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Welding plus Pipe Welding plus Study Guide with Lab Manual for Jeffus' Welding: Principles and Applications, 8th Ed. plus MindTap Welding, 4 terms 24 months Access Card for Jeffus' Welding: Principles and Applications: Principles and Applications 8 PCK HAR/

Larry Jeffus

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Išleidimo metai: 19-Aug-2016
Leidėjas: Delmar Pub
ISBN-10: 1337810452
ISBN-13: 9781337810456

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Industrial chemistry & manufacturing technologies - (Šiuo metu turimos knygos: 7 prekės)

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Formatas:
Išleidimo metai: 19-Aug-2016
Leidėjas: Delmar Pub
ISBN-10: 1337810452
ISBN-13: 9781337810456

Kitos knygos pagal šią temą:

Industrial chemistry & manufacturing technologies - (Šiuo metu turimos knygos: 7 prekės)

Pastovi nuoroda: https://www.kriso.lt/db/9781337810456.html

Preface

xvi

Features of the Text

xix

Acknowledgments

xxi

About the Author

xxiii

Index of Experiments and Practices

xxv

SECTION 1 Introduction

(48)

Chapter 1 Introduction to Welding

(18)

† (AWS SENSE Module 1 Occupational Orientation)

Objectives

(1)

Key Terms

(1)

Introduction

(2)

Welding Terminology

(1)

Welding Defined

(1)

Uses of Welding

(2)

Welding and Cutting Processes

(1)

Welding Processes

(3)

Oxyacetylene Welding, Brazing, and Cutting

(1)

Shielded Metal Arc Welding (SMAW)

(1)

Gas Tungsten Arc Welding (GTAW)

(2)

Gas Metal Arc Welding (GMAW)

(1)

Flux Cored Arc Welding (FCAW)

(1)

Thermal Cutting Processes

(1)

Oxyfuel Gas Cutting

(1)

Plasma Arc Cutting

(1)

Selection of the Joining Process

(1)

Occupational Opportunities in Welding

(1)

Training for Welding Occupations

(1)

Job-Related Skills

(1)

Beginning a Welding Career

(1)

Job Prospects

(1)

AWS SENSE Welder Certification

(1)

Level I Qualification Procedures

(1)

Practical Knowledge Qualification Written Test

(1)

Performance Qualification---Workmanship Samples and Test Plates

(1)

Thermal Cutting Principles and Practices

(1)

Welding Inspection and Testing Principles and Practices

(1)

Level II Advanced Welder Qualification

(1)

Skills USA

(1)

Experiments and Practices

(1)

Welding Video Series

(1)

Metric Units

(2)

Summary

(1)

Review

(2)

Chapter 2 Safety in Welding

(28)

† (AWS SENSE Module 2 Safety and Health of Welders)

Objectives

(1)

Key Terms

(1)

Introduction

(1)

Burn Classification

(2)

First-Degree Burns

(1)

Second-Degree Burns

(1)

Third-Degree Burns

(1)

Burns Caused by Light

(1)

Personal Protection Equipment (PPE)

(7)

General Work Clothing

(1)

Special Protective Clothing

(2)

Face and Eye Protection

(1)

Goggles

(1)

Full Face Shield

(1)

Welding Helmets

(1)

Auto Darkening Welding Helmets

(1)

Shop Noise

(1)

Respiratory Protection

(2)

Ventilation

(1)

Safety Data Sheets (SDSs)

(1)

Handling and Storing Cylinders

(2)

Securing Gas Cylinders

(1)

Storage Areas

(1)

Cylinders with Valve Protection Caps

(1)

General Precautions

(1)

Acetylene

(1)

Fire Protection

(2)

Fire Watch

(1)

Fire Extinguishers

(1)

Location of Fire Extinguishers

(1)

Using Fire Extinguishers

(1)

Equipment Maintenance

(1)

Hoses

(1)

Work Area Cleaning

(1)

Hand Tools

(1)

Hand Tool Safety

(1)

Hammer Safety

(1)

Electrical Safety

(4)

Electrical Safety Systems

(1)

Voltage Warnings

(1)

Extension Cords

(1)

Safety Rules for Portable Electric Tools

(1)

Power Tools

(3)

Grinders

(1)

Drills

(1)

Metal Cutting Machines

(1)

Material Handling

(1)

Lifting

(1)

Hoists or Cranes

(1)

Ladder Safety

(2)

Types of Ladders

(1)

Ladder Inspection

(1)

Rules for Ladder Use

(1)

Summary

(1)

Review

(2)

SECTION 2 Shielded Metal Arc Welding

(100)

Chapter 3 Shielded Metal Arc Equipment, Setup, and Operation

(18)

† (AWS SENSE Module 4 Shielded Metal Arc Welding (SMAW))

Objectives

(1)

Key Terms

(1)

Introduction

(1)

Welding Current

(1)

Electrical Measurement

(3)

Temperature and Heat

(1)

SMA Welding Arc Temperature

(1)

SMA Welding Arc Heat

(1)

Types of Welding Currents

(1)

Types of Welding Power Supplies (Machines)

(5)

Open Circuit Voltage

(1)

Operating Voltage

(1)

Arc Blow

(1)

Types of Power Sources

(3)

Movable Coil or Core

(1)

Inverter

(1)

Generator-Type and Alternator-Type Welders

(1)

Routine Maintenance

(1)

Converting AC to DC

(1)

Duty Cycle

(1)

Welder Accessories

(1)

Welding Cables

(2)

Electrode Holders

(1)

Work Clamps

(1)

Equipment Setup

(1)

Summary

(1)

Review

(1)

Chapter 4 Shielded Metal Arc Welding of Plate

(32)

† (AWS SENSE Module 4 Shielded Metal Arc Welding (SMAW))

Objectives

(1)

Key Terms

(1)

Introduction

(2)

Effect of Current Settings that Are Too Low or Too High

(1)

Too Low of a Current Setting

(1)

Too High of a Current Setting

(1)

Experiments

(1)

Electrode Size and Heat

(1)

Arc Length

(1)

Travel Angle, Electrode Angle and Work Angle

(1)

Leading Angle

(1)

Perpendicular Angle

(1)

Trailing Angle

(1)

Electrode Manipulation

(3)

Positioning of the Welder and the Plate

(1)

Practice Welds

(1)

Electrodes

(1)

F3 E6010 and E6011 Electrodes

(1)

F2E6012 and E6013 Electrodes

(1)

F4E7016 and E7018 Electrodes

(1)

Electrode Selection

(1)

Stringer Beads

(2)

Square Butt Joint

(4)

Edge Weld

(4)

Outside Corner Joint

(3)

Lap Joint

(3)

Tee Joint

(3)

Summary

100

(1)

Review

100

(1)

Chapter 5 Shielded Metal Arc Welding of Pipe

101

(21)

Objectives

101

(1)

Key Terms

101

(1)

Introduction

101

(2)

Pipe and Tubing

103

(1)

Pipe Specifications

103

(1)

Tubing Specifications

103

(1)

Pipe Applications

104

(1)

Tubing Applications

104

(1)

Advantages of Welded Pipe

104

(2)

Strength

104

(1)

Less Maintenance Required

104

(2)

Longer Lasting

106

(1)

Smoother Flow

106

(1)

Lighter Weight

106

(1)

Preparation and Fit-up

106

(2)

Practice Welds

108

(1)

Weld Standards

109

(1)

Weld Passes

109

(2)

Root Weld Pass

109

(1)

Hot Weld Pass

110

(1)

Filler Weld Pass

110

(1)

Cover Weld Pass

111

(1)

1G Horizontal Rolled Position

111

(5)

AWS SENSE Certification Test 1G

116

(1)

2G Vertical Fixed Position

116

(1)

AWS SENSE Certification Test 1G

117

(1)

5G Horizontal Fixed Position

117

(2)

AWS SENSE Certification Test 5G

119

(1)

6G 45° Inclined Position

119

(1)

AWS SENSE Certification Test 6G

120

(1)

Summary

121

(1)

Review

121

(1)

Chapter 6 Shielded Metal Arc Welding AWS SENSE Certification

122

(27)

Objectives

122

(1)

Key Terms

122

(1)

Introduction

122

(1)

Root Pass

123

(4)

Hot Pass

127

(2)

Filler Pass

129

(1)

Cover Pass

130

(1)

Plate Preparation

130

(3)

