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Welding: Principles and Applications 9th edition [Kietas viršelis]

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(Eastfield College (Emeritus))
  • Formatas: Hardback, 960 pages, aukštis x plotis x storis: 40x223x279 mm, weight: 2290 g
  • Išleidimo metai: 14-Feb-2020
  • Leidėjas: Delmar Cengage Learning
  • ISBN-10: 0357377656
  • ISBN-13: 9780357377659
Kitos knygos pagal šią temą:
Welding: Principles and Applications 9th editionDidesnis paveikslėlis
  • Formatas: Hardback, 960 pages, aukštis x plotis x storis: 40x223x279 mm, weight: 2290 g
  • Išleidimo metai: 14-Feb-2020
  • Leidėjas: Delmar Cengage Learning
  • ISBN-10: 0357377656
  • ISBN-13: 9780357377659
Kitos knygos pagal šią temą:
Pastovi nuoroda: https://www.kriso.lt/db/9780357377659.html
Raktažodžiai:
This proven guide provides the knowledge and skills you need to complete AWS SENSE Level I and Level II programs, create Workmanship Qualification Specimens, and earn professional certification. Advancing rapidly from basic concepts and processes to today's most complex, cutting-edge welding technologies and practices, this comprehensive text features valuable information on topics such as welding metallurgy, metal fabrication, weld testing and inspection, joint design, job costing, and environmental and conservation tips. The author opens each section by introducing you to the materials, equipment, setup procedures, and critical safety information you need to execute a specific process successfully, while subsequent chapters focus on individual welding tasks leading to SENSE certification. In addition to hundreds of new photos showcasing current welding tools and techniques, the Ninth Edition includes new and updated information on GTAW cup walking, induction welding machine operations, innovations in PAC equipment, and other industry advances you are likely to encounter as you begin your career as a welding professional.
Preface xvi
Features of the Text xix
Acknowledgments xxi
About the Author xxiii
Index of Experiments and Practices xxv
Section 1 Introduction 1(53)
Chapter 1 Introduction to Welding (AWS SENSE Module 1 Occupational Orientation)
3(22)
Objectives
3(1)
Key Terms
3(1)
Introduction
3(1)
Welding Terminology
4(1)
Welding Defined
4(1)
Uses of Welding
5(1)
Welding and Cutting Processes
5(2)
Welding Processes
7(3)
Oxyacetylene Welding, Brazing, and Cutting
7(1)
Shielded Metal Arc Welding (SMAW)
7(1)
Gas Tungsten Arc Welding (GTAW)
8(1)
Gas Metal Arc Welding (GMAW)
9(1)
Flux Cored Arc Welding (FCAW)
9(1)
Thermal Cutting Processes
10(1)
Oxyfuel Gas Cutting
10(1)
Plasma Arc Cutting
10(1)
Selection of the Joining Process
10(1)
Occupational Opportunities in Welding
11(2)
Training for Welding Occupations
13(1)
Job-Related Skills
13(1)
Beginning a Welding Career
13(1)
Job Prospects
14(1)
Job-Related Personal Skills
14(3)
Teamwork
14(1)
Communication
15(1)
Problem Solving
15(1)
Reading and Understanding Text
15(1)
Punctuality
16(1)
Missing Work
16(1)
Continued Education
17(1)
AWS SENSE Welder Certification
17(1)
Level I Qualification Procedures
17(2)
Practical Knowledge Qualification-Written Test
17(1)
Performance Qualification-Workmanship Samples and Test Plates
17(1)
Thermal Cutting Principles and Practices
18(1)
Welding Inspection and Testing Principles and Practices
18(1)
Level II Advanced Welder Qualification
19(1)
SkillsUSA
20(1)
Experiments and Practices
20(1)
Welding Video Series
21(1)
Metric Units
21(2)
Summary
23(1)
Review
23(2)
Chapter 2 Safety in Welding (AWS SENSE Module 2 Safety and Health of Welders)
25(29)
Objectives
25(1)
Key Terms
25(1)
Introduction
25(1)
Burn Classification
26(2)
First-Degree Burns
26(1)
Second-Degree Burns
26(1)
Third-Degree Burns
26(1)
Burns Caused by Light
27(1)
Personal Protection Equipment (PPE)
28(7)
General Work Clothing
29(1)
Special Protective Clothing
30(1)
Face and Eye Protection
31(1)
Goggles
31(1)
Full Face Shield
31(1)
Welding Helmets
31(1)
Auto Darkening Welding Helmets
32(1)
Shop Noise
32(1)
Respiratory Protection
33(2)
Hazardous Gases
35(1)
Ventilation
35(1)
Safety Data Sheets (SDSs)
36(1)
Handling and Storing Cylinders
36(2)
Securing Gas Cylinders
37(1)
Storage Areas
37(1)
Cylinders with Valve Protection Caps
37(1)
General Precautions
37(1)
Acetylene
38(1)
Caution
38(1)
Fire Protection
39(2)
Fire Watch
39(1)
Fire Extinguishers
39(1)
Location of Fire Extinguishers
40(1)
Using Fire Extinguishers
41(1)
Equipment Maintenance
41(1)
Hoses
41(1)
Work Area Cleaning
42(1)
Hand Tools
42(1)
Hand Tool Safety
43(1)
Hammer Safety
