Fabrication and Welding Engineering

by Timings; Roger

• ISBN13: 9780750666916
• ISBN10: 0750666919
• Edition: 1st
• Format: Nonspecific Binding
• Copyright: 2008-07-11
• Publisher: Routledge

Summary

Fabrication & Welding Engineering is a brand new text from the leading engineering author Roger Timings, which offers a fully up to date textbook resource for this area of mechanical engineering and workshop practice. Taking into account the current trend in industry that sees several workshop skill areas addressed concurrently within the workforce, and the reflection of this in current teaching practice, Roger Timings provides a highly practical and accessible text that presents both fabrication and welding engineering together in one volume. This unrivalled comprehensive level of coverage is made readily accessible to newcomers in the field through extensive use of illustrations to demonstrate practical application of the procedures described, as well as vital textbook pedagogical features incorporated throughout the book, including: chapter aims; self-assessment questions, practice assignments, all designed to maximise accessibility of the text to the reader. Content has been matched to the fabrication and welding units from an extensive range of City & Guilds awards up to and including Level 3. In addition to this unit matching, essential material for non-technical City & Guilds units is also incorporated, with chapters such as Personal Development, and Using & Communicating Technical Information key areas for all engineering students embarking on City & Guilds courses, which do not tend to be addressed in traditional fabrication and/or welding texts. Relevant course mapping includes: Introductory Welding Skills 3267; Applying Engineering Principles Progression Award 6983; Engineering Production 1692; Certificate in Fabrication & Welding Engineering 1681. In addition, a close match has been ensured to the relevant units of Performing Engineering Operations (PEO) NVQ from EAL and City & Guilds (2251). Trainee engineers in industry and those taking Apprenticeships at Levels 2 and 3 will also find this text to be essential reading throughout their studies, with coverage sufficiently broad to ensure this will be a vital ongoing source of reference in day to day working practice. * Welding & Fabrication topics presented together in one text, in line with current teaching practice * Fully up to date with the latest City & Guilds and EAL specifications for fabrication & welding course units * Essential non-technical units from C&G schemes are also included: Personal Development and Using & Communicating Technical Information

