Advanced Welding Processes: Technologies and Process Control

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high-frequency high-voltage arc initiation 75–6 high-frequency pulsed GTAW 79–81 high-power diode lasers 156–7 high-voltage DC arc initiation 75 hot wire GTAW 83, 168–70 hybrid control systems 216 Hybrid Laser GMAW 155 hybrid power regulation systems 36–7 hydrogen control 45 hydrogen shielding gas 58–9, 60, 64, 72 hydrogen-assisted cold cracking (HACC) 181–2 inductive sensors 209 inductor control 29 integrated automation systems 240–1 intermediate-current plasma welding 89 inverse bremsstrahlung effect 149 ionization 58 iron powder additions 46–7 ISO 4063 numbering system 2–3 jigging systems 232 joining processes 1 joints completion times 18–19 configuration 154, 161, 166 design 18–19, 233 location sensors 207–8 performance assessment 182 preparation 166–7 profiles 181 properties 62 quality control 17–18 keyhole mode laser welding 148, 152 see also plasma keyhole welding laser range finders 212 laser welding 15, 24, 144–57 applications 151–4 austenitic stainless steel welds 153 beam oscillation 150 carbon dioxide lasers 144–5 microwave-excited 156 carbon monoxide lasers 156 characteristics of laser beams 147–8 control systems 151 diode-pumped lasers 156 Index 283 excimer lasers 156 fibre lasers 157 gases 71–2 high frequency pulsing 150 high-power diode lasers 156–7 Hybrid Laser GMAW 155 inverse bremsstrahlung effect 149 joint configuration 154 keyhole mode 148, 152 laser-enhanced GTAW 155 low-carbon steel welds 153 melt-in (conduction-limited) mode 148 metallurgical problems 153 multiple laser operation 155 Nd:YAG lasers 146–7 nickel welds 154 plasma control 150 plasma formation 149–50 pulsing of laser output 151 RF excitation systems 156 robotic systems 228 safety 154–5 shielding gases 71–2, 148–9 titanium welds 154 laser-enhanced GTAW 155 learning control 205 light sensors 212–13 line following systems 206–11 location sensors 207–8 long extensions on electrodes 54 Lorentz force 84 low-current plasma welding 89 MAG welding 12–13 magnetic amplifiers 29–30 magnetic impulse welding 24 magnetically impelled arc butt (MIAB) welding 7–8, 69 manipulators <strong>and</strong> positioners 222 manual control techniques 180–8 calibration of equipment 184–7 determination of parameters 181–2 joint performance assessment 182 open-loop system 188 procedure amendment 183 procedure control 180–7 procedure development 180–1 procedure management 184–7 procedure monitoring 187
284 Index procedure qualification 184 record keeping 184 selection of welding processes 181 validity of parameters 184–7 manual metal arc welding (MMAW) 9–10, 22 consumables 44–6 filler materials 44–6 hydrogen control 45 stainless steel MMA electrodes 45–6 toughness of weld metal 45 Marangoni Flow 96 master-slave manipulators (MSM) 237 measuring systems 189–90 sound measurement 212 see also parameters mechanical manipulation systems 225–7 mechanized wire-feed systems 82–3 melt-in (conduction-limited) laser welding 148 melting rate phenomena 114–16 metal active gas (MAG) welding 12–13 metal inert gas (MIG) welding 12–13 metal transfer 100–13 aerodynamic drag 111 controlled transfer techniques 120–8 dip transfer 105–7, 116–17, 126–8, 133, 197–8 drop spray transfer 104–5, 133 electromagnetic forces 111–12 explosive droplet transfer 107 flux cored arc welding (FCAW) 108–9 free-flight transfer 100 globular drop transfer 101–2 globular repelled transfer 102 gravitational force 111 physics 110–13 projected spray transfer 102–3 rotating transfer 107–8 slag protected transfer 108–9 streaming transfer 103–4 surface tension 113 vapour jet forces 112–13 metal-cored wires 53, 108, 125 MIAB welding 7–8, 69 microplasma welding 89 microprocessor control 40–1 microwave-excited lasers 156 MIG welding 12–13 MMAW see manual metal arc welding (MMAW) modular automation 236 monitoring techniques 188–203 computer-based data loggers 190–3 deviation monitors 199–203 event-monitoring 192 measuring systems 189–90 parameter monitors 193–6 stability monitors 196–8 MOSFETS 36 moving-iron control 28–9 moving-iron meters 194–5 multicathode GTAW 89–91 multiple laser operation 155 multiport nozzles 140 narrow-gap welding 165–78 bead placement 171 filler wire positioning 172 GMAW 170–4 GTAW 168–70 joint configuration 166 joint preparation 166–7 oscillation techniques 172–4 SAW 175–7 shielding gas 171–2 torch oscillation 172–4 twist arc technique 172 wire oscillation 172–4 Nd:YAG lasers 146–7 nickel welds 68, 143, 154 nitric oxide mixtures 70–1 nitrogen 60, 68 non-vacuum EBW 163 nuclear industry 220, 223 objectives of automation <strong>and</strong> robotics 243 off-line programming 239–40 one-knob control 41–2, 128–34 open-loop control systems 188, 204–5 operating efficiency 19 orbital welding systems 224 orifice diameter 140 oscillation techniques 172–4 oscilloscopes 194 oxygen 64 ozone formation 70 parameters
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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 246 and 247: Welding automation and robotics 233
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 294 and 295: digital measuring systems 189-90 di
Page 298 and 299: current measurement 194-6 determina
Page 300 and 301: carbon dioxide 63-4, 64-6 chlorine
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