Summary

An easy-to-read and highly visual “diameter of electrodes” approach to welding.

Most textbooks do not cover smaller diameter electrodes well. Welding does. With over 50 years combined experience, the authors have created a book that is both reference-friendly and incredibly engaging to students and professionals alike. With setups for every important weld and step-by-step procedures and photos for every step, this is the only book on welding you will ever need.

Welding provides readers with cleanly designed and concise chapters. Essential coverage of safety, theory, key skills, easy-to-read reference charts and tables, detailed step-by-step procedures, and a strong emphasis on the diameter of electrodes is covered in a simple, yet comprehensive way. After an introduction to welding and to welding safety, each major welding process is presented in its own chapter so they can easily be discussed in the classroom. Following the weld processes, chapters focus on critical topics such as codes, destructive and non-destructive weld testing, welding symbols, welding metallurgy, welding ferrous and nonferrous alloys, and welding power sources.

The Second Edition has been updated to include a new chapter on pipe welding and techniques, a new macro look at metallurgy, and a more procedural approach to welding alloys. Welding codes and testing have also been split into two separate chapters, for accessibility and ease of use.

Author Biography

The authors of Welding, 2/e have experience both in industry and in the classroom. Their industry experience brings together knowledge of welding and manufacturing, welding inspection and quality control, power source design, troubleshooting, and customer service. These experiences, combined with more than 50 years of instructional expertise, inspired the development of this textbook and its accompanying technology.

David Hoffman

Member, American Welding Society

Certified Welding Inspector

Certified CRAW Technician

Fox Valley Technical College

An accomplished welder with thousands of hours of hands-on experience, Dave Hoffman has been teaching welding and fabrication for more than 25 years. He assisted with the development of an Associate Degree program in Automated Manufacturing at Fox Valley Technical College and developed an Associate Degree program for Welding Technology. He also received a state grant to redevelop the Metal Fabrication/Welding Diploma program for which he wrote program requirements, competencies, and the complete curriculum.

After completing development of the Associate Degrees in Welding Technology, Dave tested and passed the requirements to become an AWS CWI and CWE. Shortly after, he got involved with AWS and was on the B5E Committee, helping to write the B5.5: 2000, Specification for the Qualification of Welding Educators. Most of the welder certifications in that standard were already certified, however some were not. Dave welded GMAW-S vertical up and overhead plates to certify the welding procedure used in the standard.

A past winner of the prestigious Lincoln Award, Dave holds a B.S. in Industrial Education and an M.S. in Technical Education from the University of Wisconsin - Stout. He also holds (and wrote) a patent on a product he designed and built in his home shop, and since retiring from teaching, occasionally works as a weld consultant for training and testing in industry.

Kevin Dahle

Member, American Welding Society

Member, Artist Blacksmith Association of North America

Certified Welding Inspector

Fox Valley Technical College

Kevin Dahle has twenty years of experience teaching as a welding instructor at the Associate Degree and Vocational Diploma levels. In addition, he has taught welding apprentices, as well as related welding courses for transportation technology students and agriculture students. Kevin has been involved in training for industry and responsible for overseeing welder and procedure qualifications as an AWS Certified Welding Inspector.

Kevin’s educational background includes an AS in Industrial Welding Technology, a BS in Vocational, Technical and Adult Education, and an MA in English. His occupational experience in welding consists of production welding, repair welding, structural welding, and quality control — writing and overseeing quality programs for structural welding and boiler repair.

David Fisher

Member, American Welding Society

Certified Welding Inspector

Fox Valley Technical College

David Fisher has five years of experience teaching as a welding/metal fabrication instructor at the Associate Degree and Vocational Diploma levels. In addition, he has taught welding apprentices, as well as related welding courses for transportation technology students and agriculture students. David has been involved in training for industry and responsible for overseeing welder and procedure qualifications as an AWS Certified Welding Inspector.

Prior to his academic career, David worked for Miller Electric Manufacturing Company. He was initially hired to build new inverter welders and eventually joined the service department where he conducted repair, maintenance, and operation of welding power sources and accessories for customers. As an application technician for Tig Industrial Products, David provided information and advice to customers, welding distributors, and salesmen regarding the GTAW and SMAW processes.

