JOINING AND ASSEMBLY
WELDING DEFINITION: Welding is a joining process in which metals, or sometimes plastics, are heated, melted and mixed to produce a joint with properties similar to those of the materials being joined.
MIG WELDING - MIG—i.e., metal inert gas—welding is generally used for large and thick materials. It employs a consumable wire that acts as both the electrode and the filler material. Compared to TIG welding, it is much faster, resulting in shorter lead times and lower production costs.
STICK WELDING - Stick welding, also known as shielded metal arc welding (SMAW), manual metal arc welding (MMA) or flux shielded arc welding, is an electric arc welding process. This technique uses a combination of electricity and consumable rod-shaped electrodes (welding rods) coated in a flux material to create the welded joint.
TIG WELDING - Tungsten Inert Gas (TIG) welding uses the heat generated by an electric arc struck between a non-consumable tungsten electrode and the workpiece to fuse metal in the joint area and produce a molten weld pool.
PLASMA ARC WELDING - Plasma arc welding (PAW) is an arc welding process very similar to TIG welding as the arc is formed between a pointed tungsten electrode and the workpiece. However, by positioning the electrode within the body of the torch, the plasma arc can be separated from the shielding gas envelope.
RIVETING - Riveting is a forging process that may be used to join parts together by way of a metal part called a rivet. The rivet acts to join the parts through adjacent surfaces. A straight metal piece is connected through the parts. Then both ends are formed over the connection, joining the parts securely.
POP RIVETING - A POP Rivet is a blind fastener which can be inserted and set from one side of the work piece. Depending on the application, they can be used as replacements for welds, adhesives, screws, nuts and bolts. A typical POP Rivet is made up of two key parts; the rivet body and the setting mandrel.
use holding devices, formers and jigs (for sawing, drilling and bending) to assist joining and assembly
FORMERS - a tool or machine accessory so shaped that it imparts a predetermined contour or profile to the work. : a pair of light tongs with broad flat ends used in manipulating and shaping softened glass.
JIGS - Jigs are tools that hold a cutting tool in place or guide it as it performs a repetitive task like drilling or tapping holes.
understand the use of knock-down (KD) fittings for use with manufactured boards such as chipboard, including one-piece and two-piece corner blocks, scan fittings, cam lock and leg fastenings
ONE PIECE CORNER BLOCKS - The corner block is pressed against the two pieces of material (normally wood based). Screws are used to fix the block into position. This type of joint is used to fit modern cabinets such as those found in a kitchen. It is a relatively strong joint although it has the advantage that it can be dismantled using a screwdriver.
TWO PIECE CORNER BLOCKS - These are made from plastic. A bolt passes through the first fitting into the thread of the second. As the bolt is tightened it draws the two fittings together. The pins help keep the fitting straight. This gives a very strong joint and it can be dismantled using a screwdriver.
SCAN FITTINGS - These are strong enough to be either permanent or temporary joints. The cylinder is inserted into the first side of a cabinet in a pre-drilled hole. The screw is then pushed through the hole in the second side until it meets the cylinder.
CAM LOCK FITTINGS - The disk fits into a recess in the first side of the cabinet. It rotates by inserting a screwdriver into the slot in its side. The shaft is screwed into the second side of the cabinet. The collar of the shaft is passed through the hole in the second slot in the disk. When the disk rotates the shaft is locked in position. This keeps both sides of the cabinet locked together.
LEG FASTENINGS - An angle bracket or angle brace or angle cleat is an L-shaped fastener used to join two parts generally at a 90 degree angle. It is typically made of metal but it can also be made of wood or plastic. The metallic angle brackets feature holes in them for screws.
understand where to use a wide range of pre-manufactured components, including screws, nails, nuts, bolts, hinges and catches
SCREWS - Screws are also good for mounting hardware and trim, constructing cabinets, and joining furniture parts, like attaching a tabletop to a base. Because screws cause less vibration—and less potential damage—upon insertion, they're also preferable when working with more delicate materials like plaster and drywall.
Screws are preferred for such tasks as:
Hanging drywall.
Attaching ledger boards.
Installing cabinets.
Fastening wood decking.
Fabricating cabinets, wooden toys, bookcases, and other woodworking projects.
For any wood-to-wood connection that you may need to take apart.
NAILS - Nails are often preferred for large projects, like house framing and installing hardwood floors, because they are typically stronger and less expensive than screws. Since most nails have smooth heads and shafts, they insert easily and speedily with a hammer or nail gun.
NUTS / BOLTS- Electrical equipment, automobiles, and spare parts are just some of the things that use nuts and bolts for fasteners. Nuts and bolts are dimension specific and are strong and durable to ensure long life of the product that they hold together.
HYNGES - Hinges play a vital role in the movement, or opening and closing of doors and gates. They facilitate easy movement. Hinges can be of different types, which are used for various types of doors and gates.