43(1)
Electrical Safety
43(4)
Electrical Safety Systems
45(1)
Voltage Warnings
46(1)
Extension Cords
46(1)
Safety Rules for Portable Electric Tools
46(1)
Power Tools
47(3)
Grinders
47(1)
Drills
48(1)
Metal Cutting Machines
49(1)
Material Handling
50(1)
Lifting
50(1)
Hoists or Cranes
50(1)
Ladder Safety
51(1)
Types of Ladders
51(1)
Ladder Inspection
51(1)
Rules for Ladder Use
51(1)
Summary
52(1)
Review
52(2)
Section 2 Shielded Metal Arc Welding 54(109)
Chapter 3 Shielded Metal Arc Equipment, Setup, and Operation (AWS SENSE Module 4 Shielded Metal Arc Welding (SMAW))
56(21)
Objectives
56(1)
Key Terms
56(1)
Introduction
56(2)
Welding Current
58(1)
Electrical Measurement
58(2)
Temperature and Heat
59(1)
SMA Welding Arc Temperature
59(1)
SMA Welding Arc Heat
59(1)
Types of Welding Currents
59(1)
Types of Welding Power Supplies (Machines)
60(6)
Open Circuit Voltage
61(1)
Operating Voltage
61(1)
Arc Blow
61(1)
Types of Power Sources
62(4)
Movable Coil or Core
66(1)
Inverter
66(1)
Generator-Type and Alternator-Type Welders
67(1)
Routine Maintenance
68(1)
Converting AC to DC
68(1)
Duty Cycle
69(1)
Welder Accessories
70(1)
Welding Cables
70(1)
Electrode Holders
70(2)
Work Clamps
72(1)
Equipment Setup
72(1)
Arc Force Control
73(2)
Hot Start
75(1)
Summary
76(1)
Review
76(1)
Chapter 4 Shielded Metal Arc Welding of Plate (AWS SENSE Module 4 Shielded Metal Arc Welding (SMAW))
77(37)
Objectives
77(1)
Key Terms
77(1)
Introduction
77(2)
Practices
79(2)
Effect of Current Settings That Are Too Low or Too High
81(1)
Too Low of a Current Setting
81(1)
Too High of a Current Setting
81(1)
Experiments
82(1)
Electrode Size and Heat
82(1)
Arc Length
83(2)
Travel Angle, Electrode Angle and Work Angle
85(2)
Leading Angle
85(1)
Perpendicular Angle
86(1)
Trailing Angle
86(1)
Electrode Manipulation
87(2)
Positioning of the Welder and the Plate
89(1)
Practice Welds
89(1)
Electrodes
89(1)
F3 E6010 and E6011 Electrodes
89(1)
F2 E6012 and E6013 Electrodes
90(1)
F4 E7016 and E7018 Electrodes
90(1)
Electrode Selection
90(1)
Stringer Beads
90(4)
Padding
91(3)
Square Butt Joint
94(4)
Edge Weld
98(4)
Outside Corner Joint
102(3)
Lap Joint
105(4)
Tee Joint
109(3)
Summary
112(1)
Review
113(1)
Chapter 5 Shielded Metal Arc Welding of Pipe
114(22)
Objectives
114(1)
Key Terms
114(1)
Introduction
114(1)
Pipe and Tubing
115(2)
Pipe Specifications
116(1)
Tubing Specifications
116(1)
Pipe Applications
116(1)
Tubing Applications
116(1)
Advantages of Welded Pipe
117(2)
Strength
117(1)
Less Maintenance Required
117(1)
Longer Lasting
117(1)
Smoother Flow
117(1)
Lighter Weight
117(2)
Preparation and Fit-up
119(2)
Practice Welds
121(1)
Weld Standards
121(1)
Weld Passes
121(3)
Root Weld Pass
121(1)
Hot Weld Pass
122(1)
Filler Weld Pass
122(2)
Cover Weld Pass
124(1)
Electrode Care
124(1)
1G Horizontal Rolled Position
124(5)
AWS SENSE Certification Test 1G
129(1)
2G Vertical Fixed Position
129(2)
5G Horizontal Fixed Position
131(2)
AWS SENSE Certification Test 5G
133(1)
6G 45° Inclined Position
133(1)
AWS SENSE Certification Test 6G
134(1)
Summary
135(1)
Review
135(1)
Chapter 6 Shielded Metal Arc Welding AWS SENSE Certification
136(27)
Objectives
136(1)
Key Terms
136(1)
Introduction
136(1)
Root Pass
136(2)
Arc Control
138(3)
Hot Pass
141(2)
Filler Pass
143(1)
Cover Pass
144(1)
Plate Preparation
144(3)
Restarting a Weld Bead
147(1)
Preheating and Postheating
148(1)
AWS Workmanship Standard for Preparation of Base Metal
149(1)
AWS Visual Inspection Criteria
149(1)
Preparing Specimens for Bend Testing
149(1)
AWS Specimen Preparation Criteria
149(2)
Preparation
149(1)
Testing
149(2)
AWS Acceptance Criteria for Bend Test
151(9)
Poor Fit-up
160(1)
Summary
161(1)
Review
162(1)
Section 3 Cutting And Gouging 163(110)
Chapter 7 Flame Cutting (AWS SENSE Module 8 Unit 1 Manual Oxyfuel Gas Cutting (OFC) Unit 2 Mechanized Oxyfuel Gas Cutting (OFC))
165(59)
Objectives
165(1)
Key Terms
165(1)
Introduction
166(1)
Oxyfuel Flame
166(1)
Characteristics of the Fuel-Gas Flame
166(1)
Fuel Gases
167(2)
Flame Rate of Burning
168(1)
Acetylene (C2H2)
169(4)
Heat and Temperature of Acetylene
170(1)
Pressure
170(2)
Methylacetylene-Propadiene (MPS)
172(1)
Propane and Natural Gas
173(1)
Hydrogen
173(1)
Metals Cut by the Oxyfuel Process
174(1)
The Chemistry of a Cut
174(1)
Eye Protection for Flame Cutting
175(1)
Cutting Torches
175(2)
Welding and Cutting Torches: Design and Service
177(2)
Combination Torches
178(1)
Dedicated Cutting Torches
178(1)
Cutting Tips
179(2)
Pressure Regulators
181(2)
Regulator Operation
183(1)
Regulator Gauges
183(2)
Regulator Safety Pressure Release Device
