MECHANICAL WELDING CLASS
MECHANICAL WELDING CLASS
The main feature of the welding methods belonging to this class is the mechanical effect on the metal for the purpose of heating. The generated heat melts the metal, its connection occurs. The methods by which portable welding machine is performed are friction, explosion, pressure, ultrasound.
FRICTION
The essence of the process: rotation and pressure are applied to the metal elements being welded. The technology of friction welding is considered a promising development. In the process, both workpieces can rotate, and one of them, while the other is fixed motionlessly.
Depending on the features of the technology, such welding is distinguished:
Friction with mixing.
Inertial.
Oscillatory.
With continuous drive.
Radial.
The orbital one.
In all cases, the friction force heats the metal to the melting point, which makes it possible to weld the parts.
The main advantages of this method are its high quality and strength of the resulting structure, low energy consumption in comparison with other methods. Welding in this way can be used to connect metals with different melting points. The process lends itself well to automation and is widely used for industrial purposes. Most often, such welding is used when working with rod structures and pipes of small diameter.
COLD
The use of this welding method involves connecting parts by pressure. An all-in-one attachment is formed when the elements are deformed and pressed into each other. The docking of parts becomes possible due to inter atomic bonds.
Cold welding is divided into three categories:
- suture
- butt
- point.
The technology is used to connect tires, pipes or wire. To obtain a high-quality and durable connection by cold welding, it is necessary to carefully prepare the joint site. The result also depends on the degree of compression and the nature of the impact — vibrational or static.
BY EXPLOSION
A detailed method of this welding method has not yet been developed, it is considered one of the rarest.
The explosion welding process begins with the installation of the welded work piece over the base metal. Then a detonator is installed on the welded part. The composition of granulotol, ammo nite, and rdx is most often used as explosives.
After the explosion, the shock wave directs the moving part at high speed — it hits the lower plate. The pressure at the contact point significantly exceeds the strength of metals, at which they pass into a liquid state. In a fraction of a second, the molecular connection of two metal parts with a common crystal lattice occurs. That is, strong welding is provided by synchronous plastic deformation of two elements. In this case, diffusion occurs only in the upper layers of the metal due to the low duration of the process.
Explosion welding is used for industrial purposes to connect dissimilar metals. It is used to produce large-sized blanks and parts, including bimetallic ones, and also apply a wear-resistant layer up to 45 mm thick on metal blanks.
ULTRASONIC
Ultrasonic welding is called the connection of parts using
ultrasonic waves. They create vibrations that bring the atoms of the work pieces
being welded together to a distance that allows them to connect into a common
structure. The high quality of the joints makes ultrasonic welding quite
popular, despite the high cost of equipment, in the production of small-sized
electrical circuits, the connection of metals with non-metals. Welding can be
applied point-by-point, contour or suture.
Before performing the ultrasonic connection of the parts, it is not necessary
to clean the surfaces beforehand, which saves time. When welding plastic
elements, an important role is played by the ability to control the temperature
range in order to avoid overheating. Ultrasound heats the surface in a fraction
of a second, without releasing harmful vapors and gases.
Cherepovets Metal Structures Plant has many years of experience in manufacturing bridge structures, canopies, decking, hydraulic structures and other metal structures. Welding and assembly takes place in compliance with technologies and quality standards. Our customers receive products on the agreed time and at favorable prices.
welder
But this is only one of the features, if we are talking about the production of welding works. In this material, we will tell you all the basics of welding production and tell you what skills a person who has chosen the specialty "welding production"should have. Who knows, maybe after reading it you will understand where to go and who to work with.
The content of the article
Organization of production
Technical equipment
Requirements for employees
Instead of a conclusion
ORGANIZATION OF PRODUCTION
Everything starts with the organization. You can hire professionals, purchase high-quality materials, install advanced welding equipment. But if the work is organized incorrectly, then all the advantages of qualified personnel and modern technology will not make any sense. So let's start with the organization.
So, welding can be carried out on two types of objects: it can be a construction and installation or repair facility outside the workshop, or it can be a stand-alone plant. It is believed that working at the factory is more favorable. Employees work in heated and ventilated workshops, they often have more technological equipment at their disposal.
welding production
In the process of work, the same welders can focus their attention on the quality of the resulting seam, on compliance with the welding technology, and so on. Unlike workers who perform repairs on the street, who may be hindered by unfavorable weather, insufficient maneuverability of their equipment and many other factors. However, professional craftsmen are always required at both sites.
