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AMERICAN TECHNICAL PUBLISHERS Orland Park, Illinois 60467-5756

B. J. Moniz

Welding Skills contains procedures commonly practiced in industry and the trade. Specific procedures vary with each task and must be performed by a qualified person. For maximum safety, always refer to specific manufacturer recommendations, insurance regulations, specific job-site and plant procedures, applicable federal, state, and local regulations, and any authority having jurisdiction. The material contained is intended to be an educational resource for the user. American Technical Publishers, Inc. assumes no responsibility or liability in connection with this material or its use by any individual or organization.

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© 2015 by American Technical Publishers, Inc. All rights reserved 5 6 7 8 9 – 15 – 9 8 7 6 5 4 3 2 1 Printed in the United States of America

ISBN 978-0-8269-3084-2

This book is printed on recycled paper.

The author and publisher are grateful to the following companies, organizations, and individuals for providing information, photographs, and technical assistance.

American Welding Society ASI Robicon ASME International Baker Testing Services, Inc. Bernard Welding Equipment Company Boeing Commercial Airplane Group BUEHLER LTD. Canadian Welding Bureau Institute (CWBi) Chrysler Corporation CK Worldwide, Inc. Cleaver-Brooks The Duriron Co, Inc. ESAB Welding and Cutting Products Fanuc Robotics North America Faxitron X-Ray Corporation Fel-Pro Chemical Products G.A.L. Gage Company Harrington Hoists, Inc. Haynes International, Inc. Hobart Welders Hobart Welding Products Jackson Safety, Inc. Kamweld Technologies, Inc. LECO Corporation

The Lincoln Electric Company LOCK-N-STITCH, Inc. Miller Electric Manufacturing Company Motoman, Inc. Nederman, Inc. Pandjiris, Inc. Pipe Fitters’ Training Center, Local Union 597 Rath Gibson, Inc. SMS-Meer gmbH Sciaky, Inc. Sellstrom Manufacturing Co. SIFCO Selective Plating, Cleveland, OH Smith Equipment SMS-Meer gmBH SPM Instrument, Inc. Stork Technimet, Inc. Sumner Manufacturing Co., Inc. Thermadyne Industries, Inc. Thermal Arc, a division of Thermadyne Industries, Inc. Tinius Olsen Testing Machine Co., Inc. Victor Technologies International, Inc. Wall Colmonoy Corporation Weld Tooling Corp.

Thomas J. Clark Ironworkers, Local Union 378 Charlie R. Cramlet E. I. du Pont de Nemours and Company Dave Doner formerly with Prairie State College Dave Heidemann Miller Electric Manufacturing Company Thomas P. Heraly Milwaukee Technical College

Dennis Klingman, AWS – CWI/CWE, formerly with The Lincoln Electric Company Mike Pelegrino, ASNT NDT III, #172399, Pipe Fitters’ Training Center, Local Union 597 Gary Reed SIFCO Selective Plating Glen Schulte Joliet Junior College Mark Schumann Miller Electric Manufacturing Company

Chapter

1 An Essential Skill _______________________________________________________________1 Where Welding Is Used • Development of Welding Processes • Welding Processes • Occupational Opportunities in Welding

Points to Remember: Questions for Study and Discussion:

8 8

Chapter

2 Welding Safety _________________________________________________________________9 Job-Site Safety • Safe Equipment Operation • Personal Protective Equipment (PPE) • Hazardous Substances • Oxyfuel Gas and Arc Cutting Safety • Oxyfuel Gas Welding Safety • Arc Welding Safety • Preventing Fires

Points to Remember: Questions for Study and Discussion:

29 30

Chapter

3 Joint Design and Welding Terms ______________________________________________ 31 Welding Terms • Weld Joints • Weld Types • Weld Designs

Points to Remember: Questions for Study and Discussion:

47 47

Chapter

4 OAW–Equipment _____________________________________________________________ 49 Oxyacetylene Welding • Oxygen for Welding • Acetylene for Welding • Safe Handling of Cylinders • Welding Equipment • Other Welding Gases