185(1)
Compressed Gas Cylinders
185(3)
Oxygen Cylinder Construction
185(1)
Acetylene Cylinder Construction
186(1)
Liquid Cylinder Construction
187(1)
Cryogenic Cylinders
187(1)
Cylinder Labels
188(1)
Cylinder and Regulator Fittings
188(1)
Regulator Safety Precautions
188(2)
Regulator Care and Use
190(1)
Torch Care and Use
191(1)
Backfires
192(1)
Flashbacks
192(1)
Reverse Flow and Flashback Valves
192(1)
Care of the Reverse Flow Valve and Flashback Arrestor
193(1)
Hoses and Fittings
194(1)
Hose Care and Use
194(1)
Leak Detection
195(1)
Oxyfuel Cutting, Setup, and Operation
195(1)
Torch Tip Care and Use
195(1)
Manifold Systems
196(8)
Manifold Operation
197(7)
Hand Cutting
204(3)
Layout
207(1)
Selecting the Correct Tip and Setting the Pressure
208(2)
The Physics of a Cut
210(1)
Mechanized Cutting Equipment
211(2)
Slag
213(1)
Plate Cutting
213(1)
Cutting Table
214(1)
Torch Guides
214(1)
Distortion
215(2)
Cutting Applications
217(1)
Pipe Cutting
218(3)
Oxyfuel Gouging
221(1)
Gouging Tips
221(1)
Gouging Variables
221(1)
Summary
222(1)
Review
222(2)
Chapter 8 Plasma Arc Cutting (AWS SENSE Module 8 Unit 3 Manual Plasma Arc Cutting (PAC))
224(31)
Objectives
224(1)
Key Terms
224(1)
Introduction
224(1)
Plasma
225(6)
Arc Plasma
225(1)
Plasma Torch
226(1)
Torch Body
226(1)
Torch Head
226(1)
Power Switch
226(1)
Torch Parts Commonly Serviced
227(2)
Hoses and Power Cables
229(2)
Gas Hoses
231(1)
Power Cable
231(1)
Coolant System
231(1)
Coolant
231(1)
Coolant Hoses
231(1)
Control Wire
232(1)
Compressed Air
232(1)
Power Requirements
233(1)
Voltage
233(1)
Amperage
233(1)
Watts
233(1)
Heat Input
233(1)
Distortion
233(1)
Applications
234(6)
Cutting Speed
234(1)
Metals
234(1)
Torch Standoff Distance
235(1)
Starting Methods
236(1)
Kerf
237(2)
Gas and Gases
239(1)
Compressed Air
239(1)
Oxygen
239(1)
Argon Hydrogen Mixed Gas
239(1)
Stack Cutting
240(1)
Dross
241(1)
Machine Cutting
241(1)
Water Tables
242(1)
Manual Cutting
243(1)
Setup
243(1)
Safety
243(1)
Straight Cuts
244(3)
Piercing
247(2)
Plasma Arc Gouging
249(3)
Cutting Round Stock
252(1)
Beveling Pipe
252(2)
Summary
254(1)
Review
254(1)
Chapter 9 Related Cutting Processes (AWS SENSE Module 8 Unit 4 Manual Air Carbon Arc Cutting (CAC-A))
255(18)
Objectives
255(1)
Key Terms
255(1)
Introduction
255(1)
Laser Beam Cutting (LBC) and Laser Beam Drilling (LBD)
255(1)
Lasers
256(1)
Laser Types
256(1)
Solid State Lasers
257(1)
Gas Laser
257(1)
Applications
257(2)
Laser Beam Cutting
258(1)
Laser Beam Drilling
259(1)
Laser Beam Welding
259(1)
Laser Equipment
259(1)
Air Carbon Arc Cutting (CAC-A)
259(1)
Manual Torch Design
260(2)
Electrodes
260(2)
Power Sources
262(1)
Air Supply
262(1)
Application
262(1)
Safety
263(2)
U-Grooves
265(3)
Oxygen Lance Cutting
268(1)
Applications
268(1)
Safety
269(1)
Water Jet Cutting
269(1)
Applications
269(2)
Arc Cutting Electrodes
271(1)
Applications
271(1)
Summary
271(1)
Review
272(1)
Section 4 Gas Shielded Welding 273(264)
Chapter 10 Gas Metal Arc Welding Equipment, Setup, and Operation (AWS SENSE Module 5 Gas Metal Arc Welding (GMAW, GMAW-S))
275(28)
Objectives
275(1)
Key Terms
275(1)
Introduction
276(2)
Weld Metal Transfer Methods
278(8)
Short-Circuiting Transfer GMAW-S
278(1)
Globular Transfer
279(1)
Axial Spray Metal Transfer
279(2)
Pulsed-Arc Metal Transfer
281(1)
Pulsed-Arc Metal Transfer Current Cycle
282(2)
Modulated Current Metal Transfer
284(1)
The Modulated Current Process
284(1)
Advantages of Modulated Current and Pulsed-Arc Metal Transfer
284(1)
Buried-Arc Transfer
285(1)
GMAW Filler Metal Specifications
286(1)
Wire Melting and Deposition Rates
286(1)
Welding Power Supplies
287(2)
GMA Welding Machines
287(1)
Speed of the Wire Electrode
287(1)
Power Supplies for Short-Circuiting Transfer
287(2)
Shielding Gas
289(2)
Argon
289(1)
Argon Gas Blends
289(2)
Helium
291(1)
Carbon Dioxide
291(1)
Nitrogen
291(1)
Power Settings
291(1)
Weave Pattern
291(1)
Travel Speed
291(1)
Electrode Extension
292(1)
Gun Angle
292(2)
Forehand/Perpendicular/Backhand Welding
292(2)
Metal Core Electrodes for GMA Welding
294(1)
Equipment
294(6)
Power Source
294(1)
Electrode (Wire) Feed Unit
294(1)
Types of Wire Feed Units
295(3)
Electrode Conduit
298(1)
Welding Gun
298(2)
GMA Spot Welding
300(1)
Summary
301(1)
Review
301(2)
Chapter 11 Gas Metal Arc Welding (AWS SENSE Module 5 Gas Metal Arc Welding (GMAW, GMAW-S))
303(34)
Objectives
303(1)
Key Terms
303(1)
Introduction
303(1)
Setup
304(3)
Wire-Feed Speed
307(3)
Gas Density and Flow Rates
310(1)
Arc-Voltage and Amperage Characteristics
311(2)
Electrode Extension
313(1)
Welding Gun Angle
314(1)
