Modern Welding Technology

by Cary, Howard B.; Helzer, Scott

• ISBN13: 9780131130296
• ISBN10: 0131130293
• Edition: 6th
• Format: Paperback
• Copyright: 2004-11-10
• Publisher: Pearson

Summary

This well-respected, introductory welding book 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 changes-while continuing to provide a comprehensive coverage of basic principles and theory.Contains content on hybrid welding and stir friction welding; background concepts and basic welding techniques; the latest standards, codes, and specifications provided by the AWS; the most recent information on the use of high strength metals, laser welding, and arc and oxyacetylene welding; specifications for filler materials, electrodes, brazing fluxes, etc.; computer-aided welding processes; the latest information on the training of welding personnel; and welding power sources.For any welding-related occupations, especially welding inspectors, technicians, or engineers.

Table of Contents

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

Excerpts

Welding continues to be the preferred method of joining metal parts. As welding becomes more digital, the technology becomes more complex, but its application as a process becomes simpler and more efficient. Worldwide, welding continues to grow, and that growth is dependent upon the growth of the steel and other metal industries. Since the last edition of Modern Welding Technology,much has changed in the world of welding. New processes have been born, and others have gotten married. There are now combinations of welding processes known as hybrid welding.Welding power sources have continued to get smaller, more efficient, lighter, and more controllable. Some welding processes have become more popular and others more refined. For example, the laser is more widely used, especially for cutting, and a new process, stir friction welding, is starting to be used to join aluminum for automotive and space applications. The need to improve weld quality and reduce welding costs continues to drive the welding industry. This is the highest priority because of improved materials and fabricating methods. Semiautomatic welding has largely replaced manual welding, and automatic and robotic welding are fording more applications in the industry. Adaptive control is rapidly becoming more widely used. More powerful computer controls and more rugged sensors are being used. All of this has helped take the human welder farther away from the arc and fumes and has helped clean up the welder''s environment. Throughout the world many new alloys are being developed. Metals compete with plastics, composites, ceramics, and any material that will serve the need. The end result is the most economical material for a given application. Many new steels and alloys are being welded today, including higher strength thermomechanically processed steels. Steels with lower carbon and lower impurity elements are available with high strengths based on the particular heat treatment. New steels for high-temperature applications have been developed. New grades of stainless steel that combat corrosion are appearing. New aluminums containing lithium and other elements are being utilized in the aircraft industry. Nonmetallic materials are advancing. Plastics have been greatly improved, and there are now composite beams available to build bridges. Ultimately, the most suitable material for the lowest price will be used for every application. The welding industry will determine the welding method. Welding education and training are changing. Today there is less emphasis on skill training for manual welding, but more emphasis on technology training. We must be able to select the proper application of welding to increase productivity. A more thorough understanding is needed. That is the purpose of this book. A major breakthrough has been accomplished by the joint American Welding Society (AWS) and the Welding Research Council program for providing the optimum way to make a quality weld. Standard welding procedures have been issued that show the preferred way to make a particular weld. As a result, welding costs should be greatly reduced because standard procedures save the expense of duplicating qualifying procedures and allow the portability of welding credentials. It is a great step forward. The American Welding Society continues to make welding-related occupations more professional. Through standardizing the qualification and certification of personnel, public confidence in welding will increase. AWS has become the welding authority in the United States and is providing ways to educate welding inspectors, teachers, technicians, and engineers. This is done through increased training, testing, and certification of knowledge, based on proficiency testing. The original concept of this book has been maintained, with emphasis on the arc welding processes and the use of steel for industrial and construction uses. The book still follows faithfully the standards, codes, and specifications provided by the AWS. It allows the reader to keep up-to-date as welding technical information and technology improvements advance. Truly, the industry is moving rapidly, and the welding process is improved and more productive.