Restarting a Weld Bead

133

(1)

Preheating and Postheating

133

(1)

AWS Workmanship Standard for Preparation of Base Metal

134

(1)

AWS Visual Inspection Criteria

135

(1)

Preparing Specimens for Bend Testing

135

(1)

WS Specimen Preparation Criteria

135

(2)

Preparation

135

(1)

Testing

135

(2)

AWS Acceptance Criteria for Bend Test

137

(9)

Poor Fit-Up

146

(1)

Summary

147

(1)

Review

147

(2)

SECTION 3 Cutting and Gouging

149

(88)

Chapter 7 Flame Cutting

151

(39)

† (AWS SENSE Module 8 Unit 1 Manual Oxyfuel Gas Cutting (OFC)

Unit 2 Mechanized Oxyfuel Gas Cutting (OFC))

Objectives

151

(1)

Key Terms

151

(1)

Introduction

152

(1)

Metals Cut by the Oxyfuel Process

152

(1)

The Chemistry of a Cut

152

(1)

Eye Protection for Flame Cutting

152

(1)

Cutting Torches

153

(1)

Cutting Tips

154

(6)

Pressure Regulators

160

(1)

Regulator Operation

160

(1)

Regulator Gauges

161

(1)

Regulator Safety Pressure Release Device

161

(1)

Cylinder and Regulator Fittings

161

(2)

Regulator Safety Precautions

163

(1)

Regulator Care and Use

164

(1)

Backfires

165

(1)

Flashbacks

165

(1)

Reverse Flow and Flashback Valves

165

(2)

Care of the Reverse Flow Valve and Flashback Arrestor

167

(1)

Hoses and Fittings

167

(1)

Hose Care and Use

167

(1)

Leak Detection

168

(1)

Oxyfuel Cutting, Setup, and Operation

168

(1)

Torch Tip Care and Use

168

(3)

Hand Cutting

171

(3)

Layout

174

(1)

Selecting the Correct Tip and Setting the Pressure

175

(2)

The Physics of a Cut

177

(1)

Slag

178

(2)

Plate Cutting

180

(1)

Cutting Table

180

(1)

Torch Guides

180

(2)

Distortion

182

(1)

Cutting Applications

183

(1)

Pipe Cutting

184

(4)

Summary

188

(1)

Review

188

(2)

Chapter 8 Plasma Arc Cutting

190

(29)

† (AWS SENSE Module 8 Unit 3 Manual Plasma Arc Cutting (PAC))

Objectives

190

(1)

Key Terms

190

(1)

Introduction

190

(1)

Plasma

191

(6)

Arc Plasma

192

(1)

Plasma Torch

192

(1)

Torch Body

192

(1)

Torch Head

192

(1)

Power Switch

193

(1)

Torch Parts Commonly Serviced

193

(2)

Hoses and Power Cables

195

(1)

Gas Hoses

195

(2)

Power Cable

197

(1)

Coolant System

197

(1)

Coolant

197

(1)

Coolant Hoses

197

(1)

Control Wire

198

(1)

Compressed Air

198

(1)

Power Requirements

199

(1)

Voltage

199

(1)

Amperage

199

(1)

Watts

199

(1)

Heat Input

199

(1)

Distortion

199

(1)

Applications

200

(6)

Cutting Speed

200

(1)

Metals

200

(1)

Torch Standoff Distance

201

(1)

Starting Methods

202

(1)

Kerf

203

(2)

Gases

205

(1)

Stack Cutting

206

(1)

Dross

206

(1)

Machine Cutting

206

(1)

Water Tables

207

(1)

Manual Cutting

207

(1)

Setup

208

(1)

Safety

209

(1)

Straight Cuts

209

(2)

Piercing

211

(2)

Plasma Arc Gouging

213

(2)

Cutting Round Stock

215

(1)

Beveling Pipe

216

(1)

Summary

217

(1)

Review

217

(2)

Chapter 9 Related Cutting Processes

219

(18)

† (AWS SENSE Module 8 Unit 4 Manual Air Carbon Arc Cutting (CAC-A))

Objectives

219

(1)

Key Terms

219

(1)

Introduction

219

(1)

Laser Beam Cutting (LBC) and Laser Beam Drilling (LBD)

220

(1)

Lasers

220

(1)

Laser Types

221

(1)

Solid State Lasers

221

(1)

Gas Laser

222

(1)

Applications

222

(2)

Laser Beam Cutting

222

(1)

Laser Beam Drilling

223

(1)

Laser Beam Welding

223

(1)

Hybrid Laser Process

224

(1)

Laser Beam Welding with Gas Metal Arc Welding

224

(1)

Laser Beam with Gas Metal Arc Welding Surfacing

224

(1)

Laser Beam Welding with Gas Tungsten Arc Welding

224

(1)

Laser Equipment

225

(1)

Air Carbon Arc Cutting (CAC-A)

225

(1)

Manual Torch Design

226

(1)

Electrodes

226

(1)

Power Sources

227

(1)

Air Supply

227

(1)

Application

228

(1)

Safety

228

(1)

U-Grooves

229

(3)

Oxygen Lance Cutting

232

(1)

Applications

233

(1)

Safety

233

(1)

Water Jet Cutting

233

(1)

Applications

233

(1)

Arc Cutting Electrodes

233

(2)

Applications

235

(1)

Summary

235

(1)

Review

235

(2)

SECTION 4 Gas Shielded Welding

237

(250)

Chapter 10 Gas Metal Arc Welding Equipment, Setup, and Operation

239

(28)

† (AWS SENSE Module 5 Gas Metal Arc Welding (GMAW, GMAW-S))

Objectives

239

(1)

Key Terms

239

(1)

Introduction

240

(2)

Weld Metal Transfer Methods

242

(6)

Short-Circuiting Transfer GMAW-S

242

(1)

Globular Transfer

243

(1)

Axial Spray Metal Transfer

243

(2)

Pulsed-Arc Metal Transfer

245

(1)

Pulsed-Arc Metal Transfer Current Cycle

246

(2)

Modulated Current Metal Transfer

248

(2)

The Modulated Current Process

248

(1)

Advantages of Modulated Current and Pulsed-Arc Metal Transfer

248

(2)

Buried-Arc Transfer

250

(1)

GMAW Filler Metal Specifications

250

(1)

Wire Melting and Deposition Rates

251

(1)

Welding Power Supplies

251

(2)

GMA Welding Machines

251

(1)

Speed of the Wire Electrode

252

(1)

Power Supplies for Short-Circuiting Transfer

252

(1)

Shielding Gas

253

(2)

Argon

254

(1)

Argon Gas Blends

254

(1)

Helium

255

(1)

Carbon Dioxide

255

(1)

Nitrogen

255

(1)

Power Settings

255

(1)

Weave Pattern

256

(1)

Travel Speed

256

(1)

Electrode Extension

256

(1)

Gun Angle

256

(2)

Forehand/Perpendicular/Backhand Welding

257

(1)

Metal Core Electrodes for GMA Welding

258

(1)

Equipment

259

(5)

Power Source

260

(1)

Electrode (Wire) Feed Unit

260

(2)

Electrode Conduit

262

(1)

Welding Gun

263

(1)

GMA Spot Welding

264

(2)

Summary

266

(1)

Review

266

(1)

Chapter 11 Gas Metal Arc Welding

267

(31)

† (AWS SENSE Module 5 Gas Metal Arc Welding (GMAW, GMAW-S))

Objectives

267

(1)

Key Terms

267

(1)

Introduction

267

(1)

Setup

268

(3)

Wire-Feed Speed

271

(3)

Gas Density and Flow Rates

274

(1)

Arc-Voltage and Amperage Characteristics

275

(2)

Electrode Extension

277

(1)

Welding Gun Angle

278

(1)

Effect of Shielding Gas on Welding

279

(2)

Practices

281

(1)

Metal Preparation

282

(1)

Flat Position, 1G and 1F Positions

283

(4)

Vertical Up 3G and 3F Positions

287

(1)

Vertical Down 3G and 3F Positions

288

(1)

Horizontal 2G and 2F Positions

289

(1)

Overhead 4G and 4F Positions

290

(3)

Globular Metal Transfer, 1G Position

293

(3)

Axial Spray

296

(1)

Summary

297

(1)

Review

297

(1)

Chapter 12 Flux Cored Arc Welding Equipment, Setup, and Operation

298

(22)

