Welding No. 2 : Principles and Practices

by Raymond Sacks

• ISBN13: 9780026661201
• ISBN10: 0026661209
• Format: Hardcover
• Copyright: 1999-01-01
• Publisher: GLENCOE

Summary

Ideal for training programs, vocational and college courses, the Third Edition of Sacks & Bohnart's Welding: Principles and Practices provides a balanced mix of theory and practice for all important welding techniques. Learning features, such as the numerous "Practice Jobs" and "About Welding" sections help build basic, hands-on skills. The new edition features coverage of modern welding technologies, as well as the basics of arc welding. Practical coverage of safety, testing and inspection, and the reading of shop drawings is also included. New and revised instructor resources are available to aid in testing, grading, and classroom presentation of course materials. A Student Workbook provides an extensive resource of activities for students. Book jacket.

Table of Contents

Preface	p. xiii
Acknowledgments	p. xv
Introduction to Welding and Oxyfuel	p. 2
History of Welding	p. 3
Overview	p. 3
The History of Metalworking	p. 4
Welding as an Occupation	p. 7
Industrial Welding Applications	p. 8
Review	p. 12
Industrial Welding	p. 15
Fabrication	p. 16
Maintenance and Repair	p. 16
Industries	p. 17
Review	p. 34
Steel and Other Metals	p. 37
History of Steel	p. 38
Raw Materials for the Making of Steel	p. 39
The Smelting of Iron	p. 52
Steelmaking Processes	p. 55
Metalworking Processes	p. 75
Metal Internal Structures	p. 80
Physical Properties of Metals	p. 83
Effects of Common Elements on Steel	p. 87
Types of Steel	p. 92
SAE/AISI Steel Numbering System	p. 98
Types of Cast Iron	p. 103
Aluminum-making in the United States	p. 107
Titanium-making in the United States	p. 109
Unique Metals	p. 111
Effects of Welding on Metal	p. 111
Review	p. 123
Basic Joints and Welds	p. 127
Types of Joints	p. 128
The Four Weld Types	p. 128
Weld Size and Strength	p. 129
Weld Positions	p. 135
Strength of Welds	p. 139
Common Weld and Weld-Related Discontinuities	p. 140
Review	p. 151
Gas Welding	p. 155
Oxyacetylene Welding	p. 155
Gases	p. 157
General Cylinder Handling, Storage, and Operation Safety Concerns	p. 161
Welding Equipment	p. 166
Supporting Equipment	p. 181
Safety Equipment	p. 182
General Safety Operating Procedures	p. 184
Review	p. 185
Flame Cutting Principles	p. 189
Oxyacetylene and Other Fuel Gas Cutting	p. 189
Oxygen Lance Cutting	p. 198
Review	p. 200
Flame Cutting Practice: Jobs 7-J1-J3	p. 203
Review of Flame Cutting Principles	p. 204
Cutting Different Metals	p. 206
Cutting Technique	p. 207
Surface Appearance of High Quality Flame Cuts	p. 211
Arc Cutting	p. 213
Practice Jobs	p. 213
Review	p. 227
Gas Welding Practice: Jobs 8-J1-J38	p. 231
Sound Weld Characteristics	p. 232
The Oxyacetylene Welding Flame	p. 233
Setting Up the Equipment	p. 235
Flame Adjustment	p. 238
Closing Down the Equipment	p. 239
Safety	p. 240
Practice Jobs	p. 241
Low Carbon Steel Plate	p. 241
Heavy Steel Plate and Pipe	p. 252
Review	p. 260
Braze Welding and Advanced Gas Welding Practice: Jobs 9-J39-J53	p. 263
