WeldingWelding is a fabrication process that joins materials, usually metals or thermoplastics, by using high heat to melt the parts together and allowing them to cool, causing fusion. Welding is distinct from lower temperature techniques such as brazing and soldering, which do not melt the base metal (parent metal). In addition to melting the base metal, a filler material is typically added to the joint to form a pool of molten material (the weld pool) that cools to form a joint that, based on weld configuration (butt, full penetration, fillet, etc.
Arc weldingArc welding is a welding process that is used to join metal to metal by using electricity to create enough heat to melt metal, and the melted metals, when cool, result in a binding of the metals. It is a type of welding that uses a welding power supply to create an electric arc between a metal stick ("electrode") and the base material to melt the metals at the point of contact. Arc welding power supplies can deliver either direct (DC) or alternating (AC) current to the work, while consumable or non-consumable electrodes are used.
Gas tungsten arc weldingGas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG) welding, is an arc welding process that uses a non-consumable tungsten electrode to produce the weld. The weld area and electrode are protected from oxidation or other atmospheric contamination by an inert shielding gas (argon or helium). A filler metal is normally used, though some welds, known as autogenous welds, or fusion welds do not require it. When helium is used, this is known as heliarc welding.
Residual stressIn materials science and solid mechanics, residual stresses are stresses that remain in a solid material after the original cause of the stresses has been removed. Residual stress may be desirable or undesirable. For example, laser peening imparts deep beneficial compressive residual stresses into metal components such as turbine engine fan blades, and it is used in toughened glass to allow for large, thin, crack- and scratch-resistant glass displays on smartphones.
Gas metal arc weldingGas metal arc welding (GMAW), sometimes referred to by its subtypes metal inert gas (MIG) and metal active gas (MAG) is a welding process in which an electric arc forms between a consumable MIG wire electrode and the workpiece metal(s), which heats the workpiece metal(s), causing them to fuse (melt and join). Along with the wire electrode, a shielding gas feeds through the welding gun, which shields the process from atmospheric contamination. The process can be semi-automatic or automatic.
Fatigue (material)In materials science, fatigue is the initiation and propagation of cracks in a material due to cyclic loading. Once a fatigue crack has initiated, it grows a small amount with each loading cycle, typically producing striations on some parts of the fracture surface. The crack will continue to grow until it reaches a critical size, which occurs when the stress intensity factor of the crack exceeds the fracture toughness of the material, producing rapid propagation and typically complete fracture of the structure.
Stress (mechanics)In continuum mechanics, stress is a physical quantity that describes forces present during deformation. An object being pulled apart, such as a stretched elastic band, is subject to tensile stress and may undergo elongation. An object being pushed together, such as a crumpled sponge, is subject to compressive stress and may undergo shortening. The greater the force and the smaller the cross-sectional area of the body on which it acts, the greater the stress. Stress has units of force per area, such as newtons per square meter (N/m2) or pascal (Pa).
Shielded metal arc weldingShielded metal arc welding (SMAW), also known as manual metal arc welding (MMA or MMAW), flux shielded arc welding or informally as stick welding, is a manual arc welding process that uses a consumable electrode covered with a flux to lay the weld. An electric current, in the form of either alternating current or direct current from a welding power supply, is used to form an electric arc between the electrode and the metals to be joined. The workpiece and the electrode melts forming a pool of molten metal (weld pool) that cools to form a joint.
ConvectionConvection is single or multiphase fluid flow that occurs spontaneously due to the combined effects of material property heterogeneity and body forces on a fluid, most commonly density and gravity (see buoyancy). When the cause of the convection is unspecified, convection due to the effects of thermal expansion and buoyancy can be assumed. Convection may also take place in soft solids or mixtures where particles can flow. Convective flow may be transient (such as when a multiphase mixture of oil and water separates) or steady state (see Convection cell).
Plasma arc weldingPlasma arc welding (PAW) is an arc welding process similar to gas tungsten arc welding (GTAW). The electric arc is formed between an electrode (which is usually but not always made of sintered tungsten) and the workpiece. The key difference from GTAW is that in PAW, the electrode is positioned within the body of the torch, so the plasma arc is separated from the shielding gas envelope. The plasma is then forced through a fine-bore copper nozzle which constricts the arc and the plasma exits the orifice at high velocities (approaching the speed of sound) and a temperature approaching 28,000 °C (50,000 °F) or higher.