† (AWS SENSE Module 6 Flux Cored Arc Welding (FCAW-G/GM, FCAW-S))

Objectives

298

(1)

Key Terms

298

(1)

Introduction

299

(2)

Principles of Operation

301

(1)

Flux Core

301

(1)

Gas Formers

302

(1)

Slag

302

(1)

Equipment

302

(1)

Power Supply

302

(1)

FCA Welding Guns

302

(1)

Electrode Feed

303

(1)

Advantages

303

(1)

Limitations

304

(1)

FCAW Electrodes

304

(2)

Electrode Cast and Helix

306

(1)

FCA Welding Electrode Flux

306

(2)

Types of FCAW Fluxes

308

(3)

Flux Cored Steel Electrode Identification

309

(1)

Mild Steel

309

(1)

Stainless Steel Electrodes

309

(1)

Metal Cored Steel Electrode Identification

309

(2)

Care of Flux Core Electrodes

311

(1)

Shielding Gas

311

(1)

Welding Techniques

312

(1)

Gun Angle

312

(1)

Forehand/Perpendicular/Backhand Techniques

313

(2)

Advantages of the Forehand Technique

313

(1)

Disadvantages of the Forehand Technique

314

(1)

Advantages of the Perpendicular Technique

314

(1)

Disadvantages of the Perpendicular Technique

314

(1)

Advantages of the Backhand Technique

314

(1)

Disadvantages of the Backhand Technique

314

(1)

Travel Speed

314

(1)

Mode of Metal Transfer

315

(2)

Spray Transfer---FCAW-G

315

(1)

Globular Transfer---FCAW-G

315

(1)

Electrode Extension

316

(1)

Porosity

316

(1)

Troubleshooting FCA Welding

317

(1)

Summary

318

(1)

Review

319

(1)

Chapter 13 Flux Cored Arc Welding

320

(28)

† (AWS SENSE Module 6 Flux Cored Arc Welding (FCAW-G/GM, FCAW-S))

Objectives

320

(1)

Key Terms

320

(1)

Introduction

320

(1)

Practices

321

(3)

Flat-Position Welds

324

(2)

Square-Groove Welds

326

(1)

V-Groove and Bevel-Groove Welds

327

(3)

Root Pass

328

(1)

Filler Pass

329

(1)

Cover Pass

329

(1)

Fillet Welds

330

(3)

Vertical Welds

333

(3)

Horizontal Welds

336

(4)

Overhead-Position Welds

340

(1)

Thin-Gauge Welding

341

(3)

Plug Welds

344

(2)

Summary

346

(1)

Review

346

(2)

Chapter 14 Gas Metal Arc and Flux Cored Arc Welding of Pipe

348

(12)

Objectives

348

(1)

Key Terms

348

(1)

Introduction

348

(1)

Joint Preparation

349

(2)

End Preparation

349

(1)

Joint Fitup

349

(1)

Tack Welds

349

(1)

Root Pass

349

(1)

Hot Pass

350

(1)

Filler Pass

350

(1)

Cover Pass(es)

351

(1)

Visual Inspection

351

(1)

Practice Pipe Welds

351

(1)

Pipe to Plate Welds

351

(8)

Tack Welds

355

(1)

Root Pass

355

(1)

Hot Pass

355

(1)

Filler Pass(es)

355

(1)

Cover Pass

356

(3)

Summary

359

(1)

Review

359

(1)

Chapter 15 Gas Metal Arc and Flux Cored Arc Welding AWS SENSE Certification

360

(29)

† (AWS SENSE Modules 5 Gas Metal Arc Welding (GMAW, GMAW-S) and 6 Module 6 Flux Cored Arc Welding (FCAW-G/GM, FCAW-S))

Objectives

360

(1)

Key Terms

360

(1)

Introduction

360

(1)

Practice Welds

360

(28)

Metal Preparation

361

(1)

Practice Weld Equipment and Consumables

361

(27)

Summary

388

(1)

Review

388

(1)

Chapter 16 Gas Tungsten Arc Welding Equipment, Setup, Operation, and Filler Metals

389

(25)

† (AWS SENSE Module 7 Gas Tungsten Arc Welding (GTAW))

Objectives

389

(1)

Key Terms

389

(1)

Introduction

390

(1)

Tungsten

390

(2)

High Temperature

390

(1)

Good Conductor

390

(1)

Tungsten Erosion

390

(2)

Tungsten Electrode End Shape

392

(1)

Types of Tungsten Electrodes

392

(2)

Pure Tungsten, EWP

393

(1)

Thoriated Tungsten, EWTh-1 and EWTh-2

393

(1)

Zirconium Tungsten, EWZr-1

393

(1)

Cerium Tungsten, EWCe-2

393

(1)

Lanthanum Tungsten, EWLa-1.5

394

(1)

Rare Earth Tungsten, EWG

394

(1)

Shaping the Tungsten

394

(1)

Precision Machine Tungsten Grinder

394

(1)

Hand Grinding

394

(1)

Breaking and Remelting

395

(1)

Chemical Cleaning and Pointing

396

(1)

Pointing and Remelting

397

(1)

GTA Welding Equipment

397

(4)

Torches

398

(1)

Hoses

399

(1)

Nozzles

400

(1)

Gas Lens

401

(1)

Flowmeter

401

(1)

Types of Welding Current

402

(2)

DCEN

402

(1)

DCEP

402

(1)

402

(2)

Electronic Controls of AC Welding Currents

404

(2)

EP and EN Time Control

405

(1)

Sine Wave Form Control

405

(1)

Frequency Control

405

(1)

Shielding Gases

406

(1)

Argon

406

(1)

Helium

406

(1)

Hydrogen

407

(1)

Nitrogen

407

(1)

Hot Start

407

(1)

Preflow

407

(1)

Postflow

408

(1)

Shielding Gas Flow Rate

408

(1)

Remote Controls

409

(3)

Summary

412

(1)

Review

413

(1)

Chapter 17 Gas Tungsten Arc Welding of Plate

414

(27)

† (AWS SENSE Module 7 Gas Tungsten Arc Welding (GTAW))

Objectives

414

(1)

Key Terms

414

(1)

Introduction

415

(1)

Torch Angle

415

(1)

Filler Rod Manipulation

416

(1)

Tungsten Contamination

417

(1)

Current Setting

417

(1)

Experiments

418

(1)

Gas Flow

419

(1)

Practice Welds

420

(1)

Low Carbon and Mild Steels

420

(1)

Stainless Steel

421

(1)

Aluminum

422

(1)

Metal Preparation

422

(17)

Summary

439

(1)

Review

440

(1)

Chapter 18 Gas Tungsten Arc Welding of Pipe

441

(22)

Objectives

441

(1)

Key Terms

441

(1)

Introduction

441

(1)

Practices

442

(1)

Joint Preparation

442

(1)

V-Groove

442

(1)

Joint Cleaning

442

(1)

Root

443

(3)

Incomplete Fusion

444

(1)

Concave Root Surface

445

(1)

Excessive Root Reinforcement

445

(1)

Root Contamination

445

(1)

Backing Gas

446

(1)

Purging

446

(1)

Filler Metal

447

(2)

Consumable Inserts

447

(2)

Cup Walking

449

(1)

Cup Walking Setup

449

(1)

Cup Walking Technique

450

(1)

Practice Welds

450

(3)

Hot Pass

453

(4)

Root Surface

453

(1)

Lack of Root Fusion

454

(3)

Filler Pass

457

(1)

Cover Pass

458

(3)

Summary

461

(1)

Review

461

(2)

Chapter 19 Gas Tungsten Arc Welding Plate and Pipe AWS SENSE Certification

463

(24)

Objectives

463

(1)

Key Terms

463

(1)

Introduction

463

(1)

GTA Sheet Welds

463

(1)

GTA Tubing Welds

464

(1)

AWS SENSE GTA Sheet Practice Welds

464

(2)

Weld Inspection and Testing

464

(1)

Butt Joint Welds

464

(1)

Fillet Welds, Lap and Tee Joints

464

(2)

Tubing Welds

466

(1)

Mechanical, Destructive Testing

466

(1)

Filler Metal

466

(1)

Sheet Metal Practice Welds

467

(12)

Tubing and Pipe Practice Welds

479

(5)

Summary

484

(1)

Review

485

(2)

SECTION 5 Related Technologies

487

(258)

