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Applications</a></p></header><div class="excerpt"><p>Ultrasonic Welding | Working , parts , Advantages and Applications
ULTRASONIC WELDING
Ultrasonic welding is a solid state welding process in which two work pieces are bonded as a result of a...</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/ultrasonic-welding-working-parts-advantages-and-applications/" aria-label="View Post: Ultrasonic Welding | Working , parts , Advantages and Applications">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"Ultrasonic Welding | Working , parts , Advantages and Applications","url":"\/\/www.gunkrazy.com\/ultrasonic-welding-working-parts-advantages-and-applications\/","articleBody":"Ultrasonic Welding | Working , parts , Advantages and Applications\r\nULTRASONIC WELDING\r\nUltrasonic welding is a solid state welding process in which two work pieces are bonded as a result of a pressure exerted to welded parts combined with application of high frequency acoustic vibration (ultrasonic). It uses the principle of conversion of high frequency electrical energy into high frequency mechanical energy. This mechanical energy is a vertical motion excess of 15000 cycles\/second. Ultrasonic vibration causes friction between parts which results in a closer contact between two surfaces with simultaneous local heating of the contact area. Interatomic bonds formed under these conditions provide strong joint.\r\n\r\nThe components to be joined are held together under pressure and subjected to vibrations, usually at a frequency of 15 kHz to 6o kHz. The vibrations produced by a welding sonotrode or sonometer or horn are used to soften or melt the thermoplastic material at the joint line. Welding times are lower than 3 seconds. The welding can proceed with or without the application of external heat. Thickness of the welded parts is limited by the power of the ultrasonic generator.\r\n\r\nultrasonic welding diagram\r\nEquipment\u2019s:\r\nPower Supply:\r\nThe ultrasonic welding needs high frequency and high voltage power supply. This power is needed by the transducer to generate vibrations.\r\n\r\nTransducer:\r\nTransducer is a device which can convert high frequency electric signal into high frequency mechanical vibration. This is connected with the welding head. The converter or piezoelectric transducer used in this welding process.\r\n\r\nBooster and Horn:\r\nThe mechanical vibration created by the transducer is supplied to the booster which amplifies this vibration and supply to the horn. Horn is a device which supply this amplified vibration to the welding plates.\r\n\r\nFixture or clamping devices:\r\nThis device is essential in the ultrasonic welding. This uses either electrical, hydraulic, pneumatic or mechanical energy to hold the plates into desire location.\r\n\r\nWorking of Ultrasonic Welding Equipment\r\nIn ultrasonic welding, electrical power supply is applied to a transducer at a frequency of 50 to 60 Hz into a high frequency electrical supply operating at 20, 30 or 40 kHz. Here transducer converts electrical energy into mechanical energy. This electrical energy is supplied to the transducer which converts to mechanical energy at ultrasonic frequencies. The vibrating energy is then transmitted through the booster that increases the amplitude of the acoustic wave. The acoustic waves are then transmitted to the horn . The horn is an acoustic tool that transfers the vibrating energy directly to the components being assembled and it additionally applies a welding pressure.\r\n\r\nThe vibrations are transmitted through the workpiece to the joint area. The parts are \u201cscrubbed\u201d together under pressure at 20,000 cycles per second. Here, the vibrating energy is converted to heat through friction. It then softens or melts the thermoplastic and joins the components together. As the atoms are combined between components to be welded, a real metallurgical bond is made. Most of the thermoplastic materials can be ultrasonic weldable.\r\n\r\nThe sequence of operations is as follows: -\r\n\r\nStep 1: The parts to be welded are placed into a locating holder.\r\nStep 2: The ultrasonic tool descends to apply a clamping pressure between the weld parts\r\nStep 3: When ultrasonic power flows for a given time, the tool then vibrates at a frequency 1- 40kHz.\r\nStep 4 : The base metals are then mechanically mixed causing a metallurgical bond between parts . The parts are immediately welded. There is no hold time or curing time .\r\nStep 5: Force is removed and machine deloaded\r\nAdvantages, Limitations and Applications of Ultrasonic Welding\r\nAdvantages of Ultrasonic Welding :\r\n1. Since no bulk heating of the work pieces is involved, there is no danger of any mechanical or metallurgical bad effects.\r\n2. The process is excellent for joining thin sheets to thick sheets.\r\n3. Local plastic deformation and mechanical mixing result into sound welds.\r\n4. Dissimilar metals may be joined.\r\n5. High quality weld is obtained.\r\n6. The process can be integrated into automated production lines.\r\n7. Moderate operator skill level is enough.\r\n8. The process is fast, economical and automated.