8. Welding Processes
There are various welding processes used to join different parts of the automobile exhaust system. These include:
8.1. High-frequency Resistance welding
8.2. High frequency resistance seam welding
8.3. Laser welding
8.4. Resistant Spot welding
8.5. Gas Tungsten Arc welding
8.6. Brazing and
8.7. Gas Metal Arc Welding (GMAW) with solid or metal-cored wires
These welding processes can be made semi-automatic, mechanized or fully robotic based on various factors. Out of all these welding processes, GMAW process is mostly used to fabricate the exhaust system. Further, GMAW process using stainless steel metal-cored wires are much easier and less costly than solid wires to weld new stainless steel materials being used in the manufacturing of the automobile exhaust system. [ ]
8.1. Resistance Welding
Welding process in which joining takes place by the heat produced from the resistance of the work piece to the flow of low- voltage, high density electric current in a circuit. Work piece is the part of the circuit. In resistance welding pressure is applied constantly so that continuous electric circuit can be maintained. This pressure will help the heated parts to forge together. In this process parts are not melted for joining rather it is heated to the plastic state just before melting and then forced together for joining.
In automotive exhaust welding seam welds are usually used to weld one part to another. So, the type of resistance welding process used in automotive exhaust to produce seam weld is High-Frequency Resistance Seam Welding.
8.2. High-Frequency Resistance Seam Welding
In this process welding current is supplied as high-frequency (200-500 kHz). This high frequency provides localized heating. So, this lo...
... middle of paper ...
... systems are-
12.2.1. Arcaloy MC 308L
12.2.2. Arcaloy MC 309L
12.2.3. Arcaloy MC 316L.A
9.2.1. Arcaloy MC308L (AWS A5.9-93, EC 308L): AISI types of 301, 302, 304, 304L, 308 and 308L are welded by Arcaloy 308L.
9.2.2. Arcaloy MC309L (AWS A5.9-93, EC 316L): It is used to weld different joints made between carbon steels and various stainless steels.
9.2.3. Arcaloy MC316L.A( AWS A5.9-93, EC 316L): This type of Austenitic grade is used to weld AISI 316 and 316L grades of stainless steel to avoid pitting corrosion.
The following table shows the composition of the austentic grades of SSMC wires-
Table 9: Composition of Austenitic grades of SSMC wires [24]
Ferritic and Austenitic SSMC wires of Arcaloy family are generally packed in 15 Kg, 20 Kg spools and even in 227 Kg marathon packs but these marathon packs of 227 Kg are usually preferred by exhaust system fabricators.
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
Another type of welding is”Tig welding” which is when a electrode such as aluminum or tungsten that is melted with a strong torch or electrical arc. Another type of welding is “Mig welding” that is when you have a spool of wire and a inert gas such as argon or Co2 which acts as an insulator for the arc that is created in order to weld a bead. There are many more types of welding that you can learn when you are studying to become a welder or fabricator. When studing for welding you can and will learn about so much more stuff like oxy torch cutting and flux core welding which i hope many people will have the ability to at least try welding
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
What is welding some may ask. “Welding is the use of brazing or soldering to join together or split apart pieces of metal.” Says miller electric inc. The First recorded forms of welding was from the bronze age when metal boxes were made by “pressure welding lap joints together.” In medieval times welding was used by hammer to forge weapons of different types. “It was actually not until the late 1800’s that traditional welding
-Some programs are specific to certain types of pipe welding, such as shielded metal arc and gas tungsten arc welding, which are the most common welds used by pipe welders.
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.
There is different types of rods and different types of ways to weld. You need a lot of training for it. There are many schools and colleges you can go to receive welding education. The most common welding processes are Gas Metal Arc Welding, Flux Core Arc Welding, Gas Tungsten Arc Welding and Shielded Metal Arc Welding. The easiest of these is the Gas Metal Arc Welding. Welding options are stick, flux core, tig, and mig. The pipeline tig and stick welds a lot more than the other .The pipeline use many types of techniques but, the most common on the pipeline is downhill root pass and the up hill pass. The median annual wage of welders, cutters, solderers, and brazers is
50% of america uses welding for some type of way. There is tons of different types of
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.
Aluminum is one of a number of soft metals that scientists call "poor" metals. It can be shaped and twisted into any form. It can be rolled into thick plates for armored tanks or into thin foil for chewing gum wrappers. It may be drawn into a wire or made into cans. Aluminum is a generally popular metal because it does not rust and it resists wear from weather and chemicals. (Bowman, 391) Aluminum is an element. Its atomic number is thirteen and its atomic weight is usually twenty-seven. Pure aluminum melts at 660.2ºC and boils at 2500ºC. Its density is 2.7 grams per cube centimeter. Aluminum is never found uncombined in nature. (Bowman, 391) Aluminum is a very useful metal that is light, easy to shape and can be strong. This makes aluminum one of the most used metals in the world, right behind iron and steel. (Geary, 185) In its pure state, aluminum is quite weak compared to the other metals. However, its strength can be greatly increased by adding small amounts of alloying elements, heat-treating, or cold working. Only a small percentage of aluminum is used in its pure form. It is made into such items as electrical conductors, jewelry, and decorative trim for alliances and cars. A combination of the three techniques has produced aluminum alloys that, pound for pound, are stronger than structural steel. Some common metals used in alloys for aluminum are copper, magnesium and zinc.(Walker, 31) The added elements give the aluminum strength and other properties. (Newmark, 41) Aluminum is one of the lightest metals. It weighs about 168.5 pounds per cubic foot, about a third as much as steel which weighs 487 pounds per cubic foot. (Neely, 214) As a result, aluminum has replaced steel for many uses. For example, some ...
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
"Using GMAW-P with Aluminum and Stainless Steel." - TheFabricator.com. Kodi Welch, 05 Nov. 2013. Web. 28 Apr. 2014.
?Automation Reduces Weld Spatter? Welding Design & Fabrication (Jun. 2001): 37 EBSCOhost. Online. Nov. 2002 .