Table Of Content

Welding Handbook Ninth Edition Volume 2 WELDING PROCESSES, PART 1 Prepared under the direction of the Welding Handbook Committee Annette O’Brien Editor American Welding Society 550 N.W. LeJeune Road Miami, FL 33126 0 2004 by American Welding Society All rights reserved No portion of this book may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, including mechanical, photocopying, recording, or otherwise, without the prior written permission of the copyright owner. Authorization to photocopy items for internal, personal, or educational classroom use only, or the internal, personal, or educational classroom use only of specific clients, is granted by the American Welding Society (AWS)p ro- vided the appropriate fee is paid to the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923; telephone: (978)7 50-8400; Internet: www.copyright.com. Library of Congress Control Number: 2001089999 ISBN: 0-87171-729-8 The Welding Handbook is the result of the collective effort of many volunteer technical specialists who provide information to assist with the design and application of welding and allied processes. The information and data presented in the Welding Handbook are intended for informational purposes only. Rea- sonable care is exercised in the compilation and publication of the Welding Handbook to ensure the authenticity of the contents. However, no representation is made as to the accuracy, reliability, or completeness of this information, and an independent substantiating investigation of the information should be undertaken by the user. The information contained in the Welding Handbook shall not be construed as a grant of any right of manufac- ture, sale, use, or reproduction in connection with any method, process, apparatus, product, composition, or system, which is covered by patent, copyright, or trademark. Also, it shall not be construed as a defense against any liability for such infringement. Whether the use of any information in the Welding Handbook would result in an infringement of any patent, copyright, or trademark is a determination to be made by the user. Printed in Canada PREFACE Welding Processes, Part 2 is the second of the five volumes of the 9th edition of the Welding Handbook. The fifteen chapters of this volume provide updated information on the arc welding and cutting processes, oxyfuel gas welding and cutting, brazing, and soldering. Volume 3, Welding Processes, Part 2 will cover resistance, solid state, and other welding and cutting processes. Volumes 4 and 5 of the Welding Handbook will address welding materials and applications. These volumes represent the practical application of the principles discussed in the chapters of Volume 1, Welding Science and Technology, published in 2001. This peer-reviewed volume of the Welding Handbook reflects a tremendous leap forward in welding technology. While many basics of the welding processes have remained substantially the same, the precise control of welding parameters, advanced techniques, complex applications and new materials discussed in this updated volume are dramatically changed from those described in previous editions. In particular, advancements in digital or comput- erized control of welding parameters have resulted in consistently high weld quality for manual and mechanized welding and the repeatability necessary for successful automated operations. Chapter 1 of Welding Processes, Part 2 is a compilation of information on arc welding power sources. Subsequent chapters present specific information on shielded metal arc welding, gas tungsten arc welding, gas metal arc welding, flux cored arc welding, submerged arc welding, plasma arc welding, electrogas welding, arc stud welding, electroslag welding, oxyfuel gas welding, brazing, soldering, oxygen cutting, and arc cutting and gouging. Appendix A and B address safety issues. Appendix A reproduces the American Welding Society Lens Shade Selec- tor. Appendix B is a list of national and international safety standards applicable to welding, cutting, and allied processes. Although each chapter in this volume has a section on safe practices as they pertain to the specific process, readers should refer to Chapter 17, “Safe Practices,” of Volume 1 and to the appropriate standards listed in Appendix B. Appendix C is a list of American Welding Society filler metal specifications and related documents. An index of this volume and a major subject index of previous volumes are included. This volume was compiled by the members the Welding Handbook Volume 2 Committee and the Chapter Com- mittees, with oversight by the Welding Handbook Committee. Chapter committee chairs, chapter committee members, and oversight persons are recognized on the title pages of the chapters. An important contribution to this volume is the review of each chapter provided by members of the Technical Activities Committee and the Safety and Health Committee of the American Welding Society. The Welding Handbook Committee welcomes your comments and suggestions. Please address them to the Editor, Welding Handbook, American Welding Society, 550 N.W. LeJeune Road, Miami, Florida 33126. Harvey R. Castner, Chair Ian D. Harris, Chair Welding Handbook Committee Volume 2 Committee Annette O’Brien, Editor Welding Handbook xiii ...................................................................................................................................... ACKNOWLEGMENTS xii ... ........................................................................................................................................................... PREFACE xlii ...................................................................................................................................................... REVIEWERS xiv ............................................................................................................................................. CONTRIBUTORS xv .................................................................................................. CHAPTER 1 A R CP OWER SOURCES 1 ......................................................................................................................................................... Introduction 2 .................................................................................................................................................... Fundamentals 2 .......................................................................................................................................... Principles of Operation 4 ............................................................................................................................... Volt-Ampere Characteristics 12 ....................................................................................................................................................... Duty Cycle 16 ......................................................................................................................................... Open-Circuit Voltage 17 .................................................................................................................... NEMA Power Source Requirements 19 ..................................................................................................................... Alternating-Current Power Sources 20 .......................................................................................................................... Direct-Current Power Sources 30 ...................................................................................................................................................... Economics 42 ....................................................................................................................................................... Safe Practices 44 ..................................................................................................................................................... Conclusion 48 ....................................................................................................................................................... Bibliography 48 ................................................................................. CHAPTER 2-SHIELDED METAL ARC WELDING 51 ................................................................................................................................................... Introduction 52 .................................................................................................................................................... Fundamentals 52 ........................................................................................................................................................... Equipment 60 ........................................................................................................................................................... Materials 68 ...................................................................................................................................................... Applications 80 ........................................................................................................................... Joint Design and Preparation 82 .............................................................................................................................................. Welding Variables 85 ...................................................................................................................................................... Weld Quality 96 ........................................................................................................................................................ Economics 98 ...................................................................................................................................................... Safe Practices 99 ................................................................................................................................................... Conclusion 101 ...................................................................................................................................................... Bibliography 101 .................................................................................. CHAPTER 3-GAS TUNGSTEN ARC WELDING 103 ................................................................................................................................................... Introduction 104 ................................................................................................................................................. Fundamentals 104 ...................................................................................................................................................... Applications 107 ....................................................................................................................................................... Equipment 109 ....................................................................................................................................................... Techniques 128 ........................................................................................................................................................... Materials 135 ....................................................................................................................................................... Joint Design 139 ................................................................................................................................................. Weld Quality 140 ......................................................................................................................................................... Economics 142 .................................................................................................................................................... Safe Practices 142 ...................................................................................................................................................... Conclusion 144 ...................................................................................................................................................... Bibliography 144 .......................................................................................... CHAPTER &GAS METAL ARC WELDING 147 ................................................................................................................................................. Introduction 148 vii ..................................................................................................................................................... Fundamentals 148 Principles of Operation ...............................................................................................................................................1..5..0.. . .......................................................................................................................................................... Equipment 160 ............................................................................................................................... Materials and Consumables 171 ................................................................................................................................................ Process Variables 178 ............................................................................................................................................. Weld Joint Designs 188 .............................................................................................................................. Inspection and Weld Quality 189 ................................................................................................................................................. Troubleshooting 195 .......................................................................................................................................................... Economics 199 ...................................................................................................................................................... Safe Practices 201 ......................................................................................................................................................... Conclusion 203 ....................................................................................................................................................... Bibliography 204 ......................................................................................... CHAPTER !%-FLUX CORED ARC WELDING 209 ..................................................................................................................................................... Introduction -210 .................................................................................................................................................... Fundamentals -210 ....................................................................................................................................................... Applications 211 .......................................................................................................................................................... Equipment 215 ........................................................................................................................................................... Materials -219 .................................................................................................................................................. Process Control 237 ............................................................................................................... Joint Designs and Welding Procedures 241 ...................................................................................................................................................... Weld Quality 247 ................................................................................................................................................. Troubleshooting 247 ......................................................................................................................................................... Economics -247 ...................................................................................................................................................... Safe Practices 250 ........................................................................................................................................................ Conclusion -252 ....................................................................................................................................................... Bibliography 252 ......................................................................................... CHAPTER 6 .. SUBMERGED ARC WELDING 255 ....................................................................................................................................................... Introduction 256 ..................................................................................................................................................... Fundamentals 256 ......................................................................................................................................................... Equipment -258 ............................................................................................................................................................ Materials 268 ............................................................................................................................................... Process Variables -278 ......................................................................................................................................... Operating