Advanced Welding Processes: Technologies and Process Control

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Appendices 259 Carbon Manganese steels have a CM prefix, Carbon-Molybdenum steels an A prefix, Chromium-Molybdenum steels a B prefix, Nickel steels an Ni prefix and Manganese Molybdenum steels a D prefix and other alloys a K, G or W prefix European classification of ferritic GMAW consumables The European Standard EN 758 supersedes the British Standard BS 7084 and is based on the following: Prefix ‘EN 758’ referring to the standard and ‘T’ for tubular wire followed by the following alphanumeric designation: X– The yield strength of the weld metal divided by 10 in N/mm 2 X– The toughness of the weld metal; a single digit representing the temperature at which 47J is achieved X– An alphanumeric code representing the alloy type (for example, l Ni = 1 %Nickel) X– A letter representing the flux type (R – Rutile, P – Positional Rutile, B – basic, M – Metal, U to Y self shielded) X– Gas type (M for mixed, C for carbon dioxide, N for no gas) HX – Hydrogen control (diffusible hydrogen level indicated by suffix).
Consumable type Plain carbon steel Pearlitic steel Martensitic– pearlitic steel Martensitic steel Austenitic manganese–nickel Austenitic stainless steel Chromium carbide white irons 260 Features Appendix 5 Flux-cored wire for surfacing and wear resistance Low alloy content, hardness up to 200 VPN. Ductile, tough deposit Higher carbon/manganese content, hardness 250 VPN. Ductile, tough deposit Low-alloy ferritic steel with hardness up to 400 VPN. Poor ductility and toughness High-alloy (C, Mn, Cr, Mo, B). Hardness up to 800 VPN. Not machinable, low ductility Carbon steel alloyed with manganese and nickel. Low hardness (200 VPN), good ductility as deposited, work hardens to 500 VPN Normally 308- or 309-type stainless steel. Very good ductility and toughness, good impact and corrosion resistance, low abrasion resistance High chromium–carbon white iron. Hard carbide particles in austenitic, pearlitic or martensitic matrix. Very good abrasion resistance, poor impact, fair corrosion resistance. Hardness depends on matrix; from 350 to 800 VPN Applications Build-up of ferritic carbon steels before surfacing Build-up and repair of friction (metal to metal) wear (e.g. idler rolls on tracked vehicles) Friction and mildly abrasion resistant applications, e.g. crusher rolls Low-impact abrasion situations. Cutting edges and digger teeth Repair of austenitic manganese steel. Crusher hammers. Good impact resistance and fair surface abrasion properties Good buffer layer for highimpact loading, good wetcorrosion properties. Use as build up on gyratory crushers and heavy hammers. High cost Abrasion-resistant surfacing of earth-moving parts. Abrasion resistance best with martensitic matrix, impact and corrosion best with austenitic matrix. Very flexible range
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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 222 and 223: Monitoring and control of welding p
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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 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 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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