\r\n9. It is used in mass production up to 60 parts per minute.\r\n10. It ensures increased flexibility and versatility.\r\n11. It produces high strength joints.\r\n12. Very thin materials can be welded.\r\nLimitations of ultrasonic Welding :\r\n1. Only small and thin parts may be welded.\r\n2. Work pieces and equipment components may fatigue at reciprocating loads provided by ultrasonic vibration.\r\n3. Work pieces may bond to the anvil.\r\n4. It is not suitable for ductile materials since they yield under the stresses.\r\n5. It needs specially designed joints.\r\n6. Ultrasonic vibrations can damage electrical components.\r\n7. Tooling costs for fixtures are high.\r\nApplications of Ultrasonic Welding :\r\n1. Ultrasonic welding is used mainly for bonding small workpieces in electronics, manufacturing communication devices, medical tools and watches.\r\n2. It is used in automotive, medical and toy production.\r\n3. It is used in health care industries due to clean welds.\r\n4. Ring-type continuous welds can be used for hermetic sealing.\r\n5. It is-used in sealing and packaging, aircraft, missiles and fabrication of nuclear components.\r\n6. It is also used in armatures, slotted commuters, starter motor armatures, joining of braded brush wires, brush plates and wire terminals.\r\n7. Ultrasonic welding is used in the automotive industry to fabricate headlamp parts, dashboards, buttons and switches, fuel filter, fluid vessels, seat-belt locks, electronic key fobs, lamp assemblies and air ducts.\r\n8. In electronic appliances such as switches, sensors and data storage keys are fabricated using ultrasonic welding.\r\n9. Ultrasonic welding is also used to make medical parts such as filters, catheters, medical garment and masks.\r\n10. It is used in welding of tubes to sheets in solar panels.\r\n11. Packing applications such as blister packs, pouches, tubes, storage containers and carton spouts can be fabricated using ultrasonic welding,","headline":"Ultrasonic Welding | Working , parts , Advantages and Applications","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2019-04-11","mainEntityOfPage":"False","dateModified":"February 20, 2020","image":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2019\/04\/ultrasonic-welding-diagram-300x295.jpg","height":295,"width":300},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <article class="article-card horizontal "> <a href="//www.gunkrazy.com/explosive-welding-principle-advantages-and-disadvantages/" rel="nofollow"><div class="image-container" style="background-image: url('//www.gunkrazy.com/wp-content/uploads/2019/04/principle-of-explosive-welding-290x300.jpg')"></div><span class="sr-only">link to Explosive welding | principle , Advantages and Disadvantages</span></a><div class="copy-container"><header><p><a style="color: #ff392e!important" href="//www.gunkrazy.com/explosive-welding-principle-advantages-and-disadvantages/">Explosive welding | principle , Advantages and Disadvantages</a></p></header><div class="excerpt"><p>Explosive welding | principle , Advantages and Disadvantages
Explosive welding (EXW) is a solid state (solid-phase) welding process that uses a controlled application of large pressure generated by...</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/explosive-welding-principle-advantages-and-disadvantages/" aria-label="View Post: Explosive welding | principle , Advantages and Disadvantages">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"Explosive welding | principle , Advantages and Disadvantages","url":"\/\/www.gunkrazy.com\/explosive-welding-principle-advantages-and-disadvantages\/","articleBody":"Explosive welding | principle , Advantages and Disadvantages\r\nExplosive welding (EXW) is a solid state (solid-phase) welding process that uses a controlled application of large pressure generated by the detonation of applied explosives. In explosive welding, welded parts (plates) are metallurgically bonded as a result of oblique impact pressure exerted on them by a controlled detonation of an explosive charge.\r\n\r\nThe following terms are frequently used in the explosive welding.\r\n\r\n(i) Cladding metal or cladder is the thinner plate that is either in direct contact with the explosive or it is shielded by a flyer plate from the explosive.\r\n(ii) Flyer plate is a sacrificial plate placed between cladder and explosive to protect the cladder metal.\r\n(iii) Interlayer is a thin metal layer which is sometimes placed between cladder and base plate to enhance joining.\r\n(iv) Base plate or backer is the plate that the cladder is being joined.\r\n(v) Anvil is the surface on which backer rests during the joining operation.\r\n(vi) Standoff is the distance between cladder and base plate prior to the joining operation.\r\n(vii) Bond window is the range of process variables such as velocity, dynamic bend and standoff distance that-result in a successful weld.\r\n(viii) Bonding operation is the detonation of the explosive which results in the weld.