Procedures 282 ..................................................................................................................... Process Variations and Techniques 287 ....................................................................................................................................................... Applications 294 ...................................................................................................................................................... Weld Quality 297 ......................................................................................................................................................... Economics -299 ...................................................................................................................................................... Safe Practices 299 ......................................................................................................................................................... Conclusion 300 ....................................................................................................................................................... Bibliography 300 .................................................................................................. CHAPTER 7-PLASMA ARC WELDING 303 ....................................................................................................................................................... Introduction 304 ..................................................................................................................................................... Fundamentals 305 .......................................................................................................................................................... Equipment 310 ............................................................................................................................................................ Materials 319 .......................................................................................................................................... Application Methods 324 .............................................................................................................................................. Process Variations 326 ............................................................................................................................................ Welding Procedures 332 ...................................................................................................................................................... Weld Quality 332 .......................................................................................................................................................... Economics 332 ..................................................................................................................................................... Safe Practices 334 ........................................................................................................................................................ Conclusion 335 ...................................................................................................................................................... Bibliography 33.5 ................................................................................................ CHAPTER 8-ELECTROGAS WELDING 337 ...................................................................................................................................................... Introduction 338 .................................................................................................................................................... Fundamentals 338 ......................................................................................................................................................... Equipment 343 ........................................................................................................................................................... Materials 348 ............................................................................................................................................... Process Variables 350 ...................................................................................................................................................... Applications 366 ....................................................................................................................................................... Joint Design 367 ............................................................................................................................. Inspection and Weld Quality 369 ......................................................................................................................................................... Economics 387 ..................................................................................................................................................... Safe Practices 387 .................................................................................................................................................. Conclusion 390 ...................................................................................................................................................... Bibliography 390 ....................................................................................................... CHAPTER 9A.. RC STUD WELDING 393 ...................................................................................................................................................... Introduction 394 .................................................................................................................................................... Fundamentals 394 ...................................................................................................................................................... Applications 395 ............................................................................................................................... Equipment and Technology 398 ......................................................................................................................... Designing for Arc Stud Welding 406 ............................................................................................................................... Special Process Techniques 416 .................................................................................................................... Capacitor Discharge Stud Welding 417 .......................................................................................................................... Stud Welding Process Selection 423 ................................................................................................................ Weld Quality, Inspection, and Testing 427 ......................................................................................................................................................... Economics 430 ..................................................................................................................................................... Safe Practices 432 ........................................................................................................................................................ Conclusion 433 ...................................................................................................................................................... Bibliography 433 ............................................................................................ CHAPTER 10-ELECTROSLAG WELDING 435 ..................................................................................................................................................... Introduction 436 ................................................................................................................................................... Fundamentals 436 ........................................................................................................................................................ Equipment 441 .......................................................................................................................................................... Materials 444 .............................................................................................................................................. Welding Variables 446 ........................................................................................................................................... Welding Procedures 448 ...................................................................................................................................................... Applications 455 ......................................................................................................................... Inspection and Quality Control 457 ..................................................................................................................................................... Weld Quality 459 ......................................................................................................................................................... Economics 460 ..................................................................................................................................................... Safe Practices 463 ........................................................................................................................................................ Conclusion 464 ..................................................................................................................................................... Bibliography 464 ........................................................................................... CHAPTER 1 14XYFUEL GAS WELDING 467 ...................................................................................................................................................... Introduction 468 ........................................................................................................... Fundamentals of Oxyfuel Gas Welding 468 ........................................................................................................................................................... Materials 471 Oxyfuel Gas Welding Equipment ....................................................................................................................... 479 Process Variables and Operating Procedures ....................................................................................................4..8 9 ....................................................................................................................................................... Applications 491 Weld Quality ...................................................................................................................................................... 494 Welding with Other Fuel Gases .......................................................................................................................... 495 ......................................................................................................................................................... Economics -495 Safe Practices ...................................................................................................................................................... 495 ......................................................................................................................................................... Conclusion 498 ....................................................................................................................................................... Bibliography 498 ........................................................................................................................... CHAPTER 12-BRAZING 501 ....................................................................................................................................................... Introduction 502 ..................................................................................................................................................... Fundamentals 502 ....................................................................................................................................................... Applications 503 Principles of Operation ...................................................................................................................................... 503 ............................................................................................................... Processes, Equipment, and Techniques 504 ........................................................................................................................................................ Automation 515 ............................................................................................................................................................ Materials 517 ....................................................................................................................................................... Joint Design 532 .......................................................................................................................................................... Procedures 541 ........................................................................................................................................................... Inspection 544 ................................................................................................................................................. Troubleshooting 546 .................................................................................................................................................... Braze Welding 546 .......................................................................................................................................................... Economics 550 ...................................................................................................................................................... Safe Practices 550 ......................................................................................................................................................... Conclusion 555 ....................................................................................................................................................... Bibliography 555 CHAPTER 13.4 OLDERING .................................................................................................................5..5.9.. ....................................................................................................................................................... Introduction 560 ..................................................................................................................................................... Fundamentals 560 ....................................................................................................................................................... Applications 561 .............................................................................................................................................. Process Variations 563 .......................................................................................................................................................... Equipment 570 ............................................................................................................................................................ Materials 571 .......................................................................................................................................................... Procedures 584 ............................................................................................................................................... Process Variables -588 ........................................................................................................................................ Inspection and Testing 590 .......................................................................................................................................................... Economics 592 ...................................................................................................................................................... Safe Practices 593 ......................................................................................................................................................... Conclusion 594 ....................................................................................................................................................... Bibliography 594 ......................................................................................................... CHAPTER 1& OXYGEN CUTTING 597 ....................................................................................................................................................... Introduction 598 ....................................................................................................................... Fundamentals of Oxygen Cutting 598 ......................................................................................................................................... Oxyfuel Gas Cutting -599 ......................................................................................................................................................... Equipment -602 .................................................................................................................................................................. Gases 608 ......................................................................................................................................... Operating Procedures 612 .............................................................................................................................................. Process Variations 617 . . ....................................................................................................................................................... Appllcatlons 620 ............................................................................................................................................................... Quality 626 .......................................................................................................................................... Oxygen Arc Cutting 630 ....................................................................................................................................... Oxygen Lance Cutting 630 ....................................................................................................................................... Metal Powder Cutting 631 ...................................................................................................................................................... Flux Cutting 632 ......................................................................................................................................................... Economics 632 .................................................................................................................................................... Safe Practices 633 ........................................................................................................................................................ Conclusion 635 ...................................................................................................................................................... Bibliography 635 ................................................................................... CHAPTER 15-ARC CUTTING AND GOUGING 637 ...................................................................................................................................................... Introduction 638 ........................................................................................................................................... Plasma Arc Cutting 638 .......................................................................................................................................... Plasma Arc Gouging 648 ..................................................................................................................................... Air Carbon Arc Cutting 651 .............................................................................................................................. Other Arc Cutting Processes 659 ........................................................................................................................................................ Economics 662 ..................................................................................................................................................... Safe Practices 665 ........................................................................................................................................................ Conclusion 669 .................................................................................................................................................. Bibliography 670 ........................................................................................... APPENDIX A-LENS SHADE SELECTOR 673 ................................. APPENDIX B-HEALTH AND SAFETY CODES AND OTHER STANDARDS 675 .............................................................................. APPENDIX C-FILLER METAL SPECIFICATIONS 679 INDEX OF MAJOR SUBJECTS: ........................................................... Eighth Edition and Ninth Edition. Volume 1 and Volume 2 681 ............................................................................................ INDEX OF NINTH EDITION. Volume 2 699 CHAPTER 1 Prepared by the Welding Handbook Chapter Committee on Arc Welding Power Sources: ARC WELDING S. P. Moran, Chair Miller Electric Manufacturing Company D. J. Erbe POWER SOURCES Panasonic Factory Automation W, E. Herwig Miller Electric Manufacturing Company W. E. Hoffman ESA B Welding and Cutting Products C. Hsu The Lincoln Electric Company J. 0.R eynolds Miller Electric Manufacturing Company Welding Handbook Committee Member: C. E. Pepper ENGlobal Engineering Contents Introduction Fundamentals Principles of Operation Volt-Ampere Characteristics Duty Cycle Open-Circuit Voltage NEMA Power Source Requirements Alternating-Current Power Sources Direct-Current Power Sources Economics Safe Practices Conclusion Bibliography Supplementary Reading List 2 CHAPTER1 ARC WELDING POWER SOURCES CHAPTER 1 ARC WELD1 NG POWER SOURCES INTRODUCTION This chapter presents a general overview of the voltage (CV) and constant-current (CC) characteristics electrical power sources used for arc welding. It required for welding processes. explores the many types of welding power sources The voltage supplied by power companies for indus- available to meet the electrical requirements of the trial purposes-120 volts (V), 230 V, 380 V, or 480 V- various arc welding processes. is too high for use in arc welding. Therefore, the first Welding has a long and rich history. Commercial arc function of an arc welding power source is to reduce the welding is over a hundred years old, and scores of pro- high input or line voltage to a suitable output voltage cesses and variations have been developed. Over the range, 20 V to 80 V. A transformer, a solid-state years, power sources have been developed or modified inverter, or an electric motor-generator can be used to by equipment manufacturers in response to the changes reduce the utility power to terminal or open-circuit and improvements in these processes. As welding pro- voltage appropriate for arc welding. cesses continue to evolve, power sources continue to Alternatively, a power source for arc welding may provide the means of controlling the welding current, derive its power from a prime mover such as an internal voltage, and power. This chapter provides updated combustion engine. The rotating power from an inter- information on the basic electrical technologies, cir- nal combustion engine is used to rotate a generator or cuits, and functions designed into frequently used an alternator for the source of electrical current. welding power sources. Topics covered in this chapter Welding transformers, inverters, or generator/ include the following: alternators provide high-amperage welding current, generally ranging from 30 amperes (A) to 1500 A. The 1. The volt-ampere (V-A) characteristics required output of a power source may be alternating current for common welding processes, (ac), direct current (dc) or both. It may be constant 2. Basic electrical technologies and terminology current, constant voltage, or both. Welding power used in power sources, sources may also provide pulsed output of voltage or 3. Simplified explanations of commonly used current. power source circuits, and Some power source configurations deliver only cer- 4. An introduction to useful national and inter- tain types of current. For example, transformer power national standards. sources deliver ac only. Transformer-rectifier power A basic knowledge of electrical power sources will sources can deliver either alternating or direct current, provide the background for a more complete under- as selected by the operator. Electric motor-generator standing of the welding processes presented in the other power sources usually deliver dc output. A motor- chapters of this book. alternator delivers ac, or when equipped with rectifiers, . dc Power sources can also be classified into subcate- FUNDAMENTALS gories. For example, a gas tungsten arc welding power source might be identified as transformer-rectifier, constant-current, ac/dc. A complete description of any This section introduces the fundamental functions of power source should include welding current rating, welding power sources and the concepts of constant- duty cycle rating, service classification, and input power

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This book presents comprehensive information to assist welding professionals with the design and application of welding and applied processes. Contains detailed information on arc welding power sources; shielded metal arc, gas tungsten arc, gas metal arc, flux cored arc, submerged arc, and plasma ar

Welding Handbook, Volume 2 - Welding Processes, Part 1 PDF

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