Welding Principles and Applications

by Jeffus, Larry

• ISBN13: 9780827382404
• ISBN10: 0827382405
• Additional ISBN(s): 9781401810467
• Edition: 4th
• Format: Hardcover
• Copyright: 1997-09-30
• Publisher: CENGAGE Delmar Learning
• More Book Details
• Purchase Benefits

Summary

This all-encompassing guide covers all aspects of welding, as progressively guiding them from the absolute basics to AWS Certified Welder Test preparation. Experiments and practices are designed to familiarize the student with a wide range of machine settings, production of quality welds, while minimizing wasted stock and nonskilled work such as grinding and finishing.Based on standards established by the American Welding Society, the student learns to develop industry-acceptable practices for professional application.

Table of Contents

Preface	xi
Acknowledgments	xv
Index of Experiments and Practices	xvi
SECTION 1 INTRODUCTION
Introduction to Welding
Introduction	2	(1)
Welding Defined	3	(1)
Uses of Welding	4	(2)
Welding Processes	6	(4)
Occupational Opportunities in Welding	10	(2)
Training for Welding Occupations	12	(1)
Experiments and Practices	12	(2)
Metric Units	14	(5)
Safety in Welding
Introduction	19	(1)
Burns	20	(1)
Eye and Ear Protection	21	(4)
Respiratory Protection	25	(1)
Material Specification Data Sheets (MSDS's)	26	(1)
Ventilation	26	(1)
Electrical Safety	27	(1)
General Work Clothing	28	(1)
Special Protective Clothing	28	(2)
Handling and Storing Cylinders	30	(1)
Fire Protection	31	(2)
Equipment Maintenance	33	(1)
Work Area	33	(1)
Hand Tools	34	(1)
Power Tools	34	(2)
Metal Cutting Machines	36	(1)
Material Handling	37	(1)
Safety First	38	(6)
SECTION 2 SHIELDED METAL ARC WELDING
Shielded Metal Arc Equipment, Setup, and Operation
Introduction	44	(1)
Welding Current	45	(2)
Types of Welding Power	47	(1)
Open Circuit Voltage	47	(1)
Operating Voltage	48	(1)
Arc Blow	48	(1)
Types of Power Sources	49	(3)
Generators and Alternators	52	(1)
Rectifiers	53	(1)
Duty Cycle	54	(1)
Welding Cables	55	(1)
Electrode Holders	55	(2)
Work Clamps	57	(1)
Setup	58	(3)
Shielded Metal Arc Welding of Plate
Introduction	61	(2)
Effect of Too High or Too Low Current Settings	63	(1)
Electrode Size and Heat	64	(1)
Arc Length	65	(1)
Electrode Angle	66	(3)
Electrode Manipulation	69	(1)
Positioning of the Welder and the Plate	70	(1)
Practice Welds	71	(1)
Stringer Beads	72	(2)
Square Butt Joint	74	(4)
Lap Joint	78	(3)
Tee Joint	81	(5)
Shielded Metal Arc Welding of Pipe
Introduction	86	(1)
Pipe and Tubing	87	(4)
Preparation and Fitup	91	(1)
Practice Welds	92	(3)
1G Horizontal Rolled Position	95	(4)
2G Vertical Fixed Position	99	(2)
5G Horizontal Fixed Position	101	(1)
6G 45° Inclined Position	102	(5)
Advanced Shielded Metal Arc Welding
Introduction	107	(1)
Root Pass	108	(5)
Hot Pass	113	(2)
Filler Pass	115	(2)
Cover Pass	117	(1)
Plate Preparation	117	(2)
Preparing Specimens for Testing	119	(2)
Restarting a Weld Bead	121	(1)
Preheating and Postheating	121	(9)
Poor Fit	130	(8)
SECTION 3 CUTTING AND GOUGING
Flame Cutting
Introduction	138	(1)
Eye Protection for Flame Cutting	139	(1)
