Welding Technology Fundamentals

by Bowditch, William A.; Bowditch, Kevin E.; Bowditch, Mark A.

• ISBN13: 9781590704059
• ISBN10: 1590704053
• Edition: 3rd
• Format: Hardcover
• Copyright: 2005-03-15
• Publisher: Goodheart-Willcox Pub

Summary

Covers the equipment and techniques associated with the welding and cutting processes most widely used in industry today.

Table of Contents

Introduction	4	(9)
Section 1 Introduction to Welding
Safety in the Welding Shop	13	(8)
Personal Safety and Clothing	14	(1)
Fire Hazards	14	(2)
Electrical Hazards	16	(1)
Machinery Hazards	16	(1)
Fumes and Ventilation	16	(1)
Storing Compressed Gases	16	(1)
Lifting	17	(1)
Hazardous Obstacles	17	(1)
Hand and Power Tools	17	(1)
Designated Welding and Cutting Areas	17	(1)
Suffocation Hazards	17	(1)
Welding on Hazardous Containers	18	(1)
Additional Safety Publications	18	(3)
Welding and Cutting Processes	21	(8)
The Welding Process	21	(1)
Advantages of Welding and Cutting Processes	22	(1)
History of Welding	22	(2)
Recent Developments in Welding and Cutting Processes	24	(1)
Obtaining and Holding a Job in the Welding Industry	24	(2)
Suggested School Subjects for Success	26	(1)
Personal Traits Sought by Employers	26	(1)
Academic Skills Sought by Employers	26	(1)
Factors That Can Lead to Rejection for Employment	26	(1)
Factors That May Lead to Termination from a Job	27	(2)
The Physics of Welding	29	(8)
Welding Theory	30	(1)
Properties of Metals	30	(1)
Effects of Welding	31	(2)
Heat-Treating	33	(1)
Electrical Principles	33	(1)
Units of Measurement	34	(3)
Weld Joints and Positions	37	(14)
Basic Weld Joints	37	(4)
Types of Welds	41	(1)
Joint Geometry	42	(2)
Welding Positions	44	(7)
Section 2 Shielded Metal Arc Welding
SMAW: Equipment and Supplies	51	(14)
Shielded Metal Arc Welding Principles	51	(1)
SMAW Current and Polarity	52	(1)
SMAW Outfit	53	(12)
SMAW: Equipment Assembly and Adjustment	65	(6)
Welding Machine	65	(2)
Electrode and Workpiece Leads	67	(1)
Inspecting the SMAW Outfit	68	(1)
Adjusting the Machine	68	(3)
SMAW: Electrodes	71	(10)
Covered Electrodes	71	(4)
Electrode Amperage Requirements	75	(6)
SMAW: Flat Welding Position	81	(14)
Preparing to Weld	81	(1)
SMAW Safety Precautions	82	(1)
Striking an Arc	82	(1)
Arc Blow	83	(2)
Running a Weld Bead	85	(2)
Drag Welding	87	(1)
Cleaning the Weld	88	(1)
Reading the Bead	88	(1)
Fillet Welding	89	(2)
Butt Joint	91	(4)
SMAW: Horizontal, Vertical, and Overhead Welding Positions	95	(10)
Preparing to Weld	95	(1)
Horizontal Welding Position	96	(3)
Vertical Welding Position	99	(2)
Overhead Welding Position	101	(1)
Weld Defects	102	(3)
Surfacing	105	(10)
Surfacing Principles	105	(1)
Surfacing Electrodes	106	(4)
Surfacing Process	110	(1)
Surfacing with a Shielded Metal Arc	110	(5)
Section 3 Gas Metal Arc Welding
GMAW: Equipment and Supplies	115	(14)
Gas Metal Arc Welding Principles	116	(1)
Metal Transfer	116	(4)
GMAW Equipment	120	(6)
Protective Clothing and Equipment	126	(3)
GMAW: Equipment Assembly and Adjustment	129	(12)
Assembly and Setup	129	(4)
Selecting the Shielding Gas	133	(2)
Selecting the Electrode Wire	135	(1)
Welding Machine Settings	136	(1)
Preparing the Base Metal	137	(1)
Safety Precautions	138	(1)
Shutting Down a GMAW or FCAW Station	138	(3)
GMAW: Flat Welding Position	141	(12)
Gas Metal Arc Welding Principles	141	(1)
