An Overview of Metal Welding Technologies and Practices in Ghana

This report provides a comprehensive overview of metal welding technologies, with a specific focus on practices within Ghanaian industries. It begins by introducing welding as a critical process in various sectors, highlighting its evolution and interdisciplinary nature. The report then addresses the current state of welding in Ghana, noting the lack of readily available information on training programs, welding methods, safety practices, and overall technology adoption. The aims and objectives include conducting a review of current welding practices, investigating welding practices in Ghanaian enterprises, identifying needs and challenges, and exploring safety practices. The research scope encompasses educational foundations, welding processes, quality control systems, design considerations, and safety practices across various industries in Ghana. Methodologies involve literature review, study visits, surveys, and data analysis. The report also includes a literature review of advanced joining techniques such as laser processing, friction stir welding, metal to composite joining, and reduced pressure EB welding, emphasizing their significance and advantages. Finally, the report is structured into six sections covering introduction, literature review, research design, data analysis, results, discussions, conclusions, and recommendations. Desklib provides access to similar solved assignments and past papers for students.

METAL WELDING TECHNOLOGIES
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Introduction
Welding previously developed as a strategy of essential economic significance when the
utilization of iron ended up across the board, it being required not just so as to make finished
products yet additionally as a component of the iron-production itself. Welding comprises of
combination or joining of at least two bits of materials (metals or plastics) by the use of warmth
as well as weight.
Around the world, welding is a multibillion-dollar creation innovation utilized broadly in the
development of structures and connects and in the car, flying machine, aviation, energy,
shipbuilding, and electronic enterprises (Brand et al., 2015). Maybe in light of the fact that
welding is a development method, it is seen by numerous individuals as a crude science. Over
the most recent a very long while, welding has developed as an interdisciplinary action requiring
combination of information from different trains and consolidating the most progressive
instruments of different essential and connected sciences.
Researchers from various disciplines, for example, arc as well as plasma physics,
thermodynamics, high-temperature science, materials science, transport wonders, scientific
displaying, software engineering, apply autonomy, financial aspects, and an assortment of
designing fields including mechanical, concoction, and electrical building are as of now making
new commitments. Agarwal and Manghnani, (1992) in their book titled, ―Welding Engineering
likewise expressed that, ―welding includes a larger number of sciences and factors than some
other modern procedure. The main sciences associated with welding are Physics, Chemistry and
Metallurgy generation, and little parts manufacture, welding is still to a great extent a manual
procedure done by human administrators (Cao, Yu, Chen and Wang, 2013).

Kenneth et al (2004) in their examination ―Virtual Training for Welding‖ detailed at the
Proceedings of the Third Institute of Electrical and Electronics Engineers (IEEE) and
Relationship for Computing Machinery (ACM) International Symposium on Mixed and
Expanded Reality (ISMAR 2004) that, ―training of new welders is a huge action both for
industry and for the professional training network. Preparing is particularly imperative for
welders dealing with basic things, for example, weight vessels, atomic funnelling, what's more,
maritime boats, where welds are painstakingly assessed. It is assessed that the consolidated
welder preparing costs for all U.S. shipyards is in abundance of $5 million every year. There is
consequently a functioning enthusiasm among maritime shipbuilders in diminishing welder
preparing costs.
Welding as a joining procedure has its very own favourable circumstances and downsides. The
most evident preferred standpoint is that: Welding is generally the most affordable method for
joining parts regarding material utilization and manufacture costs (Chang et al., 2015). Elective
mechanical strategies for get together require increasingly complex shape portrayal (for instance
boring of gaps and expansion of clasp for instance bolts and jolts). The subsequent mechanical
get together is generally heavier than the relating welding. A portion of the downsides are that,
most welding activities are performed physically and are costly as far as work cost; many
welding tasks are viewed as gifted exchanges, and the work to perform these activities might be
rare. Most welding procedures, including the utilization of high vitality, are characteristically
perilous and the welded joint can experience the ill effects of certain quality imperfections that
diminish the quality of the joint.

