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| موضوع: كتاب Welding - Principles and Applications الجمعة 26 يونيو 2020, 12:47 am | |
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أخوانى فى الله أحضرت لكم كتاب Welding - Principles and Applications Eighth EDitiON Larry Jeffus
و المحتوى كما يلي :
Contents Preface xvi Features of the Text xix Acknowledgments xxi About the Author xxiii Index of Experiments and Practices xxv Section 1 Introduction 01 Chapter 1 Introduction to Welding 03 Objectives 3 Key Terms Introduction 3 Welding Terminology 5 Welding Defined 5 Uses of Welding 5 Welding and Cutting Processes 7 Welding Processes 7 Oxyacetylene Welding, Brazing, and Cutting 7 Shielded Metal Arc Welding (SMAW) 7 Gas Tungsten Arc Welding (GTAW) 7 Gas Metal Arc Welding (GMAW) 9 Flux Cored Arc Welding (FCAW) 10 Thermal Cutting Processes 10 Oxyfuel Gas Cutting 10 Plasma Arc Cutting 10 Selection of the Joining Process 11 Occupational Opportunities in Welding 12 Training for Welding Occupations 13 Job-Related Skills 14 Beginning a Welding Career 14 Job Prospects 14 AWS SENSE Welder Certification 14 Level I Qualification Procedures 15 Practical Knowledge Qualification— Written Test 15 Performance Qualification— Workmanship Samples and Test Plates 15 Thermal Cutting Principles and Practices 15 Welding Inspection and Testing Principles and Practices 16 Level II Advanced Welder Qualification 16 SkillsUSA 16 Experiments and Practices 16 Welding Video Series 17 Metric Units 17 Summary 19 Review 19 Chapter 2 Safety in Welding 21 Objectives 21 Key Terms 21 Introduction 21 Burn Classification 22 First-Degree Burns 22 Second-Degree Burns 22 Third-Degree Burns 22 Burns Caused by Light 23 Personal Protection Equipment (PPE) 24 General Work Clothing 24 Special Protective Clothing 25 Face and Eye Protection 27 Goggles 27 Full Face Shield 27 Welding Helmets 27 Auto Darkening Welding Helmets 28 Shop Noise 28 Respiratory Protection 29 Ventilation 31 Safety Data Sheets (SDSs) 32 Handling and Storing Cylinders 32 Securing Gas Cylinders 33 Storage Areas 33 Cylinders with Valve Protection Caps 33 General Precautions 33 Acetylene 34 Fire Protection 34 Fire Watch 34 Fire Extinguishers 34 Location of Fire Extinguishers 35 Using Fire Extinguishers 35 Equipment Maintenance 36 Hoses 36 Work Area Cleaning 36 Hand Tools 37 Hand Tool Safety 37 Hammer Safety 38 Electrical Safety 38 Electrical Safety Systems 40 Voltage Warnings 40 Extension Cords 41 Safety Rules for Portable Electric Tools 42 Power Tools 42 Grinders 42 Drills 43 Metal Cutting Machines 44 Material Handling 45 Lifting 45 Contents v Hoists or Cranes 45 Ladder Safety 45 Types of Ladders 45 Ladder Inspection 45 Rules for Ladder Use 46 Summary 47 Review 47 Section 2 Shielded Metal Arc Welding 49 Chapter 3 Shielded Metal Arc Equipment, Setup, and Operation 51 Objectives 51 Key Terms 51 Introduction 52 Welding Current 52 Electrical Measurement 52 Temperature and Heat 52 SMA Welding Arc Temperature 53 SMA Welding Arc Heat 54 Types of Welding Currents 54 Types of Welding Power Supplies (Machines) 55 Open Circuit Voltage 55 Operating Voltage 56 Arc Blow 56 Types of Power Sources 57 Movable Coil or Core 60 Inverter 61 Generator-Type and Alternator-Type Welders 62 Routine Maintenance 63 Converting AC to DC 63 Duty Cycle 64 Welder Accessories 64 Welding Cables 64 Electrode Holders 66 Work Clamps 66 Equipment Setup 67 Summary 68 Review 68 Chapter 4 Shielded Metal Arc Welding of Plate 