Points to Remember: Questions for Study and Discussion:

61 62

5 OAW–Setup and Operation___________________________________________________ 63

Chapter

Welding Equipment Assembly

Points to Remember: Exercises: Questions for Study and Discussion:

Chapter

69 69 70

6 OAW–Flat Position ____________________________________________________________ 71 Carrying a Weld Pool • Adding Filler Metal • Welding Butt Joints • Welding Other Joints • OAW–Cast Iron • OAW–Aluminum • OAW–Steel

Points to Remember: Exercises: Questions for Study and Discussion:

Chapter

80 80 87

7 OAW–Other Positions _________________________________________________________ 89 Horizontal and Vertical Welding • Overhead Welding

Points to Remember: Exercises: Questions for Study and Discussion:

90 90 92

Chapter

8 SMAW–Equipment ____________________________________________________________ 93 Shielded Metal Arc Welding • Electrical Principles • Welding Machine Output • Constant-Current Welding Machines • Static Power Sources • Engine-Driven Power Sources • Welding Machine Ratings • Welding Equipment • Shop Tools and Equipment • Personal Protective Equipment

Points to Remember:

Questions for Study and Discussion:

109 110

Chapter

9 SMAW–Selecting Electrodes _________________________________________________ 111 Electrodes • Electrode Classification Groups • Electrode Selection Variables

Points to Remember:

Questions for Study and Discussion:

Chapter

122 122

10 SMAW–Striking an Arc _______________________________________________________ 123 Basic Principles of Sustaining a Welding Arc

Points to Remember: Exercises:

Questions for Study and Discussion:

126 127 129

11 SMAW–Depositing a Continuous Bead ______________________________________ 131 Chapter

Essentials of Arc Welding • Crater Formation • Cleaning Welds

Points to Remember: Exercises:

Questions for Study and Discussion:

137 138 139

Chapter

12 SMAW–Flat Position __________________________________________________________ 141 Weld Passes • Joints Welded in Flat Position • Surfacing • SMAW Flat Position Problems

Points to Remember: Exercises:

Questions for Study and Discussion:

147 148 154

13 SMAW–Horizontal Position ___________________________________________________ 155 Chapter

Horizontal Position Welding

Points to Remember:

Exercises: Questions for Study and Discussion:

Chapter

156 157 160

14 SMAW–Vertical Position______________________________________________________ 161 Downhill Welding • Uphill Welding • Low-Hydrogen Electrode Welding Techniques

Points to Remember: Exercises:

Questions for Study and Discussion:

Chapter

163 163 166

15 SMAW–Overhead Position ___________________________________________________ 167 Overhead Welding

Points to Remember: Exercises:

Questions for Study and Discussion:

168 169 170

Chapter

16 GTAW–Equipment __________________________________________________________ 171 Gas Tungsten Arc Welding • Welding Power Sources for GTAW • GTAW Equipment • GTAW Filler Metals

Points to Remember:

Questions for Study and Discussion:

189 189

Chapter

17 GTAW–Procedures _________________________________________________________ 191 GTAW Considerations • GTAW Procedures • Hot Wire Welding • Pulsed GTAW (GTAW-P)

Points to Remember: Exercises:

Questions for Study and Discussion:

202 202 210

18 GTAW–Applications ________________________________________________________ 211 Chapter

Carbon Steels • Stainless Steels • Aluminum • Magnesium • Copper and Copper Alloys

Points to Remember:

Questions for Study and Discussion:

216 216

Chapter

19 GMAW–Equipment __________________________________________________________ 217 Gas Metal Arc Welding • GMAW Current Selection • GMAW Welding Power Sources • GMAW Equipment • GMAW Welding Wire

Points to Remember:

Questions for Study and Discussion:

233 234

Chapter

20 GMAW–Procedures _________________________________________________________ 235 GMAW Procedures • GMAW Set-Up Procedures • Metal Transfer Modes • GMAW Weld Discontinuities

