Welding Principles and Applications

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ISBN: 9780827382404 | 0827382405
Cover: Hardcover
Copyright: 9/30/1997

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This all-encompassing guide covers all aspects of welding, as progressively guiding them from the absolute basics to AWS Certified Welder Test preparation. Experiments and practices are designed to familiarize the student with a wide range of machine settings, production of quality welds, while minimizing wasted stock and nonskilled work such as grinding and finishing.Based on standards established by the American Welding Society, the student learns to develop industry-acceptable practices for professional application.

Preface

Acknowledgments

Index of Experiments and Practices

xvi

SECTION 1 INTRODUCTION

Introduction to Welding

Introduction

(1)

Welding Defined

(1)

Uses of Welding

(2)

Welding Processes

(4)

Occupational Opportunities in Welding

(2)

Training for Welding Occupations

(1)

Experiments and Practices

(2)

Metric Units

(5)

Safety in Welding

Introduction

(1)

Burns

(1)

Eye and Ear Protection

(4)

Respiratory Protection

(1)

Material Specification Data Sheets (MSDS's)

(1)

Ventilation

(1)

Electrical Safety

(1)

General Work Clothing

(1)

Special Protective Clothing

(2)

Handling and Storing Cylinders

(1)

Fire Protection

(2)

Equipment Maintenance

(1)

Work Area

(1)

Hand Tools

(1)

Power Tools

(2)

Metal Cutting Machines

(1)

Material Handling

(1)

Safety First

(6)

SECTION 2 SHIELDED METAL ARC WELDING

Shielded Metal Arc Equipment, Setup, and Operation

Introduction

(1)

Welding Current

(2)

Types of Welding Power

(1)

Open Circuit Voltage

(1)

Operating Voltage

(1)

Arc Blow

(1)

Types of Power Sources

(3)

Generators and Alternators

(1)

Rectifiers

(1)

Duty Cycle

(1)

Welding Cables

(1)

Electrode Holders

(2)

Work Clamps

(1)

Setup

(3)

Shielded Metal Arc Welding of Plate

Introduction

(2)

Effect of Too High or Too Low Current Settings

(1)

Electrode Size and Heat

(1)

Arc Length

(1)

Electrode Angle

(3)

Electrode Manipulation

(1)

Positioning of the Welder and the Plate

(1)

Practice Welds

(1)

Stringer Beads

(2)

Square Butt Joint

(4)

Lap Joint

(3)

Tee Joint

(5)

Shielded Metal Arc Welding of Pipe

Introduction

(1)

Pipe and Tubing

(4)

Preparation and Fitup

(1)

Practice Welds

(3)

1G Horizontal Rolled Position

(4)

2G Vertical Fixed Position

(2)

5G Horizontal Fixed Position

101

(1)

6G 45° Inclined Position

102

(5)

Advanced Shielded Metal Arc Welding

Introduction

107

(1)

Root Pass

108

(5)

Hot Pass

113

(2)

Filler Pass

115

(2)

Cover Pass

117

(1)

Plate Preparation

117

(2)

Preparing Specimens for Testing

119

(2)

Restarting a Weld Bead

121

(1)

Preheating and Postheating

121

(9)

Poor Fit

130

(8)

SECTION 3 CUTTING AND GOUGING

Flame Cutting

Introduction

138

(1)

Eye Protection for Flame Cutting

139

(1)

Cutting Torches

139

(2)

Cutting Tips

141

(2)

Oxyfuel Cutting, Setup, and Operation

143

(3)

Hand Cutting

146

(3)

Layout

149

(1)

Selecting the Correct Tip and Setting the Pressure

149

(2)

The Chemistry of a Cut

151

(1)

The Physics of a Cut

152

(3)

Plate Cutting

155

(1)

Methods of Improving Cuts

155

(1)

Distortion

156

(2)

Cutting Applications

158

(1)

Pipe Cutting

159

(6)

Plasma Arc Cutting

Introduction

165

(1)

Plasma

166

(1)

Arc Plasma

166

(1)

Plasma Torch

166

(2)

Power and Gas Cables

168

(2)