Holding the Welding Gun	142	(1)
Laying a Weld Bead	143	(2)
Making a Fillet Weld	145	(3)
Welding Aluminum	148	(2)
Weld Defects	150	(3)
GMAW: Horizontal, Vertical, and Overhead Welding Positions	153	(10)
Out-of-Position GMAW or FCAW	153	(1)
Welding in the Horizontal Welding Position	154	(2)
Welding in the Vertical Welding Position	156	(3)
Welding in the Overhead Welding Position	159	(4)
Section 4 Gas Tungsten Arc Welding
GTAW: Equipment and Supplies	163	(12)
Gas Tungsten Arc Welding Principles	163	(1)
GTAW Equipment	164	(3)
Torches	167	(1)
Cables and Hoses	168	(2)
Shielding Gases	170	(1)
Regulators and Flowmeters	170	(1)
Remote Current Control	171	(1)
Protective Equipment	171	(4)
GTAW: Equipment Assembly and Adjustment	175	(12)
Equipment Assembly	175	(3)
Welding Machine Settings	178	(3)
Selecting and Preparing the Electrode	181	(3)
Preparing Metal for Welding	184	(3)
GTAW: Flat Welding Position	187	(14)
Gas Tungsten Arc Welding Principles	187	(3)
Welding a Bead on Plate	190	(1)
Welding a Bead on Plate with Filler Metal	191	(2)
Welding without Filler Metals	193	(1)
Fillet Welding a Lap Joint	194	(1)
Welding Inside Corner and T-Joints	195	(1)
Welding Butt Joints	196	(1)
Welding Other Metals	197	(1)
Weld Defects	198	(3)
GTAW: Horizontal, Vertical, and Overhead Welding Positions	201	(10)
Out-of-Position GTAW	201	(1)
Welding in the Horizontal Welding Position	202	(2)
Welding in the Vertical Welding Position	204	(1)
Welding in the Overhead Welding Position	205	(2)
Welding Other Metals	207	(4)
Section 5 Plasma Arc Cutting
Plasma Arc Cutting	211	(14)
Plasma Arc Cutting Principles	211	(1)
Plasma Arc Cutting Equipment and Supplies	212	(4)
Equipment Assembly	216	(1)
Safety Equipment	216	(1)
Preparing to Cut	216	(1)
Cutting Procedure	216	(4)
Plasma Arc Gouging	220	(5)
Section 6 Oxyfuel Gas Processes
Oxyfuel Gas Cutting and Welding: Equipment and Supplies	225	(22)
Oxyfuel Gas Cutting and Welding	225	(2)
Acetylene	227	(3)
Oxygen	230	(3)
Manifolds	233	(1)
Pressure Regulators	234	(1)
Hoses and Fittings	234	(3)
Cutting Torches	237	(2)
Welding Torches	239	(4)
Protective Clothing	243	(4)
Oxyfuel Gas Cutting and Welding Equipment: Assembly and Adjustment	247	(12)
Assembling the Cutting or Welding Outfit	247	(2)
Turning on an Oxyacetylene Cutting or Welding Outfit	249	(2)
Checking for Leaks	251	(1)
Flames	252	(1)
Lighting and Adjusting a Positive Pressure Cutting Torch	252	(2)
Shutting Down a Positive Pressure Cutting Torch	254	(1)
Lighting and Adjusting a Positive Pressure Cutting Torch Attachment	254	(1)
Shutting Down a Positive Pressure Cutting Torch Attachment	254	(1)
Lighting and Adjusting the Flame---Recommended Method	255	(1)
Lighting and Adjusting the Flame---Alternate Method	255	(1)
Shutting down an Oxyacetylene Welding Outfit	255	(4)
Oxyfuel Gas Cutting	259	(12)
Oxyfuel Gas Cutting Principles	259	(1)
Oxyfuel Gas Cutting Equipment	260	(1)
Preparing to Cut	260	(1)
Manual Cutting	260	(6)
Cutting Machines and Pattern Tracers	266	(5)
Oxyfuel Gas Welding: Flat Welding Position	271	(16)
Flat Position Welding	271	(1)
Preparing to Weld	272	(1)
Holding the Torch	272	(1)
Describing the Torch Angles	273	(1)
Creating a Continuous Weld Pool	273	(2)
Welding without a Welding Rod	275	(2)
Selecting a Welding Rod	277	(1)
Laying a Weld Bead	278	(9)