Points to Remember: Exercises:

Questions for Study and Discussion:

247 248 253

Chapter

21 GMAW–Applications ________________________________________________________ 255 Carbon Steels • Aluminum • Stainless Steels • Copper

Points to Remember:

Questions for Study and Discussion:

261 262

Chapter

22 Flux Cored Arc Welding (FCAW) ____________________________________________ 263 Flux Cored Arc Welding (FCAW) • FCAW Equipment • FCAW Applications

Points to Remember: Exercises:

Questions for Study and Discussion:

272 273 276

Chapter

23 Brazing, Braze Welding, and Soldering _______________________________________ 277 Brazing • Braze Welding • Soldering

Points to Remember:

Questions for Study and Discussion:

Chapter

292 292

24 Surfacing and Hardfacing ___________________________________________________ 293 Surfacing • Wear Types • Surfacing and Hardfacing by Welding • Surfacing and Hardfacing by Thermal Spraying

Chapter

Points to Remember: Questions for Study and Discussion:

313 314

25 Cutting Operations __________________________________________________________ 315 Oxyfuel Gas Cutting (OFC) • Plasma Arc Cutting (PAC) • Air Carbon Arc Cutting (CAC-A) • Safety Precautions

Points to Remember: Exercises:

Questions for Study and Discussion:

Chapter

326 326 329

26 Repair Welding ____________________________________________________________ 331 Evaluating Repair Methods • Mechanical Repair Methods • Weld Repair Methods • Weld Repair Plans

Points to Remember:

Questions for Study and Discussion:

349 350

Chapter

27 Pipe Welding ____________________________________________________________ 351 Seamless and Welded Wrought Steel Pipe • Pipe Size • Pipe and Tubing • Direction of Welding • Pipe Welding Positions • Pipe Connections • Joint Design • Tack Welding • Welding Passes • Welding Pipe with SMAW • Depositing Roots Beads with GTAW • Depositing Root Beads with Modified GMAW-S • Welding Pipe with GMAW and FCAW • Welding In-Service Pipe • Orbital Welding

Points to Remember:

Questions for Study and Discussion:

375 376

Chapter

28 Production Welding _________________________________________________________ 379 Resistance Welding • Gas Tungsten Arc Spot Welding • Gas Metal Arc Welding in Production Welding • Stud Welding • Electron Beam Welding • Friction Welding • Laser Beam Welding • Plasma Arc Welding • Submerged Arc Welding • Ultrasonic Welding • Electrogas Welding • Friction Stir Welding • Other Welding Processes

Points to Remember:

Questions for Study and Discussion:

403 404

Chapter

29 Automation and Robotic Welding __________________________________________ 405 Automation in Production Welding • Automatic Welding Equipment • Work Area and Safety

Points to Remember:

Questions for Study and Discussion:

Chapter

415 415

30 Other Joining Techniques ___________________________________________________ 417 Types of Plastics • Plastic Welding Techniques • Hot Gas Welding • Heated-Tool Welding • Friction Welding • Adhesive Bonding

Points to Remember:

Questions for Study and Discussion:

425 426

Chapter

31 Destructive Testing _______________________________________________________ 427 Destructive Test Types • Specimen Preparation

Points to Remember:

Questions for Study and Discussion:

450 451

Chapter

32 Nondestructive Examination ________________________________________________ 453 Nondestructive Examination (NDE) Terminology • Nondestructive Examination Techniques • Visual Examination (VT) • Liquid Penetrant Examination (PT) • Magnetic Particle Examination (MT) • Ultrasonic Examination (UT) • Radiographic Examination (RT) • Electromagnetic Examination (ET) • Proof Testing

Points to Remember: Questions for Study and Discussion:

485 486

Chapter

33 Metallography ______________________________________________________________ 487 Microscopic Examination • Macroscopic Examination

Points to Remember: Questions for Study and Discussion:

