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Read and translate the text.
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Text B
Tin-Lead Solder
The largest portion of all solders in use is solders of the tin-lead alloy group. They have good corrosion resistance and can be used for joining most metals. Their compatibility with soldering processes, cleaning, and most types of flux is excellent.
In describing solders, it is the custom of industry to state the tin content first; for example, a 40/60 solder means to have 40% tin and 60% lead.
Tin-lead alloy melting characteristics depend upon the ratio of tin to lead. The higher the tin content, the lower the melting temperature. Tin also increases the wetting ability and lowers the cracking potential of the solder.
100% lead melts at 327,22°C and 100% tin melts at 232,22°C. Solders that contain 19.5% to 97.5% tin remain a solid until they exceed 182,22°C. The eutectic composition for tin-lead solder is about 63% tin and 37% lead. (“Eutectic” means the point in an alloy system that all the parts melt at the same temperature.) A 63/37 solder becomes completely liquid at 182,78°C. Other compositions do not. Instead, they remain in the pasty stage until the temperature increases to the melting point of the other alloy. For instance, 50/50 solder has a solid temperature of 182,78°C and a liquid temperature range of 213,89°C. The pasty temperature range is 13,33°C – the difference between the solid and the liquid.
Solders with lower tin content are less expensive and primarily used for sheet metal products and other high-volume solder requirements. High tin solders are extensively used in electrical work. Solders with 60% tin or more are called fine solders and are used in instrument soldering where temperatures are critical.
Tin-Antimony-Lead Solder
Antimony is added to a tin-lead solder as a substitute for some of the tin. The antimony, up to 6%, increases the strength and mechanical properties of the solder. A word of caution, solders having a high antimony content should not be used on aluminum, zinc, or zinc-coated materials.
They form an intermetallic compound of zinc and anti-mony that causes the solder to become very brittle.
Tin-Zinc Solder
Several tin-zinc solders have come into use for the joining of aluminum alloys.
The 91/9 and 60/40 tin-zinc solders are for higher tem-perature ranges (above 300°F), and the 80/20 and 70/30 tin-zinc alloys are normally used as precoating solders.
Lead-Silver Solder
Lead-silver solders are useful where strength at moderately high temperatures is required. The reason lead by itself cannot be used is that it does not normally wet steel, cast iron, or copper and its alloys. Adding silver to lead results in alloys that more readily wet steel and copper. Flow characteristics for straight lead-silver solders are rather poor, and these solders are susceptible to humidity and corrosion during storage. The wetting and flow characteristics can be enhanced as well as an increased resistance to corrosion by introducing a tin content of 1%.
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Lead-silver solders require higher soldering temperatures and special fluxing techniques. The use of a zinc-chloride base flux or uncoated metals is recommended, because rosin fluxes decompose rapidly at high temperatures.
Tin-Antimony Solder
Tin-antimony solders are used for refrigeration work or for joining copper to cast-iron joints. The most common one is the 95/5 solder.
Tin-Silver Solder
Tin-silver solder (96/4) is used for food or beverage containers that must be cadmium and lead-free. It also can be used as a replacement for tin-antimony solder (95/5) for refrigeration work.
UNIT 4
Read and translate the text.
Text A
Electron Beam Welding
Electron beam welding (EBW) is a welding process which produces coalescence of metals with the heat obtained from a concentrated beam composed primarily of high-velocity electrons impinging upon the surfaces to be joined. Heat is generated in the workpiece as it is bombarded by a dense stream of high-velocity electrons. Virtually all of the kinetic energy the energy of motion-of the electrons is transformed into heat upon impact.
The electron beam welding process had its inception in the 1950s in the nuclear field. There were many requirements to weld refractory and reactive metals. These metals, because of their affinity for oxygen and nitrogen of the air, are very difficult to weld.
The original work was done in a high vacuum. The process utilized an electron gun similar to that used in an X-ray tube. In an X-ray tube the beam of electrons is focused on a target of either tungsten or molybdenum which gives off X-rays. The target becomes extremely hot and must be water-cooled. In welding, the target is the base metal which absorbs the heat to bring it to the molten stage. In electron beam welding, X-rays may be produced if the electrical potential is sufficiently high.