69 Objectives 69 Key Terms 69 Introduction 70 Effect of Current Settings that Are Too Low or Too High 72 Too Low of a Current Setting 72 Too High of a Current Setting 72 Experiments 73 Electrode Size and Heat 73 Arc Length 74 Travel Angle, Electrode Angle and Work Angle 75 Leading Angle 75 Perpendicular Angle 76 Trailing Angle 76 Electrode Manipulation 76 Positioning of the Welder and the Plate 79 Practice Welds 80 Electrodes 80 F3 E6010 and E6011 Electrodes 80 F2 E6012 and E6013 Electrodes 80 F4 E7016 and E7018 Electrodes 80 Electrode Selection 80 Stringer Beads 81 Square Butt Joint 83 Edge Weld 87 Outside Corner Joint 91 Lap Joint 94 Tee Joint 97 Summary 100 Review 100 Chapter 5 Shielded Metal Arc Welding of Pipe 101 Objectives 101 Key Terms 101 Introduction 101 Pipe and Tubing 103 Pipe Specifications 103 Tubing Specifications 103 Pipe Applications 104 Tubing Applications 104 Advantages of Welded Pipe 104 Strength 104 Less Maintenance Required 104 Longer Lasting 106 Smoother Flow 106 Lighter Weight 106 Preparation and Fit-up 106 Practice Welds 108 Weld Standards 109 Weld Passes 109 Root Weld Pass 109 Hot Weld Pass 110 Filler Weld Pass 110 Cover Weld Pass 111 1G Horizontal Rolled Position 111 AWS SENSE Certification Test 1G 116 2G Vertical Fixed Position 116 AWS SENSE Certification Test 1G 117 5G Horizontal Fixed Position 117 AWS SENSE Certification Test 5G 119 6G 458 Inclined Position 119 AWS SENSE Certification Test 6G 120 Summary 121 Review Chapter 6 Shielded Metal Arc Welding AWS SENSE Certification 122 Objectives 122 Key Terms 122 Introduction 122 Root Pass 123 Hot Pass 127 Filler Pass 129 Cover Pass 130 Plate Preparation 130 Restarting a Weld Bead 133 Preheating and Postheating 133 AWS Workmanship Standard for Preparation of Base Metal 134 AWS Visual Inspection Criteria 135 Preparing Specimens for Bend Testing 135 WS Specimen Preparation Criteria 135 Preparation 135 Testing 135 AWS Acceptance Criteria for Bend Test 137 Poor Fit-Up 146 Summary 147 Review 147 Section 3 Cutting and Gouging 149 Chapter 7 Flame Cutting 151 Objectives 151 Key Terms 151 Introduction 152 Metals Cut by the Oxyfuel Process 152 The Chemistry of a Cut 152 Eye Protection for Flame Cutting 152 Cutting Torches 153 Cutting Tips 154 Pressure Regulators 160 Regulator Operation 160 Regulator Gauges 161 Regulator Safety Pressure Release Device 161 Cylinder and Regulator Fittings 161 Regulator Safety Precautions 163 Regulator Care and Use 164 Backfires 165 Flashbacks 165 Reverse Flow and Flashback Valves 165 Care of the Reverse Flow Valve and Flashback Arrestor 167 Hoses and Fittings 167 Hose Care and Use 167 Leak Detection 168 Oxyfuel Cutting, Setup, and Operation 168 Torch Tip Care and Use 168 Hand Cutting 171 Layout 174 Selecting the Correct Tip and Setting the Pressure 175 The Physics of a Cut 177 Slag 178 Plate Cutting 180 Cutting Table 180 Torch Guides 180 Distortion 182 Cutting Applications 183 Pipe Cutting 184 Summary 188 Review 188 Chapter 8 Plasma Arc Cutting 190 Objectives 190 Key Terms 190 Introduction 190 Plasma 191 Arc Plasma 192 Plasma Torch 192 Torch Body 192 Torch Head 192 Power Switch 193 Torch Parts Commonly Serviced 193 Hoses and Power Cables 195 Gas Hoses 195 Power Cable 197 Coolant System 197 Coolant 197 Coolant Hoses 197 Control Wire 198 Compressed Air 198 Power Requirements 199 Voltage 199 Amperage 199 Watts 199 Heat Input 199 Distortion 199 Applications 200 Cutting Speed 200 Metals 200 Torch Standoff Distance 201 