for this lecture I'm going to be talking a little bit about welding processes and weld callouts and then we're going to talk about surface finish and surface forness so uh here are just a list of different kinds of welding processes um and I got some pictures of them so you can see looks like here we got some underwater welding this would be like a hyperbaric situation um I got some brazing down here so um brazing is when you use filler material and a torch to join two materials that temperature of brazing is a lot lower than traditional welding um soldering and uh brazing are lower temperature joining processes and then up here it looks like I've got a gas metal Arc weld or mig weld there's a few types of welds I think the most common ones covered in the weld in classic CPO are gas metal Arc welds or Mig welds and gas tungsten Arc welds or TIG welds gas metal Arc welds or or Mig which stands for metal inert gas um uses an inert gas and a constant voltage and direct current to create the weld with gas tungsten arc welding or TIG welding this is used to join thick sections of stainless steel or other nonf feris metals and it uses a fixed consumable tugon electrode uh to produce the weld it's actually much more time consuming than metal inert gas welding okay and then as I mentioned earlier there's brazing soldering they're done at lower temperatures so there's really a type of welding for every application okay welding drawings so this is a weldment is just a part that's welded together so this is a drawing of a truss which is going to be welded together and then you can see there's lots of weld call outs on here we're doing a weldment in one of our Labs coming up so um so we'll need to know how to do proper weld call outs for that detail drawing we have many different kinds of joints a butt joint is when uh we have two pieces butted up next to each other hence the name a corner joint obviously produces a corner like this a t joint is shown above and then a lap joint is when two materials overlap in an edge joint the metal surfaces are placed together so that the edges are even and then you would weld that portion right there these are the common welds applied to butt Corner te lap and Edge joints um for a butt joint um you could use a backing or you can do any of these uh types here typically for a corner joint you use a fillet Weld and then if you have a lap joint a plug or slot weld Works uh well so for a plug or slot you would machine out in the top piece here you're going to machine out this slot and then will weld through that slot you could also do it with a plug by by drilling holes in the top material and then using that to weld down okay when it comes to butt joint we have many different options I'm going to zoom in here so you can see um the material for a square joint here is not machined at all it's just straight um you get less penetration with a square joint than you do with maybe a v joint because you can see I have to machine down the surfaces of the V joint so I get more contact with the welding surface so a v joint is stronger than a square joint and a bevel weld right you would only have to machine one side so that's going to be stronger than a square joint is up well but not as strong as a v joint okay a U joint is stronger than the V it has a lot more surface area but it's harder to machine um and if you machine both sides again it's going to be more expensive A J weld is where we have machine down only one side of that weld so right the more complicated the Machining like for example the U is going to be the more expensive weld type the J is going to be more expensive than the bevel right cuz that curve is is harder to make than a slant so it says here remember plug the bevel you J weld require Groove fabrication and therefore more costly um these welds should be dictated by load conditions or the necessity of having the weld flush with the surface so you're going to be have an easier time if you zoom in on the V weld here grinding down the top of this weld to make it flat if you have more penetration inside the weld so um for a square joint you may not want to grind that down but for V or bevel weld or u j any of the other welds you could do that all right let's talk about weld call outs so I this is a lot of information on the slide and I expect that this is just a slide you can come back to to refer to as you're trying to do your weld call outs so um the flag here in indicates a field weld which means the the weld will be created on site and not you know wherever the part was machine then there's a bunch of information here which I think will make more sense obviously you can come look over here and see s is the weld size you would put your weld symbol next and then follow right other side it says other side it means it's talking about the other side of the weld so I'll show you that in an example um and then there's right the F would be your finish if you have one right you don't have to have something in every single location here right so this is just everything you could put on here but generally you don't use every single piece of information here also one last thing to note on this slide before I look at some examples is that this one this little circle here indicates an allaround weld which just means the weld goes all the way around the surface that you're pointing to okay um so here I have have an example of different fillet welds that are called out so I'll go back to the previous slide just to kind of show you but remember if we're looking at this one right this is what this equals right this is what that that call out means so if you look back here it says Arrow side right there so if I put my call out on the bottom of the leader I'm talking about the side I'm pointing to if I put my call out on top of the leader I'm talking about the other side right as you can see up here on that W Calla talking about the other side okay so these are