Effect of Shielding Gas on Welding
315(2)
Practices
317(1)
Metal Preparation
318(1)
Flat Position, 1G and 1F Positions
319(4)
Vertical Up 3G and 3F Positions
323(2)
Vertical Down 3G and 3F Positions
325(1)
Horizontal 2G and 2F Positions
326(2)
Overhead 4G and 4F Positions
328(2)
Globular Metal Transfer, 1G Position
330(4)
Axial Spray
334(1)
Summary
335(1)
Review
335(2)
Chapter 12 Flux Cored Arc Welding Equipment, Setup, and Operation (AWS SENSE Module 6 Flux Cored Arc Welding (FCAW-G/GM, FCAW-S))
337(22)
Objectives
337(1)
Key Terms
337(1)
Introduction
337(3)
Principles of Operation
340(1)
Flux Core
340(1)
Gas Formers
341(1)
Slag
341(1)
Equipment
341(1)
Power Supply
341(1)
Inverter Welding Machines
341(1)
FCA Welding Guns
341(1)
Electrode Feed
342(1)
Advantages
342(1)
Limitations
343(1)
FCAW Electrodes
343(3)
Electrode Cast and Helix
346(1)
FCA Welding Electrode Flux
346(1)
Types of FCAW Fluxes
347(3)
Flux Cored Steel Electrode Identification
348(1)
Mild Steel
349(1)
Stainless Steel Electrodes
350(1)
Metal Cored Steel Electrode Identification
350(1)
Care of Flux Core Electrodes
350(1)
Shielding Gas
350(1)
Welding Techniques
351(1)
Gun Angle
351(1)
Forehand/Perpendicular/Backhand Techniques
352(2)
Advantages of the Forehand Technique
353(1)
Disadvantages of the Forehand Technique
353(1)
Advantages of the Perpendicular Technique
353(1)
Disadvantages of the Perpendicular Technique
353(1)
Advantages of the Backhand Technique
353(1)
Disadvantages of the Backhand Technique
354(1)
Travel Speed
354(1)
Mode of Metal Transfer
354(3)
Spray Transfer-FCAW-G
354(1)
Globular Transfer-FCAW-G
355(1)
Electrode Extension
355(1)
Porosity
355(2)
Troubleshooting FCA Welding
357(1)
Summary
358(1)
Review
358(1)
Chapter 13 Flux Cored Arc Welding (AWS SENSE Module 6 Flux Cored Arc Welding (FCAW-G/GM, FCAW-S))
359(29)
Objectives
359(1)
Key Terms
359(1)
Introduction
359(1)
Practices
360(4)
Flat-Position Welds
364(1)
Square-Groove Welds
364(2)
V-Groove and Bevel-Groove Welds
366(2)
Root Pass
367(1)
Filler Pass
367(1)
Cover Pass
368(1)
Fillet Welds
368(4)
Vertical Welds
372(4)
Horizontal Welds
376(3)
Overhead-Position Welds
379(1)
Thin-Gauge Welding
380(5)
Plug Welds
385(1)
Summary
386(1)
Review
387(1)
Chapter 14 Gas Metal Arc and Flux Cored Arc Welding of Pipe
388(13)
Objectives
388(1)
Key Terms
388(1)
Introduction
388(1)
Joint Preparation
388(3)
End Preparation
388(1)
Joint Fitup
389(1)
Tack Welds
390(1)
Root Pass
390(1)
Hot Pass
390(1)
Filler Pass
390(1)
Cover Pass(es)
390(1)
Visual Inspection
390(1)
Practice Pipe Welds
391(1)
Pipe Fillet Welds
391(9)
Tack Welds
396(1)
Root Pass
396(1)
Hot Pass
396(1)
Filler Pass(es)
396(1)
Cover Pass
397(3)
Summary
400(1)
Review
400(1)
Chapter 15 Gas Metal Arc and Flux Cored Arc Welding AWS SENSE Certification (AWS SENSE Modules 5 Gas Metal Arc Welding (GMAW, GMAW-S) and 6 Module 6 Flux Cored Arc Welding (FCAW-G/GM, FCAW-S))
401(27)
Objectives
401(1)
Key Terms
401(1)
Introduction
401(1)
Practice Welds
401(26)
Metal Preparation
401(1)
Practice Weld Equipment and Consumables
402(25)
Summary
427(1)
Review
427(1)
Chapter 16 Gas Tungsten Arc Welding Equipment, Setup, Operation, and Filler Metals (AWS SENSE Module 7 Gas Tungsten Arc Welding (GTAW))
428(30)
Objectives
428(1)
Key Terms
428(1)
Introduction
429(1)
Tungsten
429(2)
High Temperature
429(1)
Good Conductor
429(1)
Tungsten Erosion
429(1)
Tungsten Electrode End Shape
430(1)
Types of Tungsten Electrodes
431(2)
Pure Tungsten, EWP
431(1)
Thoriated Tungsten, EWTh-1 and EWTh-2
432(1)
Zirconium Tungsten, EWZr-1
432(1)
Cerium Tungsten, EWCe-2
432(1)
Lanthanum Tungsten, EWLa-1.5
432(1)
Rare Earth Tungsten, EWG
433(1)
Shaping the Tungsten
433(4)
Precision Machine Tungsten Grinder
433(1)
Hand Grinding
434(3)
Breaking and Remelting
437(1)
Pointing and Remelting
438(1)
GTA Welding Equipment
438(4)
Torches
438(2)
Hoses
440(1)
Nozzles
440(2)
Gas Lens
442(1)
Flowmeter
442(1)
Types of Welding Current
443(2)
DCEN
443(1)
DCEP
443(1)
AC
444(1)
High Frequency (HF)
445(1)
Electronic Controls of AC Welding Currents
445(2)
EP and EN Time Control
445(1)
Sine Wave Form Control
445(1)
Frequency Control
446(1)
Shielding Gases
447(1)
Argon
448(1)
Helium
448(1)
Hydrogen
448(1)
Nitrogen
448(1)
Hot Start
448(1)
Preflow
449(1)
Postflow
449(1)
Shielding Gas Flow Rate
450(1)
Remote Controls
450(5)
GTA Welding in the Field
455(2)
Summary
457(1)
Review
457(1)
Chapter 17 Gas Tungsten Arc Welding of Plate (AWS SENSE Module 7 Gas Tungsten Arc Welding (GTAW))
458(29)
Objectives
458(1)
Key Terms
458(1)
Introduction
458(1)
Torch Angle
459(1)
Filler Rod Manipulation
459(1)
