Introduction

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Transcript of Introduction

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INTRODUCTIONINTRODUCTION

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Althouse, Andrew R, et. al., Modern WeldingModern Welding, The Goodheart-Willcox Company, Inc., Illinois, 1988.

ASME, 1998 ASME Boiler & Pressure Vessel Code, Section Section IX - Welding and Brazing QualificationIX - Welding and Brazing Qualification, The American Society of Mechanical Engineers, New York, 2000.

AWS, AWS D1.1: 2002, Structural Welding Code - SteelStructural Welding Code - Steel, American Welding Society, Miami, 2002.

AWS, Certification Manual for Welding InspectorsCertification Manual for Welding Inspectors, American Welding Society, Miami, 4th Edition, 2000.

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AWS, ANSI/AWS A3.0-94, Standard Welding Terms and Standard Welding Terms and DefinitionsDefinitions, American Welding Society, Miami, 1994.

AWS, Welding Inspection HandbookWelding Inspection Handbook, American Welding Society, Miami, 3rd Edition, 2000.

Jeffus, Larry, Welding - Principles and ApplicationsWelding - Principles and Applications, Delmar Publishers Inc., Albany, 3,d Edition, 1993.

Jenney, Cynthia L., and Annette O'Brien, Welding Handbook, Volume 1 - Welding Science and TechnologyVolume 1 - Welding Science and Technology, American Welding Society, Miami, 9th Edition, 2001.

REFERENCESREFERENCES

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O'Brien, R.L., Welding Handbook, Volume 2 - Welding Volume 2 - Welding ProcessesProcesses, American Welding Society, Miami, 8th Edition, 1991.

Oates, William R., Welding Handbook, Volume 3 - Materials Volume 3 - Materials & Applications Part l& Applications Part l, American Welding Society, Miami, 8th Edition, 1996.

Oates, William R., and Alexander M. Saitta, Welding Handbook, Volume 3 – Materials & Applications Part 2Volume 3 – Materials & Applications Part 2, American Welding Society, Miami, 8th Edition, 1998.

NONMANDATORY REFERENCESNONMANDATORY REFERENCES

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Wiryosumarto, Harsono, dan Toshie Wiryosumarto, Harsono, dan Toshie Okumura, Okumura, Teknologi Pengelasan Teknologi Pengelasan LogamLogam, Pradnya Paramita, Jakarta, , Pradnya Paramita, Jakarta, Cetakan Kedelapan, 2000.Cetakan Kedelapan, 2000.

MANDATORY REFERENCESMANDATORY REFERENCES

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JOINING METHOD CHARTJOINING METHOD CHART

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Early metal-joining methods included such processes as forming a sand mold on top of a piece of metal and casting the desired shape directly on the base metal, Figure 1-1

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Another metal-joining method used in early years was to place two pieces of metal close together and pour molten metal between them. When the edges of the base metal melted, the flow of metal was then dammed and allowed to harden. Figure 1-2.

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The Industrial Revolution, from 1750 to 1850, introduced a method of joining pieces of iron together known as forge forge weldingwelding or hammer weldinghammer welding.

This process involved the use of a forge to heat the metal to a soft, plastic temperature. The ends of the iron were then placed together and hammered until fusion took place.

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Forge welding remained as the primary welding method until Elihu Elihu ThomsonThomson, in the year 1886, developed the resistance welding resistance welding techniquetechnique. This technique provided a more reliable and faster way of joining metal than did previous methods.

As techniques were further developed, riveting was replaced in the United States and Europe by fusion welding to repair ships at the end of World War I. At that time the welding process was considered to be vital to military security. Repairs to the ships damaged during World War I were done in great secrecy. Even today some aspects of welding are closely guarded secrets.

Since the end of World War I, many welding methods have been developed for joining metals. These various welding methods are playing an important role in the expansion and production of the welding industry. Welding has become a dependable, efficient, and economical method for joining metal.

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WELDING DEFINEDWELDING DEFINED

A weldA weld is defined by the American Welding Society (AWS) as "a localized coalescence (the fusion or growing together of the grain structure of the materials being welded) of metals or nonmetals produced either by heating the materials to the required welding temperatures, with or without the application of pressure, or by the application of pressure alone, and with or without the use of filler materials."

WeldingWelding is defined as "a joining process that produces coalescence of materials by heating them to the welding temperature, with or without the application of pressure or by the application of pressure alone, and with or without the use of filler metal."

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USES OF WELDINGUSES OF WELDING

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The number of different welding processes has grown in recent years. These processes differ greatly in the manner in which heat, pressure, or both heat and pressure are applied, and in the type of equipment used.

Figure 10.1 lists various welding methods. Certain methods listed in the figure require hammering, pressing, or rolling to effect the coalescence in the weld joint. Other methods bring the metal to a fluid state, and the edges flow together.

