Advanced Welding Processes: Technologies and Process Control

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References 271 Century Conference (American Welding Society), 6–8 December 2000, Orlando, Florida, USA, 165–172. [132] Manz A F, 1968 ‘One knob welder’, Welding J, 47(9). [133] Norrish J, 1972 ‘Developments in MIG welding of sheet steel and strip’, Sheet Metal Industries, Proc conf on Sheet Steel and Strip Welding, Kenilworth, England, 15–17 March Birmingham: The Welding Institute, p 6. [134] Amin M and Watkins P V C, 1977 ‘Synergic pulse MIG welding’, Weld Inst Res Rep, 46/1977/P. [135] International Institute of Welding, 1985 ‘Synergic power supplies – classification and questionnaire’, Int Inst Weld Doc, XII-905-85. [136] Lowery J, 1975 ‘Electronic control systems in welding’, Electro-Technol, 98(10). [137] Amin M and Naseer A, 1987 ‘Synergic control in MIG welding, 2 – Power– current controllers for steady DC open arc operation’, Met Constr, 19(6). [138] Lesnewich A, 1958, Control of melting rate and metal transfer in gas-shielded metal-arc welding, Parts 1 and 2, Weld J, August, 343s–353s, September 1958, 418s–425s. [139] Norrish J, 1974, High deposition MIG welding with electrode negative polarity, Proc 3rd Conference on Advances in Welding Processes, TWI, Cambridge, Paper 16. [140] Halmoy E, 1991, The “T.I.M.E” Welding Method compared with GMAW, IIW Doc. XXII-1248-91, Commission XII, IIW annual assembly, The Hague. [141] Stenbaka N, 1989, Rapidarc and Rapidmelt processes, AGA technical report, AGA, Sweden. [142] Blackman S J, 2001 High speed tandem GMAW, Proc. Conf. Recent Developments and Future Trends in Welding Technology, Cranfield University, UK, September. [143] Quigley M B C, 1986 ‘High power density processes’, The Physics of Welding, Oxford: IIW/Pergamon, p 306. [144] Ireland C L M, 1990 ‘Current state of power laser technology and future trends’, Manufacturing Technology – Europe, 1990. [145] Metcalfe J C and Quigley M B C, 1975 ‘Heat transfer in plasma arc welding’, Weld J, March. [146] Woodford D R, 1972 ‘Plasma welding data sheets’, BOC Guidance Notes. [147] Bland J, 1973 Recommended Practices for Plasma-arc Welding, AWS C5.1-73, American Welding Society, Miami. [148] Pinfold B E, 1974 ‘Plasma arc welding – part 4. Welding technology data sheet’, Weld Metal Fabric. [149] Lavigne D, Van Der Have P and Maksymowicz M, 1988 ‘Automatic plasma arc welding’, Join Mater, July. [150] Zhou Yin, 1985 ‘The influence of focusing gas flow on working stability of high capacity plasma torch’, Trans China Weld Inst, 6(2). [151] Pattee H E, Meister R P and Monroe R E, 1968 ‘Cathodic cleaning and plasma arc welding of aluminium’, Weld J, May. [152] Smart M D and Pinfold B E, 1971 ‘Comparison of modulated and unmodulated current plasma welding’, Weld Metal Fabric, September. [153] Lucas W, 1978 ‘Pulsed plasma welding’, Weld Inst Res Bull, 19. [154] Narita K et al., ‘Plasma arc welding of pipelines: a study to optimise welding conditions for horizontal fixed joints of mild steel pipes’, Int J Press Vessels Piping.
272 References [155] Miller H R and Filipski S P 1966 ‘Automated plasma arc welding for aerospace and cryogenic fabrications’, Weld J, June. [156] Woolcock A and Ruck R J, 1978 ‘Keyhole plasma arc welding of titanium plate’, Metal Construct, December. [157] Wu Chih Chiang and Pinfold B E, 1979 Operational envelopes for plasma keyhole welding of titanium’, Weld Metal Fabric, November. [158] Tomsic M J and Barhorst S W, 1983 ‘Applications of keyhole plasma arc welding of aluminium, GTAW cathode etching of aluminium tubes and dabber TIG process’, Proc 31st Ann Conf of The Australian Welding Institute, Sydney, 16–21 October. [159] (After Hill M et al., 1990 10 kW CO 2 laser welding of a high-yield-strength steel 2nd Int. Conf. on Power Beam Technology, Stratford-upon-Avon, 23–26 September. [160] Herziger G, 1985 ‘The influence of laser induced plasma on laser materials processing’, Annual Review of Laser Processing, Industrial Laser Handbook. [161] Matsunawa A, Yoshida H and Katayama S, 1985 ‘Beam plume interaction in pulsed YAG laser processing’, Int Inst Weld Doc, 212-617-85. [162] Megaw J H P C, Hill M and Johnson R, 1981 ‘Laser welding of steel plates with unmachined edges’, UKAEA Report, CLM-P649. [163] Banas C M, 1979 US Patent No 4152575. [164] Arata Y et al., 1985 ‘Fundamental phenomena in high power CO 2 laser welding’, Trans JWRI, 14(1). [165] Shinmi A et al., 1985 ‘Laser welding and its applications for steel making process’, Laser Welding, Machining and Materials Processing, Proc Int Conf on Applications of Lasers and ElectroOptics, ICALEO’85, IFS Publications. [166] Anon, 1989 ‘Laser welded parts give greater speed and accuracy’, Eng Lasers, October. [167] Roessler M D, 1990 ‘A fresh look at lasers in automotive applications’, Ind Laser Rev, February. [168] Weedon T M, Burrows G and Thompson P G, ‘Nd-YAG lasers in car body cutting and welding’, ISA TA Symp, Florence, 1989, Rugby, UK: Lumonics. [169] Metzbower E A, 1983 ‘Laser welding of mild steel at NIROP’, Minneapolis, USA, Metal Construct, 15(10). [170] Mazumder J and Steen W M, 1980 ‘Welding of Ti-6A1-4V by a continuous wave CO 2 laser’, Metal Construct, 12(9). [171] Matsuda J et al., 1988 TIG or MIG arc augmented laser welding of thick mild steel plate’, Join Mater, 1(1). [172] Steen W M and Eboo M, 1979 ‘Arc augmented laser welding’, Metal Construct, 11(7). [173] Hetcht J, 1990 Understanding Lasers Indiana, Howard W Sams. [174] Sato et al., 1989 ‘Experience with CO lasers’, Proc 6th int conf Lasers in Manufacturing, May 1989. [175] Mulima J, Hermans M, Norrish J and Di Pietro P, 2006 The Influence of High Power Diode Laser In Hybrid Laser-Controlled Dip Transfer GMA Welding, Proc. Laser Institute of America, Picalo Conference, Melbourne Australia, April. [176] Howse D S, Scudamore R J and Booth G S, 2005 Yb Fibre Laser/MAG Hybrid Processing for Welding of Pipelines, International Institute of Welding, IIW Doc. IV-880-05. [177] Quigley M B C, 1986 ‘High power density welding’, The Physics of Welding, Oxford, IIW/Pergamon, p 306.
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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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CCD camera Travel direction Torch M
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Welding automation and robotics 219
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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 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 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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