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Welding Principles and Application

Dimensions (in inches) 8 1/2" x 11"
Hard Bound

A171
901 pages
$147.95  

Author: Jeffus


Table of Contents

Preface
Acknowledgments
Index of Experiments and Practices
SECTION 1 INTRODUCTION
Chapter 1 Introduction to Welding
Introduction
Welding Defined
Uses of Welding
Welding Processes
Occupational Opportunities in Welding
Training for Welding Occupations
Experiments and Practices
Metric Units
Chapter 2 Safety in Welding
Introduction
Burns
Eye and Ear Protection
Respiratory Protection
Material Specification Data Sheets (MSDS s) Ventilation
Electrical Safety
General Work Clothing
Special Protective Clothing
Handling and Storing Cylinders
Fire Protection
Equipment Maintenance
Work Area
Hand Tools
Power Tools
Metal Cutting Machines
Material Handling
Safety First
SECTION 2 SHIELDED METAL ARC WELDING
Chapter 3 Shielded Metal Arc Equipment, Setup, and Operation
Introduction
Welding Current
Types of Welding Power
Open Circuit Voltage
Operating Voltage
Arc Blow
Types of Power Sources
Generators and Alternators
Rectifiers
Duty Cycle
Welding Cables
Electrode Holders
Work Clamps
Setup
Chapter 4 Shielded Metal Arc Welding of Plate
Introduction
Effect of Too High or Too Low Current Settings
Electrode Size and Heat
Arc Length
Electrode Angle .
Electrode Manipulation
Positioning of the Welder and the Plate
Practice Welds
Stringer Beads
Square Butt Joint
Lap Joint
Tee Joint
Chapter 5 Shielded Metal Arc Welding of Pipe
Introduction

Pipe and Tubing:
Preparation and Fitup
Practice Welds
1G Horizontal Rolled Position
2G Vertical Fixed Position
5G Horizontal Fixed Position
6G 45° Inclined Position
Chapter 6 Advanced Shielded Metal Arc Welding

Introduction
Root Pass
Hot Pass
Filler Pass
Cover Pass
Plate Preparation
Preparing Specimens for Testing
Restarting a Weld Bead
Preheating and Postheating
Poor Fit
SECTION 3 CUTTING AND GOUGING

Chapter 7 Flame Cutting
Introduction
Eye Protection for Flame Cutting
Cutting Torches
Cutting Tips
Oxyfuel Cutting, Setup, and Operation
Hand Cutting
Layout
Selecting the Correct Tip and Setting the Pressure
The Chemistry of a Cut
The Physics of a Cut
Plate Cutting
Methods of Improving Cuts
Distortion
Cutting Applications
Pipe Cutting
Chapter 8 Plasma Arc Cutting
Introduction
Plasma
Arc Plasma
Plasma Torch
Power and Gas Cables
Power Requirements
Heat Input
Distortion
Applications
Gases
Machine Cutting
Manual Cutting
Plasma Arc Gouging
Safety
Chapter 9 Related Cutting Processes
Introduction
Laser Beam Cutting (LBC) and Laser Beam Drilling (LBD)
Lasers
Applications
Laser Beam Cutting
Laser Beam Drilling
Laser Equipment
Air Carbon Arc Cutting
Manual Torch Design
Safety
Oxygen Lance Cutting
Application
Water Jet Cutting
Applications
SECTION 4 GAS SHIELDED WELDING
Chapter 10 Gas Metal Arc Welding Equipment, Setup, and Operation
Introduction
Metal Transfer
Filler Metal Specifications
Wire Melting and Deposition Rates
Welding Power Supplies
Molten Weld Pool Control
Equipment
Spot Welding
Chapter 11 Gas Metal Arc Welding
Introduction
Setup
Gas Density and Flow Rates
Arc-Voltage and Amperage Characteristics
Electrode Extension
Welding Gun Angle
Effect of Shielding Gas on Welding
Practices
Metal Preparation
Flat Position, 1G and 1F Position
Vertical Up 3G and 3F Positions
Vertical Down 3G and 3F Positions
Horizontal 2G and 2F Positions
Overhead 4G and 4F Positions
Pulsed-Arc Metal Transfer, 1G Position
Axial Spray
Chapter 12 Flux Cored Arc Welding Equipment, Setup, and Operation
Introduction
Principles of Operation
Equipment
Advantages
Limitations
Electrodes: Methods of Manufacturing
Flux
Shielding Gas
Welding Techniques
Chapter 13 Flux Cored Arc Welding
Introduction
Practices
Flat-Position Welds
Square-Groove Welds
V-Groove and Bevel-Groove Welds
Fillet Welds
Vertical Welds
Horizontal Welds
Overhead-Position Welds
Thin-Gauge Welding
Chapter 14 Other Constant Potential Welding Processes
Introduction
Submerged Arc Welding (SAW)
Weld Travel
Electrode Feed
Contact Tip
Electrode
Flux
Advantages of SAW
Disadvantages
Arc Starting
Weld Backing
Hand-Held SAW
Experiments
Electroslag Welding (ESW)
Electrogas Welding (EGW)
Chapter 15 Gas Tungsten Arc Welding Equipment,
Setup, Operation, and Filler Metals

Introduction
Types of Tungsten
Shaping the Tungsten
GTA Welding Equipment
Types of Welding Currents
Shielding Gases
Remote Controls
Chapter 16 Gas Tungsten Arc Welding of Plate
Introduction
Torch Angle
Filler Rod Manipulation
Tungsten Contamination
Current Setting
Gas Flow
Practice Welds
Chapter 17 Gas Tungsten Arc Welding of Pipe
Introduction
Practices
Joint Preparation
Root
Backing Gas
Filler Metal
Hot Pass
Filler Pass
Cover Pass