\r\n\r\nBefore welding, the surface to be welded must be cleaned. To carry out the welding process, one of the parts to be welded is kept as stationary and the other one is made as movable. The movable part is called flayer plate. The base plate kept as stationary is rested on an anvil and the flyer plate is located above the base plate with an angled or constant interface clearance as shown in Figure 3.8 (a). On top of the flyer plate, the rubber spacer is placed to avoid the rapid effect of burnt explosives. Explosives are placed on this rubber spacer with a detonator.\r\n\r\nDetonation starts at an edge of the plate and propagates at high velocity along the plate. The flyer plate moves towards the base plate at very high velocity (4 to 5 km\/s) due to the impact of kinetic energy in the form compressive stress during detonation of explosives to collide with a stationary part to be joined. The maximum detonation velocity is about 120% of the material sonic velocity. The compressive stress is in the order of thousands of MPa. The material at the intersection points behaves similar to a viscous fluid after explosion.\r\n\r\nprinciple of explosive welding\r\nAdvantages, Limitations and Applications of Explosive Welding\r\nAdvantages of Explosive Welding :\r\n1. It ensures high quality bonding such as high strength, no distortions, no porosity and no change of the metal microstructure.\u00a0\r\n2. There is no heat-affected zone (HAZ) other than weld surface.\r\n3. There is no diffusion.\r\n4. Only, minor melting occurs.\r\n5. Differences in irtateriai melting temperatures and coefficients of thermal expansion do not affect the final product.\r\n6. Combination of dissimilar metals, copper to stainless steel, aluminium to steel or titanium to steel can be easily welded.\r\n7.Explosive welding is much suited to cladding application.\r\n8. Process is simple and rapid. It also gives close thickness tolerance.\r\n\r\nLimitations of Explosive Welding :\r\n1. Brittle materials cannot be processed.\r\n2.Only, simple shape parts may be bonded.\r\n3. Thickness of flyer plate is limited.\r\n4. Safety and security aspects of storage and using explosives are difficult.\r\n5. Metals must have high enough impact resistance and ductility.\r\n6. The cladding plate cannot be too large.\r\n7. Noise and blast can require worker protection, vacuum chambers and buried in sand\/water.\r\n8. The use of explosives in industrial areas will be restricted by the noise and ground vibrations caused by the explosion.\r\n9. Area should be cleaned and sound grounded for explosion.\r\n10. Licenses are necessary to hold and use explosives\r\nApplication of Explosive Welding\u00a0 :\r\n1. This process is applied to welding of tubes and tube plates in heat exchangers, feedwater heaters and boiler tubes to clad tube plates.\r\n2. The tubes may be of steel, stainless steel or copper, aluminium brass and bronze tubes in naval brass tube plates are welded.\r\n3. It is used for manufacturing clad tubes and pipes, pressure vessels, aerospace structures, heat exchangers, bi-metal sliding bearings, ship structures and weld transitions.\r\n4. It is used to clad thick plates with corrosion resistant layers where other techniques (e.g. roll bonding) are not practical.\r\n5. It is used in tube plugging.\u00a0\r\n6. It is used in remote joining in hazardous environments.\r\n7. It is used in fixing cooling fins.\r\n8. It is also used in cryogenic industries.","headline":"Explosive welding | principle , Advantages and Disadvantages","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2019-04-11","mainEntityOfPage":"False","dateModified":"February 20, 2020","image":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2019\/04\/principle-of-explosive-welding-290x300.jpg","height":300,"width":290},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <article class="article-card horizontal "> <a href="//www.gunkrazy.com/diffusion-bonding-working-advantages-and-application/" rel="nofollow"><div class="image-container" style="background-image: url('//www.gunkrazy.com/wp-content/uploads/2019/04/diffusion-welding-226x300.jpg')"></div><span class="sr-only">link to Diffusion Bonding |  Working , Advantages and Application</span></a><div class="copy-container"><header><p><a style="color: #ff392e!important" href="//www.gunkrazy.com/diffusion-bonding-working-advantages-and-application/">Diffusion Bonding |  Working , Advantages and Application</a></p></header><div class="excerpt"><p>Diffusion Bonding | Working , Advantages and Application
It is a solid state welding process that uses heat and pressure, usually in a controlled atmosphere, with sufficient time for diffusion and...</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/diffusion-bonding-working-advantages-and-application/" aria-label="View Post: Diffusion Bonding |  Working , Advantages and Application">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"Diffusion Bonding |  Working , Advantages and Application","url":"\/\/www.gunkrazy.com\/diffusion-bonding-working-advantages-and-application\/","articleBody":"Diffusion Bonding | Working , Advantages and Application\r\nIt is a solid state welding process that uses heat and pressure, usually in a controlled atmosphere, with sufficient time for diffusion and coalescence to occur. In this process, moderate pressure of about 10 MPa is applied to carefully cleaned surfaces of the workpieces at an elevated temperature below the melting point of the metals to result primarily from diffusion. Atoms diffuse across the interface to form the bond. Diffusion involves the migration of atoms across the joint due to concentration gradients. This process requires temperatures of about 0.6Tm (Tm is the melting temperature of the metal) in order to have a high diffusion rate between parts being joined. Here, plastic deformation at surfaces is minimal and primary coalescence mechanism is solid state diffusion.