Bearing e.g. connecting rod bearing, mounting method for reciprocating piston engine of motor vehicle, involves fixedly connecting bearing housing parts by welding process, where welding of parts is performed in defined external region

The method involves dividing a bearing housing into bearing housing parts (4A, 4B) by fracture-splitting. Bearing half-shells (5) are inserted into the parts. The parts are combined to a bearing that encloses a shaft, and are fixedly connected with each other by a welding process such as resistance welding, ultrasonic welding or cold pressure welding process. The welding of the parts is performed in a defined external region. An insulation material is applied between the half-shells and/or the shaft and the housing parts before welding. The parts are pressed on each other during welding.

Exposure to fumes and gases during welding operations

The exposure to fumes and gases is one of the hazards associated with welding operations. Apart from research conducted on the mechanism of fume and gas formation and the relationship between fume formation rates and common welding parameters, little is known about the exposure process during welding. This research project aimed to identify the factors that influence exposure, develop an understanding of their role in the exposure process and through this understanding formulate strategies for the effective control of exposure during welding. To address these aims a literature review and an experimental program was conducted The literature review surveyed epidemiological, toxicological and exposure data. The experimental program involved three approaches, the first, an evaluation of the factors that influence exposure by assessing a metal inert gas/mild steel welding process in a workshop setting. The second approach involved the study of exposure in a controlled environment provided by a wind tunnel and simulated welding process. The final approach was to investigate workplace conditions through an assessment of exposure and control strategies in industry. The exposure to fumes and gases during welding is highly variable and frequently in excess of the health based exposure standards. Exposure is influenced by a number of a factors including the welding process, base material, arc time, electrode, arc current, arc voltage, arc length, electrode polarity, shield gas, wire-to-metal-work distance (metal inert gas), metal transfer mode, intensity of the UV radiation (ozone), the frequency of arc ignitions (ozone), thermal buoyancy generated by the arc process, ventilation (natural and mechanical), the welding environment, the position of the welder, the welders stance, helmet type, and helmet position. Exposure occurs as a result of three processes: the formation of contaminants at or around the arc region; their transport from the arc region, as influenced by the entry and thermal expansion of shield gases, the vigorous production of contaminants, thermal air currents produced by the heat of the arc process, and ventilation; and finally the entry of contaminants into the breathing zone of the welder, as influenced by the position of the welder, the welders stance, helmet type, and the helmet position. The control of exposure during welding can be achieved by several means: through the selection of welding parameters that generate low contaminant formation rates; through the limitation of arc time; and by isolating the breathing zone of the welder from the contaminant plume through the use of ventilation, welder position or the welding helmet as a physical barrier. Effective control is achieved by careful examination of the workplace, the selection of the most appropriate control option, and motivation of the workforce.

Weldability of duplex stainless steel

Duplex stainless steels (DSSs) have many advantages due to the unique structural combination of ferrite and austenite grains. The structural change of these materials is very complex during welding, and it deteriorates the functional properties. This research investigates different welding processes such as laser beam, resistance, tungsten inert gas, friction stir, submerged arc, and plasma arc weldings considering the research available in the literature. The welding mechanism, change of material structure, and control parameters have been analyzed for every welding process. This analysis clearly shows that DSS melts in all most all welding processes, but the thermal cycle and maximum heat input are different. This difference affects the resulting structure and functional properties of the weld significantly.

Weldability and machinability of duplex stainless steel

This chapter investigates two important processing methods, such as welding and machine of duplex stainless steel. The welding process welding generally degrades the properties of these materials by redistributing the phases during melting and solidification. On the other hand, the redistribution during machining mainly take place combined effect of stress, strain rate and temperature. Mechanism of machining process and several welding methods has been analysed in details. It was found that outcomes of welding processes depend on the welding methods. Most of the cases an appropriate annealing process can be used to restore the expected properties of the weld joints though the parameters of annealing process are different in different welding methods. Nonmetallic inclusions and the low carbon content of duplex stainless steel reduce the machinability of duplex stainless steel. SEM and optical microscopic details of the frozen cutting zone and chips revealed that the harder austenite phase dissipates in the advancement of the cutting tool, being effectively squeezed out of the softer ferrite phase. Abrasion and adhesion were the most common wear modes developed on the flank and rake faces. Adhesion wear being the most prevalent on the flank face, appeared to be initiated by built-up edge formation.