Welding Technology

WELDING TECHNOLOGY
Acc. To : AWS-QC1-96
: 24 5
88516727 :
88537359 :
www.age-co.net :
:
:
:
:
:
:
:
:
:
: 1
: 2
: 3
: 4

General Introduction to Welding Technology
www.age-co.net/training.aspx
1-1

.
.
, . ,
. .
. 1887
)(
.

, , , .
2-1
, ,
: , , , , .
:
( : , ,.
( : ,.
( :.
: ) , ,( , .
: ) , ,( ,
.
: ) , ,( , .
,
.
:
. .
. .
. .
. .
. .
3-1
:
-1
-2
.
. 450C 450C , .
4-1
: . ,
)( .
, , .
.
-
-
-1 :
, .
:
(
(
(
. : , ,
, .
(
. : ,
.
-2 :
.

, , , ,
.
:
- :

.
- : ,
.
- : .

Oxy gas Welding
OFW
Oxygen Fuel Welding
)Oxy Acetylen Welding (OAW
.
.
, .
.
-1 : -2 , -3 , ,
-4 -5 , -6 , -7 , -8 , -9 , .
:
. .
. .
. , .
. .
. (Dilution) .
:
. .
. .
. .
. .
. .
:
.
.
.1 :
, :
. .
. .
. .
. .
. .
, .
, , , , ... .
.
. .
C2H2
C2H2 .
. .
.
) ( C2Ca
, .
) (C ) (CaO . 3000
. .
, ,
, .
. ,
.
350 250
.

CaC2 , C2H2 . .
400 .
C2Ca+2H2O--------- C2H2+Ca(OH)2+400kcal
1/15 0/41+ 0/56 --------- 1+
2 ) (30 psi .
(15 psi) 1bar .
.2
, . %21
. .

, . .
. -200bar .
. ) .
(
, 4bar 200 C .
.3 -196 C -183 C .
.

:
, 80kg/mm2
. . 8 9 1800
. 75 40 ) ( .
.
.
15040=6000lit = 6m3
:
. , 4 5
. 2bar .
, .
10
25 .
, . 80 70 .
.
:
V=162515=6000lit
= =
, .
10 .
: 40 , .8 bar
:
= 40810=3200lit
:
, , .
:
.
( 900 1000 .
( 500 600 .
.
1200 1500 . .
. ) (
,
.

.
11
:
.
.
.
.
. .

2/5
) ( .
,
.

0/1 1 .
.
) (
. , ) , (
.
:
, , .
( :

.
.
12
:
.
.
.
( :

. .
:
.
, .
:
.
:
.
13
.1
.2
Ground Collar of
Type of Gas
Combustible Gases
Cylinder
Cylinder Inlet
Connections
(C2H8)Acetylene-
maroon
Left Hand Thread
(C3H8)Propane-
red
R1/2*Left
(H2)Hydrogen-
red
R1/2*Left
(O2)Oxygen-
Black
Right Hand R3/4*

Thread
Non- Combustible
Gases
Compressed Air
Gray
Right Hand (Inside)
Argon
Blue
Right Hand
(CO2)Argon /
Blue with Green
Right Hand
mixture
Carbon Dioxide(CO2)
Band
Blue with White
Right Hand
Strip
(He2)Helium-
Mid-brown
Right Hand
(N2)Nitrogen-
Gray with Black
Right Hand
Top
14
.3
.4

15
.5
.6 Gas-Mixer

16
.7( ( .
.8
.1 .2 .3 .3A .4 .5 .6 .7 .8
.9 .10 .11 .12 .13 .14 .15 .16
.20 .21 .22 .23 .24 .25 .26
.27 .
17
.3
Fuel Gases 1-12
Charaeteri 212 sties
Chemical
Term
Oxygen
Acetylene
O2
C2H2
Fuel gases
(Propane)
C3H8
Natural
Gas (Methane)
CH4
Production
Air
Liquidation
frac.
Distillation
Carbide
gasification
Chemical
Processes
Natural
Oil Distillation
Natural
Oil Location
Use
Oxy-gas
Welding, Steel
Production,
Chem.
Industry,
Medicine
Rockerty
Oxy-gas
Welding,
Chem.
Industry,
Synthetic
Material,
Fertilizer.
Fuel gas.
Household,
Industry
Heating, Oxygas Welding
Household
, Industry
Heating, Oxy
gas Welding.
Purity /
Commercial
Charaeteri 312 sties
Impurities
Volume
Weigh: [KJ/m3].
15C/1 bar
Air:1.209
[KJ/m3]
Boiling
Temperature. C
Thermal
Value. H KJ/m3
Ignition
Range in Air. %
gas in O2
Min. Ignition
Temperature with
air. C with O2
Ignition
Velocity Air, m/s ,
O2
Max.
Temperature of
Flame, with air, C
With O2
Power of
Flame.
KJ
Hydrogen
H2
ChlorineAlkaline
Electrolysis.
Electrolysis of
Water
Welding
of Aluminum
and Lead
Flame-cutting
of Higher
Thick nessed,
Furnacebrazing.
>99.5%
>99.0%
>99.8%
--
>99.75%
N2,Ar,H2O
Ar,H2O
H2,N2,O2,
CH
--
O2,H2O
1.337
1.095
1.874
0.671
0.084
-183
-0.4
-43
-102
-253
57120
92000
36000
10759
2.4+80
2.4+93
2+10
2+55
4+17
4+60
4+70
4+95
335
295
510
490
640
690
510
460
1.3
13.5
0.3
0.7
0.4
3.3
2.7
8.9
2325
3200
1925
2850
1920
2750
2045
2650
45
11.0
13.0
14.0
cm s
18

