Advanced Welding Processes: Technologies and Process Control

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carbon dioxide 63–4, 64–6 chlorine 70 ease of ionization 58 for FCAW 69 Freon 70 fusion characteristics 61–2 gas-metal reactions 60 for GMAW 64–7, 68 for GTAW 67–8, 94 helium 59, 63, 66–7, 72 hydrogen 58–9, 60, 64, 72 and joint properties 62 for laser welding 71–2, 148–9 for MIAB 69 for narrow-gap welding 171–2 nitric oxide mixtures 70–1 nitrogen 60, 68 oxygen 64 for plasma keyhole welding 140 for plasma welding 68 sulphur dioxide 70 thermal conductivity 58–9 short extensions on electrodes 54–5 simple mechanization systems 219–22 simulation 239–40 single-knob control 41–2, 128–34 skill requirements 21 slag protected transfer 108–9 slag shielding flux-cored wires 51 SMAW see shielded metal arc welding (SMAW) social implications of automation and robotics 245 solid filler wires 47–5 sound measurement 212 special-purpose automation 223–5 spectral radiation sensors 212–13 speed measurement 196 stability monitoring 197–8 statistical process control 201–3 steel carbon steel welds 64–6, 142, 153 carbon steel wires 48, 52–3 ferritic steel wires 47–8 stainless steel flux-cored wires 54, 69 stainless steel MMA 45–6 stainless steel welds 66–7, 142, 153 sticking electrodes 43 stitch welding 224–5 streaming transfer 103–4 Index 287 structured light/vision sensors 209–10 stud welding 6 submerged arc welding (SAW) 11–12, 46, 46–7 filler materials 46–7 iron powder additions 46–7 multipass per layer technique 176 narrow-gap SAW 175–7 single-pass technique 175 sulphur dioxide 70 supply flexibility 219 surface tension 113 synergic control 128–34 tactile sensors 206–7 tapped transformers 27–8 teach-by-doing 230–1 temperature measurement 193–4 thermal conductivity of shielding gases 58–9 thermocouple sensors 193–4 thermographic sensing 216 thoriated electrodes 78 through-arc sensors 208 TIG see tungsten inert gas (TIG) welding time measurement 196 titanium welds laser welding 154 plasma keyhole welding 143–4, 264 torch cleaning 232 torch oscillation 172–4 touch striking 75, 76 toughness and submerged arc welding (SAW) 46 of weld metal 45 tractor systems 220–1 training 21 transfer behaviour see metal transfer transformers see power source technology transistor series regulator 33 tungsten inert gas (TIG) welding 8–9, 60 Activated TIG (A-TIG) 91, 97 control systems 98 Paton Activated TIG (PA-TIG) 91 twist arc technique 172 ultrasonic penetration control 214 ultrasonic sensors 210–11 user parameter selection 132–3
288 Index vacuum EBW 161 validity of parameters 184–7 vapour jet forces 112–13 vapour pressure 158–9 vapour shields 162 variable inductor control 29 variable polarity GTAW 81–2 variable polarity plasma 142 vertex angle 94–5 visible spectrum monitoring 203 voltage measurement 196, 211–12 voltage oscillation 214 voltage-current characteristics 116–17 waveform representation 191–2 wear replacement 241–2 weight loss of electrodes 78–9 welding procedure specification (WPS) 182 wire feed systems 82–3, 117 wire oscillation 172–4 wolfram inert gas (WIG) welding 8–9 work flow 233 worm tracks 55
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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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Table 11.1 Robot applications Weldi
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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 296 and 297: high-frequency high-voltage arc ini
Page 298 and 299: current measurement 194-6 determina
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