Starting Methods 202 Kerf 203 Gases 205 Stack Cutting 206 Dross 206 Machine Cutting 206 Water Tables 207 Manual Cutting 207 Setup 208 Safety 209 Straight Cuts 209 Piercing 211 Plasma Arc Gouging 213 Cutting Round Stock Beveling Pipe 216 Summary 217 Review 217 Chapter 9 Related Cutting Processes 219 Objectives 219 Key Terms 219 Introduction 219 Laser Beam Cutting (LBC) and Laser Beam Drilling (LBD) 220 Lasers 220 Laser Types 221 Solid State Lasers 221 Gas Laser 222 Applications 222 Laser Beam Cutting 222 Laser Beam Drilling 223 Laser Beam Welding 223 Hybrid Laser Process 224 Laser Beam Welding with Gas Metal Arc Welding 224 Laser Beam with Gas Metal Arc Welding Surfacing 224 Laser Beam Welding with Gas Tungsten Arc Welding 224 Laser Equipment 225 Air Carbon Arc Cutting (CAC-A) 225 Manual Torch Design 226 Electrodes 226 Power Sources 227 Air Supply 227 Application 228 Safety 228 U-Grooves 229 Oxygen Lance Cutting 232 Applications 233 Safety 233 Water Jet Cutting 233 Applications 233 Arc Cutting Electrodes 233 Applications 235 Summary 235 Review 235 Section 4 Gas Shielded Welding 237 Chapter 10 Gas Metal Arc Welding Equipment, Setup, and Operation 239 Objectives 239 Key Terms 239 Introduction 240 Weld Metal Transfer Methods 242 Short-Circuiting Transfer GMAW-S 242 Globular Transfer 243 Axial Spray Metal Transfer 243 Pulsed-Arc Metal Transfer 245 Pulsed-Arc Metal Transfer Current Cycle 246 Modulated Current Metal Transfer 248 The Modulated Current Process 248 Advantages of Modulated Current and Pulsed-Arc Metal Transfer 248 Buried-Arc Transfer 250 GMAW Filler Metal Specifications 250 Wire Melting and Deposition Rates 251 Welding Power Supplies 251 GMA Welding Machines 251 Speed of the Wire Electrode 252 Power Supplies for Short-Circuiting Transfer 252 Shielding Gas 253 Argon 254 Argon Gas Blends 254 Helium 255 Carbon Dioxide 255 Nitrogen 255 Power Settings 255 Weave Pattern 256 Travel Speed 256 Electrode Extension 256 Gun Angle 256 Forehand/Perpendicular/Backhand Welding 257 Metal Core Electrodes for GMA Welding 258 Equipment 259 Power Source 260 Electrode (Wire) Feed Unit 260 Electrode Conduit 262 Welding Gun 263 GMA Spot Welding 264 Summary 266 Review 266 Chapter 11 Gas Metal Arc Welding 267 Objectives 267 Key Terms 267 Introduction 267 Setup 268 Wire-Feed Speed 271 Gas Density and Flow Rates 274 Arc-Voltage and Amperage Characteristics 275 Electrode Extension 277 Welding Gun Angle 278 Effect of Shielding Gas on Welding 279 Practices 281 Metal Preparation 282 Flat Position, 1G and 1F Positions 283 Vertical Up 3G and 3F Positions 287 Vertical Down 3G and 3F Positions 288 Horizontal 2G and 2F Positions 289 Overhead 4G and 4F Positions Globular Metal Transfer, 1G Position 293 Axial Spray 296 Summary 297 Review 297 Chapter 12 Flux Cored Arc Welding Equipment, Setup, and Operation 298 Objectives 298 Key Terms 298 Introduction 299 Principles of Operation 301 Flux Core 301 Gas Formers 302 Slag 302 Equipment 302 Power Supply 302 FCA Welding Guns 302 Electrode Feed 303 Advantages 303 Limitations 304 FCAW Electrodes 304 Electrode Cast and Helix 306 FCA Welding Electrode Flux 306 Types of FCAW Fluxes 308 Flux Cored Steel Electrode Identification 309 Mild Steel 309 Stainless Steel Electrodes 309 Metal Cored Steel Electrode Identification 309 Care of Flux Core Electrodes 311 Shielding Gas 311 Welding Techniques 312 Gun Angle 312 Forehand/Perpendicular/Backhand Techniques 313 Advantages of the Forehand Technique 313 