Tungsten Contamination
460(1)
Current Setting
461(1)
Experiments
461(1)
Gas Flow
462(1)
Practice Welds
463(1)
Low Carbon and Mild Steels
464(1)
Stainless Steel
464(1)
Aluminum
465(1)
Metal Preparation
465(21)
Summary
486(1)
Review
486(1)
Chapter 18 Gas Tungsten Arc Welding of Pipe
487(23)
Objectives
487(1)
Key Terms
487(1)
Introduction
487(1)
Practices
487(1)
Joint Preparation
487(2)
V-Groove
488(1)
Joint Cleaning
489(1)
Root
489(2)
Incomplete Fusion
490(1)
Concave Root Surface
490(1)
Excessive Root Reinforcement
491(1)
Root Contamination
491(1)
Backing Gas
491(1)
Purging
491(1)
Filler Metal
492(2)
Consumable Inserts
493(1)
Cup Walking
494(3)
Cup Walking Setup
495(1)
Cup Walking Technique
496(1)
Practice Welds
497(4)
Hot Pass
501(3)
Root Surface
501(1)
Lack of Root Fusion
501(3)
Filler Pass
504(1)
Cover Pass
505(3)
Summary
508(1)
Review
508(2)
Chapter 19 Gas Tungsten Arc Welding AWS SENSE Plate and Pipe Certification
510(27)
Objectives
510(1)
Key Terms
510(1)
Introduction
510(1)
GTA Sheet Welds
510(1)
GTA Tubing Welds
510(1)
AWS SENSE GTA Sheet Practice Welds
510(3)
Weld Inspection and Testing
512(1)
Butt Joint Welds
512(1)
Fillet Welds, Lap and Tee Joints
512(1)
Tubing Welds
512(1)
Mechanical, Destructive Testing
513(1)
Filler Metal
513(1)
Sheet Metal Practice Welds
513(13)
Tubing and Pipe Practice Welds
526(5)
Stainless Steel Pipe Welds
531(1)
Pipe Fillet Welds
531(5)
Summary
536(1)
Review
536(1)
Section 5 Related Technologies 537(270)
Chapter 20 Shop Math and Weld Cost
539(31)
Objectives
539(1)
Key Terms
539(1)
Introduction
539(1)
Shop Math
540(1)
Types of Numbers
540(1)
Whole Numbers
540(1)
Decimal Fractions
540(1)
Mixed Units
540(1)
Fractions
540(1)
General Math Rules
541(1)
Letters, Numbers, and Symbols
542(1)
Superscript and Subscripts
542(1)
Equations and Formulas
542(1)
Equations
542(1)
Formulas
542(1)
Mixed Units
543(4)
Adding and Subtracting Mixed Units
543(2)
Fractions
545(1)
Finding the Fraction's Common Denominator
545(1)
Reducing Fractions
546(1)
Multiplying and Dividing Fractions
546(1)
Converting Numbers
547(1)
Converting Fractions to Decimals
547(1)
Tolerances
547(1)
Converting Decimals to Fractions
547(1)
Conversion Charts
548(1)
Angles
548(1)
Adding and Subtracting Angles
549(1)
Triangles
549(2)
Right Triangle
549(1)
Equilateral Triangle
550(1)
Isosceles Triangle
550(1)
Perimeter
551(1)
Area
551(1)
Volume
551(2)
Measuring
552(1)
Welding Costs
553(1)
Cost Estimation
553(1)
Joint Design
554(2)
Groove Welds
555(1)
Fillet Welds
556(1)
Weld Metal Cost
556(1)
Cost of Electrodes, Wires, Gases, and Flux
557(8)
Deposition Efficiency
557(1)
Deposition Rate
558(1)
Deposition Data Tables
558(1)
Coated Electrodes
559(1)
Efficiency of Flux Cored Wires
560(1)
Efficiency of Solid Wire for GMAW
561(1)
Efficiency of Solid Wires for SAW
561(1)
Operating Factor
561(3)
Labor and Overhead
564(1)
Cost of Power
565(1)
Other Useful Formulas
565(1)
Bill of Materials
565(1)
Invoice
565(3)
Summary
568(1)
Review
568(2)
Chapter 21 Reading Technical Drawings (AWS SENSE Module 3 Drawing and Welding Symbol Interpretation)
570(22)
Objectives
570(1)
Key Terms
570(1)
Introduction
570(1)
Mechanical Drawings
571(1)
Lines
571(3)
Types of Drawings
573(1)
Pictorial Drawings
573(1)
Mechanical Drawings
574(1)
Special Views
574(1)
Dimensioning
574(1)
Drawing Scale
575(2)
Reading Mechanical Drawings
577(5)
Sketching
578(4)
Erasers and Erasing
582(1)
Graph Paper
582(4)
Computers and Drawings
586(4)
Summary
590(1)
Review
591(1)
Chapter 22 Welding Joint Design and Welding Symbols (AWS SENSE Module 3 Drawing and Welding Symbol Interpretation)
592(19)
Objectives
592(1)
Key Terms
592(1)
Introduction
592(1)
Weld Joint Design
592(3)
Weld Joint Stresses
594(1)
Welding Process
595(1)
Edge Preparation
595(1)
Joint Dimensions
595(2)
Metal Thickness
595(2)
Metal Type
597(1)
Welding Position
597(1)
Plate Welding Positions
598(1)
Pipe Welding Positions
598(1)
Code or Standards Requirements
598(1)
Welder Skill
599(1)
Acceptable Cost
599(1)
Welding Symbols
599(11)
Indicating Types of Welds
600(1)
Weld Location
601(1)
Location Significance of Arrow
601(1)
Fillet Welds
602(1)
Plug Welds
602(1)
Spot Welds
603(1)
Seam Welds
603(1)
Groove Welds
603(3)
Backing
606(1)
Flanged Welds
607(1)
Nondestructive Testing Symbols
607(3)
Summary
610(1)
Review
610(1)
Chapter 23 Fabricating Techniques and Practices
611(36)
Objectives
611(1)
Key Terms
611(1)
Introduction
611(1)
Fabrication
611(1)
Safety
612(1)
Parts and Pieces
613(1)
Preformed
613(1)
Custom Fabrication
613(1)
Layout
614(6)
Nesting
619(1)
Kerf Space
620(3)
Material Shapes
623(1)