A contributing component to the low status of assembling in Ghana might be the reality that
assembling designing exercises, for example, welding rehearses have not been created to the
dimension that they ought to be.
A visit to the Ashanti Regional Offices of the Ministry of Trade and Industry (MoTI), uncovered
that, information on the sort of preparing programs for welders, the class of welding and welding
method the welders practice, sort of welding forms the welders use, security practices of the
welders, needs and difficulties of these welders and the general innovation of welding in the
nation isn't promptly accessible. Lack of accurate information of such welding practices of the
adjacent welding industry hamper the improvement of the sector. Absence of specialized
expertise prompts the regular welding issues related with welded joints, for example, absence of
entrance, absence of combination, undercut, cover, cold lap, slag traps, porosity and blowholes,
under fill and unpleasant appearance just as wellbeing risks to the welder (Chinakhov, 2013).
It is additionally not sure that critical welding building methods, for example, weld plan, material
arrangement, test techniques for assessing welded joints, appropriate cooling component,
appropriate security insurances, and so on which must be done to guarantee imperfection free
welded segments and parts and wellbeing in the welding business are completed by nearby
welders.
Aims & Objectives
The fundamental target of this proposition work is to direct a review of current welding
rehearses, for example the sort of preparing programs for welders, the class of welding and
welding methods the welders use, sort of welding forms the welders use, security of the welders,
needs and difficulties of these welders and the welders learning of the innovation of welding in

the metal joining segment of some Ghanaian businesses and propose enhancements of designing
nature where appropriate
Other objectives
 To research the welding rehearses (for example welding procedures and methods, quality
control, structure and arranging contemplations, and so forth.) of some Ghanaian
enterprises that use welding as an upkeep and fix, fabricating and constructional
movement.
 To distinguish the necessities, difficulties and wellbeing rehearses (for example perils,
accessibility of wellbeing gear, and so forth.) of some Ghanaian businesses in the metal
welding creations segment.
 To investigate the welding practices (for instance welding methodology and strategies,
quality control, structure and orchestrating examinations, etc.) of some Ghanaian
ventures that use welding as an upkeep and fix, creating and constructional development
 To recognize the necessities, challenges and prosperity practices (for instance hazards,
openness of prosperity gear, etc.) of some Ghanaian organizations in the metal welding
manifestations section.
Research Scope
The extent of the exploration work is to direct a study of current welding rehearses in the metal
joining segment of some Ghanaian businesses. The examination review will incorporate the
accompanying explicit regions:
Educational foundation and welding preparing programs for welders in Ghana
The sort of welding forms the welders practice.

Quality control systems utilized by the welders, investigation and testing techniques for welded
joints and regular reasons for disappointment in welded joints.
Design and arranging contemplations before welding
Needs, difficulties and wellbeing practices of welders and the welding business
The exploration will cover ventures that utilization welding, as a support and fix movement, and
for assembling and constructional works in Ghana. The examination covers enterprises, for
example,
Support and Repair Industries
Micro, little scale and Medium Enterprises (MSME's, for example, welding enterprises and
carports in ―Suame Magazine, ―Asafo, in Kumasi, ―Kokompe, in Accra, ―light modern
zone in Tema and Takoradi associated with support and fix
Mining enterprises, for example, AngloGold Ashanti Limited, Ghana Bauxite Co. Ltd and
Tarkwa Gold Mines
Refineries, for example, Tema Oil Refinery (TOR)
Assembling and development Industries
Micro, little scale and Medium Enterprises (MSME's, for example, welding ventures and
carports in ―Suame Magazine‖, ―Asafo, in Kumasi, ―Kokomp, in Accra, and ―light modern
area‖ in Tema and Takoradi associated with the assembling and development of items
Gratis establishment, Tema-Heavy Industrial Area
Great Kosa Company Ltd, Mpota-Winneba.

Motor Vehicle and Equipment makers, for example, Japan Motors
Exchanging Company Ltd., Mechanical Lloyd Company Ltd., Adum-Kumasi
A. J. Fanj Construction and Industrial Engineering Ltd, development and manufacture of basic
steel for extensions, boards and structures, Asokwa-Kumasi
Methodology
The methodology below will be used:
 Review of writing on the best present day welding rehearses in the metal joining segment
pertinent to the investigation.
 Study visits to certain businesses that utilization welding as an upkeep and fix, fabricating
and constructional action in Kumasi, Accra, Tema and Takoradi.
 Preparation and appropriation of surveys and talking of ventures and MSMEs that work
on welding
 Collection of information, and examination of information utilizing a fitting PC
programming bundle
Thesis Structure
The study has been organized into six sections. Part one has the introduction, which is comprised
of: foundation of welding, the condition of welding in Ghana, issue proclamation, objective and
goals of the examination, extent of the exploration, support or hugeness of the investigation, the
philosophy received and a segment sketching out the structure of the postulation. Section two has
the writing audit, which surveys distinctive writing pertinent to the investigation. Section three
involves the exploration structure and technique, which expounds in subtleties how the

examination was done and the approach utilized. Section four is comprised of information
investigation. Part five, results and discourses, demonstrates the results got from the information
investigation and the following discourses. Part six involves recommendations as well as
conclusions.
Literature Review
This section audits a portion of the propelled joining strategies that have risen as of late from
work at TWI and different associations. TWI is the world's head community for materials joining
innovation, with somewhere in the range of 500 staff in various areas inside the UK and different
pieces of the world (Wagner, Balle and Eifler, 2013). Its central command is situated in
Cambridge, UK. TWI is a private, non-benefit disseminating organization that gives R&Dmp;D,
consultancy, preparing, innovation exchange and guidance for its2000+ Industrial Members
around the world. The aeronautic trade division, including airframe, air motor and segments
providers presently speaks to over 10% of TWI's Industrial Membership (Ding, Pan, Cuiuri and
Li, 2015).
In this section, four innovations will be checked on and their significance and advantages to the
aeronautic trade talked about. These advances are:
 Laser processing
 Friction Stir Welding
 Metal to composite joining
 Reduced pressure EB welding