Braze Welding	p. 263
Welding Cast Iron	p. 267
Welding of Aluminum	p. 270
Welding Other Metals with the Oxyacetylene Process	p. 275
Hard Facing (Surfacing)	p. 279
Review	p. 283
Soldering and Brazing Principles and Practice: Jobs 10-J54-J55	p. 287
Soldering and Brazing Copper Tubing	p. 287
Soldering	p. 288
Practice Jobs: Soldering	p. 296
Torch Brazing (TB)	p. 298
Practice Jobs: Brazing	p. 308
Review	p. 313
Shielded Metal Arc Welding	p. 316
Shielded Metal Arc Welding Principles	p. 317
Process Capability	p. 317
Operating Principles	p. 318
Welding Power Sources	p. 319
Machines for Shielded Metal Arc Welding	p. 323
Multiple-Operator Systems	p. 331
Power Supply Ratings	p. 332
Cables and Fasteners	p. 333
Electrode Holders	p. 336
Other Electric Arc Processes	p. 337
Personal Safety Equipment	p. 338
Review	p. 343
Shielded Metal Arc Welding Electrodes	p. 345
Introduction	p. 345
Shielded Metal Arc Welding Electrodes	p. 346
Functions of Electrode Coverings	p. 347
Composition of Electrode Coverings	p. 348
Identifying Electrodes	p. 349
Electrode Selection	p. 351
Specific Electrode Classifications	p. 362
Packing and Protection of Electrodes	p. 376
Review	p. 380
Shielded Metal Arc Welding Practice: Jobs 13-J1-J28 (Plate)	p. 383
Introduction	p. 383
Approach to the Job	p. 384
Learning Welding Skills	p. 387
Practice Jobs	p. 392
Review	p. 444
Shielded Metal Arc Welding Practice: Jobs 14-J26-J42 (Plate)	p. 447
Introduction	p. 447
Practice Jobs	p. 448
Review	p. 487
Shielded Metal Arc Welding Practice: Jobs 15-J43-J55 (Plate)	p. 491
Introduction	p. 491
Practice Jobs	p. 492
Tests	p. 520
Review	p. 531
Pipe Welding and Shielded Metal Arc Welding Practice: Jobs 16-J1-J17 (Pipe)	p. 535
Introduction	p. 535
Shielded Metal Arc Welding of Pipe	p. 543
Joint Design	p. 544
Codes and Standards	p. 549
Practice Jobs	p. 566
Tools for Pipe Fabrication	p. 581
Review	p. 588
Arc Cutting and Gas Tungsten Arc Welding	p. 594
Arc Cutting Principles and Arc Cutting Practice: Jobs 17-J1-J7	p. 595
Arc Cutting	p. 595
Learning Arc Cutting Skills	p. 614
Practice Jobs	p. 614
Review	p. 627
Gas Tungsten Arc and Plasma Arc Welding Principles	p. 631
Gas Shielded Arc Welding Processes	p. 631
Gas Tungsten Arc Welding	p. 636
TIG Hot Wire Welding	p. 664
Review	p. 676
Gas Tungsten Arc Welding Practice: Jobs 19-J1-J19 (Plate)	p. 681
Gas Tungsten Arc Welding of Various Metals	p. 681
Joint Design and Practices	p. 691
Setting Up the Equipment	p. 693
Safe Practices	p. 694
Arc Starting	p. 696
Welding Technique	p. 698
Practice Jobs	p. 700
Review	p. 716
Gas Tungsten Arc Welding Practice: Jobs 20-J1-J17 (Pipe)	p. 719
Joint Design	p. 720
Porosity in Gas Tungsten Arc Welds	p. 724
Practice Jobs	p. 725
Review	p. 741
Gas Metal Arc, Flux Cored Arc and Submerged Arc Welding	p. 746
Gas Metal Arc and Flux Cored Arc Welding Principles	p. 747
Overview	p. 747
GMAW/FCAW Welding Equipment	p. 757
Summary	p. 803
Review	p. 804
Gas Metal Arc Welding Practice with Solid and Metal Core Wire: Jobs 22-J1-J23 (Plate)	p. 807
Operating Variables That Affect Weld Formation	p. 807
Weld Defects	p. 818
Safe Practices	p. 820