Cutting Torches	139	(2)
Cutting Tips	141	(2)
Oxyfuel Cutting, Setup, and Operation	143	(3)
Hand Cutting	146	(3)
Layout	149	(1)
Selecting the Correct Tip and Setting the Pressure	149	(2)
The Chemistry of a Cut	151	(1)
The Physics of a Cut	152	(3)
Plate Cutting	155	(1)
Methods of Improving Cuts	155	(1)
Distortion	156	(2)
Cutting Applications	158	(1)
Pipe Cutting	159	(6)
Plasma Arc Cutting
Introduction	165	(1)
Plasma	166	(1)
Arc Plasma	166	(1)
Plasma Torch	166	(2)
Power and Gas Cables	168	(2)
Power Requirements	170	(1)
Heat Input	171	(1)
Distortion	171	(1)
Applications	172	(3)
Gases	175	(1)
Machine Cutting	176	(1)
Manual Cutting	177	(1)
Plasma Arc Gouging	178	(1)
Safety	179	(7)
Related Cutting Processes
Introduction	186	(1)
Laser Beam Cutting (LBC) and Laser Beam Drilling (LBD)	186	(1)
Lasers	187	(2)
Applications	189	(1)
Laser Beam Cutting	189	(1)
Laser Beam Drilling	190	(1)
Laser Equipment	190	(1)
Air Carbon Arc Cutting	191	(1)
Manual Torch Design	192	(3)
Safety	195	(4)
Oxygen Lance Cutting	199	(1)
Application	199	(1)
Water Jet Cutting	199	(1)
Applications	200	(6)
SECTION 4 GAS SHIELDED WELDING
Gas Metal Arc Welding Equipment, Setup, and Operation
Introduction	206	(2)
Metal Transfer	208	(5)
Filler Metal Specifications	213	(1)
Wire Melting and Deposition Rates	213	(1)
Welding Power Supplies	213	(3)
Molten Weld Pool Control	216	(4)
Equipment	220	(5)
Spot Welding	225	(5)
Gas Metal Arc Welding
Introduction	230	(1)
Setup	230	(7)
Gas Density and Flow Rates	237	(1)
Arc-Voltage and Amperage Characteristics	238	(1)
Electrode Extension	239	(2)
Welding Gun Angle	241	(1)
Effect of Shielding Gas on Welding	241	(2)
Practices	243	(1)
Metal Preparation	244	(1)
Flat Position, 1G and 1F Position	245	(4)
Vertical Up 3G and 3F Positions	249	(2)
Vertical Down 3G and 3F Positions	251	(1)
Horizontal 2G and 2F Positions	252	(1)
Overhead 4G and 4F Positions	253	(2)
Pulsed-Arc Metal Transfer, 1G Position	255	(3)
Axial Spray	258	(5)
Flux Cored Arc Welding Equipment, Setup, and Operation
Introduction	263	(1)
Principles of Operation	264	(2)
Equipment	266	(1)
Advantages	266	(1)
Limitations	267	(1)
Electrodes: Methods of Manufacturing	267	(1)
Flux	268	(4)
Shielding Gas	272	(1)
Welding Techniques	273	(6)
Flux Cored Arc Welding
Introduction	279	(1)
Practices	280	(3)
Flat-Position Welds	283	(1)
Square-Groove Welds	284	(2)
V-Groove and Bevel-Groove Welds	286	(5)
Fillet Welds	291	(6)
Vertical Welds	297	(5)
Horizontal Welds	302	(4)
Overhead-Position Welds	306	(4)
Thin-Gauge Welding	310	(7)
Other Constant Potential Welding Processes
Introduction	317	(1)
Submerged Arc Welding (SAW)	318	(1)
Weld Travel	318	(1)
Electrode Feed	319	(1)
Contact Tip	320	(1)
Electrode	320	(1)
Flux	320	(1)
Advantages of SAW	321	(1)
Disadvantages	321	(1)
Arc Starting	322	(1)
Weld Backing	322	(1)
Hand-Held SAW	322	(1)
Experiments	322	(1)
Electroslag Welding (ESW)	323	(2)
Electrogas Welding (EGW)	325	(4)
Gas Tungsten Arc Welding Equipment, Setup, Operation, and Filler Metals
Introduction	329	(3)
Types of Tungsten	332	(1)
Shaping the Tungsten	333	(2)
GTA Welding Equipment	335	(4)