Disadvantages of the Forehand Technique 314 Advantages of the Perpendicular Technique 314 Disadvantages of the Perpendicular Technique 314 Advantages of the Backhand Technique 314 Disadvantages of the Backhand Technique 314 Travel Speed 314 Mode of Metal Transfer 315 Spray Transfer—FCAW-G 315 Globular Transfer—FCAW-G 315 Electrode Extension 316 Porosity 316 Troubleshooting FCA Welding 317 Summary 318 Review 319 Chapter 13 Flux Cored Arc Welding 320 Objectives 320 Key Terms 320 Introduction 320 Practices 321 Flat-Position Welds 324 Square-Groove Welds 326 V-Groove and Bevel-Groove Welds 327 Root Pass 328 Filler Pass 329 Cover Pass 329 Fillet Welds 330 Vertical Welds 333 Horizontal Welds 336 Overhead-Position Welds 340 Thin-Gauge Welding 341 Plug Welds 344 Summary 346 Review 346 Chapter 14 Gas Metal Arc and Flux Cored Arc Welding of Pipe 348 Objectives 348 Key Terms 348 Introduction 348 Joint Preparation 349 End Preparation 349 Joint Fitup 349 Tack Welds 349 Root Pass 349 Hot Pass 350 Filler Pass 350 Cover Pass(es) 351 Visual Inspection 351 Practice Pipe Welds 351 Pipe to Plate Welds 351 Tack Welds 355 Root Pass 355 Hot Pass 355 Filler Pass(es) 355 Cover Pass 356 Summary 359 Review 359 Chapter 15 Gas Metal Arc and Flux Cored Arc Welding AWS SENSE Certification 360 Objectives 360 Key Terms 360 Introduction 360 Practice Welds 360 Metal Preparation 361 Practice Weld Equipment and Consumables 361 Summary 388 Review 388 Chapter 16 Gas Tungsten Arc Welding Equipment, Setup, Operation, and Filler Metals 389 Objectives 389 Key Terms 389 Introduction Contents ix Tungsten 390 High Temperature 390 Good Conductor 390 Tungsten Erosion 390 Tungsten Electrode End Shape 392 Types of Tungsten Electrodes 392 Pure Tungsten, EWP 393 Thoriated Tungsten, EWTh-1 and EWTh-2 393 Zirconium Tungsten, EWZr-1 393 Cerium Tungsten, EWCe-2 393 Lanthanum Tungsten, EWLa-1.5 394 Rare Earth Tungsten, EWG 394 Shaping the Tungsten 394 Precision Machine Tungsten Grinder 394 Hand Grinding 394 Breaking and Remelting 395 Chemical Cleaning and Pointing 396 Pointing and Remelting 397 GTA Welding Equipment 397 Torches 398 Hoses 399 Nozzles 400 Gas Lens 401 Flowmeter 401 Types of Welding Current 402 DCEN 402 DCEP 402 AC 402 Electronic Controls of AC Welding Currents 404 EP and EN Time Control 405 Sine Wave Form Control 405 Frequency Control 405 Shielding Gases 406 Argon 406 Helium 406 Hydrogen 407 Nitrogen 407 Hot Start 407 Preflow 407 Postflow 408 Shielding Gas Flow Rate 408 Remote Controls 409 Summary 412 Review 413 Chapter 17 Gas Tungsten Arc Welding of Plate 414 Objectives 414 Key Terms 414 Introduction 415 Torch Angle 415 Filler Rod Manipulation 416 Tungsten Contamination 417 Current Setting 417 Experiments 418 Gas Flow 419 Practice Welds 420 Low Carbon and Mild Steels 420 Stainless Steel 421 Aluminum 422 Metal Preparation 422 Summary 439 Review 440 Chapter 18 Gas Tungsten Arc Welding of Pipe 441 Objectives 441 Key Terms 441 Introduction 441 Practices 442 Joint Preparation 442 V-Groove 442 Joint Cleaning 442 Root 443 Incomplete Fusion 444 Concave Root Surface 445 Excessive Root Reinforcement 445 Root Contamination 445 Backing Gas 446 Purging 446 Filler Metal 447 Consumable Inserts 447 Cup Walking 449 Cup Walking Setup 449 Cup Walking Technique 450 Practice Welds 450 Hot Pass 453 Root Surface 453 Lack of Root Fusion 454 Filler Pass 457 Cover Pass 458 Summary 461 Review 461 Chapter 19 Gas Tungsten Arc Welding Plate and Pipe AWS SENSE Certification 463 