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Microelectronics Clean Room Electrical and Computer Engineering

Microelectronics Clean Room Electrical and Computer Engineering. Orbital Tube Welder. Overview. General Information Safety Set-up Tube Preparation: facing, cleaning Operation Weld Schedules Weld Evaluation. Orbital Tube Welding. Gas Tungsten Arc Welding (GTAW) process Fusion Welding

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Microelectronics Clean Room Electrical and Computer Engineering

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  1. Microelectronics Clean RoomElectrical and Computer Engineering Orbital Tube Welder by Clayton Gatewood

  2. Overview • General Information • Safety • Set-up • Tube Preparation: facing, cleaning • Operation • Weld Schedules • Weld Evaluation by Clayton Gatewood

  3. Orbital Tube Welding • Gas Tungsten Arc Welding (GTAW) process • Fusion Welding • Model 8 Weld Head • Model 207A Power Supply • Argon Gas Cylinder • Facing Tool • ARC Machines, Inc. by Clayton Gatewood

  4. Gas Tungsten Arc Welding (GTAW) Process • Used to weld tubing that remains in-place while the tungsten electrode rotates around the target joint. • Material edges are heated by an arc and are fused together without a filler. by Clayton Gatewood

  5. Safety • Electricity Hazard: Shock, RF Starting, Pacemaker, Electric Storage Devices • Fire Hazard: Clothing, Sealed Containers, Welded Material Hot to Touch • Harmful UV Radiation (eyes and skin) • Toxic Fumes from Welding Stainless Steel, Hexavalent Chromium (lung cancer) • Air Displacement by Argon Gas • Factory Training Essential • Keep Hands and Fingers Clear • Compressed Gas Cylinders • Cleaning Chemicals by Clayton Gatewood

  6. Set-Up • Ensure Power is Off • Connections: Weld Head, Argon Gas, main power cord • Apply Argon (¼ turn) @ 20 psi by Clayton Gatewood

  7. Tube Preparation • Facing by Clayton Gatewood

  8. Welding Cleanliness • Materials to be welded must be free of grease, oil, rust, dirt, paint and other contaminants. • Dirty materials can result in porosity, discoloration, slag deposits, and generally poor quality welds. by Clayton Gatewood

  9. Operation • Align target joint with tungsten electrode • Connect Argon Purge Line and set for 5 psi (for ¼” OD tubing) • Select Weld Schedule • Ensure Power Supply is “Ready to Weld” • Press “Seq Start” • Prepurge, Weld, Downslope, Postpurge by Clayton Gatewood

  10. Weld Schedule Development • An orbital tube weld may be done in 4 or more levels. • It must include enough time for tie-in before the downslope. by Clayton Gatewood

  11. Weld Schedules • Pre / Post Purge Time • Up / Downslope • Rotation Direction • Rotation Delay • Pulse Mode • Rotation Mode • RPM (Rotor Travel Speed) • Level Times • Level Amps • Background Amps • Pulse Times by Clayton Gatewood

  12. Power Supply Sequence by Clayton Gatewood

  13. Sample Weld Schedules by Clayton Gatewood

  14. Weld Evaluation • 60 to 80% overlap on outer diameter • Poor rotation delay • Borescope to inspect inner diameter • Full penetration • No cracks, undercut, crevices, pits, or embedded or protruding material by Clayton Gatewood

  15. Weld Profiles by Clayton Gatewood

  16. Weld Defects by Clayton Gatewood

  17. Argon Purge and Oxygen • Left to Right = effect of increasing levels of oxygen in the argon purge by Clayton Gatewood

  18. Possibilities … by Clayton Gatewood

  19. Works Cited "MODEL 207 Operator Training Guidelines." Arc Machines, Inc.CD-ROM.Pacoima, CA: Arc Machines, Inc., 2007. Model 207 Microprocessor-Controlled Power Supply.1 Nov. 1996. Arc Machines, Inc.. 16 Oct. 2007.<http://www.arcmachines.com/prodMed/m207ps/m207ps.html>. by Clayton Gatewood

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