Welding Design of Copper Brew Kettles

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University of Waterloo Mechanical Engineering Project – Welding of Copper Brew Kettles ME 436 – Welding and Joining Professor Michael Mayer Prepared By: Jordan McCormack – 20264784 Derek Podsiadly –20280409 Wednesday July 20th , 2011 Table of Contents List of Figures iii List of Tables iv 1.0 Introduction 1 2.0 Process Selection 3 2.1 Gas Tungsten Arc Welding 3 2.1.1 GTAW Basic Principles 3 2.2 Shielded Metal Arc Welding (SMAW) 4 2.2.1 SMAW Basic Principles 4 2.3 Friction Stir Welding 5 2.3.1 Friction Stir Welding Basic Principles 5 2.4 Plasma Arc Welding 7 2.4.1 Plasma Arc Welding Basic Principles 7 2.5 Brazing 8 2.5.1 Brazing Basic Principles 8 3.0 Discussion 10 3.1 Feasibility 10 3.2 Friction Stir Welding 11 3.3 Plasma Arc Welding 14 3.4 Brazing 16 3.5 Risks 18 Conclusions 20 Recommendations 21 Selection Process Guideline 21 References 22 Appendix A: 23 * List of Figures Figure 1 - Example Copper Circular Seam Joint 2 Table 1- GTAW Process Variables 4 Figure 2 - Shielded Metal Arc Welding Process 4 Table 2- SMAW Process Variables 5 Table 3 - Friction Stir Welding Process Variables 6 Figure 3 - Friction Stir Welding Process 6 Table 4- PAW Key Process Variables 7 Figure 4 - Plasma Arc Welding Process 8 Table 5- Brazing Key Process Variables 8 * List of Tables Figure 1 - Example Copper Circular Seam Joint 2 Table 1- GTAW Process Variables 4 Figure 2 - Shielded Metal Arc Welding Process 4 Table 2- SMAW Process Variables 5 Table 3 - Friction Stir Welding Process Variables 6 Figure 3 - Friction Stir Welding Process 6 Table 4- PAW Key Process Variables 7 Figure 4 - Plasma Arc Welding Process 8 Table 5- Brazing Key Process Variables 8 Abstract Introduction Welding has been an integral part of fabrication and construction for

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