Volume 03 Issue 10-2023
251
International Journal of Advance Scientific Research
(ISSN
–
2750-1396)
VOLUME
03
ISSUE
10
Pages:
251-259
SJIF
I
MPACT
FACTOR
(2021:
5.478
)
(2022:
5.636
)
(2023:
6.741
)
OCLC
–
1368736135
A
BSTRACT
Welding is a very versatile process, which is used in many industries to join metals of one type (brand) and
different types (brand). This allows parts and structures to be joined permanently and firmly. Advances in
welding technology have led to more precise and automated methods such as laser beam and electron
beam welding. This, in turn, made it possible to create high-quality seams.
K
EYWORDS
Welding, electric arc welding, welding, electrode, CO2, contact welding, welding speed, spot welding,
continuous welding, disc electrode, gas welding, exothermic chemical reaction, laser welding, electron
beam welding, vacuum chamber, friction welding, flywheel, anvil, filler, ultrasonic welding, ultrasound,
interatomic friction, intermolecular bonding.
I
NTRODUCTION
Journal
Website:
http://sciencebring.co
m/index.php/ijasr
Copyright:
Original
content from this work
may be used under the
terms of the creative
commons
attributes
4.0 licence.
Research Article
MODERN METHODS OF THE METAL WELDING PROCESS:
REVIEW AND PROPOSALS
Submission Date:
October 20, 2023,
Accepted Date:
October 25, 2023,
Published Date:
October 30, 2023
Crossref doi:
https://doi.org/10.37547/ijasr-03-10-40
Farruhbek Oxunjonov
Assistant, Kokan Branch of the Tashkent State Technical University Named after Islam Karimov, Kokan,
Uzbekistan
Shohijakhon Tuybozorov
Trainee Lecturer, Kokan Branch of the Tashkent State Technical University Named after Islam Karimov,
Kokan, Uzbekistan
Zaylobiddin Rakhmonov
Assistant, Fergana Polytechnic Institute, Fergana, Uzbekistan
Volume 03 Issue 10-2023
252
International Journal of Advance Scientific Research
(ISSN
–
2750-1396)
VOLUME
03
ISSUE
10
Pages:
251-259
SJIF
I
MPACT
FACTOR
(2021:
5.478
)
(2022:
5.636
)
(2023:
6.741
)
OCLC
–
1368736135
Welding is a manufacturing process that joins
together materials, usually metals as well as
thermoplastics. During welding, high heat is
applied to the materials to be joined, melting and
sometimes liquefying them, which allows them to
flow and mix together when solidified by a certain
environment or process. Welding is commonly
used in automotive, shipbuilding, piping, and
structural projects.
There are several types of material welding
technology widely used in various industries.
Below are types of welding, welding concepts and
information:
1. Electric arc welding
Electric arc welding is a widely used welding
method that uses an electric arc between an
electrode and a metal to create a weld. Welding
uses a power source to create an electric arc
between the electrode and the metal to melt the
metals at the welding point.
Factors such as welding current, voltage,
electrode type, filler material, welding direction
and shielding gas affect the quality and properties
of the weld. In the welding process, the electrode
can be consumable or non-consumable to form
the weld. Consumable electrodes become part of
the weld. An inert shielding gas such as CO2 or
argon is often used to protect the weld area from
oxidation and contamination during welding.
Electric arc welding allows you to weld a variety
of metals, including steel, aluminium and alloys,
in all positions.
Advantages: Electric arc welding provides good
penetration and welding speed. Produces strong,
durable welds suitable for structural and
pressure processes.
Disadvantages: Common weld defects include
porosity, lack of fusion, and cracking, which can
affect weld strength.
For safety reasons, due to the UV rays and heat
involved in the welding process, proper safety
equipment such as welding helmets and gloves
should be considered.
Figure 1. Electric arc welding.
2. Contact welding
Contact welding involves the process of joining
metals together by passing an electric current
through the metal parts to be welded, and heat is
generated on the metal surface unit. Heat causes
the metal to soften and fuse. Contact welding is
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International Journal of Advance Scientific Research
(ISSN
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2750-1396)
VOLUME
03
ISSUE
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Pages:
251-259
SJIF
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MPACT
FACTOR
(2021:
5.478
)
(2022:
5.636
)
(2023:
6.741
)
OCLC
–
1368736135
commonly used to join thin metal parts in the
automotive,
household,
and
construction
industries. Proper electrode design, current, time,
and pressure are critical to obtaining quality
welds without defects.
Advantages, high welding speed, reproducibility
and low heat application prevent heat
deformation on the metal surface. It is an
alternative welding rod as a robust and
inexpensive weld suitable for mass production. It
can weld a variety of metals including steel,
aluminium and stainless steel, typically less than
3mm thick.
Subtypes of contact welding are divided into the
following types:
a)
spot welding
b)
welding continuous seams
c)
projection welding
Spot welding is the most common type. In spot
welding, two metal plates are fastened together
and a contact is made by passing a large electric
current through electrodes touching the top and
bottom of the weld. As a result of the thermal
energy generated as a result of the contact, a weld
is formed.
Figure 2. Spot welding.
Continuous welding is used to continuously move the work metals between a pair of disk electrodes and
press them together to form a long weld.