POWER GENERATORS IN WELDING
19

(1 . .
.
-
- :
.
.

.
(1 ) (
(2 )(
(

.
:
.
.
.
.
.
=
:
(
20
( .
( .
( .
(
:
.
.
:

.
.
. .
:

DC AC .
:

.
.
21
) (
. .
.
22
:

.
.
DC AC .
:
.
. 500
500 .
%30 %60 %100
500 %30 3 500 7
. : 300 %60 300
6 4 . : 200
%100 200 .

.
.
23
)2 ( =
)2 (
300 %60 370
= 350 2 60 = %40
370 2
:
70 80
.
:
( ) (
-
:
.
.
24

.
.
(C.C) .
5-8 .
.
.

.

.
.
25

) (Hot.start .
1/5
. .
.
.
HF
.
) ( ) (HF ) (Life Arc .
) ( ) : (HF .

.

)(
HF ) (HF AC
HF AC
.
) (HF NCN
) (HF .
26
)(Left Arc
) (HF

10-15
.

.
27

GAS SHIELDED ARC WELDING
28

) ( ) (1
GTAW )( T.I.G .

.
) (1
D.C

.
) (A.C
.
GMAW M.I.G
.

.
29
Ar + 18%co2
Ar + 2.5%co2
)(co2

.
-2
. .
. .
) 4 (3 15cm

.
30

.
12 20000 400 .
.

DC
High voltage Dc
High voltage. High frequency
High voltage
Touch striking

.
.
TIG GMAW .
DC

5-10KV .
31

) (3kv, 5MHZ
.
TIG Radio noise
.... .
GTAM 6
.
-
GMAW
7 GMAW
GMAW
-
.
) (22
GMAW .
32

. .
.
Inert Gases
.

0.9% .
. .
TIG

.
CO2 O2 .

.
-
)(11
TIG
MIG/MAG .

33
)Forming gas (Backing gas

.

%90 N2/10% H2
%80 N2/20% H2
10%
-1 : ) (12
-2 :
) (13
-3
.

.
Solid wire
)
(
Flux cored wire
1927
)(14
15 u
.
34

TUNGSTEN INERT GAS
GAS TUNGSTEN ARC WELDING
35
GTAW
)( .
. ) (
.
GTAW .
. . 1920
. .
.
.
.
) (TIG . )(AWS
GTAW . .

. .

. .
... .

) ( .
.
. .
.
36
.
. GTAW :
-
-2 -3
-4

- .
- .
- .
- .
- .
- .
- .
- .
- .
- .
:
:
-1 .
-2 .
-3 10 .
-4 .
37
:
-1 .
-2 .
-3 .
-4 .
-5 DC .
:
: ) ( .
(Q=I2Rtk) .
. ) .
(
:
. .
. .
.
. .
.
. .
.. .
. .
.
.
38
:
. :
-1
-2
-3
-4
.
.
. DCEN
.
.
.
.
:
.
. .

.
.
.
:
.
.
.
39
) (Under Cut .
.
:
GTAW .
.
:

.
.
.
120 ) ( .
)( 90 .
.

.
) ( :
.
. 200
.
:
.
.
.
.
40
500 1000 .
.
.

. 50 . .
.
:
): (Collet
. .
. ) (Cap .
.
:
.
. .
:
. .
.
. . .
250
.
. .
.
.
41
. .
.
.
.
.
.
.
.
. .
:
GTAW .
.
SMAW,GMAW,SAW .
. 6170
3410 . ) (
. . .
.
42
43
:
) (
.
.
.
. .
) (DCEP .
.

44
%10 .
. AC
DCEP DCEN . DCEP %50 DCEN.
EWP
EWP %99/5 .
. AC
. . DC
. .
EWTh
)( .
.
) .(3
. EWTh-1 EWTh-2 1 2 )
(ThO2 .
. ) %20 (ThO2
.
. EWTh-1,2 DCEN .
.
AC .
. .
. EWTh-3
. % 10 %20 .
0/35 0/55 .
.
45
EWCe
1920 .
. EWCe-2 %2 ) (CeO2 .
.
. EWCe-2 .
EWLa
. %1
) (La2O3 . ) (EWCe
.
EWZr
) (ZrO2 .
. EWZr
AC .
.