Power Requirements

170

(1)

Heat Input

171

(1)

Distortion

171

(1)

Applications

172

(3)

Gases

175

(1)

Machine Cutting

176

(1)

Manual Cutting

177

(1)

Plasma Arc Gouging

178

(1)

Safety

179

(7)

Related Cutting Processes

Introduction

186

(1)

Laser Beam Cutting (LBC) and Laser Beam Drilling (LBD)

186

(1)

Lasers

187

(2)

Applications

189

(1)

Laser Beam Cutting

189

(1)

Laser Beam Drilling

190

(1)

Laser Equipment

190

(1)

Air Carbon Arc Cutting

191

(1)

Manual Torch Design

192

(3)

Safety

195

(4)

Oxygen Lance Cutting

199

(1)

Application

199

(1)

Water Jet Cutting

199

(1)

Applications

200

(6)

SECTION 4 GAS SHIELDED WELDING

Gas Metal Arc Welding Equipment, Setup, and Operation

Introduction

206

(2)

Metal Transfer

208

(5)

Filler Metal Specifications

213

(1)

Wire Melting and Deposition Rates

213

(1)

Welding Power Supplies

213

(3)

Molten Weld Pool Control

216

(4)

Equipment

220

(5)

Spot Welding

225

(5)

Gas Metal Arc Welding

Introduction

230

(1)

Setup

230

(7)

Gas Density and Flow Rates

237

(1)

Arc-Voltage and Amperage Characteristics

238

(1)

Electrode Extension

239

(2)

Welding Gun Angle

241

(1)

Effect of Shielding Gas on Welding

241

(2)

Practices

243

(1)

Metal Preparation

244

(1)

Flat Position, 1G and 1F Position

245

(4)

Vertical Up 3G and 3F Positions

249

(2)

Vertical Down 3G and 3F Positions

251

(1)

Horizontal 2G and 2F Positions

252

(1)

Overhead 4G and 4F Positions

253

(2)

Pulsed-Arc Metal Transfer, 1G Position

255

(3)

Axial Spray

258

(5)

Flux Cored Arc Welding Equipment, Setup, and Operation

Introduction

263

(1)

Principles of Operation

264

(2)

Equipment

266

(1)

Advantages

266

(1)

Limitations

267

(1)

Electrodes: Methods of Manufacturing

267

(1)

Flux

268

(4)

Shielding Gas

272

(1)

Welding Techniques

273

(6)

Flux Cored Arc Welding

Introduction

279

(1)

Practices

280

(3)

Flat-Position Welds

283

(1)

Square-Groove Welds

284

(2)

V-Groove and Bevel-Groove Welds

286

(5)

Fillet Welds

291

(6)

Vertical Welds

297

(5)

Horizontal Welds

302

(4)

Overhead-Position Welds

306

(4)

Thin-Gauge Welding

310

(7)

Other Constant Potential Welding Processes

Introduction

317

(1)

Submerged Arc Welding (SAW)

318

(1)

Weld Travel

318

(1)

Electrode Feed

319

(1)

Contact Tip

320

(1)

Electrode

320

(1)

Flux

320

(1)

Advantages of SAW

321

(1)

Disadvantages

321

(1)

Arc Starting

322

(1)

Weld Backing

322

(1)

Hand-Held SAW

322

(1)

Experiments

322

(1)

Electroslag Welding (ESW)

323

(2)

Electrogas Welding (EGW)

325

(4)

Gas Tungsten Arc Welding Equipment, Setup, Operation, and Filler Metals

Introduction

329

(3)

Types of Tungsten

332

(1)

Shaping the Tungsten

333

(2)

GTA Welding Equipment

335

(4)

Types of Welding Currents

339

(2)

Shielding Gases

341

(2)

Remote Controls

343

(8)

Gas Tungsten Arc Welding of Plate

Introduction

351

(1)

Torch Angle

352

(1)

Filler Rod Manipulation

352

(1)

Tungsten Contamination

353

(1)

Current Setting

354

(1)

Gas Flow

355

(2)

Practice Welds

357

(24)