fillet W call outs let's look at some other ones if I do both top and bottom you'll notice the one on the bottom of the leader is talking about the side I'm pointing to and that's going to be a quarter inch fillet Weld and this 31 is talking about the other side so you'll see that that's calling out the other side weld sizes are only carried out to two decimal places you may also use fractional uh sizes as well and then in metric you would use whole numbers okay so um here are some skip welds these ones are right on top of each other so you can see that the symbols for the fillets are stacked on top of each other just like that so now the welds are stacked on top of each other just like that okay they are two wide so that's your length of your Weld and this is your pitch of your weld the distance between welds all right looking at the other example um I have staggered welds here and so you can see I staggered the symbols here to get those staggered welds and then I have um 3 mm width of the wels the size of the wels and then they are 10 apart so again that's the pitch so typical Groove weld symbol so this equals this okay so it's a half inch deep bevel weld we're giving it an e in gap and a 60° angle okay this one gets a little more comp complicated so on the Arrow side that's going on this side okay the lower part goes on the Arrow side so you can see that the 7 over 8 is on the Arrow side and it's a 45° and we're leaving an E8 inch gap on that on the remaining weld we specify the depth is a/4 inch and again also 45° right and then I've got a u weld that has no distance right zero we're going to butt them up now next to each other and a 30° angle and it penetrates 3/4 deep and again I put it on the top of the lader so that means I'm referring to the other side and then um these are equal so that's how this slide right so you can look at many examples of how you can call out different types of welds um whether it's a v weld that goes all the way through or full penetration or whether the V weld only goes down a/4 inch so you can see full penetration versus only going down a quar inch okay and then here I've got two different V welds um one on each side both 20 mm deep you can look through these and hopefully they make sense you can always refer back to this upper slide here um to figure out what each piece of information uh means okay weld surface Contour so we're going to have a concave weld right we might indicate that with this concavity symbol on a flush weld we' indicate it with flush and then convex uh here now um you may want to specify how you're going to get it to be concave flush or convex and so your options are listed right here right you got chipping grinding hammering Machining and rolling as you can see I want this to be concave but I'm going to grind that down this one I'm going to use I'm going a machine it flush right so um so that's where you would specify the method for achieving your surface Contour so you're just going to want to be uh careful when you're grinding offer machine to achieve your surface Contour because um it it can create minor imperfections in that surface and increased stress concentrations meaning that your part May prematurely fail okay so um you want to be aware that that can happen and then kind of design around that wild testing there's non-destructive testing and there is destructive testing so destructive testing would be to break the part um so in this case I believe they cut this part in half and they looked at the penetration of the weld uh after it was cut and you can see that you're going to get more penetration right through here and then on this side you have less penetration um of on the upper side here um so that's how they can kind of see if the welding process is working well so that would be a destructive test to break it and then inspect the weld um you can do uh radiographic testing or x-rays um and you can look for defects and I actually did this when I worked for vandenbberg Air Force Spas they have a lot of pressure pressure vessels and piping that we would um well mostly the pressure vessels we would x-ray them and we'd look for defects and we would see um you know a flaw and we'd try to estimate as large like the largest scenario that that flaw could be and we do flaw propagation analyses to see whether um this was going to become an issue um and how many life cycles do we have left if we we find a flaw um and then there's ultrasonic testing so this would be an ultrasonic testing they're taking a little ultrasonic device and they're testing different locations on it looks like a piece of piping to see if there are any flaws uh in those regions thing I want to talk about is a Surface finish and we've done a little bit of surface finish call out in our lab so right in our notes section of our lab we always tend to put a little check mark with some sort of number here 63 is generally what we might use on an inch part and we write FAO right this 63 is in micro Ines and it is the rough height so uh you can look here and see the roughness height is right here so that's our roughness height also just called the roughness and it's the distance or the height between small surface irregularities um so we're using a 63 microinch finish and the FAO here is a finish all over means finished all over unless specified otherwise right in our notes was unless otherwise specified this has a 63 microinch surface finish so we call this a surface finish we could also call out a surface texture so an example of that would be right here on this slide that's our surface texture call out and you would do that on a specific surface you wouldn't say do this on the whole part because that would be very expensive to manufacture this is a very precise smooth called out uh surface texture and so the symbol with the line over the top is the surface texture symbol where we're just using the surface finish symbol okay so some things to note