Chapter 20 Shop Math and Weld Cost

489

(31)

Objectives

489

(1)

Key Terms

489

(1)

Introduction

489

(1)

Shop Math

490

(1)

Types of Numbers

490

(1)

Whole Numbers

490

(1)

Decimal Fractions

490

(1)

Mixed Units

490

(1)

Fractions

490

(1)

General Math Rules

491

(1)

Letters, Numbers, and Symbols

492

(1)

Superscript and Subscripts

492

(1)

Equations and Formulas

492

(1)

Equations

492

(1)

Formulas

492

(1)

Mixed Units

493

(4)

Adding and Subtracting Mixed Units

493

(2)

Fractions

495

(1)

Finding the Fraction's Common Denominator

495

(1)

Reducing Fractions

496

(1)

Multiplying and Dividing Fractions

496

(1)

Converting Numbers

497

(1)

Converting Fractions to Decimals

497

(1)

Tolerances

497

(1)

Converting Decimals to Fractions

497

(1)

Conversion Charts

498

(1)

Angles

498

(1)

Adding and Subtracting Angles

499

(1)

Triangles

499

(2)

Right Triangle

499

(1)

Equilateral Triangle

500

(1)

Isosceles Triangle

500

(1)

Perimeter

501

(1)

Area

501

(1)

Volume

501

(2)

Measuring

502

(1)

Welding Costs

503

(1)

Cost Estimation

503

(1)

Joint Design

504

(2)

Groove Welds

505

(1)

Fillet Welds

506

(1)

Weld Metal Cost

506

(1)

Cost of Electrodes, Wires, Gases, and Flux

507

(8)

Deposition Efficiency

507

(1)

Deposition Rate

508

(1)

Deposition Data Tables

508

(1)

Coated Electrodes

509

(1)

Efficiency of Flux Cored Wires

510

(1)

Efficiency of Solid Wire for GMAW

510

(1)

Efficiency of Solid Wires for SAW

511

(1)

Operating Factor

511

(3)

Labor and Overhead

514

(1)

Cost of Power

514

(1)

Other Useful Formulas

514

(1)

Bill of Materials

515

(1)

Invoice

516

(1)

Summary

517

(1)

Review

518

(2)

Chapter 21 Reading Technical Drawings

520

(22)

† (AWS SENSE Module 3 Drawing and Welding Symbol Interpretation)

Objectives

520

(1)

Key Terms

521

(1)

Introduction

521

(1)

Mechanical Drawings

521

(2)

Lines

523

(2)

Types of Drawings

523

(1)

Pictorial Drawings

523

(1)

Mechanical Drawings

524

(1)

Special Views

524

(1)

Dimensioning

525

(2)

Drawing Scale

527

(1)

Reading Mechanical Drawings

528

(4)

Sketching

528

(4)

Erasers and Erasing

532

(3)

Graph Paper

535

(3)

Computers and Drawings

538

(3)

Summary

541

(1)

Review

541

(1)

Chapter 22 Welding Joint Design and Welding Symbols

542

(19)

† (AWS SENSE Module 3 Drawing and Welding Symbol Interpretation)

Objectives

542

(1)

Key Terms

542

(1)

Introduction

542

(1)

Weld Joint Design

543

(2)

Weld Joint Stresses

544

(1)

Welding Process

545

(1)

Edge Preparation

545

(1)

Joint Dimensions

545

(2)

Metal Thickness

545

(2)

Metal Type

547

(1)

Welding Position

547

(1)

Plate Welding Positions

548

(1)

Pipe Welding Positions

548

(1)

Code or Standards Requirements

548

(1)

Welder Skill

549

(1)

Acceptable Cost

549

(1)

Welding Symbols

549

(11)

Indicating Types of Welds

550

(1)

Weld Location

551

(1)

Location Significance of Arrow

551

(1)

Fillet Welds

552

(1)

Plug Welds

552

(1)

Spot Welds

553

(1)

Seam Welds

553

(1)

Groove Welds

553

(3)

Backing

556

(1)

Flanged Welds

557

(1)

Nondestructive Testing Symbols

557

(3)

Summary

560

(1)

Review

560

(1)

Chapter 23 Fabricating Techniques and Practices

561

(26)

Objectives

561

(1)

Key Terms

561

(1)

Introduction

561

(1)

Fabrication

562

(1)

Safety

562

(1)

Parts and Pieces

563

(1)

Preformed

563

(1)

Custom Fabrication

563

(1)

Layout

564

(6)

Nesting

569

(1)

Kerf Space

570

(3)

Material Shapes

573

(1)

Bill of Materials Form

574

(1)

Overall Tolerance

575

(1)

Assembly

576

(2)

Overall Dimensions and Thick Materials

578

(1)

Part Identification

578

(1)

Assembly Tools

578

(3)

Fitting

581

(1)

Tack Welds

582

(2)

Welding

584

(1)

Arc Strikes

584

(1)

Finishing

585

(1)

Summary

585

(1)

Review

586

(1)

Chapter 24 Welding Codes and Standards

587

(15)

Objectives

587

(1)

Key Terms

587

(1)

Introduction

587

(1)

Codes, Standards, Procedures, and Specifications

588

(1)

Welding Procedure Qualification

588

(1)

Welding Procedure Specification (WPS)

588

(1)

Qualifying the Welding Procedure Specification

588

(1)

Qualifying and Certifying

589

(1)

General Information

589

(11)

Summary

600

(1)

Review

601

(1)

Chapter 25 Testing and Inspection

602

(27)

Objectives

602

(1)

Key Terms

602

(1)

Introduction

602

(1)

Quality Control (QC)

603

(1)

Discontinuities and Defects

603

(6)

Porosity

603

(2)

Inclusions

605

(1)

Inadequate Joint Penetration

606

(1)

Incomplete Fusion

606

(1)

Arc Strikes

607

(1)

Overlap

607

(1)

Undercut

608

(1)

Crater Cracks

608

(1)

Underfill

609

(1)

Plate-Generated Problems

609

(1)

Lamination

609

(1)

Delamination

609

(1)

Lamellar Tears

610

(1)

Destructive Testing (DT)

610

(2)

Tensile Testing

610

(2)

Fatigue Testing

612

(1)

Shearing Strength Test

612

(1)

Welded Butt Joints

612

(7)

Nick-Break Test

612

(1)

Guided-Bend Test

612

(4)

Free-Bend Test

616

(1)

Alternate Bend

616

(1)

Fillet Weld Break Test

616

(1)

Testing by Etching

617

(1)

Impact Testing

618

(1)

Nondestructive Testing (NDT)

619

(8)

Visual Inspection (VT)

619

(1)

Penetrant Inspection (PT)

619

(1)

Magnetic Particle Inspection (MT)

619

(2)

Radiographic Inspection

621

(1)

Ultrasonic Inspection

621

(4)

Leak Checking

625

(1)

Eddy Current Inspection (ET)

625

(1)

Hardness Testing

626

(1)

Summary

627

(1)

Review

627

(2)

Chapter 26 Welding Metallurgy

629

(31)

Objectives

629

(1)

Key Terms

629

(1)

Introduction

629

(1)

Heat, Temperature, and Energy

630

(1)

Heat

630

(1)

Temperature

631

(1)

Production of Metals

632

(2)

Steel Making

632

(1)

Iron Ore

632

(1)

Ingot Casting

633

(1)

Continuous Casting

633

(1)

Metal Forming

633

(1)

Grain Structure

634

(1)

Mechanical Properties

634

(2)

Hardness

634

(1)

Brittleness

635

(1)

Ductility

635

(1)

Toughness

635

(1)

Strength

635

(1)

Other Mechanical Properties

636

(1)

Structure of Solid Matter

636

(2)

Crystalline Structures of Metal

637

(1)

Phase Diagrams

638

(1)

Lead-Tin Phase Diagram

638

(1)

Iron-Carbon Phase Diagram

639

(3)

Strengthening Mechanisms

642

(2)

Solid-Solution Hardening

642

(1)

Precipitation Hardening

643

(1)

Mechanical Mixtures of Phases

643

(1)

Quench, Temper, and Anneal

644

(4)

Quenching

644

(1)

Martensitic Reactions

645

(3)

Cold Work

648

(1)

Grain Size Control

648

(1)

Heat Treatments Associated with Welding

648

(2)

Preheat

648

(1)

Stress Relief, Process Annealing

649

(1)

