Advanced Welding Processes: Technologies and Process Control

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digital measuring systems 189–90 digital signal processor (DSP) 40–1 diode-pumped lasers 156 dip transfer 105–7, 116–17, 126–8, 133, 197–8 direct control 205 direct vision sensors 210 discrete component electronic control 40 double arcing 138 drive systems 227 drop spray transfer 104–5, 133 dual-gas GTAW 84–5 duty cycle 19 dynamic characteristics of power supply 30–1 dynamic resistance curve 199–200 electrodes arc initiation 74–9 long extensions 54 plasma keyhole welding 140 short extensions 54–5 SMAW classification 250–3 stainless steel MMA 45–6 sticking 43 thoriated electrodes 78 vertex angle 94–5 weight loss 78–9 electromagnetic forces 111–12 electron beam welding 14–15, 157–64 applications 159–60 beam characteristics 158–9 beam power 161 beam traps 162 chamber loading systems 162 computer control 162–3 control systems 159, 162–3 copper welds 160 electron momentum 158–9 joint configuration 161 non-vacuum EBW 163 power sources 163 recoil pressure 158–9 safety 161 vacuum operation 161 vapour pressure 158–9 vapour shields 162 electronic power regulation systems 31–9, 42–3 design features 37–9 Index 281 feedback control 39 hybrid designs 36–7 primary-rectifier inverters 35–6 SCR (silicon-controlled rectifiers) 31–3, 36 secondary switched transistors 34–5 transistor series regulator 33 environmental hazards 21 EPROM chips 40 event-monitoring 192 excimer lasers 156 explosive droplet transfer 107 explosive welding 7 extended operation of GMAW systems 134 extensions on electrodes 54–5 external computer control 42 FCAW see flux cored arc welding (FCAW) feedback control 39 feedback signals 206 ferritic steel wires 47–8 fibre lasers 157 filler addition GTAW 95 filler materials flux cored arc welding (FCAW) 48–57 gas metal arc welding (GMAW) 47–8 manual metal arc welding (MMAW) 44–6 submerged arc welding (SAW) 46–7 fillet welds 165 fixed welding stations 222 flexibility 219 flexible manufacturing systems (FMS) 239 flux cored arc welding (FCAW) 22 applications 55 filler materials 48–57 metal transfer 108–9 shielding gases 69 flux-cored wires 48–57, 261–2 alloying addition 51 arc stabilization 51 AWS classification 257–8 carbon and alloy steel 52–3 consistency 57 cost 56 deposition rate 49–50
282 Index fumes 56–7 gas-shielded 52, 54–5 hardfacing and surfacing alloys 53–4 limitations 55–7 metal-cored 53, 108, 125 modes of operation 51–2 pulsed flux-cored 125–6 rutile flux-cored 53, 108–9, 125 self-shielded 52, 53, 54, 109 slag shielding 51 stainless steel flux-cored 54, 69 free-flight transfer 100 Freon 70 friction welding 5–7, 24 front face light sensing 214 front face vision 214–15 fully automated remote welding 237–8 fumes 56–7 fusion characteristics 61–2 fusion welding 2, 8–15 gantry robots 226–7 gas metal arc welding (GMAW) 12–13, 22–3, 47–8 arc length 117, 131–2 burn-off 116, 124–5, 254–6 control systems 113–20, 128–34 controlled droplet detachment 121–2 deposition rates 71 extended operation 134 filler materials 47–8 high deposition welding 134 Hybrid Laser GMAW 155 melting rate phenomena 114–16 metal transfer 100–13 narrow-gap GMAW 170–4 parameter selection 117–19, 132–3 power source 117–19 programmed control 128–34 pulsed GMAW 120–1, 124–5 shielding gases 64–7, 68 single-knob control 128–34 stability monitoring 197–8 stitch welders 224–5 synergic control 128–34 tractor systems 221 user parameter selection 132–3 voltage-current characteristics 116–17 wire feed systems 117 gas tungsten arc welding (GTAW) 8–9, 74–99 A-TIG welding 91 arc initiation 74–9 arc length 93 buried arc GTAW 91 cast-to-cast variation 95–8 cold-wire GTAW 82–3, 168 control systems 91–8 current and travel speed 92 dual-gas GTAW 84–5 electrode development 74–9 electrode vertex angle 94–5 filler addition 95 high current GTAW 91 high-frequency pulsed GTAW 79–81 hot-wire GTAW 83, 168–70 laser-enhanced 155 multicathode GTAW 89–91 narrow-gap welding 168–70 polarity 93 process developments 74–9 pulsed GTAW 79–81, 98 shielding gases 67–8, 94 tractor systems 221 variable polarity GTAW 81–2 gas-shielded flux-cored wires 52, 54–5 gases gas-metal reactions 60 for laser welding 71–2 shielding gases 58–73 globular drop transfer 101–2 globular repelled transfer 102 GMAW see gas metal arc welding (GMAW) gravitational force 111 GTAW see gas tungsten arc welding (GTAW) Hall-effect probes 194 hardfacing and surfacing alloys 53–4 heat affected zone (HAZ) 182 helium 59, 63, 66–7, 72 high current GTAW 91 high deposition welding 134 high frequency pulsing 150 high-current plasma welding 89 high-energy density processes 136–64 electron beam welding 14–15, 157–64 keyhole welding 137–44 laser welding 15, 24, 144–57
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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 244 and 245: Welding automation and robotics 231
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 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 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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