Figure 3. Welding continuous seams
3. Gas welding
Volume 03 Issue 10-2023
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International Journal of Advance Scientific Research
(ISSN
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2750-1396)
VOLUME
03
ISSUE
10
Pages:
251-259
SJIF
I
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FACTOR
(2021:
5.478
)
(2022:
5.636
)
(2023:
6.741
)
OCLC
–
1368736135
Gas welding uses a fuel gas such as acetylene
combined with oxygen to create a flame that
melts metal surfaces. In this method, molten
metal is combined. Types of gas welding include
oxy-acetylene welding and oxy-fuel welding. It
uses a fuel gas (such as acetylene, propane, or
hydrogen) and oxygen to create a hot flame
stream for welding. This fire is used to heat and
melt the metal. Fuel gas and oxygen are supplied
from pressure cylinders through hoses to the
mixing chamber and nozzle. Gas valves are used
to control the welding pattern. During the
welding process, an exothermic chemical reaction
occurs between fuel gas and oxygen, which
reaches a temperature higher than 3000°C. Filler
rods are used to create a weld. These rods are
usually selected depending on the type of metal to
be welded. The weld metal must have a thickness
of more than 25 mm. Commonly used in
construction, manufacturing, plumbing and
automotive repair, this method of welding
provides economical portability and low cost.
Disadvantages of gas welding include limited
control, the need to use a filler, and the risk of slag
inclusions compared to other welding methods.
Figure 4. Gas welding.
4. Laser welding
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SJIF
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)
(2022:
5.636
)
(2023:
6.741
)
OCLC
–
1368736135
Laser welding uses a high-powered laser as a heat
source to fuse metal materials together. Laser
beams concentrate a large amount of energy into
a very small area to melt metal. This type of
welding provides precise control and usually
involves a high precision process. Mainly widely
used in electronics, medical devices, automobile
and aerospace industries. Unlike some types of
welding, filler metal is not required because the
laser can melt the metal so precisely that the
materials adhere well to each other. Therefore,
there are no sparks or cinders. It is possible to
perform the welding process even on complex
surfaces.
As a welding object, thin metal sheets (0.1-3 mm),
pipes, wires and thin parts of steel, aluminum,
titanium and other alloys can be welded.
Advantages: includes high welding speed;
consistency; ease of automation; and the ability to
create small, precise stitches.
Disadvantages: the high cost of the equipment
and the need for laser protection glasses.
Figure 5. Laser welding process
5. Electron beam welding
Electron beam welding is a process that uses a
beam of high-speed electrons generated in a
vacuum by heating the tungsten filament cathode
and accelerating it with a high voltage. The
electron beam in the welding process is capable
of deep melting even thick metals. As a safety
measure in this type of welding, the welding
process is carried out under a vacuum, usually
around 0.001 torr (0.133322368 pascal), to
prevent the spread of electron beams. This is
done using a vacuum chamber. No filler metal
(filler) is needed when welding in this
environment because the beam precisely melts
and joins the materials. Thin parts and complex
shapes can be welded. Ideal welding type for
welding dissimilar and reactive metals such as
stainless steel, titanium, Inconel, etc. due to the
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SJIF
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5.478
)
(2022:
5.636
)
(2023:
6.741
)
OCLC
–
1368736135
inert vacuum environment. Welding of metals
with a thickness from 0.5 mm to 150 mm is
carried out depending on the power of the
welding equipment.
Figure 6. Electron beam welding.
The advantages include excellent welding quality,
speed, penetration and automation capabilities,
while the disadvantages include the high cost of
equipment and the need for vacuum systems.
Electron beam welding is widely used in
aerospace, nuclear, medical implants, and
electronics where strength and precision are
critical. The quality level is also very suitable for
the same areas.
6. Friction welding
Friction welding is a solid-state welding process
that generates heat through mechanical friction
to join materials without melting them. Friction
welding involves rubbing one piece (usually
called a flywheel) against another stationary part
(called an anvil) under pressure. The resulting
friction causes localized heating at the interface,
often above the recrystallization temperature of
the materials. This heating causes the materials to
soften and mix at the molecular level without
completely melting. The heated pieces of metal
are bonded together under pressure, forming a
strong bond between the working surfaces. It is
commonly used for welding metals such as steel,
aluminium, copper and titanium. Friction welding
is often an automated process. This allows precise
control of welding parameters such as rotation
speed, stroke pressure and time. Given the
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(2022:
5.636
)
(2023:
6.741
)
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complexity of welding metals of different grades
together, this type of welding allows joining
metals that are not of the same grade. It is widely
used in industries such as automotive, aerospace,
medicine and energy. The advantages of welding
over other methods include the absence of the
need to melt filler metal or welding metals, and
the ability to join materials that are difficult to
weld.
Figure 7. Friction welding
7. Ultrasonic welding
Ultrasonic welding is a welding process that uses
high-frequency ultrasonic vibrations to join
materials without melting them. It is mainly used
in various industries for welding small electronic
components, assembly of medical devices,
packaging, wire and cable connection. Ultrasonic
welding is usually used to join thin metal sheets
or wires. Produces welds that are stronger than
other welding methods. The high-frequency
vibrations cause interatomic friction without
creating thermally induced defects. The main
process parameters include vibration amplitude
and frequency, welding pressure and time.
Optimum heat generation and welding process
must be properly adjusted. One of the parts to be
joined is held in an ultrasonic transducer horn
that oscillates at ultrasonic frequencies (typically
20 kHz or higher). When the horn parts are
pressed together, the vibrations generate heat
through friction on the working surface. This
leads to the softening of materials and
intermolecular bonding.
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Figure 8. Ultrasonic welding.
C
ONCLUSION
In summary, welding is a versatile and important
process used to join materials in various
industries. In general, welding plays an important
role in the manufacturing and construction
industries. It involves the application of heat to
fuse and melt the metals, creating a weld that is
strong and durable.
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