Advanced Welding Processes: Technologies and Process Control

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Arc Metal arc Manual metal arc Resistance Resistance butt Stitch Gas Carbon arc Forge Thermit Submerged arc Blacksmith Pressure Appendix 1 Welding processes classification (British Standards Institution) [1] Fusion welding Tungsten inert gas Electron beam Metal inert gas Pressure welding Ultrasonic HF Oxyacetylene Cold Hammer Cold Laser Electroslag Arc spot Atomic hydrogen Metal active gas Diffusion Friction Flash Spot Seam Projection Percussion Multispot Butt seam Series spot Roller butt seam Roller spot Light radiation Arc image Plasma Electrogas Magnetically impelled arc butt Explosive HF resistance 249
BS 639 Appendix 2 Shielded metal arc welding (SMAW) electrode classification (reproduced by kind permission of Welding and Metal Fabrication) The standard identifies electrodes by a series of letters and digits that indicate the mechanical properties, formulation type and applications. The full electrode classification consists of a compulsory and optional parts as shown below. Compulsory E Electrode for MMA xx Tensile strength range, minimum yield strength x First digit for elongation and impact strength x Second digit indicating temperature for minimum average impact strength of 47 J NN Letters indicating coating type Optional xxx Three-digit indication of metal recovery x Welding position x Current and voltage requirements H Hydrogen-controlled electrode This classification is quite complex and it is recommended that the standard should be consulted for full details. The following notes give an indication of the typical electrode specifications. 250
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Advanced welding processes i
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Advanced welding processes Technolo
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Contents Preface ix Acknowledgement
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Contents vii 10.4 Automated control
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Welding has traditionally been rega
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Acknowledgements I would like to ac
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1.1 Introduction Welding and joinin
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An introduction to welding processe
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Stage 1 Stage 2 An introduction to
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Slag deposit on weld surface An int
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∑ no heavy slag - reduced post-we
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Electro slag SAW multi wire SAW FCA
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Weld metal used (kg m -1 ) 40 35 30
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Advanced process development trends
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% consumed 70 60 50 40 30 20 10 Adv
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Advanced process development trends
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Mains input Power regulation Contro
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Welding power source technology 29
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Three-phase transformer Three-phase
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Mains input Welding power source te
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Off line storage Operator interface
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4.2.1 Improved toughness Filler mat
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Filler materials for arc welding 47
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Flat strip Solidified slag on weld
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Gases for advanced welding processe
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CVN impact energy (J) 200 150 100 5
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∑ argon plus 15-25% carbon dioxid
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25 23 21 19 17 15 13 11 9 7 20 18 1
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Ozone emission (ml min -1 ) 4 3 2 1
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Table 5.3 Continued Argon + 1 to 7%
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Advanced gas tungsten arc welding 7
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Power source Advanced gas tungsten
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Number of arc starts 35 30 25 20 15
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Water cooling 6.7 Dual-shielded GTA
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∑ low current: 0.1-15 A; ∑ inte
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Surface tension Surface tension Adv
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7.2.1 Globular drop transfer Metal
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Gas metal arc welding 103 projected
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Droplet forming 7.6 Drop spray tran
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Number of counts 100 80 60 40 20 0
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Metal cored Rutile Basic Self-shiel
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F d Fem F v F st F g 7.13 Balance o
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Gas metal arc welding 113 is the cu
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Stick out Dip transfer Pulse/spray
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Gas metal arc welding 117 V = M + A
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Voltage (V) 50 40 30 20 10 Gas meta
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Pulse current t p 7.23 Pulsed trans
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Gas metal arc welding 123 The mean
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Wire feed rate (m min -1 ) 11 10.5
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Gas metal arc welding 127 Improveme
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Gas metal arc welding 129 and a num
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Current (A) 500 400 300 200 100 0 G
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Pulse amplitude (A) 500 400 300 200
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Gas metal arc welding 135 otherwise
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High-energy density processes 137
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High-energy density processes 139 P
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Arc voltage 30 25 20 15 10 High-ene
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High-energy density processes 143 N
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Reflecting mirror Laser cavity Powe
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High-energy density processes 147 H
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Laser beam Gas lens Plasma control
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High-energy density processes 151 P
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High-energy density processes 153 M
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High-energy density processes 155 a
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High-energy density processes 157 l
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High-energy density processes 159 p
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8.4.5 Practical considerations High
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Sliding particle stop Undeflected b
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9.1 Introduction 9 Narrow-gap weldi
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6-16 mm Parallel-sided with backing
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Water cooling Main Shielding-gas po
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Narrow-gap welding techniques 171 T
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9.7 ‘Twist arc’ narrow-gap GMAW
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GMAW torch The NOW process GMAW tor
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Narrow-gap welding techniques 177 T
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10.1 Introduction 10 Monitoring and
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Monitoring and control of welding p
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PROJECT: WELDING CODE : WELDING PRO
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TYPE TOUGHNESS TEST TYPE No. TEMP R
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Data RAM ADC I/O device Monitoring
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Current I(A) 150 140 130 120 110 Mo
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Table 10.5 Stability criteria Monit
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Page 224 and 225: CCD camera Travel direction Torch M
Page 232 and 233: Welding automation and robotics 219
Page 248 and 249: Table 11.1 Robot applications Weldi
Page 256 and 257: ∑ evaluate alternatives; ∑ eval
Page 258 and 259: Option Manual metal arc Gas metal a
Page 260 and 261: Appendices Appendices 247
Page 264 and 265: Tensile strength Appendices 251 Des
Page 266 and 267: Appendices 253 Exx16 Basic low-hydr
Page 268 and 269: GMAW stainless steel c Wire feed sp
Page 270 and 271: Appendix 4 American, Australian and
Page 272 and 273: Appendices 259 Carbon Manganese ste
Page 274 and 275: Consumable type Features Applicatio
Page 276 and 277: Appendix 7 Plasma keyhole welding o
Page 278 and 279: References [1] British Standards In
Page 280 and 281: References 267 [40] Anon, 1989 ‘S
Page 282 and 283: References 269 [88] Boughton P and
Page 284 and 285: References 271 Century Conference (
Page 286 and 287: References 273 [178] Benn B, 1988
Page 288 and 289: References 275 [224] Philpott M L,
Page 290 and 291: References 277 [269] UK Patent 8411
Page 292 and 293: Activated TIG (A-TIG) 91, 97 adapti
Page 294 and 295: digital measuring systems 189-90 di
Page 296 and 297: high-frequency high-voltage arc ini
Page 298 and 299: current measurement 194-6 determina
Page 300 and 301: carbon dioxide 63-4, 64-6 chlorine
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Advanced Welding Processes: Technologies and Process Control

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