Joining and Thermal Cutting Technology

Holders: Assoc. Prof. Klobčar Damjan

Subject description

Basic prerequisites:

Basic knowledge of material science or material behaviour, Electrotechnics, Physics and Chemistry (all from B.Sc. level) 

Content (Syllabus outline):

Introduction: Course purpose and content, necessary knowledge, using the knowledge in the practice and competences.

Basic concepts and illustrations: Welds illustrated, standards, energy sources, states of matter present in material joining, warming up metal, dilatations, melting, cooling, solidification, motion of the melt during welding, the properties of liquid metal like surface tension, wettability, capillarity, viscosity and diffusion.

Fusion welding: Arc welding in different shielding media, welding with a coated electrode, welding with a cored electrode, submerged arc welding, welding with the shielding of active and neutral gases, plasma welding, high energy density welding (energy beam) welding methods like laser welding and electron beam welding, stud welding and magnetic arc control welding. Oxy-fuel welding and other gas techniques. Hybrid fusion welding with two different processes. Electroslag welding.

Solid-state welding: Welding with mechanical energy, welding using different energies such as ultrasound, mechanical friction welding, welding by vibration, forge welding, welding with trimming, friction stir welding and similar.

Welding with chemical energy: Welding using the flame created by chemical reaction, aluminothermic welding providing both the filler material and heat by chemical reaction, and explosion welding where the mechanical force for welding is created by chemical reaction. 

Electric resistance welding: spot, projection, seam, butt welding with pressure, butt flash welding, high-frequency resistance welding, resistance soldering and resistance adhesive bonding.

Soldering and brazing: Soldering and brazing with fluxes, high-temperature brazing under shielding gas and in vacuum. Energy sources for soldering and brazing, fluxes, joint types and practical applications. Soldering and brazing different materials.

Other joining processes: Mechanical joining by riveting, self-piercing riveting, beading, clinching. Flame, plasma, electric arc, laser, cold and high-speed spraying. Adhesive bonding of metal materials.

Material weldability: Theoretical calculation or evaluation, experimental determination for very different materials and for different weld joints.

Thermal cutting of materials: Energy sources for cutting, chemical-metallurgical processes occurring during cutting, selecting the processes for concrete practical cases. Thermal cutting by heating the material to ignition, melting and sublimation. Special cutting processes. 

Objectives and competences:

The students will obtain the ability to use the assimilated general knowledge from the welding profession in the practice and to search for new knowledge from different sources, the ability to work autonomously and take the responsibility, the ability to work in a team, make decisions and lead a group of welding professionals, will behave ethically and will be able to judge their co-workers critically and fairly, will be able to manage their time, will be able to communicate orally and in writing, and will know the professional terminology in the field of joining of materials in Slovenian, English or German language. The students will make independent decisions about the selection of joining technology for concrete practical cases, about the selection of thermal cutting technology and about the selection of other joining techniques and technologies. They will know the profession, described in detail below.

Intended learning outcomes:

Knowledge and understanding

Upon passing the exam, the students must distinguish welding, soldering and brazing and adhesive bonding from the physical and chemical points of view, from the metallurgical-physical point of view they must know the behaviour of most metals when heated to the melting point and when cooled to the room temperature at different rates, they must know the fusion welding processes and the solid-state welding processes, and they must also know the weldability of the most important metal materials. The students must know the measures used to improve the weldability before, during and after welding. They must know the properties of electric arc, plasma, electron beam and laser, as well as the applications thereof. The students must distinguish the arc welding processes and their distinctive properties. The students must know the type, form and purpose of different filler materials. They must also know the basic characteristics of shielding gases used in welding.

Usage

Knowing the welding, mechanical joining, spraying, cutting, soldering and brazing processes. Distinguishing the individual processes and technology planning for practically any useful material. Selecting the process and technology for steels and non-ferrous metals.

Reflection

Critical evaluation of welding technologies, soldering and brazing technologies, selecting the welding, adhesive bonding, spraying and mechanical joining processes. Critical evaluation of thermal cutting with alternative cutting technologies.

Transferrable skills – related to more than one course

The subject matter contains all knowledge of physics, taught in the first years of study at the Faculty of mechanical engineering. There is a lot of experimental work where the students have to use practical knowledge and skills, as well as their knowledge of statistics and random processes.

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