.
EWG
EWG .
.
. .
. .
.
46

GTAW . .
AC . DC
. .
.
. DCEN
.
. .
.
.
) (Balling
AC
.
DCEP AC .
.
. 1
.
)(Grinding
.
. .
.
.
AC .
47

.
. .

.
.

.
.

.
. .
)(
.
)( )( .
.

):(mm
8/4 6 4 3 2 2/4 1/6 1 0/5 :
175 150 75 50 :
48
)(W
:
:
)(WT
:
:
:

.

DCSP
DCRP

49

MIG/MAG welding
50

GMAW : Gas metal Arc welding
MIG : metal Inert Gas
MAG : metal Active Gas
:
)1970 1980( .
.

1970
.
.
.
FCAW TIME . (Flux cored Arc welding) FCAW

GMAW
. .
.

. . .
:

:
51
( . .
.
( ) .(FCAW
. .
(
.
( .
( 2 .
( .
( .
:
( .
(
.
(
.
( .
.
:
.
) ( .
.
52
.
. .
.
:
MIG .
.
.
.
) 3000 5000 (6000 .
2000
7000
.
.
.
.
:
. 0/5
.
12 .
:
.
53
:
.
.
.
.
.
.
.
.
.
:
- : .
- : .
- : .
- )( :
-1 :
, DCRP .
DCSP ) (FCAW .
. ,
. .

, .
54
- .
. )( .
, .
, .
.
.
.
-2 :
.
. , .
.
, . , .
:
. .
3/5 2
.
0/8 3/2 ) ( 1/2
2/5 .
.
DC
. , .
. V
, .
.
55
:
, .
100 , . .
1/2 .
.
-:
.
. ,
. 15
- . , .
:
, . U ,V V
. , .
-3 ,:
GMAW )( . [ .
)( .
.
. 200
, .

. , . ,
, . ,
56
. ) (CO2 , .
, - , - , , .
. T ,
. , .
, .
. .
:
-1 ) ( : 10-22
, . ,
.
, . , .
( ) (:
.
. .
.
. .
( )(:
, ,
)( .

. ) (---
. . ,
.
57
, .
.
.
.
.
( :
, .
. ,
. , .
( :
.
( :
,
.
-4 :
, ,CO2
.
:
, ,
. . :
.
, - .

58
Ar + H2 . Ar+CO2 . Ar+O2. CO2

):(Ar
15/7 , .
, .
, ,
, . ) ( ,
) (Axial ) ( . ,
) (Spatter .
) (MIG & MAG .
.
.
, ,
.
%0/8 .
.
):(CO2
,CO2 , )( . ) 6000
( , .
CO2 O + CO
, .
, ) ( .
, , .
) ,(Super Heated , , .
59
CO2 , , ,
) ( .
.
,CO2 ) ( .
, .
, , , )
( ,TIG , , 200 300 ,
.
, ,MAG
) (Tripple Deoxidised.
):(O2
,
. 1 7 / ,
. ,
.
):(H2
.
. ) 13/5 (
. .
,
.
:
, ) , ,
( . ,
60
,
.
, [ . ,
. , ,

. , ) (
, , .
):(Ar/O2
, ,
, . 1 7
.
, ,
.
) (3Crl2 1 2
. 5 , , .
,
CO2 , .
Argoshied 40 ,
, , .
):(Ar/CO2
, CO2 2 30
. , 25 CO2 . ,
, , .
61
Argoshield 52 CO2 . Ar/CO2

.
,Ar/CO2 ,Ar/O2.
, ):(Ar/O2/CO2
Ar/CO2 .
, .
, .
, )) (Short Crircuit
, ( .
) Argoshield50 O2 ,( CO2
. ,
.
) Argoshield51 .(CO2
. .
,CO2 ) (Spatter ) CO2
( CO2 .
.
):(Ar/He
Ar/He , , ,
. ,
. , , . 25
75 . Argoshield 80T Argoshield 81T .
62
, ):(Ar/He/H2
Argoshield 71T Ar/He/H2 ,
) (TIG . , ,
,
, .

, .
):(He
, 24/5 . ,
) ( .
, .
.
, .
. .
, . ,
, .
. ,
) 269 (.
63
Vol .% OVERVIEW OF WELDING SHIELDING GASES

l1
l1
l1
l2
l3
R1
R2
R2
R2
R2
Welding grade argon

Argon 4.8
Mison A
Helium
Argon/Helium
Hydrogen
Argon W2
Argon W5
Argon Hydrogen
Argon W10
M11
M11
M11
M12
M12
M12
M12
M13
M13
M13
M21
Argon S1 Argomag S1
Argon S3 Argomag S3
Argon He25S1
Argon k2
Argon C2 Argomage k
Mison 2
Argomage He
Mixed argon 8 krysal8
Mison 8
Corgon 10
Corgon 15
Mixed argon 18 krysal 18
corgon 18
Mison 18
Corgon 20
Mixed argon 25 Corgon
25
Mison 25
Mixed argon 1
Corgon 07
Argon S8 Argomix 10
Corgon l
Mixed argon 2 Argomix
10
Argomix 20
Argon S12 Argomix S
M21
M21
M21
M21
M21
M22
M23
M23
M32
M32
M32
M33
C1
F1
F1
F2
Welding - grade carbon

