Module 3 - 1

Module 3

Metal Joining
and
Cutting
Am Processes
W
e r i c a nS e l d i n g o c i e t y
 Welding Process Module 3 - 2

Knowledge -
A Benefit to Inspectors
 Helps spot problems
 Leads to better inspection
 Gains respect of welders
 Gains cooperation

Am e r i c a n We l d i n g S o c i e t y
 WIT Coverage of Welding Module 3 - 3

Processes
 Advantages
 Limitations
 Equipment
 Filler Metals
 Techniques
 Problems

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 4

3 Basic ‘Process’ Groups

 Welding
 Brazing
 Cutting

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 5

Weldment

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 6

Common Features of
Welding Processes
 Source of energy
 Source of shielding
 Filler metal (optional)

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 7

Shielded Metal
Arc Welding
(SMAW)

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 8
SMAW

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 9

EXXXX
SMAW Electrode Identification System
Electrode

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 10

EXXXX
SMAW Electrode Identification System
Strength

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 11

EXXXX
SMAW Electrode Identification System
Position

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 12

Position Description
 1 - used in all positions
 2 - used in flat or horizontal fillets
only
 3 - not used at present time
 4 - used for ‘downhill’ progression

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 13

EXXXX
SMAW Electrode Identification System
Coating/Operating Characteristics

Am e r i c a n We l d i n g S o c i e t y
 Electrode Coating
Module 3 - 14
Classification
F #s
 F1 - EXX20, EXX24, EXX27
 F2 - EXXX2, EXXX3, EXXX4
 F3 - EXX10, EXXX1
 F4 - EXXX5, EXXX6, EXXX8

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 15

Low Hydrogen Electrodes

 Types end in a ‘5’, ‘6’, or ‘8’
 Purchase in sealed, metal
containers
 Store after opening in heated,
vented oven
 Limit atmospheric exposure

Am e r i c a n We l d i n g S o c i e t y
Electrode Suffixes - 1 of Module 3 - 16

2
- A1 0.5% Mo
- B1 0.5% Mo 0.5% Cr
- B2 0.5% Mo 1.25% Cr
- B3 1.0% Mo 2.25% Cr
- B4 0.5% Mo 2.0% Cr
-W Weathering

Am e r i c a n We l d i n g S o c i e t y
Electrode Suffixes - 2 of Module 3 - 17

2
- C1 2.5% Ni
- C2 3.5% Ni
- C3 1.0% Ni
- D1 0.3% Mo 1.5% Mn
- D2 0.3% Mo 1.75% Mn
-G 0.2% Mo 0.3% Cr 0.5% Ni
1% Mn 0.1% V

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 18

Stainless Steel Electrodes

 E308, E308L - Weld 304 and 304L
 E316, E316L - Weld 316 and 316L
 E309 - Weld Stainless to Carbon
Steel

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 19

SMAW Equipment

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 20

Constant
Current
Power
Source

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 21

Constant Current

 As arc voltage, V, drops, arc current, A, rises

 Arc V related to distance from electrode to work
 Electrode moved closer, Arc V falls, Arc A rises
 Electrode moved away, Arc V rises, Arc A drops
 Arc current directly related to heat input
 Welder controls heat input to work

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 22

SMAW Advantages
 Simple equipment
 Inexpensive
 Very portable
 Welds most alloys

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 23

SMAW Limitations
 Relatively slow
 Slag removal
 Electrode storage considerations
 Arc blow- solutions noted in text

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 24

Magnetic
Aspects of
Current Flow

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 25

Arc Blow

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 26

SMAW Discontinuities
 Porosity
 Slag inclusions
 Spatter
 Incomplete joint penetration
 Incomplete fusion

Am e r i c a n We l d i n g S o c i e t y
Gas Metal Arc Welding Module 3 - 27

(GMAW)

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 28

GMAW Schematic

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 29

ERXXS-
X
GMAW Electrode Identification System
Electrode

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 30

ERXXS-
X
GMAW Electrode Identification System
Rod
(Designation used also for GTAW
filler)
Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 31

ERXXS-
X
GMAW Electrode Identification System
Strength

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 32

ERXXS-
X
GMAW Electrode Identification System
Solid Wire

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 33

ERXXS-
X
GMAW Electrode Identification System
Chemical Composition

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 34

GMAW
Equipment

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 35

GMAW Nomenclature

Am e r i c a n We l d i n g S o c i e t y
Constant Potential Power Module 3 - 36

Source

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 37

Constant Potential Source

 Is ‘self-regulating’ (maintains
constant arc length)
 Reduces effect of vertical
movement of gun
 Less operator sensitive
 Somewhat easier to learn

