Manufacturing Processes

9.

Joining and Assembly Processes

9.1.

Welding Fundamentals

9.1.1.

Weldability of Materials

9.1.1.1.

9.1.1.2.

9.1.1.3.

Stainless Steels

9.1.1.4.

Aluminum Alloys

9.1.1.5.

Other Nonferrous Metals

9.1.2.

Weld Joint Types

9.1.2.1.

9.1.2.2.

9.1.2.3.

9.1.2.4.

9.1.2.5.

9.1.3.

9.1.3.1.

9.1.3.2.

9.1.3.3.

Plug and Slot Welds

9.1.3.4.

Surfacing Welds

9.1.4.

Welding Metallurgy

9.1.4.1.

Heat Affected Zone

9.1.4.2.

Weld Metal Structure

9.1.4.3.

Residual Stresses

9.1.4.4.

Distortion Control

9.1.5.

Welding Defects

9.1.5.1.

9.1.5.2.

9.1.5.3.

9.1.5.4.

Lack of Penetration

9.1.5.5.

9.1.5.6.

9.1.6.

Welding Symbols and Standards

9.1.6.1.

AWS Welding Symbols

9.1.6.2.

Welding Procedure Specifications

9.1.6.3.

Welder Qualification

9.2.

Arc Welding Processes

9.2.1.

Shielded Metal Arc Welding

9.2.1.1.

Equipment Components

9.2.1.2.

Electrode Classification

9.2.1.3.

Welding Techniques

9.2.2.

Gas Metal Arc Welding

9.2.2.1.

Equipment Setup

9.2.2.2.

Shielding Gases

9.2.2.3.

Wire Electrodes

9.2.2.4.

9.2.2.4.1.

Short Circuit Transfer

9.2.2.4.2.

Globular Transfer

9.2.2.4.3.

9.2.2.4.4.

9.2.3.

Gas Tungsten Arc Welding

9.2.3.1.

Equipment Components

9.2.3.2.

Tungsten Electrodes

9.2.3.3.

Shielding Gases

9.2.3.4.

Filler Materials

9.2.3.5.

AC vs DC Welding

9.2.4.

Flux Cored Arc Welding

9.2.4.1.

Self-Shielded FCAW

9.2.4.2.

Gas Shielded FCAW

9.2.4.3.

Flux Cored Wires

9.2.5.

Submerged Arc Welding

9.2.5.1.

Equipment Setup

9.2.5.2.

9.2.5.3.

Wire Electrodes

9.2.5.4.

Process Variations

9.3.

Resistance Welding

9.3.1.

9.3.1.1.

Process Parameters

9.3.1.2.

Electrode Design

9.3.1.3.

Weld Quality Assessment

9.3.2.

9.3.2.1.

Continuous Seam Welding

9.3.2.2.

Intermittent Seam Welding

9.3.3.

Projection Welding

9.3.4.

9.3.5.

9.3.6.

Resistance Welding Equipment

9.3.6.1.

Welding Transformers

9.3.6.2.

Control Systems

9.3.6.3.

Electrodes and Tooling

9.4.

Solid State Welding

9.4.1.

Friction Welding

9.4.1.1.

Rotary Friction Welding

9.4.1.2.

Linear Friction Welding

9.4.1.3.

Friction Stir Welding

9.4.2.

Ultrasonic Welding

9.4.2.1.

Process Principles

9.4.2.2.

Equipment Components

9.4.3.

Diffusion Bonding

9.4.3.1.

Process Parameters

9.4.3.2.

Surface Preparation

9.4.4.

Explosion Welding

9.4.5.

9.4.6.

9.5.

Other Welding Processes

9.5.1.

Oxyfuel Gas Welding

9.5.1.1.

Equipment Setup

9.5.1.2.

9.5.1.3.

Welding Techniques

9.5.2.

Plasma Arc Welding

9.5.2.1.

Transferred Arc Mode

9.5.2.2.

Non-Transferred Arc Mode

9.5.3.

Electron Beam Welding

9.5.3.1.

9.5.3.2.

9.5.4.

9.5.4.1.

9.5.4.2.

9.5.4.3.

9.6.

Brazing and Soldering

9.6.1.

Brazing Processes

9.6.1.1.

9.6.1.2.

Furnace Brazing

9.6.1.3.

Induction Brazing

9.6.1.4.

Resistance Brazing

9.6.1.5.

9.6.2.

Brazing Filler Materials

9.6.2.1.

Silver Brazing Alloys

9.6.2.2.

Copper-Phosphorus Alloys

9.6.2.3.

Aluminum Brazing Alloys

9.6.3.

Soldering Processes

9.6.3.1.

9.6.3.2.

9.6.3.3.

Reflow Soldering

9.6.4.

Soldering Materials

9.6.4.1.

Lead-Tin Solders

9.6.4.2.

Lead-Free Solders

9.6.4.3.

9.6.5.

Joint Design for Brazing and Soldering

9.6.5.1.

Clearance Requirements

9.6.5.2.

Joint Configurations

9.6.5.3.

Filler Metal Flow

9.7.

Adhesive Bonding

9.7.1.

Types of Adhesives

9.7.1.1.

Structural Adhesives

9.7.1.1.1.

9.7.1.1.2.

9.7.1.1.3.

9.7.1.2.

Non-Structural Adhesives

9.7.1.2.1.

9.7.1.2.2.

Pressure Sensitive Adhesives

9.7.2.

Surface Preparation

9.7.2.1.

Cleaning Methods

9.7.2.2.

Surface Treatments

9.7.2.3.

Primers and Coupling Agents

9.7.3.

Bonding Process

9.7.3.1.

Adhesive Application

9.7.3.2.

Assembly Methods

9.7.3.3.

Curing Conditions

9.7.4.

9.7.4.1.

Stress Distribution

9.7.4.2.

Joint Configurations

9.7.4.3.

Environmental Considerations

9.8.

Mechanical Fastening

9.8.1.

Threaded Fasteners

9.8.1.1.

9.8.1.1.1.

9.8.1.1.2.

Self-Tapping Screws

9.8.1.1.3.

9.8.1.2.

9.8.1.2.1.

9.8.1.2.2.

Socket Head Bolts

9.8.1.2.3.

Specialty Bolts

9.8.1.3.

Thread Standards

9.8.1.3.1.

9.8.1.3.2.

Unified Thread Standard

9.8.2.

Non-Threaded Fasteners

9.8.2.1.

9.8.2.1.1.

9.8.2.1.2.

9.8.2.1.3.

9.8.2.2.

9.8.2.2.1.

9.8.2.2.2.

9.8.2.2.3.

9.8.2.3.

Retaining Rings

9.8.2.4.

Washers and Spacers

9.8.3.

Permanent Joining Methods

9.8.3.1.

9.8.3.2.

9.8.3.3.

Adhesive Bonding of Fasteners

9.8.4.

Fastener Selection Criteria

9.8.4.1.

Load Requirements

9.8.4.2.

Environmental Conditions

9.8.4.3.

Material Compatibility

9.8.4.4.

Cost Considerations

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