CATCHES - Catches and latches are terms frequently interchangeable but importantly they are mechanical fasteners that allow the joining between two hardware surfaces that frequently are used for the enclosure of cabinets, cabinets and door furniture.
understand how sizes of screws, nails, nuts and bolts are specified
SIZE OF SCREWS - Metric Bolt Sizes
The letter 'M' indicates that this bolt uses a metric thread.
The number '8' refers to the nominal diameter of the bolt shaft in millimeters.
The number 1.0 is the thread pitch of the bolt, which is the distance between threads, in millimeters.
And the final figure, 20, is the length in millimeters.
M8 -1.0 x 20mm
SIZE OF NUTS - Standard and Fine Pitch Threads
Although various special threads are defined by the ISO standard only two are in common use in most machinery, the others are mainly used in specialist equipment such as precision instruments, optical instruments, etc.
The two threads most commonly found in plant and machinery are usuallY known as ‘standard’ and ‘fine’ pitch.
The pitch of a thread is the distance between two adjacent threads and is measured in millimetres.
The most common thread diameter and pitch combinations found in plant and machinery are listed in the table below:
be aware of a range of different adhesives to join a variety of materials and any special considerations related to preparation, application, drying times and health and safety
Adhesive, any substance that is capable of holding materials together in a functional manner by surface attachment that resists separation. “Adhesive” as a general term includes cement, mucilage, glue, and paste—terms that are often used interchangeably for any organic material that forms an adhesive bond.
EPOXY ADHESIVES - Epoxies are a type of structural adhesive. They are highly temperature and solvent resistant and can be structurally bonded to most types of materials, such as metals, ceramics, wood and plastics.
POLYVINYL - ACETATE ADHESIVE (PVA) - Polyvinyl-acetate glues encompass a range of products from Elmer’s white glue to Titebond III, a yellow glue designed to be used in extreme outdoor conditions. PVA glues are classified into three categories based on their water resistance.
Type-III (not water resistant) PVA glue consists of as much as 50% water and cures as the water evaporates. Glued surfaces must be clamped together until they reach 15% to 20% of their bond strength, generally in about an hour. It can take as long as 24 hours, however, to reach full strength.
Type-I (waterproof) and type-II (water resistant) PVA glues, such as Titebond II and III, contain water, but also strands of polymers that become entangled and chemically bonded to perform better in exterior conditions. These adhesives demand the same clamp time as type-III PVA glue, but generally have a longer open time and bond at colder temperatures.
Water resistance aside, there’s little difference in the strength of the joint made with any type of PVA glue. They all can resist forces around 3500 psi to 4000 psi. PVA glue can be cleaned up with water. Once it’s dry, you can scrape or sand away excess glue.
POLYURETHANE ADHESIVE - Polyurethane glues like Gorilla Glue and PL Turbo outperform PVA glues in several applications, such as bonding foam, stone, concrete, and ceramics.
One benefit of polyurethane glues is that because they are not water-based, they are not drawn into wood pores as drastically as PVA glue. For this reason, wood joints glued up with polyurethane accept stains and clear finishes better than with other types of glue. Polyurethane glues also enable you to glue up pieces even after a finish has been applied.
Because polyurethane glues cure by a chemical reaction triggered by moisture, they work well on wood with high moisture content or on oily woods, where PVAs have a hard time bonding. Polyurethane glues generally take six to eight hours to reach full strength and require the workpiece to be clamped for a proper bond. The clamps usually can be removed after about four hours.
The cured strength of polyurethane glue is slightly less than that of PVA—generally around 3000 psi—but still plenty strong for most any home-building application.
Prior to drying, polyurethane glue can be removed using solvents such as mineral spirits or acetone. Once the glue has cured, you can scrape or sand away squeeze-out.
CYANOACRYLATE ADHESIVE - Not all CA glues are created equal. Some are one-part systems (Krazy Glue), and others require an activator to set up properly (2P-10). You also can buy CA glues in a wide range of viscosities, from thin versions that bond in as little as 10 seconds and cure at 30 seconds to thicker gels that have about a 10-minute open time and require clamping.
Marketed as an all-purpose glue and recognized most often as Super Glue, CA glue bonds to most any surface. It’s more expensive than PVA or polyurethane glue, which means that it is seldom a smart choice for bonding large surface areas.
Many trim carpenters swear by CA glues for their strength, speed, and ease of use. If you’re working on a crown miter joint, for instance, you can apply the glue to one side, the activator to the other, then simply hold the joint in place for a few seconds until the glue bonds.
One downside of CA glues is that they are brittle, so they are more likely to fail under impact. But the strength of CA glue is not far behind PVA glues, with some capable of withstanding up to 4000 psi. Cleanup of CA glue requires a solvent, such as acetone, prior to curing. After curing, you can scrape or sand away squeeze-out.