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 38

GMAW Modes
of Transfer - 1
of 4
Spra
y

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 39

GMAW Modes of
Transfer - 2 of 4

Globul
ar

Am e r i c a n We l d i n g S o c i e t y
 GMAW Modes of Module 3 - 40

Transfer - 3 of 4

Pulsed Arc

The welding current is variable; it is

pulsed between high and low current
cycles set by the welder

Am e r i c a n We l d i n g S o c i e t y
 GMAW Modes of Module 3 - 41

Transfer - 4 of 4
Short-Circuiting Transfer

Am e r i c a n We l d i n g S o c i e t y
 Factors for Transfer Module 3 - 42

Modes
 Shielding gas
 Current level
 Voltage level
 Power supply

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 43

GMAW Advantages
 Semiautomatic process
 High productivity
 No slag to remove
 Clean process
 Continuous filler metal feed
 Welds most alloys

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 44

GMAW Limitations
 Unsuitable for windy conditions
 Little tolerance for contamination
 Usually limited to shop welding
 Equipment is more complex
 Consumables - liners, contact tips

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 45

GMAW Discontinuities
 Porosity
 Incomplete fusion
 Incomplete joint penetration

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 46

Flux Cored
Arc Welding
(FCAW)

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 47

Self-shielded FCAW

Am e r i c a n We l d i n g S o c i e t y
FCAW Guns - Gas & Self- Module 3 - 48

shielded

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 49

EXXT-X
FCAW Electrode Identification System
Electrode

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 50

EXXT-X
FCAW Electrode Identification System
Strength

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 51

EXXT-X
FCAW Electrode Identification System
Position

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 52

EXXT-X
FCAW Electrode Identification System
Tubular

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 53

EXXT-X
FCAW Electrode Identification System
Chemical Composition
Operating Characteristics

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 54

Stainless Steel Electrodes

 E308T-X - Welding 304
 E308LT-X - Welding 304L
 E316T-X - Welding 316
 E316LT-X - Welding 316L
 E309T-X - Welding SS to CS

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 55

Gas-
shielded
FCAW
Equipment

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 56

Self-
shielded
FCAW
Equipment

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 57

FCAW Advantages
 High productivity
 Deep penetration
 Tolerates contamination
 Suitable for field work

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 58

FCAW Limitations
 Slag removal
 Smoky process
 Electrode cost
 Equipment complexity

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 59

FCAW Discontinuities
 Slag inclusions
 Porosity
 Incomplete fusion
 Incomplete joint penetration

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 60

Gas
Tungsten
Arc
Welding
(GTAW)

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 61
GTAW Nomenclature

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 62

AWS Tungsten Electrode

Classifications
Class Alloy Color
EWP Pure tungsten Green
EWCe-2 1.8-2.2% ceria Orange
EWLa-1 1% lanthanum oxide Black
EWTh-1 0.8%-1.2% thoria Yellow
EWTh-2 1.7-2.2% thoria Red
EWZr 0.15-0.40% zirconia Brown

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 63

GTAW Filler Metals

Carbon Steels
 ER70S-2, ER70S-3, etc.

Stainless Steels
 ER308, ER308L, ER316, etc.

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 64

Effect of DCEN
Current on
GTAW

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 65

Effect of DCEP
Current on
GTAW

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 66

Effect of AC
Current on
GTAW

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 67

Gas Tungsten
Arc Welding
Equipment

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 68

GTAW Advantages
 Good for thin materials
 High quality welds
 Good appearance
 Very clean
 No slag
 Mechanization potential

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 69

GTAW Limitations
 Relatively slow
 Low tolerance for contamination
 Shielding gas expensive
 Purging gas expensive

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 70

GTAW Discontinuities
 Porosity
 Incomplete fusion
 Incomplete joint penetration
 Tungsten inclusions

Am e r i c a n We l d i n g S o c i e t y
 Causes of Tungsten Module 3 - 71

Inclusions
 Contact between:
– Tungsten and base metal
– Tungsten and filler metal
 Excess current
 Excess tungsten extension
 Improper tungsten tip grinding

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 72

Submerge
d Arc
Welding
(SAW)

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 73

SAW

Am e r i c a n We l d i n g S o c i e t y
FXXX-EXX
Module 3 - 74

X
SAW Filler Metal Identification System
Flux

Am e r i c a n We l d i n g S o c i e t y
FXXX-EXX
Module 3 - 75

X
SAW Filler Metal Identification System
Tensile Strength

Am e r i c a n We l d i n g S o c i e t y
FXXX-EXX
Module 3 - 76

X
SAW Filler Metal Identification System
Heat Treatment

Am e r i c a n We l d i n g S o c i e t y
FXXX-EXX
Module 3 - 77

X
SAW Filler Metal Identification System
Impact Test Temperature

Am e r i c a n We l d i n g S o c i e t y
FXXX-EXX
Module 3 - 78

X
SAW Filler Metal Identification System
Electrode

Am e r i c a n We l d i n g S o c i e t y
FXXX-EXX
Module 3 - 79

X
SAW Filler Metal Identification System
Electrode Classification
(Low, Medium, High - Mn%)