dioxide
Ar/H2
Argon W20
Forming gas-nitrogen
hydrogen
Nitrogen 3.0 to 5.0
Process
TIG MIG
TIG MIG
TIG MIG
TIG MIG
TIG MIG
TIG/WP
TIG/WP
TIG/WP
TIG/WP
TIG/WP
Ar
100
100
99.97
Rem
98
95
93.5
90
He
100
25-75
-
02
-
CO2
-
H2
100
2
5
6.5
10
N2
-
NO
0.03
-
MAGM
MAGM
MAGM
MAGM
MAGM
MAGM
MAGM
MAGM
MAGM
MAGM
MAGM
99
97
74
98
97.5
97.97
83
92
91.97
90
85
25
15
-
1
3
1
-
2
2.5
2
2
8
8
10
15
0.03
0.03
-
MAGM
82
18
MAGM
MAGM
81.97
80
18
20
0.03
-
MAGM
75
25
MAGM
MAGM
MAGM
MAGM
MAGM
74.97
82
93
92
91
3
7
8
4
25
15
5
0.03
-
MAGM
90
MAGM
MAGM
MAGM
83
80
88
4
5
-
13
15
12
MAGC
100
Forming
Forming
88
80
12
20
Forming
2-25
98-75
Forming
100
64
,:
. ,
. :
- )(Short circuit
- )(Globular transfer
- )(Spray Transfer
- )(Pulsed spray transfer
:
-
-
-
-
-
- )(Stick out
:
.
, . ,
, .
:
, , . ,
. CO2 , .
65
:Pincheffect
, .

. , .
= Pincheffect
:
.
. ,
.
,
. .
:
.
.
.
.
CO2 .
.
:
, ,
,
66
%85 , . CO2
. ,
.
32-40 250 . 100 300 .

. ,
. .
:
.
)( .

. ,
. .
, .
-:
, -
.
.
,:
. , ,
. ,
.
.
67
,:
,
, , ,
.
:
( :
:
:
:
* 12
* 10
(

.
:
, .
, .
, .
,
.
):(Deposition Rate
, . kg/h .
= kg/h
(g/m) * 60 * ) (m/mn
100
68
:
12 2 1 , :
12 x8.9 x60
= 6.4kg / h
1000
, 2 89 ,1 .
:
,U , . ) (I
.
:
, , .
:
) (Contact Tube :
) (Contact Tube :MAG
16 - 2/4 .
0/8 - 1/2 .
=F )(Stickout
=K = F+
69
(1 MIG/MAG
(2
70
(3
71

SHIELDED METAL ARC WELDING
72

SWAM .
. SMAW
.
.
.
.
) 4500 5500 ( .
. .
.
SMAW

. :
.
.
.
.
.
SMAW
.
.
.
73

AC DC .
.
: DC
.
:
.
.
.
.
:
.
.
:

( )(DCSP)(DCEN
DCSP .
.
( )(DCRP)(DCEP
DCRP .
.
.
74

.
.
.

.
: AC
.
. 50 50 .
DC . AC
. AC
AC .
:
AC .
.
:
.
.
.
AC .
75
:
AC DC SMAW .
.
.

SMAW
)( .

) ( .

(
.
.
. .
.
.
.
.
(
. .
.
.
.
. .
76
.
.
. .
. .
.
(
. .
:

.
.
.
. .
HAZ .
77
78

SUBMERGED ARC WELDING
79
.
.
.
GMAW FCAW .
. )(
.
.
.
.
.
:
-1
-2
) (AWS .

. .
.
GMAW FCAW .
.
.
.
.
. .
.
80
.
.
. .
.

. .
)
( . .
.
.
81
.
.
.

.
. SMAW
. .
)( .
. .
.

.
82
83
84
85
:

WELD DEFECTS CLASSIFICATION
:
.
) (AWS D1.1 .

) . (BS5500 ) (Rounded .
) (Elongated .
.
)(Imperfection
.
)(Discontinuity
) (
.
)(Flaw
.
. ) (
.
)(Defect
.
.
.
) ( ) ( .
.
.
.
:

86
-

: ) (Heat Input
:

:
:
:
:
-

: ) ( .

: .

.
ISO 6520 6 :
1 )(Cracks
.
.
. .
.
. )(
.
.

