كتاب Welding Principles and Practices
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 كتاب Welding Principles and Practices

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تاريخ التسجيل : 01/07/2009
العمر : 30
الدولة : مصر
العمل : مدير منتدى هندسة الإنتاج والتصميم الميكانيكى
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Welding Principles and Practices
Edward R. Bohnart
Fifth Edition

كتاب Welding Principles and Practices  W_p_a_10
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Welding Principles and Practices
Edward R. Bohnart
Fifth Edition
Titanium-Making in the United States . 97
Unique Metals . 99
Effects of Welding on Metal 99
Review 109
Chapter 4 Basic Joints and Welds 112
Types of Joints .113
The Four Weld Types 113
Weld Size and Strength 114
Weld Positions 120
Strength of Welds 124
Common Weld and Weld-Related Discontinuities . 125
Review 134
Chapter 5 Gas Welding 137
Oxyacetylene Welding 137
Gases . 139
General Cylinder Handling, Storage, and Operation
Safety Concerns 143
Welding Equipment 148
Supporting Equipment 160
Safety Equipment .161
General Safety Operating Procedures .163
Review 164
Chapter 6 Flame Cutting Principles 166
Oxyacetylene and Other Fuel Gas Cutting . 166
Oxygen Lance Cutting .175
Review .176
Preface xi
Acknowledgments xiii
UNIT 1
Introduction to Welding and Oxyfuel 1
Chapter 1 History of Welding 2
Overview 2
The History of Metalworking 3
Welding as an Occupation . 7
Industrial Welding Applications 7
Review . 11
Chapter 2 Industrial Welding 13
Fabrication 14
Maintenance and Repair . 14
Industries . 14
Review . 32
Chapter 3 Steel and Other Metals 34
History of Steel 35
Raw Materials for the Making of Steel 36
The Smelting of Iron 46
Steelmaking Processes . 49
Metalworking Processes . 65
Metal Internal Structures . 70
Physical Properties of Metals 72
Effects of Common Elements on Steel . 77
Types of Steel 82
SAE/AISI Steel Numbering System . 87
ASTM Numbering System . 92
Unified Numbering Designation . 92
Types of Cast Iron 92
Aluminum-Making in the World . 95vi Contents
Heavy Steel Plate and Pipe 223
Review 229
Chapter 9 Braze Welding and Advanced
Gas Welding Practice:
Jobs 9-J39–J49 232
Braze Welding 232
Welding Cast Iron . 236
Welding of Aluminum 238
Welding Other Metals with the
Oxyacetylene Process . 242
Hard Facing (Surfacing) . 244
Review 247
Chapter 10 Soldering and Brazing
Principles and Practice:
Jobs 10-J50–J51 250
Soldering and Brazing Copper Tubing 250
Soldering 251
Practice Jobs: Soldering . 257
Torch Brazing (TB) 260
Practice Jobs: Brazing 269
Review 274
Chapter 7 Flame Cutting Practice:
Jobs 7-J1–J3 178
Review of Flame Cutting Principles 179
Cutting Different Metals .181
Cutting Technique 182
Surface Appearance of High Quality Flame Cuts . 186
Arc Cutting 187
Practice Jobs 187
Job 7-J1 Straight Line and Bevel Cutting 193
Job 7-J2 Laying Out and Cutting Odd Shapes 197
Job 7-J3 Cutting Cast Iron 198
Review 201
Chapter 8 Gas Welding Practice:
Jobs 8-J1–J38 203
Sound Weld Characteristics 204
The Oxyacetylene Welding Flame . 205
Setting Up the Equipment . 207
Flame Adjustment . 209
Closing Down the Equipment .211
Safety 212
Practice Jobs .212
Low Carbon Steel Plate 212
UNIT 2
Shielded Metal Arc Welding 277
Chapter 11 Shielded Metal Arc Welding
Principles 278
Process Capability . 279
Operating Principles . 279
Welding Power Sources . 279
Machines for Shielded Metal Arc Welding 283
Multiple-Operator Systems 289
Power Supply Ratings 290
Cables and Fasteners . 290
Electrode Holders 293
Other Electric Arc Processes . 294
Personal Safety Equipment 294
Review 298
Chapter 12 Shielded Metal Arc Welding
Electrodes 300
Introduction 300
Shielded Metal Arc Welding Electrodes 301
Functions of Electrode Coverings . 302