Bill of Materials Form
624(1)
Overall Tolerance
625(1)
Assembly
626(2)
Overall Dimensions and Thick Materials
628(1)
Part Identification
628(1)
Assembly Tools
628(3)
Fitting
631(1)
Tack Welds
632(2)
Welding
634(1)
Arc Strikes
634(1)
Finishing
635(1)
Power Tools
635(2)
Powering Hand Tools
635(1)
Advantages of Corded Tools
635(1)
Disadvantages of Corded Tools
635(1)
Advantages of Cordless Tools
636(1)
Disadvantages of Cordless Tools
637(1)
Advantages of Pneumatic Tools
637(1)
Disadvantages of Pneumatic Tools
637(1)
Pedestal or Bench Grinders
637(1)
Grinding Stones
637(1)
Overheating a Part's Edge
637(1)
Flap Disc Grinding Safety
637(1)
Flap Discs vs Cupped Grinding Stones and Fiber Discs
637(1)
Flap Discs
637(1)
Cupped Grinding Stones and Fiber Discs
638(1)
Abrasive Flap Discs
638(1)
Flap Disc Types
639(1)
Flap Disc Selection
639(1)
Size
639(1)
Hub or Arbor
639(1)
Revolutions Per Minute (RPM)
639(1)
Disc Type or Style
639(1)
Abrasive Type
639(1)
Ceramic Alumina
639(1)
Zirconia Alumina
639(1)
Aluminum Oxide
639(1)
Abrasive Grit Sizes
640(1)
Backing Material
640(1)
Cloth Backing
640(1)
Aluminum (Metal) Backing
640(1)
Plastic Backing (Composite)
640(1)
Fiberglass (Phenolic) Backing
640(1)
Horizontal Power Saws
640(1)
Horizontal Band Saws
641(1)
Power Hacksaws
641(1)
Circular Saws
641(1)
Sheet Metal Power Hand Tools
641(2)
Handheld Power Shear
642(1)
Handheld Nibbler
642(1)
Drills
643(1)
Portable Hand Drills
643(1)
Portable Hand Drill Options
643(1)
Drill Press
643(1)
Magnetic Base Portable Drill Press
643(1)
Magnetic Bases
644(1)
Trusses
644(2)
Summary
646(1)
Review
646(1)
Chapter 24 Welding Codes and Standards
647(15)
Objectives
647(1)
Key Terms
647(1)
Introduction
647(1)
Codes, Standards, Procedures, and Specifications
647(1)
Welding Procedure Qualification
648(1)
Welding Procedure Specification (WPS)
648(1)
Qualifying the Welding Procedure Specification
648(1)
Qualifying and Certifying
648(1)
General Information
649(12)
Summary
661(1)
Review
661(1)
Chapter 25 Testing and Inspection
662(28)
Objectives
662(1)
Key Terms
662(1)
Introduction
662(1)
Quality Control (QC)
662(1)
Discontinuities and Defects
663(6)
Porosity
663(2)
Inclusions
665(1)
Inadequate Joint Penetration
665(1)
Incomplete Fusion
666(1)
Arc Strikes
667(1)
Overlap
668(1)
Undercut
668(1)
Crater Cracks
668(1)
Underfill
669(1)
Plate-Generated Problems
669(1)
Lamination
669(1)
Delamination
670(1)
Lamellar Tears
670(1)
Destructive Testing (DT)
670(2)
Tensile Testing
670(2)
Fatigue Testing
672(1)
Shearing Strength Test
672(1)
Welded Butt Joints
672(6)
Nick-Break Test
672(1)
Guided-Bend Test
672(4)
Combination Guided Bend and Tensile Test Machine
676(1)
Free-Bend Test
676(1)
Alternate Bend
676(1)
Fillet Weld Break Test
676(1)
Testing by Etching
676(2)
Impact Testing
678(1)
Nondestructive Testing (NDT)
678(11)
Visual Inspection (VT)
678(1)
Penetrant Inspection (PT)
679(1)
Magnetic Particle Inspection (MT)
679(1)
Radiographic Inspection
680(5)
Ultrasonic Inspection
685(1)
Leak Checking
686(1)
Eddy Current Inspection (ET)
686(1)
Hardness Testing
686(3)
Summary
689(1)
Review
689(1)
Chapter 26 Welding Metallurgy
690(31)
Objectives
690(1)
Key Terms
690(1)
Introduction
690(1)
Heat, Temperature, and Energy
690(2)
Heat
691(1)
Temperature
692(1)
Production of Metals
693(2)
Steel Making
693(1)
Iron Ore
693(1)
Ingot Casting
693(1)
Continuous Casting
693(1)
Metal Forming
694(1)
Grain Structure
695(1)
Mechanical Properties
695(2)
Hardness
695(1)
Brittleness
695(1)
Ductility
696(1)
Toughness
696(1)
Strength
696(1)
Other Mechanical Properties
696(1)
Structure of Solid Matter
697(1)
Crystalline Structures of Metal
697(1)
Phase Diagrams
698(2)
Lead Tin Phase Diagram
699(1)
Iron-Carbon Phase Diagram
700(3)
Strengthening Mechanisms
703(1)
Solid-Solution Hardening
703(1)
Precipitation Hardening
703(1)
Mechanical Mixtures of Phases
704(1)
Quench, Temper, and Anneal
704(5)
Quenching
704(2)
Martensitic Reactions
706(1)
Cold Work
707(1)
Grain Size Control
708(1)
Heat Treatments Associated with Welding
709(2)
Preheat
709(1)
Stress Relief, Process Annealing
709(1)
Annealing
710(1)
Normalizing
711(1)
Time-Temperature-Transformation (TTT) Diagrams
711(2)
Martensite
711(1)
Bainite
711(1)
Pearlite
711(1)
TTT Diagrams
712(1)
Thermal Effects Caused by Arc Welding
713(2)
Heat-Affected Zone (HAZ)
713(2)
Gases in Welding
715(1)
Nitrogen
715(1)
Oxygen
716(1)
Carbon Dioxide
716(1)
Hydrogen
716(1)
Metallurgical Defects
716(3)
Cold Cracking
716(1)
Hot Cracking
717(1)
Carbide Precipitation
718(1)
Summary
719(1)
Review
719(2)
Chapter 27 Weldability of Metals
721(19)
Objectives