.
87
)(Crack Orientation
)( .
) (Toe Crack .
.
.
:
-1 )(Micro Cracks/Micro Fissures
.
-2 )(Longitudinal Crack

.
.
:
-3 )(Transverse Crack
.
:
-
-1
88
-4 )(Radiated Crack
:
) (Star Cracks.
-5 )(Crater Crack
.
.
. :
-6 )(Group of Disconnected Cracks
:
-7 )(Branching Cracks
.
:
-8 )(Throat Crack
. .
) (Fillet Welds .
-9 )(Toe Crack

.
89
-2
-10 )(Under Bead Cracks
.
. :
.
.
90
-2 )(Cavities
.
-1 )(Gas Pore
.
-4
-2 )(Porosity
. .
.
.
.
.
.
-3 )(Uniformly Distributed Porosity
.
.
.
.
-4 )(Cluster Porosity

.
91
-5
-5 )(Linear Porosity
.
.
.
-6
92
-6 )(Piping Porosity
) (Elongated Cavity .
. .
. .
-7 )(Worm Hole
. .
.
-8 )(Surface Porosity
.
-9 )(Shrinkage Cavity
.
-10 )(Interdendritic Shrinkage
.
.
-11 )(Micro Shrinkage
.
.
-12 )(Crater Pipe
.
93
-3 )(Solid Inclusion
.
. .

. .
.

.
.
-1 )(Slag Inclusion

.
. .
.
.
-7
-2 )(Flux Inclusion
. :
-3 )(Oxide Inclusion
.
94
-4 )(Puckering

.
-5 )(Metallic Inclusion
. :
-6 )(Tungsten Inclusion

) (GTAW .
.
.
. .
.
-4 ) (Lack of Fusion )(Lack of Penetration

.
.
.
.
.
.
. .
-1 )(Lack of Fusion
. :
. ) (
.

95
-8
-2 )(Lack of side wall fusion

.
.
.
. .
-3 )(Lack of Penetration
.
.
.
.
.

) (Back Gouging .
. .
.
.
.
. .
.
.
96
-5 )(Imperfect Shape
.
-1 )(Undercut
. .
.
.
.
.
-9 ) (a )(b
-2 )(Underfill
.
.
-10
97
-3 )(Shrinkage Groove
.
Shrinkage Groove
-11
-4 )(Excess weld metal
.
.
IN
1 0
IN
10
MM
20
15
3/4
1/2
1/4
Excess Weld Metal

159
, 05
)Groove Joint - Butt Weld (1G-Flat
-12
98
-5 )(Excessive Convexity
.
) ( .
.
Face Convexity
78,
52
-13
-6 )(Excessive Penetration
.
) (Local Protrusion .
Excess Penetration
-14
99
-7 )(Incorrect Weld Profile

.

.
-8 )(Overlap
.

. .
.
Over Lap
Over Lap
-15
-9 )(Linear Misalignment
.
.
-16
100
-10 )(Angular Misalignment

.
.
-17
-11 )(Sagging
. :
-
-18
101
-12 )(Burn through

.
)(
.
-13 )(Incompletely Filled Groove
.
.
-19
-14 )(Excessive Asymmetry of fillet weld

.
-20
102
-15 )(Root Concavity

.

.
-21
-16 )(Root Porosity

.
-17 )(Poor Restart

.
-22
103
-6 )(Miscellaneous Imperfections
.
-1 )(Arc Strike / Stray Arc
.

.
-2 )(Spatter
.

.
-3 )(Tungsten spatter
.
-4 )(Torn Surface
.

.
-5 )(Grinding Mark
.
-6 )(Chipping Mark
-7 )(Under Flushing

.
104

) (
... .
%100
.
%100 :

.
) 8 10( )243642 48( %100
) 42( %100 .
)(Class Location
500
) 250 ( .
:
8 1 .
8 36 2 .
36 3 .
:
%10 1
%15 2
%40 3
%75 4
105

BS 5500 :
(Construction Category 1) 1
1 %100
PWHT .

.
.
.

.
.
2 .

.
.
:
(
( %10
( %10
( 12
.
.
:
(
( %10 .
3
. .
.
106
%100
) (
30
40
16
25
107
108

E6010
) ( ) E6013 ( ) E7018 ( .
E6010
) ( .
.
. )(
. .
. E6010
.
.
E6010 .
.
.
E6010 . .
.
.
.
E6010 30 . ) (TiO2
.
E6010 ) 10 ( .
.
.
8 E6010 .
109
8 E6010
)(
)(
)(
2/4
40 80
23 25
3/25
75 125
24 26
110 - 170
24 26
140 215
26 30
170 250
26 30
210 320
28 34
275 425
28 34
) (
) (
)(%

62000 70000
52000 58000
22 30
20 -29
60000 67000
47000 54000
28 - 35
E6013
E6012 . E6013
. .
.
E6012
2 1/6 2/5 . E6013 .
. .
E6013 E6012 .
E6013 E6012 .
E6013 E6012 .
E6013
.
E6013 .
.
.
E6013 .
) (
.
110
E6013 E6012 .
. E6012
.
E6013
.
E6013 E6012 . E6013
.
.
E6013
. E6012 .
.
9 E6013 .
9 E6013
)(
)(
)(
1/6
20 40
17 20
25 60
17 21
2/4
45 - 90
17 21
3/25
80 120
18 22
105 180
18 22
150 - 230
20 24
210 - 300
21 25
250 350
22 - 26
320 430
23 - 27
) (
) (
)(%

67000 72000
55000 60000
20 17

65000 71000
50000 56000
25 - 30
111
E7018
E6010 E7018
. E7018 .
25 40 .
.
) ( .
E6010 E7018.
E6010 . E7018
. ) E7018 ( .
. E7018 ) ( .

