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Welding is a manufacturing method used to assemble materials, usually, on metal or thermoplastic materials. In this method, usually the part of the working pieces to be welded is melted and filler material is added to this part, then the joint is cooled and hardened, in some cases, the heat fusion joining process is done under pressure. This method differs from soldering and brazing, in soldering and brazing methods joining occurs at low melting points and without melting of the workpieces.
Many different energy sources such as gas flame, electric arc, laser, electron beam, friction, ultrasound waves can be used for welding. In industrial processes, welding can be carried out in many different environments such as outdoors, underwater, space. However, no matter where it is made, the welding process carries a variety of dangers. It is necessary to take precautions against flame, electric shock, toxic fumes, and ultraviolet rays.
As a general principle, while welding, the welded area of the part is melted or exposed to high pressure, and the joining is provided either with or without filling (welding electrode, wire, etc.). The parts to be joined are mixed with the effect of heat and/or pressure applied.
The methods are as follows;
Oxy – Acetylene Gas Welding, Electric Arc Welding, Gas Metal Arc Welding, Submerged Arc Welding, Resistance Spot Welding, Electron Beam Welding, Laser Beam Welding, Plasma Welding
It is a resolvable joint made with the help of heat.
The molten solder enters among the surfaces by diffusion and provides the connection by forming an alloy with the parts. The melting temperature of the solder is lower than the melting temperature of the connected parts. The operating temperature to which the soldered joint will be exposed must also be lower than the melting temperature of the solder.
During soldering, there is a distinction between brazing and soft soldering. When the brazing temperature reaches above 450 degrees, brazing is mentioned. On the other hand, soft soldering is mentioned at soldering temperatures below 450°C.
The "soldering" technique is used to connect metals. Temperatures of up to 900°C can be reached during brazing. The soldering material is melted at a temperature of up to 900°C and bridges over the metal parts. Since temperatures above 450°C are reached during soldering, the liquidus temperature of the soldering material used must be greater than 450°C. In brazing, the point of junction is mechanically more durable than in soft soldering.
Soft soldering is used for sensitive electronics, however, for soldering gas pipes, brazing is used. You can braze copper, steel, brass, and silver metals.
The soldering process wets the area where the molten solder connecting piece contacts. In this wetted area, the solder alloy begins to penetrate the base material (diffusion). An alloy is then obtained, which determines the bond strength. The magnitude of the adhesion and diffusion forces at the junction area depends on the following parameters:
1. Working temperature
2. Metallurgical miscibility
3. Time exposed to heat
Advantages
Parts from different materials can be joined with solder. Since there is no melting, the heat energy required for the process is less. Excessive thermal stress, shrinkage does not occur in the parts. It is an easy, quick, and inexpensive method. There is no notch effect on the parts. Clean surfaces are formed, no additional processing is required. Good thermal and electrical conductivity. Since it will be filled with solder between the surfaces, there is no need to give tolerance. Disadvantage: It is not suitable for systems operating at high temperatures, Its strength is lower than that of the weld.
Electrical-electronics industry (printed circuits, chips), Chemical industry, Tank industry (fasteners, coatings), On airplanes and ships, Installations (in oil and compressed air pipelines), Automobile spares (radiators), Steel structures (bicycles), Food industry, Machine tools (Fixation of HM cutters to the tool holder), In shaft-hub-connections, Jewellery industry (in connection with precious stones)
Soldering Methods are as follows;
1. Soldering with a soldering iron: It is applied to soft solder.
2. Flame soldering: Applied to soft and hard solder. The soldering area is heated by a gas flame.
3. Dip soldering: Applied to soft and hard solder. A molten solder bath is used.
4. Furnace soldering: Applied to soft and hard solder. Solders in the form of foil, ring and wire are used.
5. Resistance soldering: The solder heats with low and high frequency current. It is used in mass production.