Welding processes handbook

© 2003, Woodhead Publishing Ltd

 Welding processes handbook
Klas Weman

CRC Press
Boca Raton Boston New York Washington, DC

WOODHEAD
PUBLISHING LIMITED
Cambridge, England

© 2003, Woodhead Publishing Ltd

 Published by Woodhead Publishing Ltd, Abington Hall, Abington
Cambridge CB 1 6AH, England
www.woodhead-publishing.com

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First published 2003, Woodhead Publishing Ltd and CRC Press LLC

O 2003, Woodhead Publishing Ltd

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Woodhead Publishing ISBN 1 85573 689 6

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Printed by TJ International, Padstow. Cornwall

© 2003, Woodhead Publishing Ltd

 Contents

Preface ...............................................................................................................ix

ARC WELDING.AN OVERVIEW ............................................................ 1

History of welding .................................................................................. 1
Terminology ............................................................................................ 3
Distortion ....................................................................................................
7
The welding arc ................................................................................ 8
Shielding gases ...................... . ........ ............................................. 12
Power sources ............................................................................... 13

GAS WELDING ...................................................................................... 26

Equipment ................................................................................................26

TIG WELDING ......................................................................................... 31

A description of the method .....................................................................31
Equipment ................................................................................................ 31
Consumables ........................................................................................... 35

PLASMA WELDING ...............................................................................

37
A description of the method .....................................................................37
Equipment ................................................................................................39
Gases for plasma welding ........................................................................ 40
The advantages of the plasma method ....................................................40

MIGIMAG WELDING ............................................................................... 41

Equipment ................................................................................................41
Setting of welding parameters ............................................................... 44
Consumables ........................................................................................... 47
Weld quality .............................................................................................60

METAL ARC WELDING WITH COATED ELECTRODES ...................... 63

Description of the method ........................................................................63
Equipment ................................................................................................ 63
Electrodes ................................................................................................ 64
Weld defects ............................................................................................67

SUBMERGED ARC WELDING ............................................................... 68

Description ............................................................................................... 68
Equipment ................................................................................................69
Filler material ............................................................................................ 71
The effect of the welding parameters ....................................................... 73
Productivity improvements ....................................................................... 75
Joint preparation ......................................................................................77
Risks of weld defects ...............................................................................77

© 2003, Woodhead Publishing Ltd

 CONTENTS

PRESSURE WELDING METHODS .........................................................80

Resistance welding .................................................................................. 80
Friction welding ........................................................................................86
High-frequency welding ............................................................................ 89
Ultrasonic welding ....................................................................................89
Explosion welding .................................................................................... 90
Magnetic pulse welding ............................................................................ 91
Cold pressure welding .............................................................................. 92
Diffusion welding ......................................................................................
92

OTHER METHODS OF WELDING ..........................................................

93
Electroslag welding ............................. . .................................................
93
Electrogas welding ................................................................................... 94
Stud welding ......................................................................................... 94
Laser welding ...........................................................................................
95
Electron beam welding ............................................................................. 99
Thermite welding ....................................................................................101

CUTTING METHODS ............................................................................102

Thermal cutting ......................................................................................102
Water jet cutting .....................................................................................105
Thermal gouging .................................................................................... 106

SURFACE CLADDING METHODS ....................................................... 108

Cladding to provide a corrosion-resistant layer ...................................... 108
Hardfacing ................
.. ......................................................................108
Thermal spraying ...................................................................................
110

MECHANISATION AND ROBOT WELDING ........................................114

Narrow-gap welding .......................... .. ..............................................114
Arc welding using robots ........................................................................
116
Mechanised TIG welding ........................................................................120
Quality requirements for mechanised welding .......................................122

SOLDERING AND BRAZING ................................................................124

General ..................................................................................................
124
Soft soldering ...................................................................................... 127
Brazing ...................................................................................................
129

THE WELDABILITY OF STEEL ............................................................132

Carbon steels .......................................................................................132
High-strength and extra high-strength steels ......................................... 136
Austenitic steels .....................................................................................
139

DESIGN OF WELDED COMPONENTS ................................................148

Introduction ....................
....................................................................148
Symbolic representation of welds on drawings ......................................148
Welding classes .....................................................................................
151
Residual stresses in welds. weld distortions ...................... . ............. 152

© 2003, Woodhead Publishing Ltd

 CONTENTS

Design consideration.............. . . . ......................................................... 153

Strength considerations of welded joints ................................................163
Analysis of statically loaded welded joints ..............................................163
Welded structures subjected to fatigue loads ....................................166
References ............................................................................................. 170

16 QUALITY ASSURANCE AND QUALITY MANAGEMENT ...................

171
Quality requirements for welding (EN 729) ........................................172
Welding coordination (EN 719) .......................................................... 173
Specification and approval of welding procedures (EN 288) .................. 175
Approval testing of welders (EN 287) ..................................................... 180
Non-destructive testing ..........................................................................182

17 WELDING COSTS ................................................................................184

Welding cost calculations ....................................................................... 184
Some welding cost concepts .................................................................. 184
Cost calculation ......................................................................................186
Mechanisation. automation. robot welding .............................................189

© 2003, Woodhead Publishing Ltd

vii
 Preface

Production of this guide to welding was prompted originally by a wish for an up-to-date
reference on applications in the field. The content has been chosen so that it can be used
as a textbook for European welding courses in accordance with guidelines from the
European Welding Federation. Over the last few years, an equivalent Swedish guide has
been used for courses on welding processes and equipment. The author hopes that this
guide will serve as a useful reference book for those involved in welding.
In writing the book, there has been a conscious effort to ensure that both text and
illustrative material is clear, concentrating particularly on interesting and important
aspects.
Although the book has been written in Sweden, with input from Swedish experts, it
reflects technology and methods that are internationally accepted and used. My thanks
are due to all those who have been involved in the work, with particular mention to:

Clues Olsson, HighTech Engineering, who wrote the chapter on design of welded
components.
Clues-Ove Pettersson, Sandvik, who edited the section on stainless steel.
Curt Johansson, SAQ, who wrote the chapter on quality management.
Gunnar LindLn, Air Liquide, who edited the chapter on welding costs.

Klas Weman

© 2003, Woodhead Publishing Ltd