WELDING PROCESSESWELDING PROCESSES

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The most popular processes are oxyacetylene welding oxyacetylene welding (OAW),(OAW), shielded metal arc welding (SMAW)shielded metal arc welding (SMAW) which often called stick weldingstick welding, gas tungsten arc welding gas tungsten arc welding (GTAW),(GTAW), gas metal arc welding (GMAW),gas metal arc welding (GMAW), flux cored flux cored arc welding (FCAW),arc welding (FCAW), and submerge arc welding submerge arc welding (SAW).(SAW).

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OxyacetyleneOxyacetylene is one part of the larger group of processes known as oxyfuel gas (OF). This group of processes can be used for welding (OFW),welding (OFW), cutting cutting (OFC),(OFC), and brazing (TB).brazing (TB). This group is one of the most versatile of the welding processes. The equipment required is comparatively inexpensive, and the cost of operation is low, Figure 1-7.

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Shielded metal arc welding (SMAW)Shielded metal arc welding (SMAW) is the most common method of joining metal. High-quality welds can be made rapidly and with excellent uniformity. A variety of metal types and metal thicknesses can be joined with one machine, Figure 1-8.

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Gas tungsten arc welding (GTAW)Gas tungsten arc welding (GTAW) is easily performed on almost any metal. Its clean, high-quality welds often require little or no postweld finishing, Figure 1-9.

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Gas metal arc welding (GMAW)Gas metal arc welding (GMAW) is extremely fast and economical. This process is easily used for welding on thin-gauge metal as well as on heavy plate. The high welding rate and reduced postweld cleanup are making gas metal arc welding an outstanding welding process, Figure 1-10.

Flux cored arc welding (FCAW)Flux cored arc welding (FCAW) uses the same type of equipment that is used for the gas metal arc welding process. A major advantage of this process is that with the addition of flux to the center of the filler wire the weld's properties can be changed. Although welds must be cleaned after completion, the improved quality, flexibility, and welding speed offset this requirement.

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Selection of the Joining ProcessSelection of the Joining ProcessThe selection of the joining process for a particular job depends upon many factors. No one specific rule controls the welding process to be selected for a certain job. A few of the factors that must be considered when choosing a joining process include:

Availability of equipmentAvailability of equipment - The types, capacity, and condition of equipment that can be used to make the welds.

Repetitiveness of the operationRepetitiveness of the operation - How many of the welds will be required to complete the job, and are they all the same?

Quality requirementsQuality requirements - Is this weld going to be used on a piece of furniture, to repair a piece of equipment, or to join a pipeline?

Location of workLocation of work - Will the weld be in a shop or on a remote job site?

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Materials to be joinedMaterials to be joined - Are the parts made out of a standard metal or some exotic alloy?

Appearance of the finished productAppearance of the finished product - Will this be a weldment that is only needed to test an idea, or will it be a permanent structure?

Size of the parts to be joinedSize of the parts to be joined - Are the parts small, large, or different sizes, and can they be moved or must they be welded in place?

Time available for workTime available for work - Is this a rush job needing a fast repair, or is there time to allow for pre and postweld cleanup?

Skill or experience of workersSkill or experience of workers - Do the welders have the ability to do the job?

Cost of materialsCost of materials - Will the weldment be worth the expense of special equipment materials or finishing time?

Code or specification requirementsCode or specification requirements - Often the selection of the process is dictated by the governing agency, codes, or standards.

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The welding engineer and/or the welder must not only decide on the welding process but must also select the method of applying itmust also select the method of applying it. The following methods are used to perform welding, cutting, or brazing operations.

ManualManual - The welder is required to manipulate the entire process.

SemiautomaticSemiautomatic - The filler metal is added automatically, and all other manipulation is done manually by the welder.

MachineMachine - Operations are done mechanically under the observation and correction of a welding operator.

AutomaticAutomatic - Operations are performed repeatedly by a machine that has been programmed to do an entire operation without interaction of the operator.

AutomatedAutomated - Operations are performed repeatedly by a robot or other machine that is programmed flexibly to do a variety of processes.

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Welding OccupationWelding Occupation

WelderWelder Welding foremanWelding foreman Welding supervisor Welding supervisor Welding inspectorWelding inspector Welding technicianWelding technician Welding instructor Welding instructor Welding engineerWelding engineer Welding sales representativeWelding sales representative Welding service representativeWelding service representative

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QUALIFICATION & CERTIFICATIONQUALIFICATION & CERTIFICATION

QualificationQualification is the ability of an individual to perform a job according to a

required standard.

CertificationCertification is a written statement attesting to the fact the welder has been

able to produce welds meeting a prescribed standard.


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