Am e r i c a n We l d i n g S o c i e t y
FXXX-EXX
Module 3 - 80

X
SAW Filler Metal Identification System
Electrode Classification
(8 through 16 for chemistry)

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 81

F7A6-EM12K
SAW Filler Metal Example

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 82

SAW
Equipment

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 83

SAW Advantages
 High deposition rate
 Deep penetration
 Mechanized process
 Hand-held process
 Good for overlay of large areas
 High operator appeal

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 84

SAW Limitations
 Flat or horizontal fillets only
 Extensive setup time
 Needs positioning equipment
 Arc not visible to operator
 Slag removal

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 85

SAW Discontinuities
 Groove alignment
 Slag inclusions
 Porosity
 Incomplete fusion
 Cracking (W/D ratio)

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 86

Width vs Depth Ratio

Crack

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 87

Plasma Arc
Welding
(PAW)

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 88

Plasma Arc Welding

Bare
Rod

Am e r i c a n We l d i n g S o c i e t y
 Transferred vs Module 3 - 89

Nontransferred Arc

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 90

PAW Advantages
 Intense arc
 Deep penetration
 Clean process
 Keyhole welding

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 91

Keyhole
Welding
Technique

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 92

PAW Limitations
 Shielding by gas only
 Low tolerance for contamination
 Complex equipment setup

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 93

PAW Discontinuities
 Tungsten inclusions
 Copper inclusions
 Tunneling - keyhole
 Incomplete fusion
 Incomplete joint penetration

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 94

Electroslag Welding (ESW)

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 95

Electrosla
g Welding
Equipment
----
Conventio
nal

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 96

Electroslag
Welding
Equipment
---
Consumable
Guide

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 97

ESW Advantages
 Joins heavy sections
 High deposition rates
 Single or multiple electrodes
 Minimum joint preparation
 Low distortion

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 98

ESW Limitations
 Vertical ‘casting’ process
 Very extensive setup time
 Uses water-cooled shoes
 Flux storage
 Largely confined to vertical
orientation and flat position only

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 99

ESW Discontinuities
 Gross porosity
 Slag inclusions
 Large grains
 Gross shrinkage
 Cracks

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 100

Oxyacetylene
Welding (OAW)

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 101
Oxyacetylene Welding

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 102

OAW
Equipment

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 103

OAW Filler Metals

RG - 45
RG - 60

‘R’ refers to rod

‘G’ refers to gas

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 104

OAW Advantages
 Simple equipment
 Suitable for thin materials
 Very portable
 No electricity required

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 105

OAW Limitations
 Very slow process
 Manual only
 Less concentrated heat
 Low productivity
 Flame adjustment sensitive

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 106

OAW Discontinuities
 Severe oxidation, or
 Severe carburization
 Incomplete fusion
 Incomplete joint penetration

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 107

Stud Welding
(SW)

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 108

Stud
Welding
Components

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 109

Stud
Welding
Cycle

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 110

SW Studs and Fasteners

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 111

Stud Welding - Studs

 Flux on tip cleans weld area
 ‘Stand off’ tips also used

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 112

SW Advantages
 Simple
 Fast
 Repetitive
 Automatic stud feeding (option)

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 113

SW Limitations
 Needs clean surface
 Equipment malfunctions

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 114

SW Discontinuities
 Lack of ‘flash’
 Incomplete fusion

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 115

Laser Beam
Welding
(LBW)

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 116

LBW - 1 of 2
 Laser
– Light Amplification by Stimulated Emission
of Radiation
 A fusion welding process
 Heat from concentrated light source
 Keyhole welding
 Light beam very small x-section

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 117

LBW - 2 of 2
 Light can be transmitted by fiber
optics or mirrors
 Non-contact process
 Shielding gas often required

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 118

Cross Section of LB Weld

Weld

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 119

LBW Advantages - 1 of 2
 Low heat input
– Less grain growth and distortion
 High D/W ratios of 10:1 attainable
 Relatively thick single pass welds - (up to
1.25 “)
 Welds thin metals or small diameter wires
 Closely spaced components, small welds

