PowerPoint to accompany

Welding
Principles and Practices
Third Edition

Sacks and Bohnart

History of Welding
Chapter 1
1
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Overview
Welding is joining two pieces of metal by:
Heating to temperature high enough to cause softening or melting With or without application of pressure With or without use of filler metal
Melting point same as metals beginning joined or melting point below metals but about 800 F

New methods, applications and systems

Tremendous progress in short time

Usually best method to use when fastening metal

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History of Metalworking
Began when people found they could shape rocks by chipping them with other rocks Copper probably first metal to be worked
Ductile (easily hammered, bent or drawn) In Egypt as early as 4000 B.C. and USA before 2000 B.C.

Welding began more than 3000 years ago

Hot or cold metals hammered to obtain forge weld Forged metals, bronze and iron mentioned in Old Testament
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History of Metalworking
Bronze developed between 3000 and 2000 B.C. Iron became known to Europe about 1000 B.C.
Several thousand years after use of copper Philistines had four iron furnaces about 1300 B.C.
Produced swords, chisels, daggers, and spearheads

Egyptians began making iron tools during period of 900 to 850 B.C. Replaced bronze as metal used in manufacture of utensils, armor and other applications after 800 B.C.
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History of Metalworking
Famous Damascus swords and daggers made in Syria about 1300 B.C.
Sought because of their strength and toughness Made by forge-welding iron bars of different degrees of hardness, drawing them down, and repeating process many times

Working of metals followed one another in great ancient civilizations

Copper, bronze, silver, gold, and iron
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History of Metalworking
Time of Roman Empire
Iron use common in Europe, Near East and Far East

Chinese developed ability to make steel from wrought iron in 589 A.D. Belgians responsible for progress with steel in Europe Japan manufactured steel by repeated welding and forging and controlling amount of carbon by use of fluxes
Produced famous Samurai sword
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History of Metalworking
Blast furnace developed for melting iron about 1000 to 1200 A. D. Fourteenth and fifteenth centuries saw great improvements in design of blast furnaces First cast iron cannon produced in early 1600s Industrial Revolution in the middle of the eighteenth century brought many improvements
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History of Metalworking
Present factory system of mass production introduced
American, Eli Whitney, developed idea of interchanging parts in manufacture of arms

Working of dies and molds became commonplace by beginning of nineteenth century Henry Ford involved in developing assembly line method for manufacturing automobiles early in twentieth century
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Early Developments in Welding

Edmund Davy discovered acetylene at beginning of nineteenth century Sir Humphrey Davy discovered the electric arc in 1801
Concerned with use of arc for illumination These inventions were forerunner of Demonstrated possible to maintain high voltage arc present arc welding process. for varying periods of time by 1809

Workable electrical generating devices invented and developed on practical basis by 1850
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History of Fusion Welding

First documented instance done by Auguste de Meritens in 1881
Welded lead battery plates together with carbon electrode

Two of Auguste's pupils, N. Benardos and S. Olszewski continued work and issued patent for welding process using carbon electrodes and electric power source four years later
Primary goal was repair welding
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Bare Metal Electrode Welding

Introduced in 1888 by N. G. Slavianoff (Russian)
Discovery first recognized in western Europe in 1892

C. L. Coffin was pioneer of welding industry in United States

1889 received patent on equipment and process for flash-butt welding 1890 received additional patents for spot welding 1892 received patent for bare metal electrode arc welding process
Without knowledge of Slavianoff's work
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History of Metalworking
Foresche and Picard developed first commercial oxyacetylene welding torch at turn of the century Electric arc welding method used in US until about 1920
Handicapped because of welds produced by these electrodes not as strong as metal being welded
Welding arc very unstable

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History of Metalworking
In 1907 Kjellberg (Swedish engineer) received patent covering electrode-coating process
Coating thin and acted only as stabilizer of arc Produced welds little better than bare electrodes

In 1912 Kjellberg received another patent for electrode with heavier coating made of asbestos with binder of sodium silicate In 1908, Benardos patented electroslag process of welding thick plates in one pass
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History of Metalworking
Technology of welding progressed slowly until World War I
Demands of war called for improved methods of fabrication End of war, welding widely accepted

Research on coated electrodes through 1920s resulted in electrode coatings and improved core wire
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Multipass Welds
Pass 1

Ability to make multipass welds such as this one, on plate and pipe, led to growth of industry. Welds are sound and have uniform appearance.

Pass 2

Pass 3

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History of Metalworking
Stick welding process
Advanced rapidly due to electrode coatings and improved core wire Now called shielded metal arc welding (SMAW)

X-ray development
Possible to examine internal soundness of welded joints

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Shipbuilding
5,171 vessels constructed to American Bureau of Shipping standard
Through 1945

During Maritime Commission wartime shipbuilding program

Welding was replacing riveting as main method of assembly

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Development of Modern Welding

Design of welding machines changed very little during postwar period
Done with d.c. current from batteries

Use of a.c. welding machines occurred in late 1920 and increased in the early 1930s
First high frequency a.c. industrial machine introduced in 1936 by Miller Electric Manufacturing Company High rate of metal deposition and absence of arc blow
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Inert Gas Welding

World War II spurred development Possible to produce welds of high purity and critical application Patent issued in 1930 to Hobart and Devers for use of electric arc within inert gas atmosphere
Not well received because high cost of argon and helium and lack of suitable torch equipment

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GTAW Welding
Tungsten electrode replace magnesium procedure
Patent issue in 1942

Linde Company developed gas tungsten arc welding (GTAW)

Also called tungsten inert gas (TIG) process or HELIARC Perfected water-cooled torch capable of high amperage
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Tungsten Inert Gas (TIG) Process

An aluminum weld made using the TIG process. The welding of aluminum is no longer a problem and can be done with the same ease as that of steel.