Annealing

650

(1)

Normalizing

650

(1)

Time-Temperature-Transformation (TTT) Diagrams

650

(2)

Martensite

650

(1)

Bainite

651

(1)

Pearlite

651

(1)

TTT Diagrams

651

(1)

Thermal Effects Caused by Arc Welding

652

(2)

Heat-Affected Zone (HAZ)

652

(2)

Gases in Welding

654

(2)

Nitrogen

655

(1)

Oxygen

655

(1)

Carbon Dioxide

655

(1)

Hydrogen

655

(1)

Metallurgical Defects

656

(2)

Cold Cracking

656

(1)

Hot Cracking

656

(1)

Carbide Precipitation

657

(1)

Summary

658

(1)

Review

658

(2)

Chapter 27 Weldability of Metals

660

(19)

Objectives

660

(1)

Key Terms

660

(1)

Introduction

660

(1)

Weldability

660

(3)

Thermal Cycling

661

(2)

Steel Classification and Identification

663

(1)

SAE Classification Systems

663

(1)

AISI Classification Systems

663

(1)

Unified Numbering System (UNS)

663

(1)

Carbon and Alloy Steels

663

(3)

Low-Carbon, Also Called Mild, Steel

663

(2)

Medium-Carbon Steel

665

(1)

High-Carbon Steel

665

(1)

Tool Steel

666

(1)

High-Manganese Steel

666

(1)

Low-Alloy, High-Tensile Strength Steels

666

(1)

Stainless Steels

666

(2)

Austenitic Stainless Steel

667

(1)

Ferritic Stainless Steel

667

(1)

Martensitic Stainless Steel

667

(1)

Chromium-Molybdenum Steel

668

(1)

Cast Iron

668

(5)

Preweld and Postweld Heating of Cast Iron

669

(1)

Practice Welding Cast Iron

670

(1)

Welding without Preheating or Postheating

671

(2)

Nonferrous Metals

673

(1)

Copper and Copper Alloys

673

(1)

Aluminum Weldability

673

(1)

Titanium

674

(1)

Magnesium

674

(1)

Repair Welding

674

(3)

Summary

677

(1)

Review

678

(1)

Chapter 28 Filler Metal Selection

679

(20)

Objectives

679

(1)

Key Terms

679

(1)

Introduction

679

(1)

Manufacturers' Electrode Information

680

(1)

Understanding the Electrode Data

680

(1)

Data Resulting from Mechanical Tests

680

(1)

Data Resulting from Chemical Analysis

680

(1)

Carbon Equivalent (CE)

681

(1)

SMAW Operating Information

681

(2)

Core Wire

682

(1)

Functions of the Flux Covering

682

(1)

Filler Metal Selection

683

(3)

Shielded Metal Arc Welding Electrode Selection

683

(3)

AWS Filler Metal Classifications

686

(1)

Carbon Steel

686

(4)

Carbon and Low-Alloy Steel--Covered Electrodes

686

(4)

Wire-Type Steel Filler Metals

690

(6)

Solid Wire

690

(1)

Tubular Wire

690

(2)

Metal Cored Arc Welding Electrodes

692

(1)

Stainless Steel Electrodes

692

(1)

Nonferrous Electrodes

692

(3)

Aluminum and Aluminum Alloys

695

(1)

Aluminum-Covered Arc Welding Electrodes

695

(1)

Aluminum Bare Welding Rods and Electrodes

696

(1)

Special-Purpose Filler Metals

696

(1)

Surface and Buildup Electrode Classification

696

(1)

Magnesium Alloys

696

(1)

Hydrogen Embrittlement

696

(1)

Summary

697

(1)

Review

697

(2)

Chapter 29 Welding Automation and Robotics

699

(15)

Objectives

699

(1)

Key Terms

699

(1)

Introduction

699

(1)

Manual Joining Process

700

(1)

Semiautomatic Joining Processes

701

(1)

Machine Joining Processes

702

(1)

Automatic Joining Processes

702

(1)

Automated Joining

702

(1)

Industrial Robots

703

(3)

Robot Programming

704

(2)

System Planning

706

(6)

Present and Future Needs

706

(1)

Parts Design

706

(1)

Equipment Selection

707

(3)

Safety

710

(2)

Future Automation

712

(1)

Summary

712

(1)

Review

712

(2)

Chapter 30 Other Welding Processes

714

(31)

Objectives

714

(1)

Key Terms

714

(1)

Introduction

715

(1)

Constant Current Welding Processes

715

(3)

Submerged Arc Welding (SAW)

715

(2)

Flux

717

(1)

Advantages of SAW

717

(1)

Disadvantages of SAW

718

(1)

Handheld SAW

718

(1)

Electroslag Welding (ESW)

718

(2)

Advantages

719

(1)

Disadvantages

720

(1)

Electrogas Welding (EGW)

720

(1)

Resistance Welding

720

(6)

Resistance Spot Welding (RSW)

721

(1)

Spot Welding Machines

722

(1)

Multiple-Spot Welders

722

(1)

Seam Welding (RSEW)

722

(1)

Types of Resistance Seam Welds

723

(3)

Electron Beam Welding (EBW)

726

(1)

Electron Beam Welding Gun

726

(1)

Electron Beam Seam Tracking

726

(1)

Ultrasonic Welding

727

(1)

Ultrasonic Welding (USW) Applications

728

(1)

Inertia Welding Process (FRW-I)

728

(3)

Inertia Weld Bond Characteristics

729

(2)

Advantages of the Process

731

(1)

Laser Beam Welding (LBW)

731

(1)

Laser Welding Advantages and Disadvantages

731

(1)

Laser Beam

731

(1)

Laser Beam Heat Treating

732

(1)

Plasma Arc Welding (PAW)

732

(1)

Stud Welding (SW)

733

(1)

Thermal Spraying (THSP)

733

(3)

Thermal Spraying Equipment

733

(1)

Thermospray (Powder) Process

734

(1)

Thermospray Gun

734

(1)

Torch Spraying

734

(2)

Applying Sprayed Metal

736

(1)

Plasma Spraying Process

736

(1)

Cold Welding (CW)

736

(1)

Thermite Welding

736

(2)

Hardfacing

738

(3)

Selection of Hardfacing Metals

739

(1)

Hardfacing Welding Processes

739

(1)

Quality of Surfacing Deposit

740

(1)

Hardfacing Electrodes

740

(1)

Shielded Metal Arc Method

741

(1)

Hardfacing with Gas Shielded Arc

741

(1)

Friction Stir Welding (FSW)

741

(1)

Magnetic Pulse Welding (MPW)

742

(1)

Hybrid Welding Processes

742

(1)

Summary

743

(1)

Review

743

(2)

SECTION 6 OXYFUEL PROCESSES

745

(103)

Chapter 31 Oxyfuel Welding and Cutting Equipment, Setup, and Operation

747

(38)

Objectives

747

(1)

Key Terms

747

(1)

Introduction

748

(1)

Pressure Regulators

748

(3)

Regulator Operation

748

(2)

Regulator Gauges

750

(1)

Regulator Safety Pressure Release Device

751

(2)

Cylinder and Regulator Fittings

752

(1)

Cryogenic Cylinders

752

(1)

Fittings

753

(1)

Regulator Safety Precautions

753

(1)

Regulator Care and Use

754

(1)

Welding and Cutting Torches: Design and Service

755

(1)

Combination Torches

755

(1)

Dedicated Cutting Torches

755

(1)

Mixing the Gases

756

(1)

Mixing Chamber

756

(1)

Injector Mixing

756

(1)

Torch Care and Use

757

(1)

Welding and Heating Torch Tips

757

(2)

Torch Tip Care and Use

758

(1)

Backfires and Flashbacks

759

(1)

Backfires

759

(1)

Flashbacks

759

(1)

Reverse Flow and Flashback Valves

759

(2)

Care of the Reverse Flow Valve and Flashback Arrestor

759

(2)

Hoses and Fittings

761

(1)

Hose Care and Use

761

(1)

Leak Detection Hoses

761

(1)

Leak Detection Fittings

762

(1)

Manifold Systems

762

(2)

Manifold Operation

763

(1)

Oxyfuel Flame

764

(1)

Characteristics of the Fuel-Gas Flame

764

(1)

Fuel Gases

764

(3)

Flame Rate of Burning

766

(1)

Acetylene (C2H2)

767

(4)