about this is um we're always going to need to specify the roughness height or just the roughness so we we've done that already so that's very important and I have a table of different roughnesses that you can look at to see what uh what methods can we get each of these surface rences with can we get this with Machining can we get this with um with casting like what is possible with a specific fabrication method so um up here often we actually put the um method the way that it's made so if it's Machining you would put Machining here grinding um but you could also put the waviness height and the waviness width so the waviness height is the total height change so if you look here the waviness height I'll do it in red on the picture is the total height change over the Wess width so the Wess width would be between High Point and high point or low point to low Point okay so that's what would go on the top line there you may also specify the direction the lay Direction so in this case we're saying we would like these cuts to be made perpendicular to the surface we're looking at so you can see if we're pointing at the surface here looking up in this picture here you can see that we're going perpendicular with our cut Direction that's our l Direction shown right there perpendicular to what we have there okay and then we have our roughness width it's the width between our periodic um between our Cuts right so we have our roughness height and our roughness width and so it's different right but we're we're giving a Max uh tolerance there okay and then lastly you have your roughness minus your width cut off and that roughness minus width cut off is the greatest space ing of surface that we can use to include in the um measurement of the average roughness height so it's kind of our sample size in determining that average roughness height so this is a very detailed surface finish or Surface texture call out and so it's just here as an example of like everything we could possibly uh call out um but typically you know it's not this detailed so something that might require a lot of um detail in the surface texture call out might be like bearing surfaces where they have to be very very smooth and precise in order for um to have have smooth operation of whatever the bearing is attached to so let's just look at surface finish symbols so you're most familiar hopefully with this upper symbol it's just a basic surface texture symbol and it can be used produced by any method so that could be Machining that could be grinding that could be um you know flame cutting um any method can create this and um so that's the one we typically use um if you have the line over the top for the material removed by Machining that's what that line over the top means it means that it has to be machined uh to get this surface texture um if material removal is prohibited we use this uh symbol over here and that can be um a process like casting forging um right you can read through the rest of them but common ones might be casting forging hot finishing okay and then the last one we just talked about is the surface texture symbol it has the line across the top here um and I know a lot of you in solw Works tend to still have that line across the top um but you can avoid having that line by not typing in the surface finish symbol in Sol Works typing it in the text box next to the symbol uh if you want it to say FAO you need to type it in the text box next to the surface finish symbol and so that line is where all of the surface finish information goes below okay um lay directions that you can pick um so I think this slide is fairly self-explanatory you can have a horizontal lay um you can have or parallel to the direction you're calling it out it can be perpendicular to the direction you're calling out can use concentric circles you can use um an an angular lay in both directions with the X symbol multi-directional radial um so you can read through these uh different types of lay directions okay the methods that we can uh we use to get the surface finished so if you look here and I apologize if this is a slightly blurry slide but um a 63 micro in surface finish is this side here and it's going to be this column so any box in this column means that this surface finish can be created with that method so it's less common right the these ones with the Slants in them is a less common way of doing it but you can get a 63 micro in finish with sawing planing um drilling right chemical Mill uh and then it's more common right Milling is where it starts to be like a common application and then right on the lower end of the spectrum um you have that as well so uh we typically do a 63 um so but common machine finishes are going to be a 63 or a 32 so we can be in this column as well and that would be a common Machining app application those two um anything past a 32 microinch finish is going to be much more difficult to get so you'd have to go into grinding and honing in order to get right a better machine finish after that you get Electro polish and um lapping um in order to do a better job with those hopefully this shows you the fabrication methods you can use to create different surface finishes um and keep in mind that when you're going from one column to the next so when you're going from 32 uh to 16 it is not a linear Step in Time or a linear step in cost the further down this way you go on this table the more and more expensive it gets and it's not a linear expense rate it's going to get much and much more expensive as you go that way so if you that's kind of what this last slide says parts do not go from flame cutting to lapping in one step the smooth finish requires multiple processes and each process takes more and more time and increases the part uh cost so it's not a linear increase hopefully that makes sense and um you're able to do a surface finish call out on your Labs so if you have any questions feel free to reach out