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GTAW Welding
First done with rotating d.c. welding machines Later a.c. units developed In 1950s
Selenium rectifier type d.c. welding machines a.c.-d.c. rectifier welding machines with built-in frequency for GTAW welding became available

Miller Electric Manufacturing Company developed Miller controlled-wave a.c. welder for critical welds on aircraft and missiles
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Development of Modern Welding (continued)

Use of aluminum and magnesium increased
Development of GTAW welding Desirable characteristics of reduced weight and resistance to corrosion

Thicker materials in construction, which required preheating using GTAW welding U.S. patent issued in 1948 for gas metal arc welding (GMAW) process
Superseded earlier terms of metal inert gas (MIG) and metal active gas (MAG)
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GMAW Process
Concentrates high heat at a focal point Produces
Small heat-affected zone Narrow bead width Deep penetration Faster welding speed

Responsible for over 70 percent of welds being performed today.

Now used in all industries

St Louis Car. Co.

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Development of Modern Welding (continued)

Rapid changes occurred in 1980s and 1990s
Exotic multiple gas mixes State-of-art electrodes Onboard computers Robotic welding

Methods developing that may change way welds made in future

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Processes Involving Use of the Electric Arc

Arc spot welding Atomic-hydrogen welding Electrogas Plasma arc welding Stud welding Submerged arc welding Underwater arc welding
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Specialized Processes Involving Use of the Electric Arc

Cold welding Electron beam welding Explosive welding Force welding Friction welding Friction stir welding Laser welding Oxyhydrogen welding Thermit welding Ultrasonic welding Welding of plastics

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Industry Demand
Over 90 welding processes Force new and improved developments in machines, gases, torches, electrodes, procedures, and technology Constant research for new metals done by shipbuilding, space and nuclear industries
Spurs research in welding

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Welding Associations
American National Standards Institute (ANSI) American Petroleum Institute (API) American Society of Mechanical Engineers (ASME) American Welding Society (AWS) American Bureau of Shipping (ABS)

Provide guidance and standards relating to the welding industry.

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Welding as an Occupation
Can be certified by AWS, ASME and API
Tests difficult and require many hours of practice

Key positions in major industries

Important to economic welfare of country

Gender friendly Done in every civilized country in the world Offer prestige and security Chances for advancement excellent
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Industrial Welding Applications

More than 90 different welding processes Divided into three major types
Arc Gas Resistance

Number of other types used to lesser extent

Induction, forge, thermit, flow, and brazing

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Resistance Welding
Includes spot welding, seam welding, flash welding, projection welding, and other similar processes performed on machines

Operators usually taught on job

Semiskilled workers do not need specific hands-onwelding skills

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Arc and Gas Welding

Focus of this text Combine art and science Welders have almost complete control of the process
Must know properties of metals to weld; which weld process to use; and how to plan, measure, and fabricate

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Welding Positions
Overhead

Vertical

General Electric Corp.

As well as flat and horizontal

Miller Electric Mfg. Co.

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Qualifications and Personal Characteristics

Welders certified for ability to do work and work is inspected Required to pass periodic qualification tests Certifications issued according to kind and gauge of metal and specific welding process Can hold several different certifications simultaneously

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Example of Magnetic-Particle Testing in Building

Weld testing and inspection give proof of the soundness of welds.

Circlesafe Aerosol/Circle Systems, Inc.

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Basic Tasks
Gas weld
Attaching proper tip and adjusting welding regulators for proper volume and gas pressures

Electric arc welding

Regulate welding machine for proper welding current, select proper electrode size and type, and right shielding gas

Need steady hand and have good visualization skills

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Master Welder Job Examples

Welds in these tanks must meet X-ray requirements and pass a dye penetrant test. Tanks are often lined with a very thin layer of pure silver.
Nooter Corp

Creating Art!
Enrique Vega

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Master Welder
Master craftsperson Able to weld all steels and alloys
Plus nickel, aluminum, tantalum, titanium, zirconium, and their alloys and claddings

Welds of highest quality Welds meet requirement of job

Delicate welding of silver and gold Heavy pressure vessels requiring 4-inch plate
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Welding Occupations Requiring a High School Education

Welding operator Welding fitter Combination welder Master welder Welding supervisor Welding analyst Inspector Welding foreman Welding superintendent Equipment sales Sales demonstrator Sales troubleshooter Welding instructor Robotics welder operator Jog or fabrication shop owner
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Welding Occupations Requiring a College Education

Welding engineer (metallurgical) Welding development engineer Welding research engineer Welding engineer Technical editor Welding professor Certified welding inspector (AWS/CWI) Corporation executive Owner of welding business Sales engineer

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Safety and Working Conditions

Indoors or outdoors Noisy
Hearing protection needed

Awkward positions Spacious surroundings or cramped quarters High off ground in scaffolds with safety harness
The Lincoln Electric Corp.

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Job Hazards
Fire danger Burns (including "sunburn" from electric arcs) Noxious fumes from materials vaporized at high temperatures Hazards can be minimized Eyestrain or eliminated by use Welders flash of proper protective Electric shock clothing and equipment.
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Ways to Stay Current

1. Read trade journals, service manuals, textbooks, and trade catalogs 2. Join associations such as the American Welding Society 3. Research topics on the Internet 4. Trade trips with your peers

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