Types of Welding Currents	339	(2)
Shielding Gases	341	(2)
Remote Controls	343	(8)
Gas Tungsten Arc Welding of Plate
Introduction	351	(1)
Torch Angle	352	(1)
Filler Rod Manipulation	352	(1)
Tungsten Contamination	353	(1)
Current Setting	354	(1)
Gas Flow	355	(2)
Practice Welds	357	(24)
Gas Tungsten Arc Welding of Pipe
Introduction	381	(1)
Practices	382	(1)
Joint Preparation	382	(1)
Root	383	(2)
Backing Gas	385	(2)
Filler Metal	387	(4)
Hot Pass	391	(3)
Filler Pass	394	(1)
Cover Pass	395	(11)
SECTION 5 RELATED PROCESSES
Welding Joint Design, Welding Symbols, and Fabrication
Introduction	406	(1)
Weld Joint Design	407	(6)
Mechanical Drawings	413	(5)
Welding Symbols	418	(1)
Indicating Types of Welds	418	(1)
Weld Location	419	(1)
Location Significance of Arrow	420	(1)
Fillet Welds	421	(1)
Plug Welds	421	(1)
Spot Welds	422	(1)
Seam Welds	423	(1)
Groove Welds	423	(2)
Backing	425	(1)
Flanged Welds	425	(2)
Nondestructive Testing Symbols	427	(3)
Fabrication	430	(4)
Layout	434	(8)
Material Shapes	442	(3)
Assembly	445	(1)
Assembly Tools	446	(1)
Fitting	447	(1)
Tack Welding	448	(1)
Welding	449	(2)
Finishing	451	(6)
Welding Codes, Standards and Welding Cost
Introduction	457	(1)
Codes, Standards, Procedures, and Specifications	458	(1)
Welding Procedure Qualification	459	(1)
General Information	460	(11)
Welding Costs	471	(1)
Cost Estimation	472	(2)
Weld Metal Cost	474	(7)
Factors for Cost Formulas	481	(4)
Comparing Weld Metal Costs	485	(3)
Other Useful Formulas	488	(4)
Testing and Inspection of Welds
Introduction	492	(1)
Quality Control	492	(1)
Discontinuities and Defects	493	(6)
Destructive Testing	499	(9)
Nondestructive Testing	508	(12)
Welder Certification
Introduction	520	(1)
Qualified and Certified Welders	521	(1)
AWS Entry-Level Welder Qualification and Welder Certification	521	(8)
Welding Skill Development	529	(2)
Welder Qualification and Certification Test Instructions for Practices	531	(1)
Dimensional Tolerances	531	(4)
Dimensional Tolerances	535	(3)
Layout, Assembly, and Fabrication of Weldments	538	(31)
Performance Qualification Test Record	569	(2)
Railroad Welding
Introduction	571	(1)
Rail Types	572	(3)
Continuous Welded Track	575	(1)
Rail Repairs	575	(4)
Gouging	579	(1)
Cracks	579	(1)
Rail Ends	580	(1)
Arc Welding (AW)	580	(3)
Flash Welding (FW)	583	(1)
Thermite Welding (TW)	583	(7)
SECTION 6 RELATED PROCESSES AND TECHNOLOGY
Welding Metallurgy
Introduction	590	(1)
Heat, Temperature, and Energy	591	(2)
Mechanical Properties of Metal	593	(2)
Structure of Matter	595	(1)
Crystalline Structures of Metal	595	(1)
Phase Diagrams	596	(5)
Strengthening Mechanisms	601	(6)
Heat Treatments Associated with Welding	607	(2)
Thermal Effects Caused by Arc Welding	609	(1)
Gases in Welding	610	(3)
Metallurgical Defects	613	(5)
Weldability of Metals
Introduction	618	(1)
Steel Classification and Identification	619	(1)
Carbon and Alloy Steels	619	(3)
Tool Steel	622	(1)
High-Manganese Steel	622	(1)
Low-Alloy, High-Tensile Strength Steels	623	(1)
Stainless Steels	623	(1)
Chromium-Molybdenum Steel	624	(1)
Cast Iron	624	(2)
Copper and Copper Alloys	626	(1)
Aluminum Weldability	626	(1)