721(1)
Key Terms
721(1)
Introduction
721(1)
Weldability
721(3)
Thermal Cycling
722(2)
Steel Classification and Identification
724(1)
SAE Classification Systems
724(1)
AISI Classification Systems
724(1)
Unified Numbering System (UNS)
724(1)
Carbon and Alloy Steels
724(3)
Low-Carbon, Also Called Mild Steel
724(2)
Medium-Carbon Steel
726(1)
High-Carbon Steel
726(1)
Tool Steel
727(1)
High-Manganese Steel
727(1)
Low-Alloy, High-Tensile Strength Steels
727(1)
Stainless Steels
727(2)
Austenitic Stainless Steel
728(1)
Ferritic Stainless Steel
728(1)
Martensitic Stainless Steel
728(1)
Chromium-Molybdenum Steel
729(1)
Cast Iron
729(5)
Preweld and Postweld Heating of Cast Iron
730(1)
Practice Welding Cast Iron
731(1)
Welding without Preheating or Postheating
732(2)
Nonferrous Metals
734(1)
Copper and Copper Alloys
734(1)
Aluminum Weldability
734(1)
Titanium
735(1)
Magnesium
735(1)
Repair Welding
735(3)
Summary
738(1)
Review
739(1)
Chapter 28 Filler Metal Selection
740(20)
Objectives
740(1)
Key Terms
740(1)
Introduction
740(1)
Manufacturers' Electrode Information
741(1)
Understanding the Electrode Data
741(1)
Data Resulting from Mechanical Tests
741(1)
Data Resulting from Chemical Analysis
741(1)
Carbon Equivalent (CE)
742(1)
SMAW Operating Information
742(2)
Core Wire
743(1)
Functions of the Flux Covering
743(1)
Filler Metal Selection
744(3)
Shielded Metal Arc Welding Electrode Selection
744(3)
AWS Filler Metal Classifications
747(1)
Carbon Steel
747(4)
Carbon and Low-Alloy Steel-Covered Electrodes
747(4)
Wire Type Steel Filler Metals
751(6)
Solid Wire
751(1)
Tubular Wire
751(2)
Metal Cored Arc Welding Electrodes
753(1)
Stainless Steel Electrodes
753(1)
Nonferrous Electrodes
753(3)
Aluminum and Aluminum Alloys
756(1)
Aluminum-Covered Arc Welding Electrodes
756(1)
Aluminum Bare Welding Rods and Electrodes
757(1)
Special-Purpose Filler Metals
757(1)
Surface and Buildup Electrode Classification
757(1)
Magnesium Alloys
757(1)
Hydrogen Embrittlement
757(1)
Summary
758(1)
Review
758(2)
Chapter 29 Welding Automation and Robotics
760(15)
Objectives
760(1)
Key Terms
760(1)
Introduction
760(1)
Manual Joining Process
761(1)
Semiautomatic Joining Processes
762(1)
Machine Joining Processes
763(1)
Automatic Joining Processes
763(1)
Automated Joining
763(1)
Industrial Robots
764(3)
Robot Programming
765(2)
System Planning
767(4)
Present and Future Needs
767(1)
Parts Design
767(1)
Equipment Selection
768(3)
Metal Blanks
771(2)
Safety
772(1)
Creating a WPS
773(1)
Future of Automation
774(1)
Summary
774(1)
Review
774(1)
Chapter 30 Other Welding Processes
775(32)
Objectives
775(1)
Key Terms
775(1)
Introduction
776(1)
Constant Current Welding Processes
776(3)
Submerged Arc Welding (SAW)
776(2)
Flux
778(1)
Advantages of SAW
778(1)
Disadvantages of SAW
779(1)
Handheld SAW
779(1)
Electroslag Welding (ESW)
779(2)
Advantages
780(1)
Disadvantages
781(1)
Electrogas Welding (EGW)
781(1)
Resistance Welding
781(6)
Resistance Spot Welding (RSW)
782(1)
Spot Welding Machines
783(1)
Multiple-Spot Welders
783(1)
Seam Welding (RSEW)
783(1)
Types of Resistance Seam Welds
784(3)
Electron Beam Welding (EBW)
787(1)
Electron Beam Welding Gun
787(1)
Electron Beam Seam Tracking
787(1)
Ultrasonic Welding
788(1)
Ultrasonic Welding (USW) Applications
789(1)
Inertia Welding Process (FRW-I)
789(3)
Inertia Weld Bond Characteristics
790(2)
Advantages of the Process
792(1)
Laser Beam Welding (LBW)
792(1)
Laser Welding Advantages and Disadvantages
792(1)
Laser Beam
792(1)
Laser Beam Heat Treating
793(1)
Plasma Arc Welding (PAW)
793(1)
Stud Welding (SW)
794(1)
Thermal Spraying (THSP)
794(3)
Thermal Spraying Equipment
794(1)
Thermospray (Powder) Process
795(1)
Thermospray Gun
795(1)
Torch Spraying
795(2)
Applying Sprayed Metal
797(1)
Plasma Spraying Process
797(1)
Cold Welding (CW)
797(1)
Thermite Welding
797(2)
Hardfacing
799(3)
Selection of Hardfacing Metals
800(1)
Hardfacing Welding Processes
800(1)
Quality of Surfacing Deposit
801(1)
Hardfacing Electrodes
801(1)
Shielded Metal Arc Method
802(1)
Hardfacing with Gas Shielded Arc
802(1)
Friction Stir Welding (FSW)
802(1)
Magnetic Pulse Welding (MPW)
803(1)
Hybrid Laser Process
804(1)
Laser Beam Welding with Gas Metal Arc Welding
804(1)
Laser Beam with Gas Metal Arc Welding Surfacing
805(1)
Laser Beam Welding with Gas Tungsten Arc Welding
805(1)
Summary
805(1)
Review
806(1)
Section 6 Oxyfuel Processes 807(78)
Chapter 31 Oxyacetylene Welding
809(41)
Objectives
809(1)
Key Terms
809(1)
Introduction
809(1)
Mild Steel Welds
810(1)
Filler Metals
810(1)
Ferrous Metals
810(1)
Mild Steel
811(1)
Cast Iron
811(3)