. E7018 )( .

. E6010 .
.
E7018 .
.

.
. E6010 .
. ) 4 (
.
) ( .
.
) (SUPER MR
.
. E7018-X 0/4 . E9018-X
E10018-X E11018-X 0/2 .
ASME .
. MIL-E-0022200/ID
E9018-M E11018-M 0/15 .
E12018-M .
.
. ) (
E6010 .
. .
112
E7018 10 .
10 E7018
)(
)(
)(
2/4
70 100
17 21
3/25
115 165
18 22
150 220
20 24
200 - 275
21 25
260 - 340
22 26
315 400
23 - 27
375 470
23 - 28
) (
) (
)(%

72000 78000
60000 66000
22 28
20 -29
68000 74000
55000 61000
28 - 33

.
.
.
.
.
.
.
AWS AWS
. ) ( AISI
. E309-XX E308-XX .
) ( AWS .
:

113

15 ) (E3XX-15 ) (
. . ) 8
( .
.
.
. .

. 3/2 .

16 ) (E3XX-16
. 20 .
.
.

.
.

8 20 .
. )(
)( .

.
.
.
.
.

. .
.
114
11
AISI 300
AWS
E308-15 , E308-16
19/9 18/8
E309-15 , E309-16 , E309Cb-15

E310-15, E310-16, E310Cb-15,
EE310Cb-16, E310Mo-15,
E310Mo-16
E312-15, E312-16
E316-15, E316-16, E316Cb-15,
E316Cb-16
E317-15, E317-16
25/12
AISI
302
303
304
308
309
25/20
310
29/9
312
18/12 Mo
316
18/12 Mo
18/12 Mo Cb
15/35
18/8 Cb
AISI 400
317
318
330
347
12
16
18
28
AISI 500
5
9
410
430
442
446
E330-15, E330-16
E347-15, E347-16
E410-15
E430-15
E442-15
E446-15
E502-15, 502-16, 505-18
E502-16, 505-18
502
505
115

AWS A5.32

AWS
SG A
SG C
SG He
SG H
SG N
SG O
)(%

) (

)
(
99/997
10/5
- 60
99/997
10/5
- 60
99/8
32
- 51
99/8
32
- 51
99/995
15
- 57
99/995
15
- 57
99/95
32
- 51
99/995
32
- 51
99/9
32
- 51
99/998
- 68
99/5
50
- 48
99/5
6/6
- 63
AWS
AWS
)(%
SG AC - 25
75 25
SG AO - 2
98 2
SG AHe - 10
90 10
SG AH - 5
99 5
SG HeA - 25
75 25
SG HeAC 7.5/2.5
90 7/5 2/5
+ +
SG ACO 8/2
90 8 2
+ +
SG A - G
116
-1
-2
-3
-4
-5
-6
-4
-5
-6
-1 EM12K
-2
-3
-4
-1
-5
-2

-3
-1
-2
EM12K

-1
-2
-1
-2
-1
-2
-1
-2
-3
-4
-1
-2
-3
-3
-4
-5

-6
-7

-4
-5
117
)(
-1
EM12K EM13K
-5
-6
-7
-2
-3
-4
-1 EL12
-2
-3
-4
-1 EL12
-1
-2
-3
-4
-1 ) (Tie-in

-2 )(Tie-in

-3 ) (Tie-in
-2
-3
-4
-5
-1

-2
-3
-4
-5 .

-1

-2

-3

-4

-5
6

118
119

.
.
... .
10
) (Borescope . .
:

.
.
.
.
.
.
.

.
.
. ) (
.

... . ) (
) ( .
.
.
.
.
120

.
.
.

. .
15 30 . 10 15
. .
.
.
.
. ) (
. .
:
.
.
:
) ( ) (
.
.
:

. .
121
. .
. .
.
.
:
-1 .
-2 .
-3 .
-4 .
-5 .

.
.
.
.
.
.
.
.
.
122

.
) 20 20
(
20 .
:
-1 .
-2 .

.
PZT .

.
.
) ( .
.
.

.

. 0/25 10 .
6 . .
.
.
.
.
Lamination
. .

.

.
.
.
123

.
.
.
IQI .
) (
.
IQI .
IQI
.
.

.

.
. .
. .

. .
"" "" .

.

.
.
124
B/D
B/C
) (
B/D
C/D

.

.

)
(
C/D

.