Composition of Electrode Coverings . 302
Identifying Electrodes 305
Electrode Selection . 307
Specific Electrode Classifications 315
Packing and Protection of Electrodes 325
Review 328
Chapter 13 Shielded Metal Arc
Welding Practice:
Jobs 13-J1–J25 (Plate) 330
Introduction 330
Approach to the Job .331
Learning Welding Skills 333
Practice Jobs 338
Job 13-J1 Striking the Arc and Short
Stringer Beading 339
Job 13-J2 Stringer Beading . 341Contents vii
Job 13-J3 Weaved Beading . 343
Job 13-J4 Stringer Beading . 345
Job 13-J5 Weaved Beading . 347
Job 13-J6 Welding an Edge Joint . 349
Job 13-J7 Welding an Edge Joint . 350
Job 13-J8 Welding a Lap Joint . 352
Job 13-J9 Welding a Lap Joint . 354
Job 13-J10 Stringer Beading 356
Job 13-J11 Stringer Beading 357
Job 13-J12 Welding a Lap Joint 359
Job 13-J13 Welding a Lap Joint .361
Job 13-J14 Welding a T-Joint 363
Job 13-J15 Welding a T-Joint 365
Job 13-J16 Welding a T-Joint 367
Job 13-J17 Welding a T-Joint 369
Job 13-J18 Stringer Beading 370
Job 13-J19 Weaved Beading 372
Job 13-J20 Weaved Beading .374
Job 13-J21 Welding a Lap Joint 375
Job 13-J22 Welding a T-Joint . 378
Job 13-J23 Welding a T-Joint . 380
Job 13-J24 Welding a T-Joint . 382
Job 13-J25 Welding a T-Joint . 383
Review 385
Chapter 14 Shielded Metal Arc Welding
Practice: Jobs 14-J26–J42
(Plate) 388
Introduction 388
Practice Jobs 389
Job 14-J26 Stringer Beading 389
Job 14-J27 Weave Beads 391
Job 14-J28 Welding a Single-V Butt Joint
(Backing Bar Construction) 393
Job 14-J29 Welding a T-Joint 395
Job 14-J30 Welding a Single-V Butt Joint
(Backing Bar Construction) 397
Job 14-J31 Welding a Square Butt Joint . 399
Job 14-J32 Welding an Outside
Corner Joint 400
Job 14-J33 Welding a Single-V Butt Joint 403
Job 14-J34 Welding a T-Joint 406
Job 14-J35 Welding a T-Joint 408
Job 14-J36 Welding a T-Joint .410
Job 14-J37 Welding a T-Joint .412
Job 14-J38 Welding a Single-V Butt Joint
(Backing Bar Construction) .414
Job 14-J39 Welding a Square Butt Joint 416
Job 14-J40 Welding an Outside Corner Joint 418
Job 14-J41 Welding a T-Joint 420
Job 14-J42 Welding a Single-V Butt Joint
(Backing Bar Construction) 422
Review 424
Chapter 15 Shielded Metal Arc
Welding Practice:
Jobs 15-J43–J55 (Plate) 428
Introduction 428
Practice Jobs 429
Job 15-J43 Welding a Single-V Butt Joint 429
Job 15-J44 Welding a T-Joint 431
Job 15-J45 Welding a T-Joint 434
Job 15-J46 Welding a Lap Joint 435
Job 15-J47 Welding a Lap Joint 437
Job 15-J48 Welding a Single-V Butt Joint 439
Job 15-J49 Welding a T-Joint 441
Job 15-J50 Welding a T-Joint 443
Job 15-J51 Welding a Single-V Butt Joint 444
Job 15-J52 Welding a Coupling to a
Flat Plate 447
Job 15-J53 Welding a Coupling to a Flat Plate 449
Job 15-J54 Welding a Single-V Butt Joint
(Backing Bar Construction) 450
Job 15-J55 Welding a Single-V Butt Joint 452
Tests 454
Review 465
Chapter 16 Pipe Welding and Shielded
Metal Arc Welding Practice:
Jobs 16-J1–J17 (Pipe) 469
Introduction 469
Shielded Metal Arc Welding of Pipe . 476
Joint Design 477
Codes and Standards . 483
Practice Jobs 498
Tools for Pipe Fabrication 511
Review .516viii Contents
UNIT 3
Arc Cutting and Gas Tungsten Arc Welding 521
Chapter 17 Arc Cutting Principles and Arc
Cutting Practice: Jobs 17-J1–J7 522
Arc Cutting 522
Learning Arc Cutting Skills . 535
Practice Jobs 535
Job 17-J1 Square Cutting with PAC . 538
Job 17-J2 Bevel Cutting with PAC 538
Job 17-J3 Gouging with PAC 538
Job 17-J4 Hole Piercing 539
Job 17-J5 Shape Cutting with PAC . 539
Job 17-J6 Gouging with CAC-A . 543
Job 17-J7 Weld Removal with CAC-A 544
Review 546
Chapter 18 Gas Tungsten Arc and Plasma
Arc Welding Principles 549
Gas Shielded Arc Welding Processes 549
Gas Tungsten Arc Welding 554
TIG Hot Wire Welding 580
Review 590
Chapter 19 Gas Tungsten Arc Welding
Practice: Jobs 19-J1–J19