Factors Affecting the Weld
813(1)
Characteristics of the Weld
814(1)
Mixing the Gases
815(1)
Mixing Chamber
815(1)
Injector Mixing
815(1)
Torch Care and Use
816(1)
Welding and Heating Torch Tips
817(12)
Torch Tip Care and Use
817(12)
Flat Position Welding
829(7)
Outside Corner Joint
829(1)
Butt Joint
829(4)
Lap Joint
833(2)
Tee Joint
835(1)
Out-of-Position Welding
836(1)
Vertical Welds
836(4)
Butt Joint
838(1)
Lap Joint
839(1)
Tee Joint
839(1)
Horizontal Welds
840(1)
Horizontal Stringer Bead
840(1)
Butt Joint
841(1)
Lap Joint
841(1)
Tee Joint
841(1)
Overhead Welds
841(1)
Stringer Bead
842(1)
Butt Joint
842(1)
Lap Joint
842(1)
Tee Joint
842(1)
Mild Steel Pipe and Tubing
842(1)
Horizontal Rolled Position 1G
843(2)
Horizontal Fixed Position 5G
845(1)
Vertical Fixed Position 2G
846(1)
45° Fixed Position 6G
847(1)
Thin-Wall Tubing
848(1)
Summary
848(1)
Review
849(1)
Chapter 32 Brazing, Braze Welding, and Soldering
850(35)
Objectives
850(1)
Key Terms
850(1)
Introduction
850(1)
Brazing, Braze Welding, and Soldering
851(1)
Brazing
851(1)
Braze Welding
851(1)
Soldering
851(1)
Advantages of Brazing and Soldering
851(2)
Physical Properties of the Brazed or Soldered Joint
853(1)
Tensile Strength
853(1)
Shear Strength
853(1)
Ductility
853(1)
Fatigue Resistance
853(1)
Corrosion Resistance
854(1)
Fluxes Used in Brazing, Braze Welding, and Soldering
854(2)
Flux
854(1)
Forms of Fluxes
855(1)
Fluxing Action
856(1)
Brazing and Soldering Methods
856(4)
Torch Brazing and Soldering
856(1)
Furnace Brazing and Soldering
857(1)
Induction Brazing and Soldering
858(1)
Dip Brazing and Soldering
859(1)
Resistance Brazing and Soldering
859(1)
Special Methods
860(1)
Filler Metals
860(1)
Types of Filler Metals
860(1)
Soldering Alloys
861(1)
Tin-Lead
861(1)
Tin-Antimony
861(1)
Cadmium-Silver
861(1)
Cadmium-Zinc
861(1)
Brazing Alloys
862(3)
Copper-Zinc
862(1)
Copper-Zinc and Copper-Phosphorus A5.8
863(1)
Copper-Phosphorus and Copper-Silver-Phosphorus
863(1)
Silver-Copper
864(1)
Nickel
864(1)
Nickel and Nickel Alloys A5.14
864(1)
Aluminum-Silicon (BAISi)
865(1)
Copper and Copper Alloys A5.7
865(1)
Silver and Gold
865(1)
Silver-Free Brazing Alloys
865(1)
Joint Design
865(2)
Joint Spacing
865(2)
Brazing Practices
867(7)
Surface Contamination
867(7)
Surface Buildup and Hole Fill Practices
874(2)
Silver Brazing Practices
876(3)
Silver Brazing Dissimilar Metals
878(1)
Soldering Practices
879(4)
Summary
883(1)
Review
883
Appendix
i Student Welding Report
885(1)
ii Time Sheet, Bill of Materials, and Hot Work Permit Instructions
886(4)
iii AWS SENSE Forms
890(7)
iv Conversion of Decimal-Inches to Millimeters and Fractional Inches to Decimal-Inches and Millimeters
897(1)
v Conversion Factors: U.S. Customary (Standard) Units and Metric Units (SI)
898(2)
vi Abbreviations and Symbols
900(1)
vii Metric Conversion Approximations
901(1)
viii Pressure Conversion
901(1)
ix Welding Codes and Specifications
902(1)
x Welding Associations and Organizations
903(1)
Glossary 904
Index 95
Larry Jeffus is a welder with over 60 years of experience. He maintains his own well-equipped welding shop. In his career, he has passed many welding certification tests in a wide variety of processes, positions, material types and thicknesses. Jeffus has provided welding and professional consulting services locally, nationally and internationally to major corporations, small businesses, government agencies, schools, colleges and individuals. He is a Life Member of the American Welding Society. In addition, he has over 40 years of experience as a dedicated classroom teacher and is the author of several Cengage welding publications. Prior to retiring from teaching, Jeffus taught at Dallas College, part of the Dallas County Community College District. Today he remains very active in the welding community, especially in the field of education. He serves on several welding program technical advisory committees and has visited high school, college and technical campuses in more than 40 states and four foreign countries, providing one-on-one help and guidance to welding instructors and students. Jeffus was selected as Outstanding Post-Secondary Technical Educator in the State of Texas by the Texas Technical Society, and he served for 12 years as a board member on the Texas Workforce Investment Council in the Texas Governor's office. He also served as a member of the Apprenticeship Project Leadership Team, helping establish nontraditional apprenticeship training programs for Texas, and making numerous trips to Washington lobbying for vocational and technical education.