1. Non-Arc Welding Processes Resistive heating, chemical reactions, focused light and electrons, sound waves, and friction can also be used to join materials –Resistance welding –Oxy-Fuel Welding –Friction welding (&Solid State) –Laser and electron beam welding –Brazing and soldering –Plastics joining –Adhesive bonding Introduction

2. High Energy Density Processes Focus energy onto a small area Laser –CO 2 gas: fixed position –Nd-YAG crystal: fiber-optic delivery Electron Beam High Energy Density Processes

3. These processes focus the energy onto a small area Examples Laser - 0.004 inch weld on 1-inch thick stainless steel sheet Electron Beam - 0.030-inch weld width on 0.5 inch thick steel plate 0.1.1.2.1.T2.95.12

4. Laser Beam Welding (LBW) 0.1.1.2.1.T3.95.12 Laser

5. Laser Beam Welding (LBW) Keyhole welding Laser beam Plasma plume Molten material shielding gas nozzle (optional) workpiece motion Plasma keyhole High Energy Density Processes

6. Focusing the Beam Heat Surface Welding Cutting treatmentmodification High Energy Density Processes

7. Advantages Single pass weld penetration up to 3/4” in steel High Travel speed Materials need not be conductive No filler metal required Low heat input produces low distortion Does not require a vacuum 0.1.1.2.1.T4.95.12

8. Limitations High initial start-up costs Part fit-up and joint tracking are critical Not portable Metals such as copper and aluminum have high reflectivity and are difficult to laser weld High cooling rates may lead to materials problems High Energy Density Processes

9. Electron Beam Welding (EBW) 0.1.1.2.1.T6.95.12 EB Applications

10. Electron Beam Welding (EBW) Deepest single pass weld penetration of the fusion processes –14-inch-thick steel Fast travel speeds Low heat input welds produce low distortion High Energy Density Processes Advantages

11. Limitations High initial start-up cost Not portable Part size limited by size of vacuum chamber Produces x-rays Part fit-up is critical High cooling rates may lead to materials problems High Energy Density Processes