\r\n\r\nWhen joining two materials of similar crystalline structure occurs, diffusion bonding is performed by clamping two pieces to be welded with their surfaces abutting each other. Prior to welding, these surfaces must be machined to smooth finish and kept free from chemical contaminants or other debris. Mostly, surface treatment including polishing, etching and cleaning as well as diffusion pressure and temperature are important factors regarding to process of diffusion bonding. Surface roughness value, Ra of less than 2\u00a0 micron and waviness of less than 400 micron are preferred. Oxides need to be removed.\r\n\r\nDiffusion bonding is performed under controlled atmosphere to prevent oxidation. Sometimes, a layer of filler material is needed to achieve good bonding. Any intervening material between two metallic surfaces, as shown in Figure 3.5, may prevent adequate diffusion of material because the strength of the welding depends on pressure, temperature, time of contact and cleanliness of the metal.\r\n\r\n diffusion welding\r\n\r\nThe example for diffusion welding is bonding of gold over copper. First, a thin layer of gold foil is obtained by hammering. Once clamped, the gold foil is then placed over copper and then the weight is placed on top of it, usually for many hours. In diffusion welding, the pressure may be applied by dead weights or by a press using differential gas pressure or by high-pressure autoclaves because this method allows for exact measurements of load on the parts. The assembly is then placed in a furnace and left until a good bond is obtained. The parts are usually heated in a furnace or by electrical resistance. Figure 3.6 illustrates the heating of diffusion bonding by using electrical resistance method. Diffusion bonding must be done in a vacuum or inert gas environment when using metals that have strong oxide layers such as copper.\r\nStages in Diffusion Welding\r\nDiffusion bonding occurs in three simplified stages as follows:\r\n\r\nStage 1: Deformation and interfacial boundary formation\r\nBefore the surfaces come to complete contact, very small surface defects (asperities) on the two surfaces will contact and plastically deform. As these small surface defects deform, they interlink for forming interfaces between two surfaces.\r\n\r\nStage 2: Grain boundary migration and pore elimination\r\nBoth elevated temperature and pressure cause an accelerated creep in the materials, grain boundaries and raw material migrate. The gap between two surfaces is reduced to isolated pores.\r\n\r\nStage 3: Volume diffusion pore elimination\r\nMaterial begins to diffuse across the boundary of the abutting surfaces, blends this material boundary and creates a bond.\r\n\r\n steps in diffusion welding\r\nAdvantages, Limitations and Applications of Diffusion Welding\r\nAdvantages of Diffusion Welding :\r\n1. Plastic deformation at surface is minimal.\r\n2. Dissimilar materials may be welded.\r\n3. Welds of high quality are obtained.\r\n4. There is no limitation in the thickness of workpieces.\r\n5. The bonded surface has the same physical and mechanical properties as the base material.\r\n6. The diffusion bonding is able to help us to build high precision components with complex shapes. Also, the diffusion is flexible.\r\n7. The diffusion bonding method can be used wildly, joining either similar or dissimilar materials and also important in processing composite materials.\r\n8. The process is not extremely hard to approach and the cost to perform the diffusion bonding is not high.\r\n9. The diffusion bonding process is able to produce high quality joints in which no discontinuity and porosity exist in the interface.\r\nLimitations of Diffusion Welding :\r\n1. It is a time consuming process due to low productivity.\r\n2. Time required for diffusion can range from seconds to hours.\r\n3. Very thorough surface preparation is required prior to welding process.\r\n4. The mating surfaces must be precisely fitted to each other.\r\n5. It requires relatively high initial investments in equipment.\r\nApplications of Diffusion Welding :\r\n1. It is used in joining of high-strength and refractory metals based on titanium in aerospace and nuclear industries.\r\n2. Diffusion welding is most commonly used to join sheet metal structures in nuclear and electronics industries.","headline":"Diffusion Bonding |  Working , Advantages and Application","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2019-04-11","mainEntityOfPage":"False","dateModified":"February 20, 2020","image":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2019\/04\/diffusion-welding-226x300.jpg","height":300,"width":226},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <article class="article-card horizontal "> <a href="//www.gunkrazy.com/cold-welding-diagram-advantages-and-disadvantages/" rel="nofollow"><div class="image-container" style="background-image: url('//www.gunkrazy.com/wp-content/uploads/2019/04/cold-welding-300x210.jpg')"></div><span class="sr-only">link to Cold Welding | Diagram , Advantages and Disadvantages</span></a><div class="copy-container"><header><p><a style="color: #ff392e!important" href="//www.gunkrazy.com/cold-welding-diagram-advantages-and-disadvantages/">Cold Welding | Diagram , Advantages and Disadvantages</a></p></header><div class="excerpt"><p>Cold Welding | Diagram , Advantages and Disadvantages