Robot weldingRobot welding is the use of mechanized programmable tools (robots), which completely automate a welding process by both performing the weld and handling the part. Processes such as gas metal arc welding, while often automated, are not necessarily equivalent to robot welding, since a human operator sometimes prepares the materials to be welded. Robot welding is commonly used for resistance spot welding and arc welding in high production applications, such as the automotive industry.
Latent heatLatent heat (also known as latent energy or heat of transformation) is energy released or absorbed, by a body or a thermodynamic system, during a constant-temperature process—usually a first-order phase transition. Latent heat can be understood as hidden energy which is supplied or extracted to change the state of a substance (for example, to melt or vaporize it) without changing its temperature or pressure. This includes the latent heat of fusion (solid to liquid), the latent heat of vaporization (liquid to gas) and the latent heat of sublimation (solid to gas).
Forced convectionForced convection is a mechanism, or type of transport, in which fluid motion is generated by an external source (like a pump, fan, suction device, etc.). Alongside natural convection, thermal radiation, and thermal conduction it is one of the methods of heat transfer and allows significant amounts of heat energy to be transported very efficiently. This mechanism is found very commonly in everyday life, including central heating, air conditioning, steam turbines, and in many other machines.
Thermal conductivityThe thermal conductivity of a material is a measure of its ability to conduct heat. It is commonly denoted by , , or . Heat transfer occurs at a lower rate in materials of low thermal conductivity than in materials of high thermal conductivity. For instance, metals typically have high thermal conductivity and are very efficient at conducting heat, while the opposite is true for insulating materials like mineral wool or Styrofoam.
Convection cellIn the field of fluid dynamics, a convection cell is the phenomenon that occurs when density differences exist within a body of liquid or gas. These density differences result in rising and/or falling currents, which are the key characteristics of a convection cell. When a volume of fluid is heated, it expands and becomes less dense and thus more buoyant than the surrounding fluid. The colder, denser part of the fluid descends to settle below the warmer, less-dense fluid, and this causes the warmer fluid to rise.
Cauchy stress tensorIn continuum mechanics, the Cauchy stress tensor , true stress tensor, or simply called the stress tensor is a second order tensor named after Augustin-Louis Cauchy. The tensor consists of nine components that completely define the state of stress at a point inside a material in the deformed state, placement, or configuration. The tensor relates a unit-length direction vector e to the traction vector T(e) across an imaginary surface perpendicular to e: or, The SI units of both stress tensor and traction vector are N/m2, corresponding to the stress scalar.
Combined forced and natural convectionIn fluid thermodynamics, combined forced convection and natural convection, or mixed convection, occurs when natural convection and forced convection mechanisms act together to transfer heat. This is also defined as situations where both pressure forces and buoyant forces interact. How much each form of convection contributes to the heat transfer is largely determined by the flow, temperature, geometry, and orientation. The nature of the fluid is also influential, since the Grashof number increases in a fluid as temperature increases, but is maximized at some point for a gas.
HeatIn thermodynamics, heat is the thermal energy transferred between systems due to a temperature difference. In colloquial use, heat sometimes refers to thermal energy itself. An example of formal vs. informal usage may be obtained from the right-hand photo, in which the metal bar is "conducting heat" from its hot end to its cold end, but if the metal bar is considered a thermodynamic system, then the energy flowing within the metal bar is called internal energy, not heat.
Convection (heat transfer)Convection (or convective heat transfer) is the transfer of heat from one place to another due to the movement of fluid. Although often discussed as a distinct method of heat transfer, convective heat transfer involves the combined processes of conduction (heat diffusion) and advection (heat transfer by bulk fluid flow). Convection is usually the dominant form of heat transfer in liquids and gases. Note that this definition of convection is only applicable in Heat transfer and thermodynamic contexts.
Thermal insulationThermal insulation is the reduction of heat transfer (i.e., the transfer of thermal energy between objects of differing temperature) between objects in thermal contact or in range of radiative influence. Thermal insulation can be achieved with specially engineered methods or processes, as well as with suitable object shapes and materials. Heat flow is an inevitable consequence of contact between objects of different temperature.