.
B/C
C/D
)(
A/D
A/B

.
.
A/D
B/D
A/B
A/B
125
) ( ....
126

%100 .
-1 .
-2 .
) ( 0/07 ) ( 1/5 .
-59
) ( .
-3 .
-4 0/25 0/8 )
(
-5 .
-6 )
A517 ASTM A514 48 ( .

127

AWS D1.1 ) ( .
) (Elongated ) (Rounded .
.
.
. .
.
) (Aligned
.
) (Scattered .
) (Cluster .

:
-1 33 .
-2 33 .
-3 E 6 .
50 10 . )
2( ) (
.
-4 .

.
-5 2 25 E 10 ) ( .
12 3 .
-6 6E E . 6E
.
128

.C
129
130
.
, .

.

-1
.
. :
80 90 .
:

-2
.
:
131
.
-3 .
. :
, ) ( , , , ,
, .
, ,
, , , ,

, , ,
) , , , (.
-4 3 , .
. .
, )
( . .
-5 .
. . .
-6 .
, .

.
.
, .
.
. .
, .
:
132
, ,
) (
.

.
,
.

.
.
-1
.
.
133
-2
.
.

, .
.
, .

.
-3
, , ,
, .
-4
, .
.
.
-5
.
.
.
, .
, .
,
.
.
-6
. ,
.

.
-7
. .
.

134
-8
. .
.
.
.
.
.
. , , , .
, , .
-9

.

.
-10
. ,
. .
, ,
.
-11
. , ,
.
.

, , .
, .
, .
.
.
135
(Joint Types) 3
(Spliced Butt Joints) 2
(Groove Face, Root Edge, Root Face) 6
(Edge Shapes) 10
(Double Groove) 9
(Joint Root) 5
(Single Groove) 8
(Flanged Joints) 1
(Bevel Angle, Depth of Bevel) 4
(Welds in Flanged Joints) 7
136
(Seam Welds & Spot Welds) 11
(Edge Weld, Scraf Groove) 12
(Butting and Nonbutting Members) 13
14
137
15 AWS
138
16 AWS
139
- 17
18
140
19 DIN EN 22553
20 DIN 1912
141

:
LLOYDS REGISTER OF SHIPPING DEUTSCHE INDUSTRIES NORMEN DIN 1913
BRITISH STANDARD BS 639 1976 ...
.

.

.
:
6 3 .
.
3 2 .
100 2
.
2 12 .

.
3 .
3 .
.
: 20

24 15 25
.
: .

.
e = s1 s0 5 .
142

-5
)(
)(
e = s1 s0
0/05
1/6
0/08
0/10
2/5
0/15
0/20
0/25
0/30
120 50 100
) .(24
0/01 .
) ( .
120
50 - 100 mm
120
1
7
,
9
5
0
12
21

:
. .

.
.
.
143

"" .
20
5 .
0/5 ) 10 (
.
.
3 ) (
.
.

) (25 .

) 9467-60( ) CT3 (380-71 .
.
. 1/5 .
.
) ( .
) (...
.
140
15
15
140
180
22

.
26 .
. 2
4 .
144
250 .
.
. 10 30 .
-1
-2

-3
-4
-5
23
) ( .
.
.
3/25 .

27 .
.
6 16 250 .
.
= A
= G
= r
24

7 . 10
7 45 2 0/25 . .
5 .

145
.
. .
) (
-20 0 +20 .
15
. 15

.

) ( 28
.
-1
-2 7
-3
-4
-5
25 ) (
15 20 100 .
. 30 60 2 3
.
250
) ( .
146
) ( .
) ( 28 .

27 .
. .

30 .
) 2 ( . 120
. .
.
26

7 . 30
. .
.

27
147

12 15 80 120 ) (T 31 .
.
. .
.
. ) ( .
.
) ( .
120 .
6
)(

)(
200
150
150
100
100
75

28

. ) (
148
) ( .
. ) ( .

H .
125 25 12 . 0/1 .
25 100 4 150 . 150
.
2 250 .
30 20 . 30
. 45
.
30 . 48
0/1 .
0/05 20 760 .
. 0/1
.

D.P. .
.

2 .
100 .
0/25 .
) 8 ( .
7 . 35
. .
.

32 .
. .
149

30 ) 2(.
120 3 .
.

7 .
-1
-2
-3
-4
-5
-6
29

12/5 33 .
. 160 0/25 . 4
.
. 35
. 4
4 . .

150

30

) 0/25( 12 75 300
. .
. ) (
.
.
50 . ) (
.
:
R = m2m1 / m3m4 100
:
m1
m2 ) (
m3 ) (
m4 ) +1 (
R

.
.
.
.
151
152
Welding Procedure .
.
.
.
.
.
... .
.
)(Welding Procedure Specification
WPS .
.
ASME IX-Boiler & Pressure Vessel Code .
.
WPS . ASME IX AWS D1.1
. ASME QW-
482 .
ISO9000 EN-729 . 4
.
ASME IX AWS D1.1
. EN-279 BS4870 .
API650 API1101 .

