GMP Final Presentation:

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GMP Final Presentation Welding Systems
Ashley P. Aust Megan Kearney Scott Mitchell
November 20th, 2007
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Overview

• Definition
• Applications
• Types
• Precautions
• The Future
• Conclusion
• Questions

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Definition

• Welding A fabrication process that joins
  materials by causing coalescence
• Basically, two or more pieces of metal are bonded
  by liquefying the bonding surfaces and allowing
  them to solidify creating one continuous solid.

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Applications

• Construction
• Vehicles and Equipment
• Railroads
• Shipbuilding
• Aerospace
• Nuclear

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Types

• MIG (Metal Inert Gas)
• Used primarily in industry
• TIG (Tungsten Inert Gas)
• Aerospace/Nuclear application
• Stick (Shielded Metal Arc Welding)
• Used in construction and the outdoors

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MIG

• Continuous Consumable Spooled Wire
• Fed through MIG Gun
• Shielding Gas
• Argon

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MIG

DRIVE WHEELS
CONSUMABLE ELECTRODE
POWER SOURCE
SHIELDING GAS
ARC COLUMN
BASE METAL
PUDDLE
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TIG

• Hand Fed Welding Rod
• Non Consumable Tungsten Tipped Torch
• Shielding Gas
• Argon

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TIG
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Stick

• Consumable Electrode
• Electrode Holder
• Coated in Flux
• Provides Shielding Gas

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Stick
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Precautions

• Safety
• Eyes
• Respiratory
• Bodily Harm
• Material
• Cracking
• Distortion
• Finish

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Welding Fume Hazards

• Potential Hazards
• Short term effects
• Long term effects

• Reduction of Hazards
• Identification
• Substitution of Materials
• Ventilation
• Fume Sampling
• Education

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Welding Eye Hazards

• Potential Hazards
• Projectiles
• Chemicals
• Radiation

• Reduction of Hazards
• Industrial Safety Glasses
• Face Protectors or Faceshields
• Welding Hoods or Helmets
• Goggles

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Other Health Hazards

• Noise
• Fire and Explosion
• Electrical
• Mechanical
• Tripping and Falling
• Confined Spaces
• Contact Lenses
• Pacemakers

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Material Precautions

• Cracking Distortion
• Insufficient preheating and cooling
• Welding temperature issues
• Finish
• Pass Speed
• Metal Type

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Case Study

• American Welding Society announced new welding
  process in August 2007.
• Stir Welding
• Friction and laser
• In friction stir welding the metal is not melted
  during the process to maintain original
  characteristics.

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Friction Stir Welding
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Applications of FSW

• Widely used in the aerospace industry
• Primary joining process Boeing is using on the
  new 787 Dreamliner.
• Reduces aircraft weight
• without compromising
• durability for better fuel efficiency.
• FSW is also being used by Boeing on the Delta IV
  booster rocket designed to carry a payload to
  Mars.
• It reduces the manufacturing time.

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AWS Conference

• Magnetic Pulse Welding
• Cost reduced from 1 per weld to .04 per weld
  making it a more attractive alternative.
• Time Reducing MIG technologies
• By feeding 2 wires as opposed to 1 a 48 pipeline
  that used to take 4 minutes can be cut to 1
  minute.
• Fiber Laser Welding
• Uses a single laser source to make multiple weld
  at distance up to 200 meters.

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Advantages
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Disadvantages
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Conclusion

• All welding systems are all useful in certain
  applications. When choosing a welding system
  make sure to take into account the capabilities
  and cost of the system as well as the material
  being welded, the safety issues associated with
  the welding system, and skill required.

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Sources

• Pentons Welding Magazine
• DeGarmos Materials and Processes in
  Manufacturing
• Interview with Parker Machine Representative
• Interview with Zak Inc. Representative
• OSHA 30 Hour Handbook

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Questions

• At this time we would like to field any
  questions or comments you might have.