Acetone

768

(1)

Heat and Temperature of Acetylene

769

(1)

Liquefied Fuel Gases

769

(1)

Pressure

769

(1)

Methylacetylene-Propadiene (MPS)

769

(2)

MAPP®

771

(1)

Oxy-MAPP® Flames

771

(1)

Propane and Natural Gas

772

(1)

Hydrogen

773

(3)

Filler Metals

776

(1)

Ferrous Metals

776

(1)

Mild Steel

776

(1)

Cast Iron

777

(6)

Summary

783

(1)

Review

783

(2)

Chapter 32 Oxyacetylene Welding

785

(30)

Objectives

785

(1)

Key Terms

785

(1)

Introduction

785

(1)

Mild Steel Welds

786

(1)

Factors Affecting the Weld

786

(1)

Characteristics of the Weld

787

(7)

Flat Position Welding

794

(6)

Outside Corner Joint

794

(1)

Butt Joint

794

(3)

Lap Joint

797

(1)

Tee Joint

798

(2)

Out-of-Position Welding

800

(1)

Vertical Welds

800

(5)

Butt Joint

803

(1)

Lap Joint

804

(1)

Tee Joint

804

(1)

Horizontal Welds

805

(1)

Horizontal Stringer Bead

805

(1)

Butt Joint

806

(1)

Lap Joint

806

(1)

Tee Joint

806

(1)

Overhead Welds

806

(1)

Stringer Bead

807

(1)

Butt Joint

807

(1)

Lap Joint

807

(1)

Tee Joint

807

(1)

Mild Steel Pipe and Tubing

807

(1)

Horizontal Rolled Position 1G

808

(2)

Horizontal Fixed Position 5G

810

(1)

Vertical Fixed Position 2G

811

(1)

45° Fixed Position 6G

812

(1)

Thin-Wall Tubing

813

(1)

Summary

813

(1)

Review

814

(1)

Chapter 33 Brazing, Braze Welding, and Soldering

815

(33)

Objectives

815

(1)

Key Terms

815

(1)

Introduction

815

(1)

Brazing, Braze Welding, and Soldering

816

(1)

Brazing

816

(1)

Braze Welding

816

(1)

Soldering

816

(1)

Advantages of Brazing and Soldering

816

(2)

Physical Properties of the Brazed or Soldered Joint

818

(1)

Tensile Strength

818

(1)

Shear Strength

818

(1)

Ductility

818

(1)

Fatigue Resistance

818

(1)

Corrosion Resistance

819

(1)

Fluxes Used in Brazing, Braze Welding, and Soldering

819

(2)

Flux

819

(1)

Forms of Fluxes

820

(1)

Fluxing Action

821

(1)

Brazing and Soldering Methods

821

(4)

Torch Brazing and Soldering

821

(1)

Furnace Brazing and Soldering

822

(1)

Induction Brazing and Soldering

823

(1)

Dip Brazing and Soldering

824

(1)

Resistance Brazing and Soldering

824

(1)

Special Methods

825

(1)

Filler Metals

825

(1)

Types of Filler Metals

825

(1)

Soldering Alloys

826

(1)

Tin-Lead

826

(1)

Tin-Antimony

826

(1)

Cadmium-Silver

826

(1)

Cadmium-Zinc

826

(1)

Brazing Alloys

827

(2)

Copper-Zinc

827

(1)

Copper-Zinc and Copper-Phosphorus A5.8

828

(1)

Copper-Phosphorus

828

(1)

Copper-Phosphorus-Silver

829

(1)

Silver-Copper

829

(1)

Nickel

829

(1)

Nickel and Nickel Alloys A5.14

829

(1)

Aluminum-Silicon (BAISi)

829

(1)

Copper and Copper Alloys A5.7

829

(1)

Silver and Gold

829

(1)

Joint Design

829

(3)

Joint Spacing

829

(3)

Brazing Practices

832

(6)

Surface Buildup and Hole Fill Practices

838

(1)

Silver Brazing Practices

839

(3)

Soldering Practices

842

(4)

Summary

846

(1)

Review

846

(2)

Appendix

848

(1)

I Student Welding Report

849

(1)

II SENSE

850

(1)

III SENSE

851

(1)

IV Conversion of Decimal-Inches to Millimeters and Fractional Inches to Decimal-Inches and Millimeters

852

(1)

V Conversion Factors: U.S. Customary (Standard) Units and Metric Units (SI)

853

(2)

VI Abbreviations and Symbols

855

(1)

VII Metric Conversion Approximations

856

(1)

VIII Pressure Conversion

856

(1)

IX Welding Codes and Specifications

857

(1)

X Welding Associations and Organizations

858

(1)

Glossary

859

(51)

Index

910

Introduction

vii

Section 1 Introduction

Chapter 1 Introduction to Welding

(8)

Chapter 2 Safety in Welding

(8)

Section 2 Shielded Metal Arc Welding

Chapter 3 Shielded Metal Arc Equipment, Setup, and Operation

(12)

Chapter 4 Shielded Metal Arc Welding of Plate

(34)

Chapter 5 Shielded Metal Arc Welding of Pipe

(18)

Chapter 6 Shielded Metal Arc Welding AWS SENSE Certification

(24)

Section 3 Cutting and Gouging

Chapter 7 Flame Cutting

105

(24)

Chapter 8 Plasma Arc Cutting

129

(18)

Chapter 9 Related Cutting Processes

147

(14)

Section 4 Gas Shielded Welding

Chapter 10 Gas Metal Arc Welding Equipment, Setup, and Operation

161

(4)

Chapter 11 Gas Metal Arc Welding

165

(46)

Chapter 12 Flux Cored Arc Welding Equipment, Setup, and Operation

211

(6)

Chapter 13 Flux Cored Arc Welding

217

(36)

Chapter 14 Gas Metal Arc and Flux Cored Arc Welding of Pipe

253

(16)

Chapter 15 Gas Metal Arc and Flux Cored Arc Welding AWS SENSE Certification

269

(44)

Chapter 16 Gas Tungsten Arc Welding Equipment, Setup, Operation, and Filler Metals

313

(10)

Chapter 17 Gas Tungsten Arc Welding of Plate

323

(40)

Chapter 18 Gas Tungsten Arc Welding of Pipe

363

(16)

Chapter 19 Gas Tungsten Arc Welding Plate and Pipe AWS SENSE Certification

379

(34)

Section 5 Related Technologies

Chapter 20 Shop Math and Weld Cost

413

(8)

Chapter 21 Reading Technical Drawings

421

(10)

Chapter 22 Welding Joint Design and Welding Symbols

431

(8)

Chapter 23 Fabricating Techniques and Practices

439

(16)

Chapter 24 Welding Codes and Standards

455

(8)

Chapter 25 Testing and Inspection

463

(6)

Chapter 26 Welding Metallurgy

469

(10)

Chapter 27 Weldability of Metals

479

(8)

Chapter 28 Filler Metal Selection

487

(8)

Chapter 29 Welding Automation and Robotics

495

(4)

Chapter 30 Other Welding Processes

499

(6)

Section 6 Oxyfuel Processes

Chapter 31 Oxyfuel Welding and Cutting Equipment, Setup, and Operation

505

(14)

Chapter 32 Oxyacetylene Welding

519

(48)

Chapter 33 Brazing, Braze Welding, and Soldering

567

Preface

Acknowledgments

xii

About the Author

xiii

Chapter 1 Introduction to Pipe Welding

(16)

Objectives

(1)

Key Terms

(1)

Introduction

(1)

Piping Systems

(1)

Pipe Applications

(2)

How Pipe is Made

(1)

Pipe Versus Round Tubing

(4)

Pipe Standards

(1)

Pipe Dimensioning

(1)

Tubing Dimensions

(1)

Pressure and Strength Ranges

(1)

Pipe Systems Codes and Standards

(1)

Pipe Welding Processes

(1)

Types of Pipe Welding Jobs

(1)

Teamwork

(1)

Leadership

(1)

Metric Units

(2)

Summary

(1)

Review Questions

(2)

Chapter 2 Welding Safety

(19)

Objectives

(1)

Key Terms

(1)

Introduction

(1)

Burns

(1)

Injuries

(1)

Eye, Face, and Ear Protection

(1)

Eye and Face Protection

(1)

Ear Protection

(1)

Respiratory Protection

(1)

Ventilation

(1)

Material Specification Data

(1)

