INTRODUCTION
WELDING TECHNOLOGY
NONMANDATORY REFERENCES
ASME, 2010 ASME Boiler &
Althouse, Andrew R, et. al., Pressure Vessel Code, Section IX AWS, AWS D1.1: 2010,
The - - Steel,
Goodheart-Willcox Company, The American American Welding Society,
Inc., Illinois, 1988. Society of Mechanical Engineers, Miami, 2002.
New York, 2010.
AWS AWS, ANSI/AWS A3.0-94, AWS,
, American , American Welding
Welding Society, Miami, 4th , American Welding Society, Miami, 3rd Edition,
Edition, 2010. Society, Miami, 1994. 2000.
Jenney, Cynthia L., and Annette
O'Brien, R.L.,
Jeffus, Larry, O'Brien,
,
, American Welding
Delmar Publishers Inc., Albany, , American Welding
Society, Miami, 8th Edition,
3,d Edition, 1993. Society, Miami, 9th Edition,
1991.
2001.
Oates, William R., and Alexander
Oates, William R
M. Saitta,
,
, American
American Welding Society,
Welding Society, Miami, 8th
Miami, 8th Edition, 1996.
Edition, 1998.
MANDATORY REFERENCES
JOINING METHOD CHART
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
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.
The Industrial Revolution, from
1750 to 1850, introduced a
method of joining pieces of iron
together known as forge
welding or hammer 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 Thomson, in the
year 1886, developed the resistance welding
technique. 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 Since the end of World War I, many welding
Europe by fusion welding to repair ships at the methods have been developed for joining
end of World War I. At that time the welding metals. These various welding methods are
process was considered to be vital to military playing an important role in the expansion and
security. Repairs to the ships damaged during production of the welding industry. Welding
World War I were done in great secrecy. Even has become a dependable, efficient, and
today some aspects of welding are closely economical method for joining metal.
guarded secrets.
WELDING DEFINED
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."
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."
, a weld is made when separate pieces of material to
be joined combine and form one piece when heated to a temperature high enough
to cause softening or melting and flow together. Pressure may or may not be used
to force the pieces together. In some instances, pressure alone may be sufficient to
force the separate pieces of material to combine and form one piece. Filler material
is added when needed to form a completed weld in the joint.
USE OF WELDING
ADVANTAGES OF WELDING
• Relatively inexpensive way to join
metals
• Weight-saving of the construction
• Can readily be modified to meet
changing product requirement
• Can be applied for commercial
metals
• All positions and locations
• Inexpensive design
• Relatively same strength compared
to other joining methods
• Production time for a weldment is
less than that of other
manufacturing method
LIMITATION OF WELDING
• Quality depends on welder, equipment,
material, and procedure available
• Necessary to conduct NDT & DT to the
weldment
• Metallurgical and dimension
imperfections may appear
• Stress Concentration Factor and Stress
Intensity Factor
• Heat-affected zone and residual stress
• Brittle materials
WELDING PROCESS
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.
SELECTION OF WELDING PROCESS
The 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 equipment - The types, capacity, and condition of equipment that
can be used to make the welds.
Repetitiveness of the operation - How many of the welds will be required to
complete the job, and are they all the same?
Quality 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 work - Will the weld be in a shop or on a remote job site?
Materials to be joined - Are the parts made out of a standard metal or some
exotic alloy?
Appearance 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 joined - Are the parts small, large, or different sizes,
and can they be moved or must they be welded in place?
Time 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 workers - Do the welders have the ability to do the job?
Cost of materials - Will the weldment be worth the expense of special
equipment materials or finishing time?
Code or specification requirements - Often the selection of the process is
dictated by the governing agency, codes, or standards.
The welding engineer and/or the welder must not only decide on the welding process but
. The following methods are used to
perform welding, cutting, or brazing operations.
Manual - The welder is required to manipulate the entire process.
Semiautomatic - The filler metal is added automatically, and all other manipulation is
done manually by the welder.
Machine - Operations are done mechanically under the observation and correction of
a welding operator.
Automatic - Operations are performed repeatedly by a machine that has been
programmed to do an entire operation without interaction of the operator.
Automated - Operations are performed repeatedly by a robot or other machine that is
programmed flexibly to do a variety of processes.
WELDING OCCUPATION
Welder
Welding foreman
Welding supervisor
Welding inspector
Welding technician
Welding instructor
Welding engineer
Welding sales representative
Welding service
representative
QUALIFICATIN & CERIFICATION
is the ability of an individual to perform a job according to a required standard.
is a written statement attesting to the fact the welder has been able to
produce welds meeting a prescribed standard.