Gas Tungsten Arc Welding of Pipe

Introduction

381

(1)

Practices

382

(1)

Joint Preparation

382

(1)

Root

383

(2)

Backing Gas

385

(2)

Filler Metal

387

(4)

Hot Pass

391

(3)

Filler Pass

394

(1)

Cover Pass

395

(11)

SECTION 5 RELATED PROCESSES

Welding Joint Design, Welding Symbols, and Fabrication

Introduction

406

(1)

Weld Joint Design

407

(6)

Mechanical Drawings

413

(5)

Welding Symbols

418

(1)

Indicating Types of Welds

418

(1)

Weld Location

419

(1)

Location Significance of Arrow

420

(1)

Fillet Welds

421

(1)

Plug Welds

421

(1)

Spot Welds

422

(1)

Seam Welds

423

(1)

Groove Welds

423

(2)

Backing

425

(1)

Flanged Welds

425

(2)

Nondestructive Testing Symbols

427

(3)

Fabrication

430

(4)

Layout

434

(8)

Material Shapes

442

(3)

Assembly

445

(1)

Assembly Tools

446

(1)

Fitting

447

(1)

Tack Welding

448

(1)

Welding

449

(2)

Finishing

451

(6)

Welding Codes, Standards and Welding Cost

Introduction

457

(1)

Codes, Standards, Procedures, and Specifications

458

(1)

Welding Procedure Qualification

459

(1)

General Information

460

(11)

Welding Costs

471

(1)

Cost Estimation

472

(2)

Weld Metal Cost

474

(7)

Factors for Cost Formulas

481

(4)

Comparing Weld Metal Costs

485

(3)

Other Useful Formulas

488

(4)

Testing and Inspection of Welds

Introduction

492

(1)

Quality Control

492

(1)

Discontinuities and Defects

493

(6)

Destructive Testing

499

(9)

Nondestructive Testing

508

(12)

Welder Certification

Introduction

520

(1)

Qualified and Certified Welders

521

(1)

AWS Entry-Level Welder Qualification and Welder Certification

521

(8)

Welding Skill Development

529

(2)

Welder Qualification and Certification Test Instructions for Practices

531

(1)

Dimensional Tolerances

531

(4)

Dimensional Tolerances

535

(3)

Layout, Assembly, and Fabrication of Weldments

538

(31)

Performance Qualification Test Record

569

(2)

Railroad Welding

Introduction

571

(1)

Rail Types

572

(3)

Continuous Welded Track

575

(1)

Rail Repairs

575

(4)

Gouging

579

(1)

Cracks

579

(1)

Rail Ends

580

(1)

Arc Welding (AW)

580

(3)

Flash Welding (FW)

583

(1)

Thermite Welding (TW)

583

(7)

SECTION 6 RELATED PROCESSES AND TECHNOLOGY

Welding Metallurgy

Introduction

590

(1)

Heat, Temperature, and Energy

591

(2)

Mechanical Properties of Metal

593

(2)

Structure of Matter

595

(1)

Crystalline Structures of Metal

595

(1)

Phase Diagrams

596

(5)

Strengthening Mechanisms

601

(6)

Heat Treatments Associated with Welding

607

(2)

Thermal Effects Caused by Arc Welding

609

(1)

Gases in Welding

610

(3)

Metallurgical Defects

613

(5)

Weldability of Metals

Introduction

618

(1)

Steel Classification and Identification

619

(1)

Carbon and Alloy Steels

619

(3)

Tool Steel

622

(1)

High-Manganese Steel

622

(1)

Low-Alloy, High-Tensile Strength Steels

623

(1)

Stainless Steels

623

(1)

Chromium-Molybdenum Steel

624

(1)

Cast Iron

624

(2)

Copper and Copper Alloys

626

(1)

Aluminum Weldability

626

(1)

Titanium

626

(1)

Magnesium

626

(1)

Repair Welding

627

(6)

Filler Metal Selection

Introduction

633

(7)

SMAW Operating Information

640

(1)

Core Wire

641

(1)

Functions of the Flux Covering

641

(1)