Objectives 463 Key Terms 463 Introduction 463 GTA Sheet Welds 463 GTA Tubing Welds 464 AWS SENSE GTA Sheet Practice Welds 464 Weld Inspection and Testing 464 Butt Joint Welds 464 Fillet Welds, Lap and Tee Joints 464 Tubing Welds 466 Mechanical, Destructive Testing 466 Filler Metal 466 Sheet Metal Practice Welds 467 Tubing and Pipe Practice Welds 479 Summary 484 Review 485x Contents Section 5 Related Technologies 487 Chapter 20 Shop Math and Weld Cost 489 Objectives 489 Key Terms 489 Introduction 489 Shop Math 490 Types of Numbers 490 Whole Numbers 490 Decimal Fractions 490 Mixed Units 490 Fractions 490 General Math Rules 491 Letters, Numbers, and Symbols 492 Superscript and Subscripts 492 Equations and Formulas 492 Equations 492 Formulas 492 Mixed Units 493 Adding and Subtracting Mixed Units 493 Fractions 495 Finding the Fraction’s Common Denominator 495 Reducing Fractions 496 Multiplying and Dividing Fractions 496 Converting Numbers 497 Converting Fractions to Decimals 497 Tolerances 497 Converting Decimals to Fractions 497 Conversion Charts 498 Angles 498 Adding and Subtracting Angles 499 Triangles 499 Right Triangle 499 Equilateral Triangle 500 Isosceles Triangle 500 Perimeter 501 Area 501 Volume 501 Measuring 502 Welding Costs 503 Cost Estimation 503 Joint Design 504 Groove Welds 505 Fillet Welds 506 Weld Metal Cost 506 Cost of Electrodes, Wires, Gases, and Flux 507 Deposition Efficiency 507 Deposition Rate 508 Deposition Data Tables 508 Coated Electrodes 509 Efficiency of Flux Cored Wires 510 Efficiency of Solid Wire for GMAW 510 Efficiency of Solid Wires for SAW 511 Operating Factor 511 Labor and Overhead 514 Cost of Power 514 Other Useful Formulas 514 Bill of Materials 515 Invoice 516 Summary 517 Review 518 Chapter 21 Reading Technical Drawings 520 Objectives 520 Key Terms 521 Introduction 521 Mechanical Drawings 521 Lines 523 Types of Drawings 523 Pictorial Drawings 523 Mechanical Drawings 524 Special Views 524 Dimensioning 525 Drawing Scale 527 Reading Mechanical Drawings 528 Sketching 528 Erasers and Erasing 532 Graph Paper 535 Computers and Drawings 538 Summary 541 Review 541 Chapter 22 Welding Joint Design and Welding Symbols 542 Objectives 542 Key Terms 542 Introduction 542 Weld Joint Design 543 Weld Joint Stresses 544 Welding Process 545 Edge Preparation 545 Joint Dimensions 545 Metal Thickness 545 Metal Type 547 Welding Position 547 Plate Welding Positions 548 Pipe Welding Positions 548 Code or Standards Requirements 548 Welder Skill 549 Acceptable Cost 549 Welding Symbols 549 Indicating Types of Welds 550 Weld Location 551 Location Significance of Arrow 551 Fillet Welds 552 Plug Welds 552 Spot Welds 553 Seam Welds 553 Groove Welds 553 Backing 556 Flanged Welds 557Contents xi Nondestructive Testing Symbols 557 Summary 560 Review 560 Chapter 23 Fabricating Techniques and Practices 561 Objectives 561 Key Terms 561 Introduction 561 Fabrication 562 Safety 562 Parts and Pieces 563 Preformed 563 Custom Fabrication 563 Layout 564 Nesting 569 Kerf Space 570 Material Shapes 573 Bill of Materials Form 574 Overall Tolerance 575 Assembly 576 Overall Dimensions and Thick Materials 578 Part Identification 578 Assembly Tools 578 Fitting 581 Tack Welds 582 Welding 584 Arc Strikes 584 Finishing 585 Summary 585 Review 586 Chapter 24 Welding Codes and Standards 587 Objectives 587 Key Terms 587 Introduction 587 Codes, Standards, Procedures, and Specifications 588 Welding Procedure Qualification 588 Welding Procedure