501 502

Chapter

34 Weld Discontinuities and Failures ____________________________________________ 503 Weld Discontinuities • Cracks • Cavities • Inclusions • Incomplete Fusion and Incomplete Penetration • Incorrect Shape • Miscellaneous Discontinuities

Points to Remember: Questions for Study and Discussion:

521 522

Chapter

35 Welding Procedure Qualification ____________________________________________ 523 Welding Procedure Qualification • Welding Procedure Specification (WPS) • Prequalified WPS (PWPS) • Welding Procedure Qualification Record (WPQR)

Points to Remember: Questions for Study and Discussion:

533 534

Chapter

36 Welder Performance Qualification___________________________________________ 535 Welder Performance Qualification • Welding Codes and Standards • Product-Specific Qualification Tests

Points to Remember: Questions for Study and Discussion:

541 541

Chapter

37 Welding Metallurgy _________________________________________________________ 543 Metallurgical Structure • Weld Regions • Effect of Welding on Physical Properties • Effect of Welding on Mechanical Properties • Effect of Welding Stress on Welds • Effect of Welding on Corrosion Resistance

Points to Remember: Questions for Study and Discussion:

563 564

38 Metal Identification _________________________________________________________ 565 Chapter

Manufacturer Paperwork • Materials Nonconformance Report • Visual Identification • Qualitative Identification • Semi-Quantitative Identification • Quantitative Identification

Points to Remember: Questions for Study and Discussion:

582 582

Chapter

39 Weldability of Carbon and Alloy Steels ______________________________________ 583 Weldability of Carbon and Alloy Steels

Points to Remember: Questions for Study and Discussion:

595 596

Chapter

40 Weldability of Tool Steels and Cast Irons _____________________________________ 597 Weldability of Tool Steels • Weldability of Cast Irons

Points to Remember: Questions for Study and Discussion:

610 610

Chapter

41 Weldability of Stainless Steels ________________________________________________ 611 Weldability of Stainless Steels

Points to Remember: Questions for Study and Discussion:

626 626

Chapter

42 Weldability of Nonferrous Metals_____________________________________________ 627 Weldability of Nonferrous Metals • Weldability of Aluminum Alloys • Weldability of Nickel Alloys • Weldability of Magnesium Alloys • Weldability of Titanium Alloys • Weldability of Copper Alloys

Points to Remember: Questions for Study and Discussion:

645 646

Chapter

43 Dissimilar Metal Welding ____________________________________________________ 647 Dissimilar Metal Welding • Weldability Factors • Weldability of Specific Dissimilar Metal Combinations

Points to Remember: Questions for Study and Discussion:

658 658

Chapter

44 Distortion Control____________________________________________________________ 659 Distortion • Distortion Control

Points to Remember: Questions for Study and Discussion:

672 673

Chapter

45 Welding Symbols____________________________________________________________ 675 Welding Symbols • Combining Weld Symbols • Nondestructive Examination Symbols

Points to Remember: Questions for Study and Discussion:

688 688

Chapter

46 Materials and Fabrication Standards and Codes _____________________________ 691 Materials Standards • Materials Standards Organizations • Using Materials Standards • Fabrication Standards and Codes

Points to Remember: Questions for Study and Discussion:

712 712

Appendix _________________________________________________________________________ 713 Glossary __________________________________________________________________________ 751 Index _____________________________________________________________________________ 771

• Quick Quizzes® • Illustrated Glossary • Flash Cards • Media Library • Welding Resources • ATPeResources.com

Welding Skills is an industry-leading textbook designed to provide the essential knowledge and skill-building exercises necessary to succeed in today’s welding industry. This highly readable textbook uses hundreds of full-color illustrations and application photos to illustrate key concepts, while easy-to-use charts consolidate key information for quick reference.