COLD WELDING
Cold pressure welding is a form of solid state welding which is unique because it is carried out at ambient temperature. Other...</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/cold-welding-diagram-advantages-and-disadvantages/" aria-label="View Post: Cold Welding | Diagram , Advantages and Disadvantages">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"Cold Welding | Diagram , Advantages and Disadvantages","url":"\/\/www.gunkrazy.com\/cold-welding-diagram-advantages-and-disadvantages\/","articleBody":"Cold Welding | Diagram , Advantages and Disadvantages\r\nCOLD WELDING\r\nCold pressure welding is a form of solid state welding which is unique because it is carried out at ambient temperature. Other forms of solid state welding are conducted at elevated temperature.\r\nCold welding is a bonding process during which two solids are forced to form a single piece by applying adequate pressure as shown in Figure 3.2. In other words, cold welding is a solid-state welding process in which joining of metals takes place without fusion\/heating at the interface of two parts to be welded. Cold welding is also known as contact welding. In fusion-welding precesses, no liquid or molten phase is present at the joint. In cold welding, metals are joined together without using flux.\r\n\r\nThe welding of parts is done by extreme high pressure or by contact in a high vacuum with no application of heat. Pressure is applied to points to be welded at temperature below the recrystallization temperature of metals to be welded. This applied pressure brings the atoms on the interface to be welded into such close contact that they diffuse across the interface and a cold pressure weld is made. The atoms of metals are held together by metallic bond. The metallic bond can be described as a \u2018cloud\u2019 of free and negatively charged atoms into a unit as a result of attractive forces.\r\n\r\ncold welding\r\n\r\nAll metals are surrounded by surface layers (oxide) which must be disrupted if they need to be welded. Cold pressure welding carried out at ambient temperature relies.upon the use of high compressive pressure 1400 to 2800 N\/mm2 for Aluminium and at least double that value for copper. It provides interfacial deformations of 60% to 80% that break the oxide layers to expose fresh and uncontaminated metal makes contact. In this state, take over to interatomic forces produce the weld.\r\nCharacteristics of Cold welding\r\n(i) A cold weld is generally stronger than the parent material and has the same electrical characteristics.\r\n(ii) At least one of the metals must be ductile without excessive work-hardening.\r\n(iii) Total absence of applied heating occurs.\r\n(iv) Surface preparation is important.\r\n(v) Both workpieces can be similar or dissimilar metals.\r\n(vi) Both workpieces should be cleaned.\r\n(vii) Short sections on the workpieces should sheared off.\r\nAdvantages, Limitations and Applications of Cold Welding\r\nAdvantages of Cold Working :\r\n1. There are no thermal effects on the parts being joined and the process is fast.\r\n2. As the process is performed at ambient temperature, there are no thermal effects on the parts being joined.\r\n3. The weld zone is not only metallurgically homogeneous but the metal is work hardened and stronger than the adjacent areas.\r\n4. It is simple and inexpensive to operate once dies have been produced.\r\n5. The process is fast.\r\n6. It is virtually no deformation.\r\n7. The ends of the wire or rod need no surface preparation to weld and the alignment of the two butt ends is automatic as the material is placed on the die.\r\n8. Parts are joined without contamination from sparks or dusts and vapours.\r\nLimitations of Cold Working :\r\n1. As the welds are made in the solid state, they are difficult to inspect.\r\n2. The thickness of the parts is reduced significantly at the weld where the contact surfaces are sheared together.\r\n3. It is highly specialized type of welding with respect to joint design and materials to be welded.\u00a0\r\n4. While the speed is an advantage to assemblers, it can also be a limitation.\r\n5. When a body moving that fast meets another, it will try to displace it.\r\nApplications of Cold Working :\r\n1. It is used for joining of wire, foil to wire, wire is bi-metals and scaling of heat sensitive containers such as those containing explosives.\r\n2. Rod coils are butt welded to permit continuity in post-weld drawing to smaller diameters.