Specification (WPS) 588 Qualifying the Welding Procedure Specification 588 Qualifying and Certifying 589 General Information 589 Summary 600 Review 601 Chapter 25 Testing and Inspection 602 Objectives 602 Key Terms 602 Introduction 602 Quality Control (QC) 603 Discontinuities and Defects 603 Porosity 603 Inclusions 605 Inadequate Joint Penetration 606 Incomplete Fusion 606 Arc Strikes 607 Overlap 607 Undercut 608 Crater Cracks 608 Underfill 609 Plate-Generated Problems 609 Lamination 609 Delamination 609 Lamellar Tears 610 Destructive Testing (DT) 610 Tensile Testing 610 Fatigue Testing 612 Shearing Strength Test 612 Welded Butt Joints 612 Nick-Break Test 612 Guided-Bend Test 612 Free-Bend Test 616 Alternate Bend 616 Fillet Weld Break Test 616 Testing by Etching 617 Impact Testing 618 Nondestructive Testing (NDT) 619 Visual Inspection (VT) 619 Penetrant Inspection (PT) 619 Magnetic Particle Inspection (MT) 619 Radiographic Inspection 621 Ultrasonic Inspection 621 Leak Checking 625 Eddy Current Inspection (ET) 625 Hardness Testing 626 Summary 627 Review 627 Chapter 26 Welding Metallurgy 629 Objectives 629 Key Terms 629 Introduction 629 Heat, Temperature, and Energy 630 Heat 630 Temperature 631 Production of Metals 632 Steel Making 632 Iron Ore 632 Ingot Casting 633 Continuous Casting 633 Metal Forming 633 Grain Structure 634 Mechanical Properties 634 Hardness 634 Brittleness 635 Ductility 635 Toughness 635 Strength 635 Other Mechanical Properties 636 Structure of Solid Matter 636 Crystalline Structures of Metal 637xii Contents Phase Diagrams 638 Lead-Tin Phase Diagram 638 Iron-Carbon Phase Diagram 639 Strengthening Mechanisms 642 Solid-Solution Hardening 642 Precipitation Hardening 643 Mechanical Mixtures of Phases 643 Quench, Temper, and Anneal 644 Quenching 644 Martensitic Reactions 645 Cold Work 648 Grain Size Control 648 Heat Treatments Associated with Welding 648 Preheat 648 Stress Relief, Process Annealing 649 Annealing 650 Normalizing 650 Time-Temperature-Transformation (TTT) Diagrams 650 Martensite 650 Bainite 651 Pearlite 651 TTT Diagrams 651 Thermal Effects Caused by Arc Welding 652 Heat-Affected Zone (HAZ) 652 Gases in Welding 654 Nitrogen 655 Oxygen 655 Carbon Dioxide 655 Hydrogen 655 Metallurgical Defects 656 Cold Cracking 656 Hot Cracking 656 Carbide Precipitation 657 Summary 658 Review 658 Chapter 27 Weldability of Metals 660 Objectives 660 Key Terms 660 Introduction 660 Weldability 660 Thermal Cycling 661 Steel Classification and Identification 663 SAE Classification Systems 663 AISI Classification Systems 663 Unified Numbering System (UNS) 663 Carbon and Alloy Steels 663 Low-Carbon, Also Called Mild, Steel 663 Medium-Carbon Steel 665 High-Carbon Steel 665 Tool Steel 666 High-Manganese Steel 666 Low-Alloy, High-Tensile Strength Steels 666 Stainless Steels 666 Austenitic Stainless Steel 667 Ferritic Stainless Steel 667 Martensitic Stainless Steel 667 Chromium-Molybdenum Steel 668 Cast Iron 668 Preweld and Postweld Heating of Cast Iron 669 Practice Welding Cast Iron 670 Welding without Preheating or Postheating 671 Nonferrous Metals 673 Copper and Copper Alloys 673 Aluminum Weldability 673 Titanium 674 Magnesium 674 Repair Welding 674 Summary 677 Review 678 Chapter 28 Filler Metal Selection 679 Objectives 679 Key Terms 679 Introduction 679 Manufacturers’ Electrode Information 680 Understanding the Electrode Data 680 Data Resulting from Mechanical Tests 680 Data Resulting from Chemical Analysis 