Waste Material Recycling and Disposal

(1)

Falls

(3)

Scaffolding

(1)

Ladder Safety

(1)

Types of Ladders

(1)

Ladder Inspection

(1)

Rules for Ladder Use

(1)

Excavations

(3)

Cave-ins

(1)

Excavation Walls

(1)

Other Excavation Hazards

(1)

Electrical Safety

(2)

Extension Cord Safety

(1)

Safety Rules for Portable Electric Tools

(1)

General Work Clothing

(1)

Special Protective Clothing

(1)

Fire Protection

(1)

Fire Watch

(1)

Planned Maintenance

(1)

Hoses

(1)

Cables

(1)

Hand Tools

(1)

Work Area

(1)

Material Handling

(4)

Hauling

(1)

Heavy Equipment

(2)

Rigging

(2)

Summary

(1)

Review Questions

(1)

Chapter 3 Shop Math

(14)

Objectives

(1)

Key Terms

(1)

Introduction

(1)

Shop Math

(1)

Types Of Numbers

(1)

General Math Rules

(1)

Equations and Formulas

(2)

Mixed Units

(1)

Adding and Subtracting Mixed Units

(1)

Fractions

(2)

Adding and Subtracting Fractions

(1)

Finding the Fractions' Common Denominator

(1)

Reducing Fractions

(1)

Multiplying and Dividing Fractions

(1)

Multiplying Fractions

(1)

Dividing Fractions

(1)

Converting Numbers

(1)

Converting Fractions to Decimals

(1)

Tolerances

(1)

Converting Decimals to Fractions

(1)

Conversion Charts

(1)

Volume

(3)

Tank Capacities

(1)

Measuring

(1)

Summary

(1)

Review Questions

(1)

Chapter 4 Blueprint Reading and Welding Symbols

(28)

Objectives

(1)

Key Terms

(1)

Introduction

(2)

Types of Drawing Lines

(2)

Pipe Drawings

(4)

Dimensioning

(1)

Reading Dimensions

(4)

Finding Missing Dimensions

(1)

Drawing Scale

(3)

Piping Symbols

(1)

Types of Pipe Drawings

(1)

Materials

(4)

Pipe

(2)

Fittings

(1)

Valves

(1)

Pumps

(1)

Check Valves

(1)

Material Takeoff

(2)

Welding Symbols

(6)

Types of Welds

(1)

Weld Location

(2)

Significance of Arrow Location

(1)

Groove Welds

(3)

Consumable Inserts (Backing)

(1)

Fillet Welds

(1)

Summary

(1)

Review Questions

(2)

Chapter 5 Thermal-Cutting Processes

(28)

Objectives

(1)

Key Terms

(1)

Introduction

(1)

Oxyacetylene Cutting (OFC-A)

(1)

Oxyacetylene Gouging

(1)

Plasma Arc Cutting (PAC)

(1)

Plasma Arc Gouging (PAG)

(1)

Air Carbon Arc Gouging (CAC-A)

(1)

Pipe Cutting

(2)

Freehand Pipe Cuts

(1)

Layout

(1)

Oxyacetylene Equipment Setup

(6)

Selecting the Correct Tip

(1)

Cleaning a Cutting Tip

(1)

Lighting the Torch

(2)

Getting Set to Cut

(1)

Starting a Cut

(2)

Freehand Oxyacetylene Pipe Cutting

(3)

Square Cutting Pipe

(1)

1GOFC-A Pipe Cutting

(1)

5G OF Pipe Cutting

(1)

2G OF Pipe Cutting

(1)

Rusty Nuts and Bolts

(1)

Oxyacetylene Gouging

(1)

1G OFC-A U-Grooving of a Pipe

(1)

1G OF Gouging Out a Pipe Weld

(1)

5G OF Gouging Out a Pipe Weld

(1)

2G OF Gouging Out a Pipe Weld

(1)

PAC Equipment Setup

(1)

Freehand Plasma Arc Pipe Cutting

(5)

1G PA Pipe Cutting

(1)

5G PA Pipe Cutting

(1)

2G PA Pipe Cutting

(1)

Plasma Arc Gouging (PAG)

(1)

1G PA U-Grooving of a Pipe

(1)

1G PA Gouging Out a Pipe Weld

(1)

5G PA Gouging Out a Pipe Weld

(1)

2G PA Gouging Out a Pipe Weld

(1)

Air Carbon Arc Equipment Setup

(3)

1G Air Carbon Arc U-Grooving of a Pipe

100

(1)

1G Air Carbon Arc J-Grooving of a Pipe

101

(1)

1G Air Carbon Arc Gouging Out a Pipe Weld

101

(1)

5G Air Carbon Arc Gouging Out a Pipe Weld

102

(1)

2G Air Carbon Arc Gouging Out a Pipe Weld

102

(1)

Machine Cuts

102

(2)

Summary

104

(1)

Review Questions

105

(1)

Chapter 6 Pipe Joint Design and Preparation

106

(20)

Objectives

106

(1)

Key Terms

106

(1)

Introduction

106

(2)

Joint Geometry

108

(1)

Joint Preparation

109

(1)

Oxy-Fuel Pipe Cutting

110

(3)

Pipe Layout

113

(11)

Pipe Layout Tools

113

(2)

90-Degree Saddle on Standard Wall Pipe

115

(5)

45-Degree Lateral on Standard Wall Pipe

120

(2)

Orange Peel Pipe End

122

(2)

Fabricated Versus Commercial Pipe Fittings

124

(1)

Summary

124

(1)

Review Questions

125

(1)

Chapter 7 Pipe Fit-Up and Alignment

126

(11)

Objectives

126

(1)

Key Terms

126

(1)

Introduction

126

(1)

Code Standards

127

(1)

Preparation of Pipe for Fitting

127

(1)

Alignment Tools

127

(1)

Fitting Tools

128

(1)

Pipe Offsets

129

(1)

Solving Unknown Pipe Angles and Lengths Using The Pythagorean Theorem

130

(1)

Solving Pipe Lengths Using the Angles of a Right Triangle

131

(1)

Marking Butt Weld Elbows for Nonstandard Angles

132

(2)

Take Outs and Root Opening

134

(1)

Summary

135

(1)

Review Questions

136

(1)

Chapter 8 Shielded Metal Arc Welding of Pipe

137

(20)

Objectives

137

(1)

Key Terms

137

(1)

Introduction

137

(1)

Arc Strikes

138

(1)

Technique for Striking an Arc

138

(1)

Electrode Manipulation

139

(1)

Use Both Hands for Welding

139

(1)

Weld Pass

139

(2)

Tack Welds

141

(3)

Root Pass

144

(1)

Root-Pass 1G Position

144

(1)

Hot Pass

145

(1)

Filler Passes

146

(1)

Cover Pass

147

(2)

Weld Physics---Surface Tension

149

(1)

2G Pipe-Welding Position

149

(2)

5G Pipe Welding Position

151

(5)

Summary

156

(1)

Review Questions

156

(1)

Chapter 9 Gas Metal Arc Welding of Pipe

157

(19)

Objectives

157

(1)

Key Terms

157

(1)

Introduction

157

(1)

Types of Metal Transfer

158

(2)

Welding, Volts (Potential), and Amps (Current)

160

(1)

CC Versus CP Welding Machines

160

(1)

Understanding CP and GMA Welding

161

(1)

GMAW Variables

161

(2)

Electrode Extension

161

(1)

Work Angle and Gun Angle

162

(1)

Travel Speed

162

(1)

Electrode Positioning

162

(1)

Tack Welds

163

(1)

Root Pass

163

(1)

Backing Gas

163

(1)

Welding Practices

163

(9)

Modulated Current Transfer

172

(2)

Modulated Current Process

172

(1)

Effect of Modulated Current on Welds

173

(1)

Summary

174

(1)

Review Questions

175

(1)

Chapter 10 Flux Cored Arc Welding of Pipe

176

(7)

Objectives

176

(1)

Key Terms

176

(1)

Introduction

176

(1)

Application of FCAW to Pipe

177

(5)

Root Pass Welds

177

(5)

Summary

182

(1)

Review Questions

182

(1)

Chapter 11 Gas Tungsten Arc Welding of Pipe

183

(10)

Objectives

183

(1)

Key Terms

183

(1)

Introduction

183

(1)

Preparation of Pipe for Welding

184

(1)

