Академический Документы
Профессиональный Документы
Культура Документы
Welding
Principles and Practices
4th edition
Edward R. Bohnart
History of
Welding
Chapter 1
Overview
• Welding is joining two pieces of metal by:
– Heating to temperature high enough to cause
WELDING: Principles and Practices, 4e
softening or melting
– With or without application of pressure
– With or without use of filler metal
• Melting point same as metals being joined or melting point
below metals but about 800ºF
Overview
• New methods,
WELDING: Principles and Practices, 4e
applications and
systems
– Tremendous progress
in short time
• Usually best method
to use when fastening
metal
© David H. Wells/The Image Works
History of Metalworking
• Began when people found they could shape
rocks by chipping them with other rocks
WELDING: Principles and Practices, 4e
History of Metalworking
• Bronze developed between 3000 and 2000
B.C.
WELDING: Principles and Practices, 4e
History of Metalworking
• Famous Damascus swords and daggers made
in Syria about 1300 B.C.
WELDING: Principles and Practices, 4e
History of Metalworking
• Time of Roman Empire
– Iron use common in Europe, Near East and Far
WELDING: Principles and Practices, 4e
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
History of Metalworking
• Blast furnace developed for melting iron about
1000 to 1200 A.D.
WELDING: Principles and Practices, 4e
History of Metalworking
• Present factory system of mass production
introduced
WELDING: Principles and Practices, 4e
History of Metalworking
• Foresche and Picard developed first
commercial oxyacetylene welding torch at
WELDING: Principles and Practices, 4e
History of Metalworking
• In 1907 Kjellberg (Swedish engineer) received
patent covering electrode-coating process
WELDING: Principles and Practices, 4e
History of Metalworking
• Technology of welding progressed slowly
until World War I
WELDING: Principles and Practices, 4e
Multipass Welds
Pass 1
Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
WELDING: Principles and Practices, 4e
Pass 3
History of Metalworking
• Stick welding process
– Advanced rapidly due to electrode coatings
WELDING: Principles and Practices, 4e
Shipbuilding
– Through 1945
– During Maritime Commission wartime
shipbuilding program
• Welding was replacing riveting as main
method of assembly
GTAW Welding
• Tungsten electrode replace magnesium
procedure
WELDING: Principles and Practices, 4e
Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
WELDING: Principles and Practices, 4e
GTAW Welding
• First done with rotating d.c. welding machines
• Later a.c. units developed
WELDING: Principles and Practices, 4e
• In 1950s
– Selenium rectifier type d.c. welding machines
– a.c.-d.c. rectifier welding machines with built-in
high frequency for GTAW welding became
available
• Miller Electric Manufacturing Company
developed Miller controlled-wave a.c. welder for
critical welds on aircraft and missiles
GMAW Process
• Concentrates high heat at a focal point
• Produces This and similar
WELDING: Principles and Practices, 4e
FCAW Process
• Tubular wire filled with flux: outside acts as electrical
conducting sheath and provides bulk of weld bead; core
WELDING: Principles and Practices, 4e
• Electrogas
• Plasma arc welding
• Stud welding
• Submerged arc welding
• Underwater arc welding
Include
• Cold welding • Laser welding
• Electron beam welding • Oxyhydrogen
WELDING: Principles and Practices, 4e
Industry Demand
• Over 90 welding processes defined
• Force new and improved developments in
WELDING: Principles and Practices, 4e
Welding Associations
• American National Standards Institute
(ANSI)
WELDING: Principles and Practices, 4e
Welding as an Occupation
• Can be certified by AWS, ASME and API
– Tests difficult and require many hours of
WELDING: Principles and Practices, 4e
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
– Arc
– Gas
– Resistance
• Number of other types used to lesser
extent
– Induction, forge, thermit, flow, and brazing
Resistance Welding
Welding Positions
Vertical Overhead
WELDING: Principles and Practices, 4e
As well as flat
and vertical
Miller Electric Mfg. Co. Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
Characteristics
• Welders certified for ability to do work and
work is inspected
WELDING: Principles and Practices, 4e
Testing in Building
WELDING: Principles and Practices, 4e
Basic Tasks
• Gas weld
– Attaching proper tip and adjusting welding
WELDING: Principles and Practices, 4e
Examples
WELDING: Principles and Practices, 4e
Creating Art!
Enrique Vega
Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
Master Welder
• Master craftsperson
• Able to weld all steels and alloys
WELDING: Principles and Practices, 4e
• Indoors or outdoors
• Noisy
WELDING: Principles and Practices, 4e
– Hearing protection
needed
• Awkward positions
• Spacious surroundings
or cramped quarters
• High off ground in
scaffolds with safety © Vicki Silbert/PhotoEdit
harness
© 2012 The McGraw-Hill Companies, Inc. All rights reserved.
46
Job Hazards
• Fire danger
• Burns (including “sunburn” from electric
WELDING: Principles and Practices, 4e
arcs)
• Noxious fumes from materials vaporized at
high temperatures
• Eyestrain Hazards can be minimized
or eliminated by use
• Welders flash
of proper protective
• Electric shock clothing and equipment.