680 Carbon Equivalent (CE) 681 SMAW Operating Information 681 Core Wire 682 Functions of the Flux Covering 682 Filler Metal Selection 683 Shielded Metal Arc Welding Electrode Selection 683 AWS Filler Metal Classifications 686 Carbon Steel 686 Carbon and Low-Alloy Steel–Covered Electrodes 686 Wire-Type Steel Filler Metals 690 Solid Wire 690 Tubular Wire 690 Metal Cored Arc Welding Electrodes 692 Stainless Steel Electrodes 692 Nonferrous Electrodes 692 Aluminum and Aluminum Alloys 695 Aluminum-Covered Arc Welding Electrodes 695 Aluminum Bare Welding Rods and Electrodes 696 Special-Purpose Filler Metals 696 Surface and Buildup Electrode Classification 696 Magnesium Alloys 696 Hydrogen Embrittlement 696 Summary 697 Review 697 Chapter 29 Welding Automation and Robotics 699 Objectives 699 Key Terms 699 Introduction 699 Manual Joining Process 700 Semiautomatic Joining Processes 701Contents xiii Machine Joining Processes 702 Automatic Joining Processes 702 Automated Joining 702 Industrial Robots 703 Robot Programming 704 System Planning 706 Present and Future Needs 706 Parts Design 706 Equipment Selection 707 Safety 710 Future Automation 712 Summary 712 Review 712 Chapter 30 Other Welding Processes 714 Objectives 714 Key Terms 714 Introduction 715 Constant Current Welding Processes 715 Submerged Arc Welding (SAW) 715 Flux 717 Advantages of SAW 717 Disadvantages of SAW 718 Handheld SAW 718 Electroslag Welding (ESW) 718 Advantages 719 Disadvantages 720 Electrogas Welding (EGW) 720 Resistance Welding 720 Resistance Spot Welding (RSW) 721 Spot Welding Machines 722 Multiple-Spot Welders 722 Seam Welding (RSEW) 722 Types of Resistance Seam Welds 723 Electron Beam Welding (EBW) 726 Electron Beam Welding Gun 726 Electron Beam Seam Tracking 726 Ultrasonic Welding 727 Ultrasonic Welding (USW) Applications 728 Inertia Welding Process (FRW-I) 728 Inertia Weld Bond Characteristics 729 Advantages of the Process 731 Laser Beam Welding (LBW) 731 Laser Welding Advantages and Disadvantages 731 Laser Beam 731 Laser Beam Heat Treating 732 Plasma Arc Welding (PAW) 732 Stud Welding (SW) 733 Thermal Spraying (THSP) 733 Thermal Spraying Equipment 733 Thermospray (Powder) Process 734 Thermospray Gun 734 Torch Spraying 734 Applying Sprayed Metal 736 Plasma Spraying Process 736 Cold Welding (CW) 736 Thermite Welding 736 Hardfacing 738 Selection of Hardfacing Metals 739 Hardfacing Welding Processes 739 Quality of Surfacing Deposit 740 Hardfacing Electrodes 740 Shielded Metal Arc Method 741 Hardfacing with Gas Shielded Arc 741 Friction Stir Welding (FSW) 741 Magnetic Pulse Welding (MPW) 742 Hybrid Welding Processes 742 Summary 743 Review 743 Section 6 OxyFuEl PROCESSES 745 Chapter 31 Oxyfuel Welding and Cutting Equipment, Setup, and Operation 747 Objectives 747 Key Terms 747 Introduction 748 Pressure Regulators 748 Regulator Operation 748 Regulator Gauges 750 Regulator Safety Pressure Release Device 751 Cylinder and Regulator Fittings 752 Cryogenic Cylinders 752 Fittings 753 Regulator Safety Precautions 753 Regulator Care and Use 754 Welding and Cutting Torches: Design and Service 755 Combination Torches 755 Dedicated Cutting Torches 755 Mixing the Gases 756 Mixing Chamber 756 Injector Mixing 756 Torch Care and Use 757 Welding and Heating Torch Tips 757 Torch Tip Care and Use 758 Backfires and Flashbacks 759 Backfires 759 Flashbacks 759 Reverse Flow and Flashback Valves 759 Care of the Reverse Flow Valve and Flashback Arrestor 759 Hoses and