Friction Stir Welding
Friction Stir Welding has grown rapidly, since its innovation in 1991 at TWI. It is a protected
procedure, and more than 114 associations have been conceded licenses to utilize the procedure.
It is generally utilized in various distinctive enterprises, however especially in aviation for the
joining of aluminum amalgams. Friction Stir Welding utilizes a non-consumable pivoting
apparatus, Fig.1, which moves along the joint between two segments to create great butt or lap
welds. The FSW device for the most part has a profiled stick and a shoulder with a bigger
measurement than that of the stick (Sproesser et al., 2015). The stick length is like the required
weld profundity. The stick is crossed along the joint line while the shoulder is in personal contact
with the top surface of the workpiece to abstain from removing mellowed material and give
solidification.
Figure 1: Friction stir welding principle & microstructure

FSW Tools
FSW instruments are produced from a wear safe material with great static and dynamic
properties at raised temperature. Current cutting edge devices grant up to 1000m of weld to be
created in 5mm thick aluminum expulsions without changing the device. The structure of the
erosion mix welding apparatuses is the core of this surprising and still moderately new welding
procedure.
Multi-helix devices, for example, the MX Triflute TM Fig.2, have an odd number of moderately
steeply calculated woodwinds and consolidate a coarse helical edge around the flutes' properties.
These decrease the device volume further and along these lines help the material stream, the
separation and the scattering of surface oxides (Fydrych, Łabanowski and Rogalski, 2013). The
device bear profiles under scrutiny are intended to give better coupling between the device bear
and the workpiece.
Figure 2: Mix Tiflute TM Tool

Quality of Weld
The weld piece quality in the as-welded condition can be in abundance of that in the warmth
influenced zone. On account of tempered materials, pliable tests generally bomb in the un-
influenced material well far from the weld and warmth influenced zone. The weld properties of
completely solidified (cold worked or warmth treated) aluminum compounds can be improved
by controlling the warm cycle. For ideal properties in some combinations, a warmth treatment in
the wake of welding is the best decision, in spite of the fact that this won't generally be a viable
answer for some applications (Wegrzyn, Piwnik and Hadrys, 2013).
Basic ductile properties of grinding blend welded 7000 arrangement aluminum combinations
have been accounted for to achieve 95% of those of the parent material. Fatigue testing has
demonstrated that FSW joints produce generously better outcomes, with lower dissipate, than
other joining procedures.
Aeroscope Applications of FSW
Boeing has connected FSW to the Delta II rockets, and the first of these was propelled
effectively in August 1999. The Mars Odyssey shuttle lifted off on a Delta II rocket in 2001,
which exhibited the quality and nature of longitudinal grinding mix welded joints on every one
of the three barrel shaped tank parts (Guo et al., 2013). FSW innovation for the Delta tanks
expands the weld quality by 30 to half and accomplishes 60% cost sparing, while at the same
time lessening the assembling time from three weeks to one week (Węgrzyn, Piwnik, Łazarz and
Hadrys, 2013).

Figure 3: Delta II
Four FSW machines have been introduced at Lockheed Martin's office in New Orleans for outer
fuel tanks of NASA Space Shuttles, Fig.4. The outer tank estimates 47m by 8.4m dia. also, is the
auxiliary spine of the Shuttle, engrossing a large portion of the six million lbs of push at
dispatch. FSW Benefits (over VPPA) have been accounted for to be an expansion in UTS of up
to 22%, a critical lessening in weld fluctuation and a decrease in barrel generation time from 47
hours to 19 hours
The FSW procedure offers enormous potential for minimal effort joining of lightweight
aluminum airframe structures for substantial common flying machine, for example, the Airbus
A380. Specialists at Airbus Deutschland see a high potential for joining aluminum compounds
by FSW for skin-to-skin fuselage associations (Yan, Chen, Zhu and Gou, 2014). They introduced
information that show that the mechanical and innovative properties of these welds approach the
properties of the parent material. This could prompt the decrease of expense and weight through
improved joint quality and the likelihood of new structure.