Modern Welding Technology

by Cary, Howard B.

• ISBN13: 9780130309136
• ISBN10: 0130309133
• Edition: 5th
• Format: Hardcover
• Copyright: 2002-01-01
• Publisher: Prentice Hall

Summary

For courses in Basic Welding and Welding Technology. This well-respected, introductory welding text contains coverage of the latest codes, materials, and processes necessary to become proficient in an ever more complex industry. The technology of welding is growing and the book's focus on arc welding processes and the use of steel in construction reflect those changeswhile continuing to provide a comprehensive coverage of basic principles and theory.

Table of Contents

Welding Background	1	(18)
The Importance of Welding	1	(5)
Welding Joins All Metals	6	(2)
Historical Development of Welding	8	(4)
The Welding Industry	12	(4)
The Future of Welding	16	(3)
Questions	18	(1)
References	18	(1)
Fundamentals of Welding	19	(12)
Welding Basics	19	(2)
Welding Processes and Grouping	21	(2)
Methods of Applying Welding	23	(2)
Welding Procedures	25	(2)
Welding Physics and Chemistry	27	(4)
Questions	30	(1)
Welding Personnel, Training, and Certification	31	(10)
The Work of the Welder	31	(2)
The Job Outlook for Welders	33	(1)
Where Welders Work	33	(3)
Training Programs and Schools	36	(2)
Qualifying and Certifying Welding Personnel	38	(3)
Questions	40	(1)
References	40	(1)
Safety and Health of Welders	41	(27)
Personnel Protection and Safety Rules	41	(7)
Electrical Shock Hazard	48	(2)
Arc Radiation Hazard	50	(3)
Air Contamination Hazard	53	(7)
Fire and Explosion Hazard	60	(4)
Compressed Gases Hazard	64	(1)
Weld Cleaning and Other Hazards	65	(3)
Safety for Specific Welding Processes and Occupations	66	(1)
Questions	66	(1)
References	67	(1)
Arc Welding with a Nonconsumable Electrode	68	(39)
The Nonconsumable Welding Arc	68	(4)
Gas Tungsten Arc Welding	72	(12)
Plasma Arc Welding	84	(9)
Carbon Arc Welding	93	(4)
Stud Welding	97	(5)
Other Nonconsumable Arc Welding Processes	102	(5)
Questions	105	(1)
References	106	(1)
Arc Welding with a Consumable Electrode	107	(100)
The Consumable Welding Arc	107	(7)
Metal Transfer across the Arc	114	(10)
Shielded Metal Arc Welding	124	(18)
Gas Metal Arc Welding	142	(11)
Flux-Cored Arc Welding	153	(12)
Submerged Arc Welding	165	(12)
Electroslag Welding	177	(10)
Electrogas Welding	187	(5)
Other Consumable Electrode Welding Processes	192	(1)
Arc Welding Variables	193	(9)
Arc Welding Process Selection	202	(5)
Questions	205	(1)
References	205	(2)
Gas Welding, Brazing, Soldering, and Solid-State Welding	207	(33)
Oxyfuel Gas Welding	207	(7)
Brazing	214	(9)
Soldering	223	(4)
Thermite Welding	227	(2)
Solid-State Welding	229	(8)
Miscellaneous Welding Processes	237	(3)
Questions	238	(1)
References	239	(1)
Resistance, Electron Beam, and Laser Beam Welding and Cutting	240	(30)
Resistance Welding	240	(14)
Electron Beam Welding	254	(5)
Laser Beam Welding	259	(4)
High Energy Beam Cutting	263	(7)
Questions	268	(1)
References	268	(2)
Welding-Related Processes	270	(35)
Oxygen Cutting	270	(4)
Arc and Plasma Cutting	274	(6)
Water Jet Cutting	280	(1)
Automatic Shape Cutting	281	(5)
Thermal Spraying	286	(6)
Adhesive Bonding	292	(1)
Joining Plastics	293	(4)
Joining Composites and Ceramics	297	(2)
Preheat and Postheat Treatment	299	(3)
Mechanical Stress Relief	302	(3)
Questions	304	(1)
References	304	(1)
Power Sources for Arc Welding	305	(35)
Arc Welding Electricity	305	(3)
Welding Arc Requirements	308	(6)
Types of Welding Machines	314	(1)
Rotating Welding Machines	315	(5)
Transformer Welding Machines	320	(4)
Rectifier Welding Machines	324	(6)
Inverter Welding Machines	330	(5)
Selecting and Specifying a Power Source	335	(2)
Installing and Maintaining a Power Source	337	(3)
Questions	338	(1)
References	339	(1)
Other Welding Equipment	340	(25)
Arc Welding Guns and Torches	340	(5)
Electrode Feed Systems	345	(9)
Welding Cables and Clamps	354	(4)
Auxiliary Welding Equipment	358	(2)
Weld Monitoring	360	(5)
Questions	363	(1)
References	364	(1)
Mechanized, Automated, and Robotic Arc Welding	365	(56)
Automation of Welding	365	(3)
Arc Motion Devices	368	(6)
Work Motion Devices	374	(5)
Standardized Automatic Arc Welding Machines	379	(6)
Dedicated Automatic Arc Welding Equipment	385	(4)
Flexible Automation of Welding	389	(6)
Arc Welding Robots	395	(11)