Filler Metal Selection

641

(2)

AWS Filler Metal Classifications

643

(1)

Carbon Steel

643

(9)

Aluminum and Aluminum Alloys

652

(5)

Welding Automation and Robotics

Introduction

657

(1)

Manual Joining Process

658

(1)

Semiautomatic Joining Processes

658

(1)

Machine Joining Processes

659

(1)

Automatic Joining Processes

660

(1)

Automated Joining

660

(1)

Industrial Robots

661

(11)

Future Automation

672

(4)

Other Welding Processes

Introduction

676

(1)

Resistance Welding (RW)

677

(7)

Electron Beam Welding (EBW)

684

(2)

Ultrasonic Welding (USW)

686

(1)

Inertia Welding Process

687

(3)

Laser Welding (LBW)

690

(1)

Plasma-Arc Welding Process (PAW)

691

(1)

Stud Welding (SW)

692

(1)

Hardfacing

693

(3)

Thermal Spraying (THSP)

696

(2)

Cold Welding (CW)

698

(8)

SECTION 7 OXYFUEL

Oxyfuel Welding and Cutting Equipment, Setup, and Operation

Introduction

706

(1)

Pressure Regulators

707

(6)

Welding and Cutting Torches Design and Service

713

(3)

Welding and Heating Tips

716

(1)

Reverse Flow and Flashback Valves

717

(2)

Hoses and Fittings

719

(1)

Backfires and Flashbacks

720

(1)

Types of Flames

721

(1)

Leak Detection

722

(5)

Manifold Systems

727

(2)

Safety

729

(4)

Oxyfuel Gases and Filler Metals

Introduction

733

(1)

Fuel Gases

734

(1)

Flame Rate of Burning

735

(1)

Acetylene (C2H2)

736

(3)

Liquefied Fuel Gases

739

(1)

Pressure

739

(1)

Methylacetylene-Propadiene (MPS)

739

(3)

Propane and Natural Gas

742

(1)

Hydrogen

742

(3)

Filler Metals

745

(1)

Mild Steel

746

(3)

Oxyacetylene Welding

Introduction

749

(1)

Mild Steel Welds

750

(7)

Outside Corner Joint

757

(1)

Butt Joint

758

(2)

Lap Joint

760

(3)

Tee Joint

763

(2)

Out-of-Position Welding

765

(1)

Vertical Welds

765

(1)

Butt Joint

766

(1)

Lap Joint

766

(1)

Tee Joint

767

(1)

Horizontal Welds

768

(1)

Horizontal Stringer Bead

768

(1)

Butt Joint

769

(1)

Lap Joint

769

(1)

Tee Joint

769

(1)

Overhead Welds

770

(1)

Stringer Bead

770

(1)

Mild Steel Pipe and Tubing

771

(1)

Horizontal Rolled Position 1G

771

(2)

Horizontal Fixed Position 5G

773

(2)

Vertical Fixed Position 2G

775

(1)

45° Fixed Position 6G

775

(1)

Thin-Wall Tubing

776

(4)

Soldering, Brazing, and Braze Welding

Introduction

780

(1)

Advantages of Soldering and Brazing

781

(2)

Physical Properties of the Joint

783

(1)

Fluxes

784

(2)

Soldering and Brazing Methods

786

(4)

Filler Metals

790

(4)

Joint Design

794

(8)

Building Up Surfaces and Filling Holes

802

(2)

Soldering

804

(8)

APPENDIX

I. Conversion of Decimal Inches to Millimeters and Fractional Inches to Decimal Inches and Millimeters

812

(1)

II. Conversion Factors: U.S. Customary (Standard) Units and Metric Units (SI)

813

(2)

III. Abbreviations and Symbols

815

(1)

IV. Metric Conversions Approximations

816

(1)

V. Pressure Conversion

816

(1)

VI. Structural Metal Shape Designations

817

(14)

VII. Welding Codes and Specifications

831

(1)

VIII. Welding Associations and Organizations

832

(3)

Glossary

835

(50)

Index

885

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Welding Principles and Applications

Summary

Table of Contents

Supplemental Materials