\r\n3. It is used for joining components where heating is not possible such as magnets.\r\n4. In the electronics industry, cold welding processes are used to seal tin plated steel crystal cans and copper packages for heat sensitive semiconductor devices.","headline":"Cold Welding | Diagram , Advantages and Disadvantages","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2019-04-11","mainEntityOfPage":"False","dateModified":"February 20, 2020","image":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2019\/04\/cold-welding-300x210.jpg","height":210,"width":300},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <article class="article-card horizontal "> <a href="//www.gunkrazy.com/solid-state-welding-advantages-disadvantages/" rel="nofollow"><div class="image-container" style="background-image: url('//www.gunkrazy.com/wp-content/uploads/2019/04/solid-state-welding-300x251.jpg')"></div><span class="sr-only">link to Solid State Welding Processes  |  Advantages and Disadvantages</span></a><div class="copy-container"><header><p><a style="color: #ff392e!important" href="//www.gunkrazy.com/solid-state-welding-advantages-disadvantages/">Solid State Welding Processes  |  Advantages and Disadvantages</a></p></header><div class="excerpt"><p>Solid State Welding Processes | Advantages and Disadvantages
SOLID STATE WELDING
Solid state welding is a group of welding processes which produces coalescence at temperature below the melting...</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/solid-state-welding-advantages-disadvantages/" aria-label="View Post: Solid State Welding Processes  |  Advantages and Disadvantages">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"Solid State Welding Processes  |  Advantages and Disadvantages","url":"\/\/www.gunkrazy.com\/solid-state-welding-advantages-disadvantages\/","articleBody":"Solid State Welding Processes | Advantages and Disadvantages\r\nSOLID STATE WELDING\r\nSolid state welding is a group of welding processes which produces coalescence at temperature below the melting point of base materials being welded without the addition of brazing filler metal. Metallurgical bond is created without melting the base metals. In this welding, heat may or may not be applied. These processes are sometimes called solid state bonding processes.\r\n\r\nThis group of welding processes includes the following types:\r\n(i) Cold welding\r\n(ii) Diffusion bonding\r\n(iii) Explosive welding\r\n(iv) Ultrasonic welding\r\n(v) Friction welding\r\n(vi) Forge welding\r\n(vii) Roll welding\r\n(viii) Hot pressure welding.\r\n\r\nIn all of these welding processes, time, temperature and pressure individually or in combination produce coalescence of the base metal without significant melting. Solid state welding is the oldest welding process and some of them are the newest. One of the solid state welding processes, called friction welding, is shown in Figure 3.1. In this friction welding, one of the workpiece is rotating at high speed and the other is stationary. When the stationary workpiece is forced to rotating workpiece at high pressure, the weld is formed due to friction\u00a0 between these two surfaces.\r\n\r\nsolid state welding\r\nAdvantages, Limitations and Applications of Solid State Welding\r\nAdvantages of Solid State Welding :\r\n\r\n1. The base metal does not melt and form a nugget.\r\n2. The metals being joined retain their original properties. Hence, there is no heat\u00a0\r\naffected zone problems involved.\r\n3. Metallurgical purity is maintained.\r\n4. Dissimilar metals can be bonded.\r\n5. It eliminates liquid phases.\r\n6. It can be applied at different temperatures and under different stresses.\r\n7. Weld is free from microstructure defects.\r\n8. There is no use of filler material, fluxes and shielding gas required.\r\nLimitations of Solid state Welding :\r\n1. Surface preparation is necessary.\r\n2. Joint design is limited.\r\n3. Elaborate and expensive equipment may be required.\r\n4. Non-destructive inspection is very limited.\r\n5. Equipment is expensive.\r\nApplications of Solid State Welding :\r\n1. Bonding of stainless steel liners in aluminum fry pans.\r\n2.Aluminum cladding bonded to uranium fuel rods.\r\n3. Ultrasonic and thermo-compression bonding in microelectronics industry.\r\n4. Friction welding in aerospace and automotive applications.\r\n5. Intake \/ exhaust automatic valves.","headline":"Solid State Welding Processes  |  Advantages and Disadvantages","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2019-04-11","mainEntityOfPage":"False","dateModified":"February 20, 2020","image":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2019\/04\/solid-state-welding-300x251.jpg","height":251,"width":300},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <article class="article-card horizontal "> <a href="//www.gunkrazy.com/types-of-actuators-function-of-actuators-used-in-machines/" rel="nofollow"><div class="image-container" style="background-image: url('//www.gunkrazy.com/wp-content/uploads/2019/04/types-of-actuator-300x201.jpg')"></div><span class="sr-only">link to Actuators &#8211; Types, Diagram, Working, Advantages and Disadvantages</span></a><div class="copy-container"><header><p><a style="color: #ff392e!important" href="//www.gunkrazy.com/types-of-actuators-function-of-actuators-used-in-machines/">Actuators &#8211; Types, Diagram, Working, Advantages and Disadvantages</a></p></header><div class="excerpt"><p>ACTUATORS