Oxyfuel Gas Welding: Horizontal, Vertical, and Overhead Welding Positions	287	(16)
Out-of-Position Welding	287	(1)
Welding in the Horizontal Welding Position	288	(5)
Welding in the Vertical Welding Position	293	(5)
Welding in the Overhead Welding Position	298	(5)
Brazing and Braze Welding	303	(14)
Brazing and Braze Welding Principles	303	(1)
Brazing Filler Metal	304	(2)
Preparing to Braze or Braze Weld	306	(3)
Brazing or Braze Welding Safety Precautions	309	(1)
Brazing	309	(1)
Braze Welding---Flat Position	310	(3)
Brazing and Braze Welding out of Position	313	(4)
Soldering	317	(12)
Soldering Principles	317	(2)
Advantages of Soldering	319	(1)
Soldering Filler Metals	319	(1)
Soldering Fluxes	320	(1)
Hazards of Solders and Fluxes Containing Lead	321	(1)
Acceptable Solders for Drinking Water Systems	321	(1)
Preparing to Solder	322	(1)
Soldering Safety Precautions	323	(1)
Procedures for Torch Soldering	323	(6)
Section 7 Resistance Welding
Resistance Welding: Equipment and Supplies	329	(10)
Principles of Resistance Spot Welding	329	(1)
Welding Machines	329	(6)
Safety	335	(4)
Resistance Welding: Procedures	339	(12)
Selecting the Welding Machine	339	(1)
Selecting the Welding Variables	339	(5)
Welding Mild Steel	344	(1)
Welding Aluminum	344	(1)
Projection Welding	345	(1)
Resistance Seam Welding	345	(6)
Section 8 Special Processes
Special Welding and Cutting Processes	351	(12)
Frequently Used Special Processes	351	(1)
Special Arc Welding Processes	352	(4)
Solid State Welding Processes	356	(1)
Other Welding Processes	357	(2)
Special Cutting Processes	359	(4)
Robotics in Welding	363	(8)
The Reason for Robots	363	(1)
Types of Industrial Robots	364	(1)
Robotic Welding Systems	364	(3)
Safety around Robots	367	(4)
Welding Plastics	371	(8)
Plastics in Manufacturing and Construction	371	(2)
Welding Equipment and Supplies	373	(2)
Plastics-Welding Procedure	375	(4)
Welding Pipe and Tube	379	(16)
Pipes and Tubes	379	(2)
Welding Processes	381	(1)
Types of Joints	382	(2)
Pipe or Tube Welding Positions	384	(2)
Preparations for Welding	386	(2)
Welding Procedures	388	(2)
Keyhole	390	(1)
Multiple Weld Passes	390	(1)
Restarting and Ending a Weld	391	(1)
GTAW and GMAW of Pipes and Tubes	391	(4)
Section 9 Technical Information
Welding Symbols	395	(16)
The Three-View Drawing	395	(2)
The ANSI/AWS Welding Symbol	397	(4)
Fillet Weld Size	401	(2)
Melt-Through and Backing Weld Symbols	403	(1)
Weld-All-Around and Field Weld Symbols	403	(1)
Plug and Slot Welds	404	(1)
Spot Welds	404	(2)
Seam Welds	406	(5)
Inspecting and Testing Welds	411	(16)
Reasons for Inspecting Welds	411	(1)
Types of Tests	412	(15)
Welder Certification	427	(8)
Codes and Specifications	427	(5)
Employment Considerations	432	(1)
Labor Unions	432	(3)
Appendices	435	(6)
Appendix A, Suggested Welding Procedure Specification	435	(1)
Appendix B, Suggested Welding Procedure Qualification Record	436	(2)
Appendix C, Suggested Welding Performance Qualification Test Record	438	(1)
Appendix D, Millimeter/Inch and Fraction/Decimal Equivalents	439	(1)
Appendix E, Advantages and Disadvantages of Various Welding Processes That Use Consumable Electrodes	440	(1)
Appendix F, Percentage of Welding Filler Metal That Becomes Part of a Completed Weld Joint	440	(1)
Appendix G, Variables That Affect the Cost of Welding	440	(1)
Glossary of Technical Terms	441	(15)
Index	456