Table of Contents

Preface	p. ix
Acknowledgements of figures and tables	p. xi
Health and safety	p. 1
Health, safety and the law	p. 2
Employers' responsibilities	p. 4
Employees' responsibilities	p. 5
Electrical hazards	p. 6
Fire fighting	p. 7
Fire precautions and prevention	p. 10
Accidents	p. 11
First aid	p. 14
Personal protection	p. 16
Hazards in the workplace	p. 19
Manual lifting	p. 23
Mechanical lifting equipment	p. 26
Use of lifting equipment	p. 31
Accessories for lifting gear	p. 32
Useful knots for fibre ropes	p. 35
Inspection (lifting equipment)	p. 37
Oxy-acetylene welding	p. 37
Arc-welding equipment (mains operated)	p. 43
Working on site	p. 50
Exercises	p. 53
Personal development	p. 57
Basic relationships	p. 58
Relationship with managers, supervisors and instructors	p. 59
Attitude and behaviour	p. 61
Implementing company policy	p. 62
Creating and maintaining effective working relationships with other people	p. 64
Exercises	p. 66
Engineering materials and heat treatment	p. 69
States of matter	p. 70
Properties of materials	p. 70
Classification of materials	p. 77
Ferrous metals (plain carbon steels)	p. 77
Ferrous metals (alloy steels)	p. 80
Ferrous metals (cast irons)	p. 81
Abbreviations	p. 81
Non-ferrous metals and alloys	p. 81
The identification of metals	p. 86
Non-metals (natural)	p. 86
Non-metals (synthetic)	p. 86
Forms of supply	p. 88
Heat treatment processes (introduction)	p. 91
Heat treatment processes (safety)	p. 92
The heat treatment of plain carbon steels	p. 93
The heat treatment of non-ferrous metals and alloys	p. 100
Heat-treatment furnaces	p. 102
Temperature measurement	p. 105
Atmosphere control	p. 108
Exercises	p. 109
Using and communicating technical information	p. 111
Selection of information sources	p. 112
Interpretation of information (graphical)	p. 112
Interpretation of information (tables, charts and schedules)	p. 116
Evaluating engineering information	p. 118
Recording and processing engineering information	p. 119
Methods of record keeping	p. 121
Communications (miscellaneous)	p. 121
Engineering drawing (introduction)	p. 124
First angle orthographic drawing	p. 125
Third angle orthographic drawing	p. 127
Conventions	p. 129
Redundant views	p. 132
Dimensioning	p. 132
Welding symbols	p. 136
The development of surfaces	p. 137
Interpenetration	p. 151
Pictorial views	p. 153
Exercises	p. 155
Measuring and marking out	p. 161
Introduction	p. 162
Linear measurement	p. 162
Angular measurement	p. 169
Correct use of measuring equipment	p. 171
Marking out equipment (tools for making lines)	p. 172
Marking out equipment (tools for providing guidance)	p. 177
Marking out equipment (tools for providing support)	p. 181
Techniques for marking out	p. 183
The need for templates	p. 192
The manufacture of templates	p. 192
The use of templates	p. 195
Condition and care of equipment	p. 206
Exercises	p. 208
Material removal	p. 211
Cutting tool principles	p. 212
The application of basic cutting tool angles to hand tools	p. 214
Drilling, drilling machines and routing	p. 226
Shearing sheet metal	p. 239
Portable power tools	p. 249
Blanking (stamping and piercing)	p. 259
Flame cutting	p. 263
Exercises	p. 275
Sheet and plate metalwork	p. 277
Sheet and plate metalwork (introduction)	p. 278
Roll-bending sheet metal and plate	p. 296
Flow forming sheet metal	p. 301
The principles of metal spinning	p. 318
Swaging sheet metal	p. 324
Basic fabrication procedures	p. 330
Exercises	p. 345
Structural steelwork and pipework	p. 347
Rolled steel sections	p. 348
Typical structural steel connections and assemblies	p. 348
Trusses and lattice frames	p. 353
Web stiffeners	p. 356
Fabricated lightweight beams	p. 359
Castellated beams	p. 359
Pipework (setting out bends)	p. 362
Pipe bending	p. 366
Pipe fitting	p. 373
Exercises	p. 382
Joining processes (mechanical connections)	p. 385
Mechanical connections (threaded)	p. 386
Hand reamers and reaming	p. 404
Riveted joints	p. 405
Pop Diveting	p. 411
Self secured joints	p. 418
Folding and jointing allowance	p. 421
The Pittsburgh lock	p. 425
Exercises	p. 428
Joining processes (soldering, brazing and braze-welding)	p. 429
Soft soldering	p. 430
Soft-soldered joints using lead-free solders	p. 445
Hard soldering (brazing)	p. 447
Aluminium brazing	p. 457
Types of brazed joints	p. 460
Braze-welding	p. 460
Exercises	p. 466
Joining processes (welding)	p. 467
Fusion welding	p. 468
Oxy-acetylene welding	p. 468
Manual metal-arc welding	p. 490
Workshop testing of welds	p. 504
Miscellaneous fusion welding processes	p. 506
Workholding devices for fusion welding	p. 509
Resistance welding	p. 515
Further welding processes	p. 518
Exercises	p. 519
Composite fabrication processes and adhesive bonding	p. 521
Introduction	p. 522
Lamination	p. 522
Fibre reinforcement	p. 525
Particle reinforcement	p. 531
The manipulation and fabrication of polymers (plastics)	p. 533
Adhesive bonding	p. 540
Adhesive bonding of metals	p. 545
Exercises	p. 554
Appendix A	p. 555
Index	p. 557
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