There is also another difference. Often, employees are given individual tasks "on the road" and each of them is responsible for the result himself. At best, they will be assigned a foreman or another manager to monitor the progress of the work. At the factory, everything is much more complicated.
Firstly, welding within the workshop is more versatile. In the workshop, you can perform welding of any level of complexity, so that when performing particularly responsible work, an appropriate organization is necessary. First-level welders, chief welders, technologists and engineers work. All of them work according to the conveyor type, i.e. one employee performs the part of the work assigned to him and passes it to the next employee (from the welder to the main welder, from the main welder to the technologist, and so on).
As you understand, with such work, the human factor is inevitable. Also, with a large number of responsible persons, one of them may not perform the work efficiently enough, which will affect the entire production chain. Absolutely any problems can arise here. Starting from the fact that the welders incorrectly selected the welding mode, ending with quality control specialists who could not identify hidden defects and released a defective product to the market.
Also, in addition to the welding itself, a number of other works must be performed at the production site. For example, to develop a project for the production of welding works and, in general, to compile a detailed package of technical documentation. This requires not only knowledge, but also experience. Such work is entrusted to engineers. They are the ones who draw up drawings and technological maps, select the optimal welding mode and components for performing the work. All documentation is approved, checked by other specialists and only then gets into the hands of the main welder, who already gives instructions to the welders of the first level.
Read also: We read the designations of welding seams in the drawings
In the end, the organization of welding production, the development of documentation and other stages should lead to one result — the implementation of a high-quality and durable welded joint. Yes, so many nuances must be observed in order to simply release one product.
TECHNICAL EQUIPMENT
The basics of welding production do not end with the organization. After all, in addition to employees, there is also equipment at the workplace. The basic kit consists of an inverter, a transformer and a rectifier. Any production, even the smallest, should be equipped with such equipment.
welding machine
Such a set of equipment is due to its versatility. With the help of an inverter, even beginners will be able to properly light the arc and form a seam. With the help of a transformer, professional craftsmen will be able to generate any current value. And with the help of a rectifier, you can achieve a better connection.
If the production is more or less large, then welders will have more technological devices at their disposal. They may have special functions or even perform all the work, practically without requiring the presence of a person. This process is called automation. Let's look at this in more detail.
Mechanization and automation of welding production is a necessary measure if the plant intends to consistently produce a large number of products. Due to technological progress, we have been able to manufacture modern "smart" welding machines that simplify the manual work of the welder. The simplest example of automation is a semi-automatic welding machine that feeds wire into the welding zone using a special mechanism, instead of feeding it manually.
welding robot
Do not forget that the equipment and technology of welding production are always interrelated. And if the company plans to use modern welding technologies, then the equipment should be appropriate. In recent years, the mechanization of welding production has reached incredible heights. Fully robotic welding machines operating according to a pre-set program are increasingly found in factories. Such robots do not require the presence of a welder at the workplace at all.
REQUIREMENTS FOR EMPLOYEES
We should not forget about the employees. After all, the final result depends on their professionalism.
Let's start with the welders. This is the first level of welding production. In production, there can be from two people to infinity. At the same time, each welder has his own category and a special certificate, which indicates what type of work a particular welder can be admitted to. Usually, welders of the lowest category are trusted to perform the simplest operations that do not require much experience and special skills.
requirements for the welder
Next come the main welders. They are almost not engaged in welding, rather they control the work of a welding team consisting of first-level welders. The main welders give instructions regarding the necessary volumes of work, conduct briefings and so on. This is the second level of welding production.
They are followed by a technician or technologist. It belongs to the third level. The welding production technician monitors the entire welding process, controls all welders and is responsible for quality control of welded joints.
At the last fourth level there are engineers. Everything depends on them in general. If the engineer makes a mistake, it will "turn around" at all other levels and lead to marriage. Engineers make up all the documentation and decide how the welding will be performed. It is here that higher education is simply a necessity for welding production.
All employees, from welders to engineers, must pass a special exam from the NAKS every few years. It is also recommended to take permanent advanced training
courses in order not to miss the appearance of a new welding technology.
INSTEAD OF A CONCLUSION
Welding production is a complex process consisting of many people and stages. It is for this reason that it is important to know and understand the nuances of each employee's work in order to avoid mistakes. We wish you good luck in your work!
Comments
Post a Comment