One of the important components of a mechatronic control system is the actuator. Actuators are the devices that accept a control command and produce a change in the physical system by...</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/types-of-actuators-function-of-actuators-used-in-machines/" aria-label="View Post: Actuators &#8211; Types, Diagram, Working, Advantages and Disadvantages">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"Actuators &#8211; Types, Diagram, Working, Advantages and Disadvantages","url":"\/\/www.gunkrazy.com\/types-of-actuators-function-of-actuators-used-in-machines\/","articleBody":"ACTUATORS\r\nOne of the important components of a mechatronic control system is the actuator. Actuators are the devices that accept a control command and produce a change in the physical system by generating force, motion, heat, flow, etc. It is a device that makes something to move. Normally, the actuators are used in conjunction with the power supply and a coupling mechanism. The power unit provides either AC or DC power at the rated voltage and current. The coupling mechanism acts as the interface between the actuator and the physical system. Typical mechanisms include rack and pinion, gear drive, belt drive, lead screw and nut, piston, and linkages.\r\nDefinition of Actuators :\r\n\r\n \tActuators are the device used for converting hydraulic, pneumatic, and electrical energy into mechanical energy. \r\n \tThe mechanical energy used to get the work done. Actuators perform functions just opposite to that of the pump. \r\n \tThey can be used for lifting, tilting, clamping opening, closing, metering, mixing and turning, and for many other operations.\r\n\r\nFunctions of actuation :\r\n1. Transformation of rotary motion into a translating motion as in the case of the cam and follower mechanism where the rotational motion of the cam is changed into the translational movement of the follower.\r\n2. Transformation of rotary motion for a long distance which is not possible by using gears, as in the case of belt drives.\r\n3. Transformation of rotary motion for a medium distance without slipping which is not possible by using belt drives, as in the case of belt drives.\r\n4. Transformation of linear motion into rotational motion as in the case of rack and pinion mechanism.\r\n5. Locking of rotating elements as in the case of ratchet and pawl mechanism.\r\n\r\ntypes of actuator\r\nTypes of Actuators :\r\n1.Actuators are basically classified into the following two types based on their movement.\r\n\r\n \tTranslational\r\n \tRotational\r\n\r\nIt is possible to convert one form of actuation to another. For example, translational motion is converted into rotational and vice versa by suitably designing the interfacing components around the actuator. Rack and pinion, gears, pulleys, lead screw and nut, and cams can be used as interfacing components.\r\n\r\n2. Actuators can be classified into the following types based on the type of energy.\r\n\r\n \tElectrical\r\n \tElectromechanical\r\n \tElectromagnetic\r\n \tHydraulic\r\n \tPneumatic\r\n\r\nElectrical Actuators :\u00a0\r\nAn actuator obtaining electrical energy from the mechanical system is called electric actuators. Electric actuators are generally referred to ad being those where an electric motor drives the robot links through some mechanical transmission i.e. gears.\r\n\r\nElectrical actuators comprise the following :\u00a0\r\n\r\n1. Drive system: DC motor, AC motor, Stepper motor\r\n\r\n2. Switching Device:\r\n\r\na. Mechanical switch: Solenoids, Relays\r\n\r\nb. Solid-state switch: Diodes, Thyristor, Transistors\r\nAdvantages of Electrical Actuators :\u00a0\r\n\r\n \tHige power conversion efficiency.\r\n \tThe widespread availability of power supply.\r\n \tNo pollution of the working environment.\r\n \tThe basic drive element in an electric motor is usually lighter than that for fluid power.\r\n \tStructural components can be lightweight.\r\n \tThe drive system is well suited to electronic control.\r\n\r\nDisadvantages of Electrical Actuators :\u00a0\r\n\r\n \tA larger and heavier motor must be used which is costly.\r\n \tPoor dynamics response.\r\n \tCompliance and wear problems are causing inaccuracies.\r\n \tConventional gear-driven creates a backlash.\r\n \tElectric motors are not intrinsically safe. They cannot, therefore, be used in for explosive atmospheres.\r\n\r\nElectro-mechanical actuators :\u00a0\r\nElectromechanical actuators are electrical motors that convert electrical energy into mechanical motion. Motors are the principal means of converting electrical energy into mechanical energy in industry. Broadly, they are classified into DC motors, AC motors, and stepper motors.\r\nElectro-magnetic actuators\u00a0\r\nAn electromagnetic actuator is a device that provides working motion due to an internal electromagnetic field. The solenoid is the most common electromagnetic actuator. A solenoid consists of a static, hollow-centered wire coil and a movable ferrous metal plunger. When the wire coil is energized, a magnetic field establishes that provides the force to push or pull the metal plunger.