SECTION 5 RELATED PROCESSES
Chapter 18 Welding Joint Design, Welding Symbols
Fabrication
Introduction
Weld Joint Design
Mechanical Drawings
Welding Symbols
Indicating Types of Welds
Weld Location
Location Significance of Arrow
Fillet Welds
Plug Welds
Spot Welds
Seam Welds
Groove Welds
Backing
Flanged Welds
Nondestructive Testing Symbols
Fabrication
Layout
Material Shapes
Assembly
Assembly Tools
Fitting
Tack Welding
Welding
Finishing
Chapter 19 Welding Codes, Standards and Welding Cost
Introduction
Codes, Standards, Procedures, and Specifications
Welding Procedure Qualification
General Information
Welding Costs
Cost Estimation
Weld Metal Cost
Factors for Cost Formulas
Comparing Weld Metal Costs
Other Useful Formulas
Chapter 20 Testing and Inspection of Welds
Introduction
Quality Control
Discontinuities and Defects
Destructive Testing
Nondestructive Testing
Chapter 21 Welder Certification
Introduction
Qualified and Certified Welders
AWS Entry-Level Welder Qualification and Welder Certification
Welding Skill Development
Welder Qualification and Certification Test Instructions for Practices
Dimensional Tolerances
Dimensional Tolerances
Layout, Assembly, and Fabrication of Weldments
Performance Qualification Test Record
Chapter 22 Railroad Welding
Introduction
Rail Types
Continuous Welded Track
Rail Repairs
Gouging
Cracks
Rail Ends
Arc Welding (AW)
Flash Welding (FW)
Thermite Welding (TW)
SECTION 6 RELATED PROCESSES AND TECHN0LOGY
Chapter 23 Welding Metallurgy
Introduction
Heat, Temperature, and Energy
Mechanical Properties of Metal
Structure of Matter
Crystalline Structures of Metal
Phase Diagrams
Strengthening Mechanisms
Heat Treatments Associated with Welding
Thermal Effects Caused by Arc Welding
Gases in Welding
Metallurgical Defects
Chapter 24 Weldability of Metals
Introduction
Steel Classification and Identification
Carbon and Alloy Steels
Tool Steel
High-Manganese Steel
Low-Alloy, High-Tensile Strength Steels
Stainless Steels
Chromium-Molybdenum Steel
Cast Iron
Copper and Copper Alloys
Aluminum Weldability
Titanium
Magnesium
Repair Welding
Chapter 25 Filler Metal Selection
Introduction
SMAW Operating Information
Core Wirer
Functions of the Flux Covering
Filler Metal Selection
AWS Filler Metal Classifications
Carbon Steel
Aluminum and Aluminum Alloys
Chapter 26 Welding Automation and Robotics
Introduction
Manual Joining Process
Semiautomatic Joining Processes
Machine Joining Processes
Automatic Joining Processes
Automated Joining
Industrial Robots
Future Automation
Chapter 27 Other Welding Processes
Introduction
Resistance Welding (RW)
Electron Beam Welding (EBW)
Ultrasonic Welding (USW)
Inertia Welding Process
Laser Welding (LBW)
Plasma-Arc Welding Process (PAW)
Stud Welding (SW)
Hardfacing
Thermal Spraying (THSP) Cold Welding (CW)
SECTION 7 OXYFUEL
Chapter 28 Oxyfuel Welding and Cutting Equipment
Setup, and Operation
Introduction
Pressure Regulators
Welding and Cutting Torches Design and Service
Welding and Heating Tips
Reverse Flow and Flashback Valves
Hoses and Fittings
Backfires and Flashbacks
Types of Flames
Leak Detection
Manifold Systems
Safety
Chapter 29 Oxyfuel Gases and Filler Metals
Introduction
Fuel Gases
Flame Rate of Burning
Acetylene (C2H2)
Liquefied Fuel Gases
Pressure
Methylacetylene-Propadiene (MPS)
Propane and Natural Gas
Hydrogen
Filler Metals
Mild Steel
Chapter 30 Oxyacetylene Welding
Introduction
Mild Steel Welds
Outside Corner Joint
Butt Joint
Lap Joint
Tee Joint
Out-of-Position Welding
Vertical Welds
Butt Joint
Lap Joint
Tee Joint
Horizontal Welds
Horizontal Stringer Bead
Butt Joint
Lap Joint
Tee Joint
Overhead Welds
Stringer Bead
Mild Steel Pipe and Tubing
Horizontal Rolled Position 1G
Horizontal Fixed Position 5G
Vertical Fixed Position 2G
45° Fixed Position 6G
Thin-Wall Tubing
Chapter 31 Soldering, Brazing, and Braze Welding
Introduction
Advantages of Soldering and Brazing
Physical Properties of the Joint
Fluxes
Soldering and Brazing Methods
Filler Metals
Joint Design
Building Up Surfaces and Filling Holes
Soldering
APPENDIX
I. Conversion of Decimal Inches to Millimeters and Fractional Inches to Decimal Inches and Millimeters
II. Conversion Factors: U.S. Customary (Standard) Units and Metric Units (SI)
III. Abbreviations and Symbols
IV. Metric Conversions Approximations
V. Pressure Conversion
VI. Structural Metal Shape Designations
VII. Welding Codes and Specifications
VIII. Welding Associations and Organizations
GLOSSARY
INDEX