Titanium	626	(1)
Magnesium	626	(1)
Repair Welding	627	(6)
Filler Metal Selection
Introduction	633	(7)
SMAW Operating Information	640	(1)
Core Wire	641	(1)
Functions of the Flux Covering	641	(1)
Filler Metal Selection	641	(2)
AWS Filler Metal Classifications	643	(1)
Carbon Steel	643	(9)
Aluminum and Aluminum Alloys	652	(5)
Welding Automation and Robotics
Introduction	657	(1)
Manual Joining Process	658	(1)
Semiautomatic Joining Processes	658	(1)
Machine Joining Processes	659	(1)
Automatic Joining Processes	660	(1)
Automated Joining	660	(1)
Industrial Robots	661	(11)
Future Automation	672	(4)
Other Welding Processes
Introduction	676	(1)
Resistance Welding (RW)	677	(7)
Electron Beam Welding (EBW)	684	(2)
Ultrasonic Welding (USW)	686	(1)
Inertia Welding Process	687	(3)
Laser Welding (LBW)	690	(1)
Plasma-Arc Welding Process (PAW)	691	(1)
Stud Welding (SW)	692	(1)
Hardfacing	693	(3)
Thermal Spraying (THSP)	696	(2)
Cold Welding (CW)	698	(8)
SECTION 7 OXYFUEL
Oxyfuel Welding and Cutting Equipment, Setup, and Operation
Introduction	706	(1)
Pressure Regulators	707	(6)
Welding and Cutting Torches Design and Service	713	(3)
Welding and Heating Tips	716	(1)
Reverse Flow and Flashback Valves	717	(2)
Hoses and Fittings	719	(1)
Backfires and Flashbacks	720	(1)
Types of Flames	721	(1)
Leak Detection	722	(5)
Manifold Systems	727	(2)
Safety	729	(4)
Oxyfuel Gases and Filler Metals
Introduction	733	(1)
Fuel Gases	734	(1)
Flame Rate of Burning	735	(1)
Acetylene (C2H2)	736	(3)
Liquefied Fuel Gases	739	(1)
Pressure	739	(1)
Methylacetylene-Propadiene (MPS)	739	(3)
Propane and Natural Gas	742	(1)
Hydrogen	742	(3)
Filler Metals	745	(1)
Mild Steel	746	(3)
Oxyacetylene Welding
Introduction	749	(1)
Mild Steel Welds	750	(7)
Outside Corner Joint	757	(1)
Butt Joint	758	(2)
Lap Joint	760	(3)
Tee Joint	763	(2)
Out-of-Position Welding	765	(1)
Vertical Welds	765	(1)
Butt Joint	766	(1)
Lap Joint	766	(1)
Tee Joint	767	(1)
Horizontal Welds	768	(1)
Horizontal Stringer Bead	768	(1)
Butt Joint	769	(1)
Lap Joint	769	(1)
Tee Joint	769	(1)
Overhead Welds	770	(1)
Stringer Bead	770	(1)
Mild Steel Pipe and Tubing	771	(1)
Horizontal Rolled Position 1G	771	(2)
Horizontal Fixed Position 5G	773	(2)
Vertical Fixed Position 2G	775	(1)
45° Fixed Position 6G	775	(1)
Thin-Wall Tubing	776	(4)
Soldering, Brazing, and Braze Welding
Introduction	780	(1)
Advantages of Soldering and Brazing	781	(2)
Physical Properties of the Joint	783	(1)
Fluxes	784	(2)
Soldering and Brazing Methods	786	(4)
Filler Metals	790	(4)
Joint Design	794	(8)
Building Up Surfaces and Filling Holes	802	(2)
Soldering	804	(8)
APPENDIX
I. Conversion of Decimal Inches to Millimeters and Fractional Inches to Decimal Inches and Millimeters	812	(1)
II. Conversion Factors: U.S. Customary (Standard) Units and Metric Units (SI)	813	(2)
III. Abbreviations and Symbols	815	(1)
IV. Metric Conversions Approximations	816	(1)
V. Pressure Conversion	816	(1)
VI. Structural Metal Shape Designations	817	(14)
VII. Welding Codes and Specifications	831	(1)
VIII. Welding Associations and Organizations	832	(3)
Glossary	835	(50)
Index	885