Fittings 761 Hose Care and Use 761 Leak Detection Hoses 761 Leak Detection Fittings 762 Manifold Systems 762 Manifold Operation 763 Oxyfuel Flame 764 Characteristics of the Fuel-Gas Flame 764 Fuel Gases 764 Flame Rate of Burning 766 Acetylene (C2H2) 767xiv Contents Acetone 768 Heat and Temperature of Acetylene 769 Liquefied Fuel Gases 769 Pressure 769 Methylacetylene-Propadiene (MPS) 769 MAPP 771 Oxy-MAPP Flames 771 Propane and Natural Gas 772 Hydrogen 773 Filler Metals 776 Ferrous Metals 776 Mild Steel 776 Cast Iron 777 Summary 783 Review 783 Chapter 32 Oxyacetylene Welding 785 Objectives 785 Key Terms 785 Introduction 785 Mild Steel Welds 786 Factors Affecting the Weld 786 Characteristics of the Weld 787 Flat Position Welding 794 Outside Corner Joint 794 Butt Joint 794 Lap Joint 797 Tee Joint 798 Out-of-Position Welding 800 Vertical Welds 800 Butt Joint 803 Lap Joint 804 Tee Joint 804 Horizontal Welds 805 Horizontal Stringer Bead 805 Butt Joint 806 Lap Joint 806 Tee Joint 806 Overhead Welds 806 Stringer Bead 807 Butt Joint 807 Lap Joint 807 Tee Joint 807 Mild Steel Pipe and Tubing 807 Horizontal Rolled Position 1G 808 Horizontal Fixed Position 5G 810 Vertical Fixed Position 2G 811 458 Fixed Position 6G 812 Thin-Wall Tubing 813 Summary 813 Review 814 Chapter 33 Brazing, Braze Welding, and Soldering 815 Objectives 815 Key Terms 815 Introduction 815 Brazing, Braze Welding, and Soldering 816 Brazing 816 Braze Welding 816 Soldering 816 Advantages of Brazing and Soldering 816 Physical Properties of the Brazed or Soldered Joint 818 Tensile Strength 818 Shear Strength 818 Ductility 818 Fatigue Resistance 818 Corrosion Resistance 819 Fluxes Used in Brazing, Braze Welding, and Soldering 819 Flux 819 Forms of Fluxes 820 Fluxing Action 821 Brazing and Soldering Methods 821 Torch Brazing and Soldering 821 Furnace Brazing and Soldering 822 Induction Brazing and Soldering 823 Dip Brazing and Soldering 824 Resistance Brazing and Soldering 824 Special Methods 825 Filler Metals 825 Types of Filler Metals 825 Soldering Alloys 826 Tin-Lead 826 Tin-Antimony 826 Cadmium-Silver 826 Cadmium-Zinc 826 Brazing Alloys 827 Copper-Zinc 827 Copper-Zinc and Copper-Phosphorus A5.8 828 Copper-Phosphorus 828 Copper-Phosphorus-Silver 829 Silver-Copper 829 Nickel 829 Nickel and Nickel Alloys A5.14 829 Aluminum-Silicon (BAlSi) 829 Copper and Copper Alloys A5.7 829 Silver and Gold 829 Joint Design 829 Joint Spacing 829 Brazing Practices 832 Surface Buildup and Hole Fill Practices 838 Silver Brazing Practices 839 Soldering Practices 842 Summary 846 Review 846 Appendix 848 I. Student Welding Report 849 II. SENSE 850 III. SENSE 851Contents xv IV. Conversion of Decimal-Inches to Millimeters and Fractional Inches to Decimal-Inches and Millimeters 852 V. Conversion Factors: U.S. Customary (Standard) Units and Metric Units (SI) 853 VI. Abbreviations and Symbols 855 VII. Metric Conversion Approximations 856 VIII. Pressure Conversion 856 IX. Welding Codes and Specifications 857 X. Welding Associations and Organizations 858 Glossary 859 Index 910
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عدد المساهمات : 1 التقييم : 1 تاريخ التسجيل : 27/02/2015 العمر : 56 الدولة : Syria العمل : Quality manager الجامعة : Damascus
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عدد المساهمات : 19002 التقييم : 35506 تاريخ التسجيل : 01/07/2009 الدولة : مصر العمل : مدير منتدى هندسة الإنتاج والتصميم الميكانيكى
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