\r\nHydraulic and Pneumatic Actuators :\u00a0\r\nHydraulic and pneumatic actuators are normally either rotary motors or linear pistons\/cylinders. They are ideally suited for generating very large force coupled with large motion. Pneumatic actuators use the compressed air that is more suitable for low to medium force, short stroke, and high-speed applications. Hydraulic actuators use oil under pressure which is incompressible. They can produce very large force coupled with large motion in a cost-effective manner. The rotary motors are usually used in applications where low speed and high torque are required. The cylinder\/piston actuators are suited for the application of linear motion. A proper selection of actuators and their drive systems for a particular application is of utmost importance in the design of mechatronic systems.\r\nHydraulic Actuators :\r\n\r\n \tHydraulic actuators transform the hydraulic energy stored in a reservoir into mechanical energy by means of suitable pumps.\r\n \tHydraulic actuators are also fluid power device for industrial robots which utilize high-pressure fluid such as oil to transmit forces to the point of application desired.\r\n\r\nAdvantages of hydraulic actuators :\r\n\r\n \t\r\n\r\n \tIt has the advantage of generating extremely large force from a very compact actuator.\r\n \tIt can also provide precise control at low speeds\r\n \trobust.\r\n \tself-lubricating.\r\n \tDue to the presence of an accumulator that acts as a storage device the system can meet sudden demand in power.\r\n \tNo mechanical linkages are required.\r\n \tHigh efficiency and high power to size ratio.\r\n\r\n\r\n\r\nDisadvantages of hydraulic actuators :\r\n\r\n \tThe hydraulic system is required for a large infrastructure is high-pressure pump, tank, distribution lines.\r\n \tLeakage can occur causing a loss in performance.\r\n \tHigh maintenance.\r\n \tNot suitable for a clean environment.\r\n\r\nPneumatic actuators\r\n\r\n \tPneumatic actuators utilize pneumatic energy provided by a compressor and transforms it into mechanical energy by means of a piston or turbines.\r\n \tPressurized air is used to transmit and control power.\r\n \tPneumatic actuators are devices that cause things to move by taking advantage of potential energy.\r\n\r\nAdvantages of Pneumatic Actuators :\u00a0\r\nThe advantages of Pneumatic actuators are as follows,\r\n\r\n \tControl is simple.\r\n \tWhen the source of compressed air are readily available, as they often are in engineering related facilities, pneumatic actuators may be a good choice.\r\n \tIt is the cheapest form of all actuators\r\n \tPneumatic actuators have very quick action and response time, thus allowing for fast work cycles.\r\n \tNo mechanical transmission is usually required.\r\n\r\nDisadvantages of Pneumatic Actuators :\u00a0\r\n\r\n \tMore noise and vibration.\r\n \tSince air is compressible, pneumatic cylinders are not typically used for applications requiring accurate motion between two well-defined endpoints.\r\n \tPneumatics are not suitable for heavy loads.\r\n \tIf mechanical stops are used, resetting the system can be slow.","headline":"Actuators &#8211; Types, Diagram, Working, Advantages and Disadvantages","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2019-04-11","mainEntityOfPage":"False","dateModified":"June 1, 2020","image":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2019\/04\/types-of-actuator-300x201.jpg","height":201,"width":300},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <nav class="pagination-wrapper" aria-label="article pagination"> <a class="prev page-numbers" href="?page_num=72">&laquo; PREV</a> <a class="page-numbers" href="?page_num=1"><span class="screen-reader-text">Page </span>1</a> <span class="page-numbers dots">&hellip;</span> <a class="page-numbers" href="?page_num=71"><span class="screen-reader-text">Page </span>71</a> <a class="page-numbers" href="?page_num=72"><span class="screen-reader-text">Page </span>72</a> <span aria-current="page" class="page-numbers current"><span class="screen-reader-text">Page </span>73</span> <a class="page-numbers" href="?page_num=74"><span class="screen-reader-text">Page </span>74</a> <a class="page-numbers" href="?page_num=75"><span class="screen-reader-text">Page </span>75</a> <span class="page-numbers dots">&hellip;</span> <a class="page-numbers" href="?page_num=338"><span class="screen-reader-text">Page </span>338</a> <a class="next page-numbers" href="?page_num=74">NEXT &raquo;</a></nav></section></main><aside id="secondary" class="widget-area"><div class="about-wrapper"><h2 class="widget-title" style="background: #d693c6; color: #ff392e">About Us</h2><div class="about-image" style="background-image: url('//www.gunkrazy.com/wp-content/uploads/2020/03/Sachin-Thorat-300x300-min.png')"></div><p class="about-copy">LearnMech.Com is a Mechanical Project-oriented platform run by Sachin Thorat who is a B-Tech Graduate in Mechanical Engineering. 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