ADHESIVE PREPARATION -
Removing intermediate surfaces
When considering surface preparation, first think about the materials you want to bond together. Do you want to bond paint to an oxide layer, or do you really want to bond the steel that is under the paint to the aluminium that is under that aluminium oxide layer? Do you want to bond that mold release agent to mold release agent or bond the pieces of polycarbonate under that mold release agent? In summary, use the surface treatment necessary to remove what is covering the material to be bonded.
Paint removal
Even when it appears easy to just apply adhesive epoxy directly on top of the paint, it is important to bear in mind that the strength of the joint is only going to be as good as the strength of the paint – i.e., if the paint peels off, then the bond will fail. For this reason, it is a very good idea to remove the paint and bond directly to the material underneath.
Rust/oxide layer removal
Removing rust mainly requires a good rust cleaner with oxalic acid. Try out a few brands and see what you like best. Make sure to use rubber gloves and goggles, as this stuff can be pretty abrasive.
Use a wire brush and the cleaner to scrub away the rust.
Depending on the extent of the damage caused by the rust and the adhesive you’re using, you may have to sand (or preferably abrade) the area down to a smooth surface before applying the adhesive.
It’s a good idea after all this sanding and brushing to give your metal surface a good clean off with a clean cloth and some acetone or isopropanol. These act as a good degreaser and evaporate to leave a clean, dry, contamination-free surface to bond to.
Many metals form an invisible oxide layer which can on occasion be quite weak. It is a good idea to abrade and degrease all metals before bonding, if possible. Use carborundum paper to abrade metal (similar to sand paper but more robust and less messy). If you have a lot to abrade, using a grit blaster is a good idea, so as not to end up with arms like an Olympic shot-putter.
Sanding
Okay, we all know how to sand, more or less, but there are a few tricks you can apply to improve your sanding kung fu…
Some general tips for sanding:
Use high-quality paper. It tends to last longer and be more effective.
Always start with the big, chunky, coarse papers, and work your way down to the finer grain papers. The coarser papers will even out the surface while the finer papers will smooth it down.
Tap the dust off of your sanding paper now and then to keep the grit from building up and scratching the surface or impeding the paper’s progress.
Some tips for abrading metal:
Before abrading, remove grease from metal surfaces with acetone or isopropanol. This prevents you from embedding the grime any further.
Use carborundum paper rather than sandpaper, starting with a rough grade to remove the bulk of the oxide layer and then a fine grade to get a good finish.
When dry abrading, don’t push down on the paper. Apply a light touch and let the paper do the work.
For a more consistent surface, don’t just sand in one direction, use an even, circular motion to give the adhesive a good surface to “key” into.
When wet abrading, apply a little bit of pressure and short strokes. Use plenty of water and don’t let the surface dry while sanding. It is important to dry the metal straightaway afterward to prevent rusting.
Cleaning
Of course, you need a clean surface. If you’ve got a layer of dirt on both surfaces, all you’re doing is sticking dirt to dirt.
The main task at hand is just removing any dust, grease or mould, so anything that gets the job done is fine. Know your surfaces and how to clean them. However, on some surfaces you may not be able to visibly see dirt or contamination – there may be traces of release agent if the component has been moulded or silicone-based cleaning agents which can be present on glass surfaces. Using an isopropanol wipe before bonding will set your mind at ease.
Increasing wetability
In order for an adhesive to effectively bond to a substrate, it must be able to “wet” the surface. Some surface treatments affect the surface energy. In non-technical terms it is the difference between water on a freshly waxed car which beads up and rolls off or water on an old unwaxed car that wets the entire car. Methods to increase wetability include plasma treatment, corona discharge and product-specific primers.
ADHESIVE DRYING TIMES - In most situations, you can expect the adhesive to be fully cured in 24 hours or less. Some take less, like cyanoacrylate glues, also known as CA glues. Adhesive dry times also vary depending on humidity, temperature, and the material you're bonding. In extreme moisture situations, some adhesives may not cure at all.
ADHESIVE HEALTH AND SAFETY - Use adhesives and sealants in well-ventilated areas, and avoid inhaling the vapours. Avoid build-up of solvent vapours in the work atmosphere (hot spots) by ensuring adequate ventilation and the use of flameproof exhaust fans where necessary.
The chemicals in adhesive and sealant systems can affect health when they come into contact with the skin, or if they evaporate and form a mist or vapor in the air. The main effects of overexposure are irritation of the eyes, nose, throat, and skin; skin allergies; and asthma.
If you do come into contact with adhesives, follow these guidelines: - Hands: Wash well with soap and water and use a skin moisturiser afterwards. - Eyes: Wash repeatedly with running water for at least 10 minutes. Cover the affected eye with a sterile bandage and consult an eye specialist.