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 120

LBW Advantages - 2 of 2
 Welds wide variety of materials
 Beams readily focused and aligned
 Not influenced by magnetic fields
 Welds metals of dissimilar physical
properties
 No vacuum or X-ray shielding required
 Beams transmitted to many work stations

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 121

LBW Limitations
 Joints must be accurately positioned
 Surfaces must be forced together
 Alloy reflectivity and thermal
conductivity
 Plasma control device often required
 Cost

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 122

LBW Discontinuities

 Porosity
 Embrittlement

Am e r i c a n We l d i n g S o c i e t y
Electron Beam Welding Module 3 - 123

(EBW)

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 124

EBW
 Originally required high vacuum
 Can now operate in low, or no,
vacuum
 A fusion joining process
 Heat applied from stream of high-
energy electrons from gun

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 125

EB
Schematic

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 126

Electron
Beam
Welding
Fixture

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 127

EB Weld

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 128

EBW Advantages

 Similar to LBW
 Deeper penetration capability
 High purity, especially for vacuum
environment
 High welding speeds
 Ability to change weld shape

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 129

EB Limitations
 Similar to LBW
 Vacuum chamber may be required
 Vacuum chamber size can limit
assembly size
 X-Rays generated
 Cost

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 130

EBW Discontinuities
 Cracking
 Root voids
 Porosity

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 131

Resistance
Welding - 1 of
3

Am e r i c a n We l d i n g S o c i e t y
Resistance Welding - 2 of Module 3 - 132

Am e r i c a n We l d i n g S o c i e t y
 Resistance Welding - 3 of Module 3 - 133

3
 Heat obtained from resistance of
workpieces as current flows
through them
 Electrodes are usually copper
 3 types - RSW, PW, RSEW

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 134

RSW Advantages
 Very fast welding times - < 1 sec /
spot
 Semiautomatic or automatic
 Good for thin materials
 No flux required

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 135

RSW Limitations
 Inspection of welds may be difficult
 Primarily a shop process
 Electrodes must be clean
 Metal surfaces must be clean

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 136

RSW Discontinuities
 Non-fusion areas
 Cracks
 Misalignment of RSEW electrodes

Am e r i c a n We l d i n g S o c i e t y
 Welding Applications & Module 3 - 137

Personnel

 Manual  Welder
 Semiautomatic  “
 Mechanized  Welding Operator
(machine)
 Automatic

See A3.0-94 for AWS definitions.

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 138

Brazing

Am e r i c a n We l d i n g S o c i e t y
 Brazing vs Welding vs Module 3 - 139

Soldering
 Base metal not melted in brazing or
soldering
 Brazing filler metals melt above 840 0 F
(4500 C)
 Soldering filler metals melt below 840 0
F
 Strong joints possible with all
processes if designed properly

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 140

Brazing Aspects
 Large surface area
 Very small clearance
 Clean surfaces
 Flux often used
 Capillary action

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 141

Braze Joint Configurations

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 142

Brazing Filler Metals

 Wire
 Strip
 Foil
 Paste
 Preforms

Am e r i c a n We l d i n g S o c i e t y
 AWS Brazing Filler
Module 3 - 143
Metals
Designation Primary Element
BAlSi Aluminum-Silicon
BCuP Copper-Phosphorus
BAg Silver
BAu Gold
BCu Copper
RBCuZn Copper-Zinc
BMg Magnesium
BNi Nickel

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 144
Brazing Methods
Named after heating method
 Torch
 Furnace
 Induction
 Resistance
 Dip
 Infrared

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 145

Brazing Advantages
 Strong joints
 Joins dissimilar metals
 Joins metals to nonmetals
 Joins “unweldable” metals
 Less heat, less distortion

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 146

Brazing Limitations
 Cleanliness requirements
 Joint design requirements
 Difficult to inspect

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 147

Brazing Discontinuities
 Voids, unbonded areas
 Base metal erosion
 Corrosion by flux
 Trapped flux

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 148

Cutting Processes

We will be discussing:
 Oxyfuel Cutting
 Air Carbon Arc Cutting
 Plasma Arc Cutting
 Mechanical Cutting

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 149

Oxyfuel
Cutting (OFC)

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 150

Oxyfuel Cutting (OFC)

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 151

OFC - Kerf and Drag

Am e r i c a n We l d i n g S o c i e t y
 Oxyfuel Cutting Gases Module 3 - 152

Commonly used

 Acetylene
 Methane
 Propane
 MPS

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 153

OFC Torches

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 154

OFC Cut

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 155

OFC Advantages
 Simple equipment
 Very portable
 Cuts thin or thick materials
 Good accuracy
 Manual or mechanized

Am e r i c a n We l d i n g S o c i e t y