameters.
This is another property which relates the fatigue to tensile property of any material. It can be defined as the ratio of the endurance limit (Se) to the ultimate strength (Su) of the material of any structure. The value of fatigue ratio ranges from 0.25 to 0.60. It’s value solely depends upon the type of the material.
According to Pickwelder, “This type of welding is used in welding wide varieties of metals and alloys such as magnesium, steel, stainless steel, nickel, copper, aluminum, bronze and many other nonferrous metals” (James). MIG can be used with a number of different metals making it very diverse. This is a good quality as it can bond to any metal with the right settings and welding wire. According to JobsiteUS, “A range of material thicknesses can be welded from thin gauge sheet metal right up to heavier structural plates” (Peter Apalais). MIG welding can weld through all different metals and their thicknesses. This is good for production because this process can do both while some processes can only weld thin or thick metal. According to Coastal Media Brand, “Capable for a variety of applications, including – trailer hitches, auto body repair and restoration, farm/ranch equipment, household projects, repairing wheel barrows, bicycles, etc” (Coastalmedia843) The multivariate MIG has so many possibilities that can be used for nearly anything that involves repair work or production. It is good for commercial use and even for your home. This shows the extent that MIG welding can go up to, and the list goes on. All in all Gas Metal Arc Welding is the best process that can be used for an expansive amount of uses for anything consumer grade and
Welding is a very important job in today’s society. With new building designs, and bridges to every day metal products, welders are needed to do these tasks. Almost everything that you use every day has some sort of weld to it.
Even though welding has been around for a long time, most of the best inventors were around during the 19th century and have changed the way thing are done today. During the 20th century, many technological advancements developed and have made welding easier because of the different types of welding that have been developed. Welding impacted the world during World War l, because during the war armaments that were going to be utilized were ordered in tremendous amounts. Therefore, welding has been around since the Iron Age and has let people build strong steel and powerful armament such as Weapons, tanks, and planes. Finally, welding has had many advancements, and will continue to do so in the future, because the world needs
The reason for this is so that they know what they are supposed to be doing for that certain job. Welders are also to maintain their equipment and machinery. Meaning, have their machines all set to the right settings required for the job they are working on at the time. Inspecting structures or materials to be welded is another part of a welder’s job. They have to do this to be sure that there is nothing in the structure or material that could possibly cause any problems (The Occupational Handbook).
Welders can use hand held welders or even robotic welders to produce welds. Both equally requiring a incredible amount of knowledge. They can also fill holes, produce structures and build custom parts for automotive race shops. Welders often work fulltime on shipyards, oil rigs, and pipelines or anywhere else where a specific job is needed. Welders are often required to interpret blueprints or sketches and weld accordingly to fulfill job duties. Arc welding is the most common type of welding today and is what most welders use. (bls) There are over 100 different welding processes that a welder can learn how to use however, Stick, Tig and Mig are the 3 most common used in the industry. These are used most to maintain equipment
In the world of welding, there is a large variety of career paths, and with that comes a range of salaries. A welders salary depends on many different variables. Such as experience, certifications, amount of demand, type of job, and where production is located. Many young adults are not aware of the possibilities and pay of being a welder. But with the correct training, and right opportunity a welder can earn a large annual salary.
Xie, J. "Weld Morphology and Thermal Modeling in Dual-beam Laser Welding." Was.org. American Welding Society, n.d. Web. 24 Mar. 2014. .
To begin with a welder uses equipment to apply heat to metal in order to create a permanent bond. In doing so, they weld metal parts, fill holes, and can even repair cracks in a brace. Because of its heavy duty strength, welds can be used to repair cars, ships, and even airplanes. Also, welds are used in the construction of buildings and bridges. Various tools are needed to perform proper welding techniques, for example, a person may need clamps, welding rods, a chipping hammer, a torch, glasses, a welding helmet, an apron or non flammable clothing to properly weld metal. In addition, a person may also need a specific type of welder for a certain occasions. For example if a person wants to weld aluminum a mig welder would be used along with argon and helium gases. Safety is always important for the welder. Welders are exposed to a variety of environments and situations that put their safety in jeopardy. They are at risk for cuts, bites, stings, and burns since they work outdoors. They are also exposed to gases, dust, fumes, and foul odors due to working in poorly ventilated areas. It is ev...
Welding is a very important tool used in our daily lives. Welding is the process of joining two metal pieces together by applying heat. A filler helps to make the joint. Everything we use from trucks to houses have some type of welding in them. There are many types of welding careers to choose from. There is a great demand for welders today. My project was to build a table and candelabra out of metal. Most of the metal I gathered came from junk yards and had to be cleaned of rust.
Welding can be traced back to the ancient times. One of the earliest methods of welding is bronze age. when ancient people back then had small gold circular were made by pressured welding lap joined together. Then in the Iron Age the Egyptians and people in the eastern area learned to weld pieces of iron together. In the middle age blacksmithing was developed. Blacksmithing is when you weld a piece of metal and hammering it but it was in the 19 century that welding was invented as they know it today.
Welding is a fabrication process that joins materials, usually metals or thermoplastics, by causing coalescence. This is often done by melting the workpieces and adding a filler material to form a pool of molten material that cools to become a strong joint, with pressure sometimes used in conjunction with heat, or by itself, to produce the weld.
Welding is an art, science, and high paying career all in one. Welding is the most effective way to join two pieces of metal, it is the only way to join them so they act as one. Numerous things in our daily lives has been welded from coffeepots to skyscrapers. Welding can be done almost anywhere outdoors, indoors, underwater, and even space (“Welding Basics”). It is practically
GMAW (Gas Metal Arc Welding) is more economic; Springer reports that “ GMAW is an economic process because it has higher speeds and higher deposition rates than manual arc welding. There is also no need to constantly change electrodes” ( Page 11). GMAW has a higher speed, which means that you can get the job done faster. It also has high deposition rates which makes the weld look clean and smooth.” This method can be used for a high range of work, but it is not suited for repair work because of it’s weld quality” (Page 4). This process can be used for many variations of work including root welds, joints, T’s, butts, laps, and many more applications. Even though its used for many practices, it is not recommended to use this method for repair work because of the quality of the welds. “ It’s easy to use and it is inexpensive to afford now with 110v machines. But you cannot weld for a long time like a 220v machines would produce. Both have different duty cycles” (Parag. 7). M.I.G is something anyone can learn easily, it’s inexpensive to afford. 110v machines don't bring out the best power to weld, because these machines do not have a good duty cycle. Most people prefer 220v machines because they produce more work, even if they are more expensive. GMAW is the cheapest most reliable process for welding.
?Automation Reduces Weld Spatter? Welding Design & Fabrication (Jun. 2001): 37 EBSCOhost. Online. Nov. 2002 .