David holds an AS Degree in Electrical Engineering Technology and is currently working on his BS in Mechanical Engineering.

Part 1 Introductory Materials

Chapter 1 Welding Jobs and Employment Skills

Introduction

Chapter 2 Safety in Welding

Safety Overview

The Hazardous Materials Identification System

Personal Protective Equipment (PPE)

Electrical Considerations

Secondary Welding Output

Gases and Fumes

Ventilation

Fire Prevention

Explosion

Compressed Cylinders

Part 2 Commonly Used Welding Processes

Chapter 3 Shielded Metal Arc Welding

Introduction

SMAW Safety

Power Source and Peripherals

Controls and Characteristics

SMAW Setup

Technique

Electrodes

Chapter 4 Gas Metal Arc Welding

Introduction

Safety

Power Source and Peripherals

Controls and Characteristics

GMAW Setup

Technique

Modes of Metal Transfer

Electrodes

Shielding Gases 123

Chapter 5 Flux Cored Arc Welding

Introduction

Safety

Power Source and Peripherals

Controls and Characteristics

FCAW Setup

Technique

Electrodes

Shielding Gases

Chapter 6 Gas Tungsten Arc Welding

Introduction

Safety

Power Source and Peripherals

Controls and Characteristics

Optional Controls and Characteristics

Technique

Filler Metal

Shielding Gases

Electrodes

Chapter 7 Pipe Welding

Introduction

Pipe Welding Primer

Joint Preparation

Weld Joint Fit Up

Tack Welds

Root Pass Welding

Fill Pass Welding

Cap Pass Welding

Technique

Welding Tables

Part 3 Other Welding and Related Processes

Chapter 8 Other Welding Processes

Introduction

Oxygen-Fuel Welding

Torch Shutdown

Plasma Arc Welding

Resistance Welding

Stud Welding

Submerged Arc Welding

Electroslag Welding

Solid State Welding Processes

Chapter 9 Cutting Processes

Introduction

Cutting Terminology

Oxygen-Fuel Cutting

Step-By-Step Torch Shutdown

Air Carbon Arc Cutting

Plasma Arc Cutting

Laser Beam Cutting

Abrasive Water Jet Cutting

Part 4 Metals and Alloys

Chapter 10 Metals and Welding Metallurgy

Welding Metallurgy

Physical and Mechanical Properties of Metals

Metal Identification Methods

Crystalline Structure of Metals

Iron-Carbon Phase Diagram

Heat-Treating Processes

Welding Cooling Rate Effects

Transverse And Longitudinal Shrinkage

Chapter 11 Welding Ferrous Alloys

Introduction

Welding Carbon and Low-Alloy Steels

Welding Stainless Steels

Welding Tool Steels

Welding Cast Irons

Chapter 12 Welding Nonferrous Alloys

Welding Aluminum

Welding Magnesium

Welding Nickel-Based Alloys

Welding Reactive Metals Titanium

Part 5 Welding Related Concentrations

Chapter 13 Welding Symbols

Introduction

Welding Symbols

Weld Symbols

Fillet Weld Symbol

Seam Weld Symbol

Spot Weld Symbol

Projection Weld Symbol

Stud Weld Symbol

Plug Weld Symbol

Slot Weld Symbol

Groove Weld Symbols

Edge Weld Symbol

Surface Weld Symbol

NonDestructive Weld Symbols

Chapter 14 Welding Codes

Introduction

The Welding Inspector—General

Codes, Standards, and Specifications

Qualifications

Welding Procedures

Essential and Nonessential Variables

Chapter 15 Weld Testing

Weld Testing

Testing Fillet Welds

Nondestructive Testing

Radiographic Testing

Ultrasonic Testing

Magnetic Particle Testing

Dye Penetrant Testing

Chapter 16 Power Sources

Introduction

Electron Theory

Electrical Current

Direct Current

Alternating Current

Power Sources

Power Source Ratings

Part 6 Supplementary Information

Appendix A Troubleshooting

Appendix B Conversion

Appendix C Properties

Appendix D Pipes and Beams

Appendix E Load Strength

Appendix F Welding Formulas and Costs

Appendix G Periodic Table

Glossary

Index

Supplemental Materials

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