Controls for Automatic Arc Welding	406	(5)
Sensors and Adaptive Control	411	(6)
Tooling and Fixtures	417	(4)
Questions	419	(2)
Electrodes and Filter Metals	421	(19)
Types of Welding Consumables	421	(3)
Covered Electrodes	424	(5)
Solid Electrode Wires	429	(2)
Cored Electrode Wires	431	(1)
Packaging of Electrode Wires	432	(4)
Welding Fluxes	436	(1)
Other Welding Materials	437	(3)
Questions	439	(1)
Gases Used in Welding	440	(18)
Shielding Gases	440	(5)
Fuel Gases for Welding and Cutting	445	(4)
Atmosphere Gases	449	(1)
Gas Containers and Apparatuses	450	(8)
Questions	456	(1)
References	456	(2)
Metals and Their Weldability	458	(37)
Properties of Metals	458	(9)
Metal Specifications and Steel Classifications	467	(5)
Identification of Metals	472	(4)
Heat and Welding	476	(4)
Welding Metallurgy	480	(11)
Weldability of Metals	491	(4)
Questions	494	(1)
References	494	(1)
Welding Steels	495	(21)
Welding Carbon and Low-Alloy Steels	495	(3)
Welding Alloy Steels	498	(5)
Welding Stainless Steels	503	(8)
Welding Ultrahigh-Strength Steels	511	(5)
Questions	514	(1)
References	515	(1)
Welding Nonferrous Metals	516	(31)
Aluminum and Aluminum Alloys	516	(11)
Copper and Copper-Base Alloys	527	(4)
Magnesium-Base Alloys	531	(4)
Nickel-Base Alloys	535	(2)
Reactive and Refractory Metals	537	(7)
Other Nonferrous Metals	544	(3)
Questions	546	(1)
References	546	(1)
Welding Special and Dissimilar Metals	547	(21)
Cast Iron and Other Irons	547	(4)
Tool Steels	551	(3)
Reinforcing Bass	554	(3)
Coated Steels	557	(2)
Other Metals	559	(2)
Clad Metals	561	(3)
Dissimilar Metals	564	(4)
Questions	567	(1)
Design for Welding	568	(37)
Advantage of Welded Construction	568	(2)
Weldment Design Factors	570	(5)
Welding Positions and Weld Accessibility	575	(4)
Design of Weld Joint and Welds	579	(11)
Influence of Specifications on Design	590	(1)
Design Conversion to Weldments	591	(4)
Computer-Aided Design (CAD)	595	(2)
Weldment Redesign to Reduce Cost	597	(2)
Welding Symbols	599	(6)
Questions	604	(1)
References	604	(1)
Cost of Welding	605	(16)
Weldment Cost Elements	605	(1)
Weld Metal Required for Joints	606	(5)
Filler Metal and Materials Required	611	(4)
Time and Labor Required	615	(1)
Power and Overhead Costs	616	(1)
Weld Cost Formulas and Examples	617	(4)
Questions	619	(2)
Quality Control and Evaluation of Welds	621	(36)
Quality Control Program	621	(2)
Destructive Testing	623	(5)
Visual Inspection	628	(3)
Nondestructive Testing	631	(7)
Corrective Actions for Weld Defects	638	(10)
Workmanship Specimens and Standards	648	(6)
Nondestructive Examination Symbols	654	(3)
Questions	656	(1)
References	656	(1)
Welding Specifications, Procedures, and Qualifications	657	(26)
Weld Reliability	657	(1)
Welding Codes and Specifications	658	(3)
Welding Procedures and Qualifying Them	661	(8)
Standard Welding Procedure Specifications (SWPS)	669
Qualifying and Certifying Welders	667	(16)
Questions	681	(1)
References	682	(1)
Welding Problems and Solutions	683	(24)
Arc Blow	683	(3)
Welding Distortion and Warpage	686	(8)
Heat Forming and Straightening	694	(3)
Weld Stresses and Cracking	697	(3)
In-Service Cracking	700	(4)
Welding-Painting	704	(3)
Questions	706	(1)
References	706	(1)
Failure Analysis, Repair Welding, and Surfacing	707	(23)
Weld Failure Analysis	707	(6)
Developing a Rework Procedure	713	(2)
Making the Repair Weld	715	(4)
Rebuilding and Overlay Welding	719	(2)
Surfacing for Wear Resistance	721	(6)
Surfacing for Corrosion Resistance	727	(1)
Other Surfacing Applications	728	(2)
Questions	729	(1)
References	729	(1)
Welding Pipe and Tubing	730	(24)
Tubular Products	730	(5)
Pipe and Tube Welding	735	(7)
Manual and Semiautomatic Pipe Welding	742	(1)
Mechanized Pipe and Tube Welding	743	(5)
Automated Pipe Welding	748	(2)
Tube to Sheet Welding	750	(4)
Questions	753	(1)
References	753	(1)
Special Welding Applications	754	(21)
Arc Spot Welding	754	(5)
Sheet Metal Welding	759	(3)
One-Side Welding	762	(2)
Narrow Gap Welding	764	(3)
Underwater Welding	767	(4)
Welding in Space	771	(2)
Microjoining	773	(2)
Questions	774	(1)
References	774	(1)
Appendies	775	(16)
A-1 Glossary of Welding Terms	775	(4)
A-2 Organizations Involved with Welding	779	(2)
A-3 Computer Software Programs	781	(1)
A-4 Information Sources Using a Computer	782	(2)
A-5 Conversion Information	784	(3)
A-6 Weights and Measures	787	(4)
Index	791