.
WPS
1 WPS AWS D1.1 . 1 7
WPS . . AWS
:
-1
-2 WPS
-3 Revisions
153
-4
-5 Supporting PQR No.
-6
)(Type
... .
Manual .
FCAW
.
:
WPS .
)(Joints
) (QW-402 WPS .
.
.
. WPS .
)(Groove Design
2 .
:
-
-
-
154
AWS -1
Symbols
Joint Type
Butt Joint
Corner Joint
T- Joint
BC
Butt or Corner Joint
TC
T- or Corner Joint
BTC
Butt, T- or Corner Joint
Symbols
Base metal thickness and penetration
Limited thickness-complete joint penetration
Unlimited thickness-complete joint penetration
Partial joint penetration
Symbols
Weld type
Square-Groove
Single V- Groove
Double V- Groove
(X) V
Single Bevel Groove
Double Bevel Groove
(K)
Single U- Groove
( ) U
Double U- Groove
Single J- Groove
Double J- Groove
T
T

155
-3
-4
156
-5
157
)(Welding Procedure Qualification Record

PQR

WPS . PQR :
-
-
-
- )(Approval

.
.

. .
:
- )(Tension Test
- )(Root Bend Test
- )( )(Face Bend Test
- )(Side Bend Test
- )(Longitudinal Face , Root Bend Test
- (All-Weld metal Test) ESW , EGW
- ESW , EGW )(Impact Test
- )(Macro-etch Test
:
-
-
-

t<10mm :
: ASME ) (180 )(180
: AWS D1.1 ) (180 )(180
: BS4870 ) (90
)(90
158

AWS D1.1
. .
-18
159
160

.
. Corner T
. 25.4mm .
ASME QW-451 QW-452 .
-19
-20
161
:
AWS D1.1
:
-
AWS Sec.6-PartB or C .
AWS Sec.10-Part E and F .
-
:

:
.

.
-14
162
-15
-16
163
) (
.

19 .
WPS . 25.4mm
. T Corner Root Face .
:
- WPS AWS .
.
-
.
-
.
. .
)(Fillet
AWS D1.1 20 .
T . .
.
:
-
-
) . (
:
- .
- 1G .
- .
- .
- .
164
-17
165
-18
166
-19
167
PQR
. 38.1mm
.

PQR
.
PQR WPS
WPS WPS .
.
:
- QW-150
-
- .
- .
- ) (
- lb
- Psi
-
- QW-160
- QW-462
- :
Acceptable
-a
Satisfactory
-b
No Defect
-c
Good
-d
- QW-170 ESW,EGW

-
W.M,HAZ,W.B,B.M .
.

lb/ft
.
. .
.

168
- QW-180 .
.
.

-
.
PQR
.

.
.

PQR .
PQR
PQR .
WPS PQR .
QW-200 WPS WPS
PQR . QW-415 PQR
WPS .
)(WPQ
.
ASME IX PQR .
AWS D1.1 . ASME
.
)(SMAW
QW-535 SMAW :
)(402.4
-1
(403.16) QW-425
-2
(403.18) P-No.
-3
(404.11) F-No.
-4
(404.30) QW-451,452
-5
)(405.1
-6

-7

169

ASME :
QW-352=OFW
QW-354=SAW
)QW-355=GMAW (FCAW
QW-356=GTAW
QW-357=PAW
170
171
172

Welding Technology

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Welding Technology

Uploaded by

Copyright:

Available Formats

WELDING TECHNOLOGY

Left Hand Thread

Right Hand R3/4*

Right Hand (Inside)

Blue with Green

Gray with Black

300 %60 370

High voltage. High frequency

)Forming gas (Backing gas

FCAW TIME . (Flux cored Arc welding) FCAW

Ar + H2 . Ar+CO2 . Ar+O2. CO2

Argoshield 52 CO2 . Ar/CO2

Vol .% OVERVIEW OF WELDING SHIELDING GASES

Welding grade argon

Welding - grade carbon

-4 ) (Lack of Fusion )(Lack of Penetration

-2 )(Lack of side wall fusion

Excess Weld Metal

)Groove Joint - Butt Weld (1G-Flat

-7 )(Incorrect Weld Profile

-10 )(Angular Misalignment

-12 )(Burn through

-15 )(Root Concavity

-16 )(Root Porosity

-17 )(Poor Restart

E309-15 , E309-16 , E309Cb-15

(Spliced Butt Joints) 2

(Groove Face, Root Edge, Root Face) 6

(Bevel Angle, Depth of Bevel) 4

(Welds in Flanged Joints) 7

(Seam Welds & Spot Welds) 11

(Edge Weld, Scraf Groove) 12

(Butting and Nonbutting Members) 13

Butt or Corner Joint

Butt, T- or Corner Joint

Base metal thickness and penetration

Limited thickness-complete joint penetration

Unlimited thickness-complete joint penetration

Partial joint penetration

Single Bevel Groove

Double Bevel Groove

)(Welding Procedure Qualification Record

You might also like