Care and Use of Equipment	p. 823
Welding Technique	p. 828
Process and Equipment Problems	p. 829
Practice Jobs	p. 829
Gas Metal Arc Welding of Other Metals	p. 847
Review	p. 852
Flux Cored Arc Welding Practice (Plate), Submerged Arc Welding, and Related Processes: Jobs FCAW-G Jobs 22-J1-11, FCAW-S Jobs 22-1-12, SAW 22-1	p. 855
Flux Cored Wire Welding	p. 855
Flux Cored Arc Welding-Gas Shielded Practice Jobs	p. 868
Flux Cored Arc Welding-Self-Shielded	p. 873
Flux Cored Arc Welding-Self-Shielded Practice Jobs	p. 874
Automatic welding processes	p. 877
Submerged Arc Welding Semiautomatic Practice Job	p. 887
Choice of Welding Process	p. 892
Review	p. 893
Gas Metal Arc Welding Practice: Jobs 22-J1-J15 (Pipe)	p. 899
Industrial Applications of GMAW Pipe Welding	p. 899
Use of Equipment and Supplies	p. 901
Welding Operations	p. 903
Practice Jobs	p. 905
Review	p. 920
High Energy Beams, Automation, Robotics, and Weld Shop Management	p. 924
High Energy Beams and Related Welding and Cutting Process Principles	p. 925
Introduction	p. 925
High Energy Beam Processes	p. 926
Summary	p. 937
Review	p. 939
General Equipment for Welding Shops	p. 941
Screens and Booths	p. 941
Work-Holding Devices	p. 942
Preheating and Annealing Equipment	p. 955
Sandblasting Equipment	p. 956
Spot Welder	p. 957
Hydraulic Tools	p. 957
Power Squaring Shears	p. 962
Small Hand Tools	p. 963
Portable Power Tools	p. 965
Machine Tools	p. 972
Review	p. 980
Automatic and Robotic Arc Welding Equipment	p. 983
Arc Control Devices	p. 986
Arc Monitoring	p. 989
Controller Communication	p. 995
Robotic Arc Welding Systems	p. 996
Robot Ratings	p. 999
Robot Programming	p. 1000
Training, Qualification, and Certification	p. 1000
Conclusion	p. 1003
Review	p. 1004
Joint Design, Testing, and Inspection	p. 1007
Joint Design	p. 1008
Code Welding	p. 1015
Nondestructive Testing (NDT)	p. 1019
Destructive Testing	p. 1037
Visual Inspection	p. 1054
Summary	p. 1063
Review	p. 1066
Reading Shop Drawings	p. 1069
Introduction	p. 1069
Standard Drawing Techniques	p. 1072
Gauges	p. 1081
Types of Views	p. 1081
Review	p. 1088
Welding Symbols	p. 1103
Fillet Welds and Symbol	p. 1105
Weld-All-Around Symbol	p. 1108
Groove Welds	p. 1108
Edge Welds	p. 1111
Combination Symbols	p. 1111
Contour Symbol	p. 1112
Applications of Welding Symbols	p. 1112
Review	p. 1114
Pressure Vessel	p. 1116
Pressure Vessel Review	p. 1119
Safety	p. 1121
Safety Practices: Electric Welding Processes	p. 1122
Safety Practices: Oxyacetylene Welding and Cutting	p. 1139
Review	p. 1150
Welding and Bonding of Plastics	p. 1157
Know Your Plastics	p. 1159
Characteristics of Plastics	p. 1161
Welding as a Method of Joining Plastics	p. 1163
Inspection and Testing	p. 1175
Practice Jobs	p. 1180
Review	p. 1193
Appendix	p. 1195
Glossary	p. 1209
Illustrated Guide to Welding Terminology	p. 1231
Welding and Allied Processes	p. 1248
Major Agencies Issuing Codes, Specifications and Associations	p. 1250
Sources of Welding Information	p. 1251
Metric Conversion Information for the Welding Industry	p. 1252
Index	p. 1253
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