As developments continued, two basic designs evolved: (1) the low-voltage electron beam system, which uses accelerating voltages in 30,000 volts or (30 kV) to 60,000-volt (60 kV) range and (2) the high-voltage system with accelerating voltages in the 100,000- volt (100 kV) range. The higher voltage system emits more X-rays than the lower voltage system.
In both systems, the electron gun and the work piece are housed in a vacuum chamber. There are three basic components in an electron beam-welding machine. These are (1) the electron beam gun, (2) the power supply with controls, and (3) a vacuum work chamber with work-handling equipment. The electron beam gun emits electrons, accelerates the beam of electrons, and focuses it on the work piece.
Recent advances in equipment allow the work chamber to operate at a medium vacuum or pressure. In this system, the vacuum in the work chamber is not as high. It is sometimes called a "soft" vacuum. This vacuum range allowed the same contamination that would be obtained in atmosphere of 99.995% argon. Mechanical pumps can produce vacuums to the medium pressure level.
One of the major advantages of electron beam welding is its tremendous penetration. This occurs when the highly accelerated electron hits the base metal. It will penetrate slightly below the surface and at that point release the bulk of its kinetic energy which turns to heat energy. The addition of the heat brings about a substantial temperature increase at the point of impact. The succession of electrons striking the same place causes melting and then evaporation of the base metal. This creates metal vapors but the electron beam travels through the vapor much easier than solid metal. This causes the beam to penetrate deeper into the base metal. The width of the penetration pattern is extremely narrow. The depth-to-width can exceed a ratio of 20 to 1. As the power density is increased penetration is increased.
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The heat input of electron beam welding is controlled by four variables: (1) the number of electrons per second hitting the work piece or beam current, (2) the electron speed at the moment of impact, the accelerating potential, (3) the diameter of the beam at or within the work-piece, the beam spot size, and (4) the speed of travel or the welding speed. The first two variables, beam current and accelerating potential, are used in establishing welding parameters. The third factor, the beam spot size, is related to the focus of the beam, and the fourth factor is also part of the procedure.
Since the electron beam has tremendous penetrating characteristics, with the lower heat input, the heat-affected zone is much smaller than that of any arc welding process. In addition, because of the almost parallel sides of the weld nugget, distortion is greatly minimized. The cooling rate is much higher and for many metals this is advantageous; however, for high-carbon steel this is a disadvantage and cracking may occur.
The weld joint details for electron beam welding must be selected with care. In high vacuum chamber welding special techniques must be used to properly align the electron beam with the joint. Welds are extremely narrow and therefore preparation for welding must be extremely accurate.
Filler metal is not used in electron beam welding; however, when welding mild steel highly deoxidized filler metal is sometimes used. This helps deoxidize the molten metal and produce dense welds.
Almost all metals can be welded with the electron beam welding process. The metals that are most often welded are the super alloys, the refractory metals, the reactive metals, and the stainless steels. Many combinations of dissimilar metals can also be welded.
One of the disadvantages of the electron beam process is its high capital cost. The price of the equipment is very high and it is expensive to operate due to the need for vacuum pumps. In addition, fit up must be precise and locating the parts with respect to the beam must be perfect.
Read and learn the following words and expressions:
| Electron Beam Welding coalescence to obtain primarily to impinge upon dense impact inception requirement affinity nitrogen target molten accelerating voltage to emit to allow contamination succession evaporation to penetrate beam current tremendous weld nugget distortion cracking to occur to align stainless steel | - электронно-лучевая сварка - слияние, объединение - получать; добывать - сначала, сперва, первоначально - падать на - плотный; сжатый; густой - сильное воздействие; влияние - начало, отправная точка - требование; - сходство, близость - азот - цель - расплавленный - ускоряющее напряжение - испускать, излучать - позволять - загрязнение - последовательность - испарение - проникать - ток луча; ток пучка - огромный - ядро сварной точки; сварная точка - искажение; искривление - растрескивание - происходить, случаться - выравнивать - нержавеющая сталь |
1. Answer the following questions:
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1. Give the definition of electron beam welding.
2. What are three basic components in an electron beam-welding machine?
3. What do recent advances in equipment allow?
4. What is on of the major advantages of electron beam welding?
5. How is the heat input of electron beam welding is controlled?
6. Why is the heat-affected zone much smaller than that of any arc welding process?
7. Is filler metal used in electron beam welding?
8. What kind of metals can be welded with the electron beam welding process?
9. What are the disadvantages of the electron beam process?
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