The chapters are organized into eight sections. Section one includes an introduction to the welding industry, a comprehensive chapter on welding safety, and an introduction to joint design and welding terms. Sections two through six are devoted to in-depth coverage of the major welding processes, including equipment operating principles, electrode selection, equipment set-up and procedures for welding in all positions, and specific applications for carbon steel, stainless steel, and aluminum. Section six also includes detailed coverage of oxyfuel and arc cutting processes, pipe welding, and production welding. Section seven covers evaluation and testing, including destructive testing and nondestructive examination, weld discontinuities and defects, and welder and welding procedure qualification. Section eight covers the practical theory behind the metallurgy and weldability of ferrous and nonferrous metals, metal identification, and distortion control, as well as the latest AWS welding symbols.

Key features of this new edition include the following: • Comprehensive coverage of welding safety based on ANSI/AWS Z49.1 • Expanded coverage of pipe welding, including modified GMAW-S • Reorganized and expanded coverage of essential metallurgy and weldability of ferrous and nonferrous metals • Updated coverage of weld evaluation and testing methods • Use of standard AWS terminology throughout For training organizations participating in the AWS SENSE program, Welding Skills, Welding Skills Workbook, and Printreading for Welders include all the essential theory, practical exercises, and industry standard tests necessary to build entry-level through advanced welding knowledge and skills.

The author, Bert J. Moniz, has over 40 years of experience in metallurgy and in many facets of welding. Mr. Moniz currently serves as a materials engineering consultant with DuPont Company and is involved with selecting materials for construction, fabrication, and failure analysis worldwide. His vast knowledge and expertise are reflected throughout the textbook.

Welding skills is one of several products available from ATP. To learn more about related training products, visit the ATP website at atplearning.com.

The Publisher

Chapter introductions provide a brief overview of content to be covered.

Objectives identify key learning goals for each chapter.

Key points highlight essential content throughout the text.

Industrial application photos supplement text and illustrations.

Detailed illustrations show the operation of equipment and welding processes.

Technical facts provide additional information related to topics discussed.

Points to remember highlight fundamental concepts at the end of each chapter.

Exercises provide step-by-step procedures for welding applications.

Welding Skills also includes access to digital resources that reinforce textbook content and enhance learning. These resources can be accessed by either of the following: • keying ATPeResources.com/QuickLinks into a web browser and entering the QuickLink™ code: 970435 • using a Quick Response (QR) reader app to scan the QR code with a mobile device

The Digital Resources include the following features: • Quick Quizzes® that provide interactive questions for each chapter with embedded links to highlighted content within the textbook and glossary terms • An Illustrated Glossary that defines commonly used terms and provides links to selected interactive illustrations and media clips • Flash Cards that provide a self-study/review tool for common welding terms, definitions, and symbols presented in the textbook • A Media Library that consists of animated illustrations and videos that reinforce and expand upon textbook content • Welding Resources that consist of reference tables and illustrations of welding concepts presented in the text • ATPeResources.com, which provides access to additional online reference materials

Workbook The Welding Skills Workbook includes review questions, activities, and section exams that support and expand upon the information presented in the textbook.

Review questions include true-false, multiple choice, and completion questions that assess comprehension of chapter material.

Section-based activities help develop a learner’s understanding of welding concepts and also reinforce knowledge with over 300 performance-based welding exercises.

Section exams include true-false and multiple choice questions that test a learner’s comprehension of information from each section.

Instructor Resources The Welding Skills online Instructor Resources provide a comprehensive teaching resource that includes a detailed Instructional Guide, editable PowerPoint® Presentations, an interactive Image Library, Assessments, and Answer Keys as well as access to the digital resources used with the textbook.

The Instructional Guide explains how to best use the learning resources provided and includes instructional plans for each chapter that identify images and media pieces for an enhanced learning experience.

PowerPoint® Presentations provide a review of key concepts from each chapter of Welding Skills and include chapter objectives, illustrations, and review questions. Instructor notes are also provided.

The Image Library includes all the numbered illustrations in a format that can be displayed for maximum instructional effectiveness.

Assessments include sets of questions based on objectives and key concepts from each section and consist of an exam, a pretest, a posttest, and test banks.

Answer Keys provide answers for each section exam, pretest, posttest, and study guide question.