GTAW Pipe Techniques

185

(1)

Techniques for Adding Filler Metal

186

(6)

Summary

192

(1)

Review Questions

192

(1)

Chapter 12 Pipe Welding with Multiple Processes

193

(11)

Objectives

193

(1)

Key Terms

193

(1)

Introduction

193

(1)

Preparation of Pipe for Welding

194

(1)

GTAW Pipe Techniques

195

(1)

GTAW Root Weld

195

(1)

GMAW Root Weld

196

(3)

Filler and Cover Pass---SMAW Process

199

(3)

Summary

202

(1)

Review Questions

203

(1)

Chapter 13 Machine and Automatic Pipe Welding

204

(7)

Objectives

204

(1)

Key Terms

204

(1)

Introduction

204

(2)

Automation

206

(1)

Planning for Automation

206

(1)

Property

206

(1)

Skilled Welders

207

(1)

Types of Equipment

207

(1)

Stationary Pipe-Welding Equipment

207

(1)

Orbiting Pipe-Welding Equipment

207

(1)

Multiple Weld Heads

208

(1)

Welding Torch Setup

208

(1)

Wire Feeder

209

(1)

Orbital Welding Head Setup

209

(1)

Summary

209

(1)

Review Questions

210

(1)

Chapter 14 Filler Metals

211

(8)

Objectives

211

(1)

Key Terms

211

(1)

Introduction

211

(1)

Preheat, Interpass, and Postheat Temperatures

212

(1)

SMAW Electrodes

212

(1)

E6010 AWS A5.1-04

212

(2)

E7010 AWS A5.5-96

212

(1)

E8010 AWS A5.5-96

212

(1)

E9010 AWS A5.5-96

213

(1)

E7016 AWS A5.1-04

214

(1)

E8016 AWS A5.5-96

214

(1)

E9016 AWS A5.5-96

214

(1)

E8018 AWS A5.5-96

214

(1)

E9018 AWS A5.5-96

214

(1)

E10018 AWS A5.5-96

214

(1)

E11018 AWS A5.5-96

214

(1)

E12018 AWS A5.5-96

214

(1)

GMAW Solid Wire

214

(1)

ER70S AWS A5.28-96

214

(1)

ER80S AWS A5.18-01

215

(1)

ER90S AWS A5.18-01

215

(1)

GTAW Filler Metals

215

(1)

Mild Steel Filler Metals

215

(1)

Stainless Steel Electrodes

215

(1)

Consumable Inserts

215

(1)

Filler Metal Storage and Handling

216

(1)

Hydrogen Embrittlement

216

(1)

Summary

217

(1)

Review Questions

218

(1)

Chapter 15 Welding Metallurgy

219

(11)

Objectives

219

(1)

Key Terms

219

(1)

Introduction

219

(1)

ASTM, AS ME, and API

220

(1)

Carbon Steel Pipe

220

(1)

Mechanical Properties of Pipes

220

(2)

Hardness

220

(1)

Ductility

221

(1)

Brittleness

221

(1)

Toughness

221

(1)

Strength

221

(1)

Other Mechanical Concepts

222

(1)

Corrosion

222

(1)

Types of Corrosion

223

(1)

Factors that Affect Corrosion

223

(1)

Allowing for Corrosion

224

(1)

Heat, Temperature, and Energy

224

(1)

Example 1 Temperature versus Heat

224

(1)

Example 2 Temperature versus Heat

224

(1)

Example 3 Heat versus Temperature

224

(1)

Example 4 Heat versus Temperature

224

(1)

Grain Structures of Metal

224

(2)

Weld Metal Grain Structure

225

(1)

Heat-Affected Zone

225

(1)

Stainless Steels

226

(1)

Weld Distortion

226

(2)

Thermal Expansion

227

(1)

Thermal Conductivity

228

(1)

Summary

228

(1)

Review Questions

229

(1)

Chapter 16 Weld Discontinuities and Defects

230

(13)

Objectives

230

(1)

Key Terms

230

(1)

Introduction

231

(1)

Discontinuities

231

(1)

Types of Discontinuities

231

(8)

Porosity

231

(3)

Inclusions

234

(1)

Inadequate Joint Penetration

235

(1)

Incomplete Fusion

235

(1)

Arc Strikes

236

(1)

Overlap

237

(1)

Undercut

237

(1)

Underfill

237

(2)

Weld Problems Caused By Inherent Pipe Discontinuities

239

(1)

Laminations

239

(1)

Delaminations

239

(1)

Cracks

239

(2)

Types of Cracks

239

(2)

Summary

241

(1)

Review Questions

242

(1)

Chapter 17 Pipe Weld Repairs

243

(5)

Objectives

243

(1)

Key Terms

243

(1)

Introduction

243

(1)

Repair Considerations

244

(1)

Nonmetallic Inclusions

244

(2)

Incomplete Joint Penetration

246

(1)

Repair of Cracks

246

(1)

Summary

247

(1)

Review Questions

247

(1)

Chapter 18 Testing and Inspecting Welds

248

(18)

Objectives

248

(1)

Key Terms

248

(1)

Introduction

248

(1)

Quality Assurance (QA) and Quality Control (QC)

248

(1)

Codes and Standards

249

(1)

Codes and Standards Organizations

249

(1)

Welding Procedure Specification (WPS)

249

(1)

WPS Form

250

(1)

Weld Testing

250

(1)

Destructive Testing (DT)

250

(6)

Tensile Testing

250

(1)

Nick-Break Test

251

(1)

Guided-Bend Test

251

(3)

Guided-Bend Test Procedure

254

(1)

Free-Bend Test

254

(1)

Alternate Bend

255

(1)

Impact Testing

255

(1)

Nondestructive Testing (NDT)

256

(7)

Visual Inspection (VT)

256

(1)

Penetrant Inspection (PT)

257

(2)

MT Procedure

259

(1)

Radiographic Inspection (RT)

259

(2)

Hydrostatic Testing

261

(1)

Ultrasonic Inspection (UT)

262

(1)

Eddy Current Inspection (ET)

263

(1)

Corrosion Protection

263

(2)

Pipe Preparation

263

(1)

Corrosion Protection Inspection

264

(1)

Summary

265

(1)

Review Questions

265

(1)

Chapter 19 Pipe Welding Certification---Welding Procedures

266

(8)

Objectives

266

(1)

Key Terms

266

(1)

Introduction

266

(1)

Qualified Versus Certified Welders

267

(1)

AWS SENSE

267

(5)

SENSE Certification

267

(1)

SENSE Visual Inspection Tools

267

(1)

SENSE Visual Inspection Testing

267

(2)

SENSE Visual Inspection Test Results

269

(1)

SENSE Guided Bend Test Specimen Selection

269

(1)

SENSE Guided Bend Test Specimen Preparation

270

(1)

SENSE Guided Bend Test Jig

271

(1)

SENSE Guided Bend Test Results

271

(1)

Certification Records

271

(1)

Summary

272

(1)

Review Questions

272

(2)

Chapter 20 Pipe Threads

274

(13)

Objectives

274

(1)

Key Terms

274

(1)

Introduction

275

(1)

Types of Threads

275

(1)

Thread Specifications

276

(2)

Thread Gauges

277

(1)

Bolts, Machine Screws, and Studs

278

(1)

Bolt Grades

278

(1)

Cutting Oils

278

(1)

Using Thread Cutting Oils

279

(1)

Recycling Thread Cutting Oil

279

(1)

Disposing of Used Thread Cutting Oil

279

(1)

Disposing of Oil-Soaked Rags

279

(1)

Pipe Threading

279

(4)

Storing Taps and Dies

279

(4)

Tightening Threads

283

(1)

Torque Wrenches

283

(1)

Pipe Dope and Teflon Tape

283

(1)

Tightening Pipe Fittings

283

(1)

Summary

284

(1)

Review Questions

284

(3)

Appendix

I Student Welding Report and/or SENSE Record

287

(1)

II AWS SENSE Drawing Detail Form

288

(1)

III AWS SENSE Workmanship Sample Drawing Form

289

(1)

Glossary/Glosario

290

(15)

Index

305

Welding plus Pipe Welding plus Study Guide with Lab Manual for Jeffus' Welding: Principles and Applications, 8th Ed. plus MindTap Welding, 4 terms 24 months Access Card for Jeffus' Welding: Principles and Applications: Principles and Applications 8 PCK HAR/

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