Advanced Welding Processes: Technologies and Process Control

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Tensile strength Appendices 251 Designation Strength (N mm –2 ) Minimum yield strength (N mm –2 ) 43 430–550 330 51 510–650 360 First digit: elongation and impact Digit Minimum elongation (%) Impact test temperature (∞C) ———————————— for impact value of 28 J E43 E51 20 18 Not specified 1 20 18 +20 2 22 18 0 3 24 20 – 20 4 24 20 – 30 5 24 20 – 40 Second digit: toughness Digit Temperature (∞C) 0 Not specified 1 + 20 2 0 3 – 20 4 – 30 5 – 40 6 – 50 7 – 60 8 – 70 Coating type B Basic CaCO 3, CaF 2 BB Basic iron powder CaCO 3, CaF 2 + iron powder C Cellulosic Organic O Oxidizing FeO R Medium-coated rutile TiO 2 RR Heavy-coated rutile TiO 2, CaCO 3 S Others Welding position 1 All positions 2 All except vertically down
252 Advanced welding processes 3 Flat and horizontal 4 Flat 5 Flat, vertically down, HV fillets 9 Any combination not classified in 1–5 Current and polarity Digit DC AC 0 As recommended Not suitable by manufacturer 1 + or – 50 minimum OCV 2 – 50 minimum OCV 3 + 50 minimum OCV 4 + or – 70 minimum OCV 5 – 70 minimum OCV 6 + 70 minimum OCV 7 + or – 80 minimum OCV 8 – 80 minimum OCV 9 80 minimum OCV Typical example The classification for an all positional basic (with iron powder) hydrogencontrolled electrode with a minimum UTS of 510 N mm –2 and yield strength over 450 N mm –2 and impact properties better than 28 J at –40 ∞C and 47 J between –40 and –50 ∞C would be: E 51 5 5 BB 160 2 8 H American Welding Society (AWS) Standard A5.1 The AWS Standard is less complicated, consisting of a prefix E followed by only two sets of digits: E Electrode xxx Two or three digits indicating the tensile strength in 10000 psi units. xx Two digits indicating the coating type and application as follows: Exx10 Cellulosic, DC +ve. Deep penetration, all position Exx11 As Exx 10, but usable on AC Exx12 Rutile, AC/DC, flat and HV positions Exx13 Rutile, AC/DC, all positions Exx14 Iron powder rutile, high speed Exx15 Basic low-hydrogen, DC +ve, all positions
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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 214 and 215: Monitoring and control of welding p
Page 224 and 225: CCD camera Travel direction Torch M
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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 262 and 263: Arc Metal arc Manual metal arc Resi
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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