Chapter 1Welding Technology
Fundamental1
11Modern Engineering Structural Material1
12Mechanical Property of Metal Material3
13Thermophysical Property of Metal
Material4
131Specific Heat4
132Thermal Expansion5
133Thermal Conductivity5
134Melting Point or Melting Range5
135Thermionic Work Function6
14Principal Types of Heat Treatment of
Steel6
15Arc Physics6
151Stability of Electric Arc6
152Stability of AC Arc 8
Chapter 2Arc Welding Power
Source16
21Classification of Power Source16
211AC Power Supplies16
212DC power supplies19
213Inverse Source of Arc Welding20
22Electrical Characteristics of Power
Source21
221Constant Voltage21
222Constant Current21
223Combined ConstantCurrent and
ConstantVoltage Characteristics22
23Selecting and Specifying a Power
Source22
Chapter 3Arc Welding Process25
31Shielded MetalArc Welding25
32Gas ShieldedArc Welding27
321Specific Advantages of Gasshielded
Arc28
322Types of GasShielded Arc
Processes28
323Gas Tungsten ArcTig28
324Gas Metal ArcMig31
325CO2 Welding34
326Pulsed Arc Welding35
33Submerged Arc Welding Fundamentals of
the process36
331Definition and general description36
332Principles of operation37
34Plasma Arc Welding38
341Keyhole Action39
342Arc Shaping39
343Operating Data39
344Applications40
345Summary40
Chapter 4Other Welding Methods41
41Resistance Welding41
411Introduction41
412Resistance Spot Welding(RSW)42
413Projection Welding44
414Resistance Seam Welding
(RSEW)45
415Upset Butt Welding 46
416Flash Butt Welding47
42Friction Stir Welding49
421Introduction49
422Principles50
423Friction Stir Tool51
424Friction Stirring Imperfections55
43Laser Beam Welding56
431Introduction56
432Principles58
433Metals Welded60
434Machines60
435Parameters and Technology62
44Electron Beam Welding63
441Introduction63
442Principles64
443Variations66
444Equipment67
445Safety68
Chapter 5Welding Metallurgy69
51Chemical Reactions in Welding69
511Overview69
512GasMetal Reactions70
513SlagMetal Reactions 79
52Weld Metal Solidification85
521Epitaxial Growth at Fusion
Boundary85
522Nonepitaxial Growth at Fusion
Boundary86
523Competitive Growth in Bulk
Fusion Zone87
524Effect of Welding Parameters on
Grain Structure88
525Weld Metal Nucleation
Mechanisms89
526Grain Structure Control94
53The Microstructure and Properties
of Heataffected Zone97
531Welding Thermal Cycle98
532The Microstructure Changes
in the HAZ98
533Hardness Distribution in the
HAZ101
534Welding Cracks in the HAZ105
Chapter 6Weldability of Material109
61Weldability of Material and Testing
Method109
611Weldability of Material109
612Weldability Evaluation and Test
Method112
62Weldability of low carbon steel114
621Metallurgy of the liquid weld
metal114
622Solidification and solidification
cracking119
623Stress intensification,embrittlement
and cracking of fusion welds below
the solidus121
624Lamellar tearing124
625Reheat Cracking125
63Weldability of Magnesium and Its Alloys128
631Alloys and Welding Procedures128
632Oxide Film Removal128
633Cracking128
634Mechanical Properties129
635Corrosion Resistance and Fire
Risk129
Chapter 7Residual Stresses,Distortion
and Fatigue130
71Residual stresses130
711Development of residual stresses130
712Analysis of Residual Stresses131
72Distortion133
721Cause133
722Remedies133
73Fatigue134
731Mechanism134
732Fractography135
733SN Curves135
734Effect of Joint Geometry135
735Effect of Stress Raisers136
736Effect of Corrosion137
737Remedies137
74Case Studies138
741Failure of a Steel Pipe Assembly138
742Failure of a Ball Mill138
Chapter 8Automation of Welding140
81Introduction of Automatic Welding
System140
82Flexible Automation of Welding143
83ARC Welding Robots145
831Introduction145
832Robot Manipulator Configuration147
833Robot Welding Application151
834Buying a Welding Robot154
835Robot Safety154
84Controls for Automatic Arc Welding156
841Automatic Welding Controllers156
842Robot Controllers159
843Teaching the Robot159
844Robot Memory161
845Weld Execution161
85Sensors and Adaptive Control162
851Introduction162
852Contact Sensors164
853Noncontact Sensor Systems165
86Tooling and Fixtures168
Chapter 9Welding Quality Inspection171
91Welding Defects171
911Definition and Types171
912Cracks171
913Porosity172
914Solid Inclusion172
915Lack of Fusion and Inadequate or
incomplete penetration173
916Imperfect Shape173
92Nondestructive Testing174
921Radiographic Testing174
922Ultrasonic Testing(UT)177
923Magnetic Particle Inspection(MPI)178
924Liquid Penetrant Testing(PT)179
93Destructive Test182
931Tension Tests182
932Bend Tests182
933Charpy Tests183
934Hardness Testing183
94Radiograph Interpretation184
941General Welding Discontinuities184
942Other Discontinuities188
References190