(Plate) 593
Gas Tungsten Arc Welding of Various Metals 593
Joint Design and Practices . 604
Setting Up the Equipment . 607
Safe Practices . 608
Arc Starting 609
Welding Technique 611
Practice Jobs .613
Review 628
Chapter 20 Gas Tungsten Arc Welding
Practice: Jobs 20-J1–J17
(Pipe) 630
Joint Design .631
Porosity in Gas Tungsten Arc Welds . 635
Practice Jobs 635
Review 650
UNIT 4
Gas Metal Arc, Flux Cored Arc, and Submerged
Arc Welding 655
Chapter 21 Gas Metal Arc and Flux Cored Arc
Welding Principles 656
Overview 656
GMAW/FCAW Welding Equipment . 665
Summary 702
Review 706
Chapter 22 Gas Metal Arc Welding Practice
with Solid and Metal Core Wire:
Jobs 22-J1–J23 (Plate) 708
Operating Variables That
Affect Weld Formation . 708
Weld Defects 717
Safe Practices . 720
Care and Use of Equipment 722
Welding Technique . 726
Process and Equipment Problems . 727
Practice Jobs 727
Gas Metal Arc Welding of Other Metals .745
Review .749
Chapter 23 Flux Cored Arc Welding Practice
(Plate), Submerged Arc Welding, and
Related Processes: FCAW-G Jobs
23-J1–J11, FCAW-S Jobs
23-J1–J12; SAW Job 23-J1 751
Flux Cored Wire Welding 751
Flux Cored Arc Welding—Gas Shielded
Practice Jobs 763Contents ix
Flux Cored Arc Welding—Self-Shielded . 768
Flux Cored Arc Welding—Self-Shielded
Practice Jobs 769
Automatic or Mechanized
Welding Applications . 771
Submerged Arc Welding Semiautomatic
Practice Job 780
Choice of Welding Process 784
Review 785
Chapter 24 Gas Metal Arc Welding
Practice: Jobs 24-J1–J15
(Pipe) 790
Industrial Applications of GMAW
Pipe Welding . 790
Use of Equipment and Supplies . 792
Welding Operations 794
Practice Jobs 795
Review .811
UNIT 5
High Energy Beams, Automation, Robotics,
and Weld Shop Management 815
Chapter 25 High Energy Beams and
Related Welding and Cutting
Process Principles 816
Introduction .816
High Energy Beam Processes .817
Summary 828
Review 830
Chapter 26 General Equipment for
Welding Shops 832
Screens and Booths 832
Work-Holding Devices 833
Preheating and Annealing Equipment 845
Sandblasting Equipment . 846
Spot Welder 846
Hydraulic Tools . 847
Power Squaring Shears . 850
Small Hand Tools 851
Portable Power Tools . 853
Machine Tools 860
Review 868
Chapter 27 Automatic and Robotic
Arc Welding Equipment 870
Arc Control Devices 872
Arc Monitoring . 875
Controller Communication . 881
Robotic Arc Welding Systems 882
Robot Ratings . 885
Robot Programming 886
Training, Qualification, and Certification . 887
Conclusion . 889
Review 889
Chapter 28 Joint Design, Testing,
and Inspection 891
Joint Design 892
Code Welding . 898
Nondestructive Testing (NDT) 902
Destructive Testing . 920
Visual Inspection 936
Summary 943
Review 947
Chapter 29 Reading Shop Drawings 949
Introduction 949
Standard Drawing Techniques 952
Types of Views 962
Review 967
Chapter 30 Welding Symbols 978
Fillet Welds and Symbol 980
Weld-All-Around Symbol . 983
Groove Welds . 983
Edge Welds . 986
Combination Symbols 986
Contour Symbol . 986
Applications of Welding Symbols . 987
Review 988x Contents
Chapter 31 Welding and Bonding of Plastics 994
Know Your Plastics 995
Characteristics of Plastics . 998
Welding as a Method of Joining
Plastics 999
Inspection and Testing 1010
Practice Jobs 1014
Tack Welding .1015
Review . 1024
Chapter 32 Safety 1026
Safety Practices: Electric Welding Processes . 1027
Safety Practices: Oxyacetylene Welding
and Cutting 1043
Review 1052
Appendixes
A: Conversion Tables 1058
B: Illustrated Guide to Welding Terminology .1071
C: Welding Abbreviation List . 1086
D: Major Agencies Issuing Codes,
Specifications, and Associations 1088
E: Sources of Welding Information 1090
F: Metric Conversion Information
for the Welding Industry 1092
Glossary 1093
Index.


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