Welding Handbook - 9 Edition, Volume 3

Welding Handbook - 9 Edition, Volume 3

Welding Processes, Part 2

This authoritative resource brings together 600 pages of comprehensive information on solid-state and other welding and cutting processes. The book includes chapters on the following welding processes: resistance spot and seam, projection, flash and upset, and high-frequency. The final chapter covers various other welding and cutting processes, including modernized water jet cutting. Written, updated, and peer reviewed by a group of highly respected technical and scientific experts.

  • Provides a comprehensive chapter on resistance welding equipment, with photos of state-of-the-art equipment and accompanied by new electrical diagrams and drawings.
  • In addition to a chapter on friction welding, a new chapter introduces friction stir welding, the process that has users excited about its significant advantages.
  • Discusses the most recent developments in beam technology in greatly expanded chapters on laser beam welding and cutting and electron beam welding.
  • Presents a diverse array of processes in chapters on ultrasonic welding, explosion welding, diffusion welding and diffusion brazing, adhesive bonding, and thermal and cold spraying.
  • Also discusses various other welding and cutting processes, including sections on two emerging processes: magnetic pulse welding and electro-spark deposition, plus the return of water jet cutting as a modern process.
  • Includes a section on safe practices specific to the process in each chapter.

This volume is devoted to information on resistance welding, solid state processes, and other joining and cutting methods. It contains updated resistance welding chapters: spot and seam welding, projection welding, flash and upset welding, high-frequency welding, and resistance welding equipment. The chapter on friction welding been updated. New in this edition is a separate chapter on the developing process variation of friction stir welding. Other chapters explore ultrasonic welding, explosion welding, adhesive bonding, thermal spraying and cold spraying, diffusion welding, and diffusion brazing. The chapters on electron beam welding and laser beam welding and cutting contain significantly expanded technology. The last chapter, Other Welding and Cutting Processes, contains information on two new or revitalized processes, magnetic pulse welding, and electro-spark depositing. New information is presented on water jet cutting, which is reappearing in many current applications as a modern, efficient process.

The chapters in this volume reflect the dramatic changes brought into the welding process over the past decade by the precise control of welding parameters made possible by digital controls and microprocessors as applied to new techniques and advanced materials. Each chapter draws on the expertise of highly qualified experts enthusiastic about the subject process and headed by a chapter chair with an admirable dedication to the details of infusing state-of-the-art information into the basics of processes.

One hundred and ten volunteers contributed, representing university, government, and private welding research and development institutions, manufacturers of welding equipment and materials and manufacturers, fabricators, and welders who use this technology.

This volume, like the others preceding it, is a voluntary effort by the members of the Welding Handbook Committee, The Welding Handbook Volume 3 Committee, and the Chapter Committees. An important contribution is the review of each chapter provided by AWS’s Technical Activities Committee and other specialists.


Table of Contents

PREFACE
ACKNOWLEDGMENTS
CONTRIBUTORS

CHAPTER 1--RESISTANCE SPOT AND SEAM WELDING

  • Introduction
  • Fundamentals
  • Equipment
  • Surface Preparation for Spot and Seam Welding
  • Resistance Spot Welding
  • Resistance Seam Welding
  • Metal Properties and Weldability
  • Economics of Resistance Welding
  • Safe Practices
  • Conclusion
  • Bibliography
  • Supplementary Reading List

CHAPTER 2--PROJECTION WELDING

  • Introduction
  • Equipment
  • Welding Variables
  • Welding Schedules
  • Metals Welded
  • Weld Quality
  • Cross Wire Welding
  • Economics
  • Safe Practices
  • Conclusion
  • Bibliography
  • Supplementary Reading List

CHAPTER 3--FLASH AND UPSET WELDING

  • Introduction
  • Flash We
  • lding
  • Fundamentals
  • Applications
  • Equipment
  • Welding Procedures
  • Welding Machine Settings
  • Upset Welding
  • Fundamentals
  • Process Variations
  • Applications
  • Sheet, Strip, and Wire Welding
  • Continuous Upset Welding
  • Weld Quality
  • Examination and Testing
  • Economics
  • Safe Practices
  • Conclusion
  • Bibliography
  • Supplementary Reading List

CHAPTER 4--RESISTANCE WELDING EQUIPMENT

  • Introduction
  • Equipment Selection
  • Electrodes
  • Actuators
  • Power Conversion Equipment
  • Resistance Welding Controls
  • Quality Control Functions
  • Electric Service Equipment
  • Economics
  • Safe Practices
  • Conclusion
  • Bibliography
  • Supplementary Reading List

CHAPTER 5--HIGH-FREQUENCY WELDING

  • Introduction
  • Fundamentals
  • Applications
  • Induction Seam Welding of Pipe and Tubing
  • Contact Seam Welding of Pipe and Tubing
  • Welding Parameters
  • Equipment
  • Inspection and Quality Control
  • Economics
  • Safe Practices
  • Conclusion
  • Bibliography
  • Supplementary Reading List

CHAPTER 6--FRICTION WELDING

  • Introduction
  • Fundamentals
  • Welding Variables
  • Joint Design
  • Equipment
  • Welding Procedures
  • Applications
  • Weld Quality
  • Economics
  • Safe Practices
  • Conclusion
  • Bibliograph
  • y
  • Supplementary Reading List

CHAPTER 7--FRICTION STIR WELDING

  • Introduction
  • Fundamentals
  • Equipment and Controls
  • Tool Design
  • Welding Parameters
  • Regions of a Friction Stir Weld
  • Factors Affecting Weldability
  • Heat Transfer
  • Material Flow
  • Applications
  • Mechanical Properties
  • Weld Quality
  • Economics
  • Safe Practices
  • Conclusion
  • Bibliography

CHAPTER 8--ULTRASONIC WELDING

  • Introduction
  • Fundamentals
  • Equipment
  • Welding Variables and Procedures
  • Metals Welded
  • Applications
  • Mechanisms of Ultrasonic Welding
  • Ultrasonic Microwelding
  • Weld Quality
  • Economics
  • Safe Practices
  • Conclusion
  • Bibliography
  • Supplementary Reading List

CHAPTER 9--EXPLOSION WELDING

  • Introduction
  • Fundamentals
  • Equipment and Facilities
  • Testing Equipment
  • Welding Variables
  • Materials
  • Applications
  • Cylinders
  • Transition Joints
  • Heat Exchangers
  • Weld Quality and Testing
  • Economics
  • Safe Practices
  • Conclusion
  • Bibliography
  • Supplementary Reading List

CHAPTER 10--ADHESIVE BONDING

  • Introduction
  • Fundamentals
  • Adhesives
  • Joint Design
  • Surface Preparation
  • Procedures
  • Equipment
  • Quality Control
  • Economics
  • Safe Practices
  • Conclusion
  • Bibliography
  • Supplementary Reading List

CHAPTER 11--THERMAL SPRAYING AND COLD SPRAYING

  • Introduction
  • Fundamentals
  • Process Variables
  • Process Variations
  • Equipment and Materials
  • Characteristics of Spray-Deposited Materials
  • Post-spray Treatments
  • Applications
  • Quality Assurance
  • Economics
  • Safe Practices
  • Conclusion
  • Bibliography
  • Supplementary Reading List

CHAPTER 12--DIFFUSION WELDING AND DIFFUSION BRAZING

  • Introduction
  • Advantages and Limitations
  • Surface Preparation
  • Diffusion Welding
  • Fundamentals
  • Applications
  • Process Variables
  • Process Variations
  • Techniques
  • Equipment
  • Tooling
  • Metals Welded
  • Diffusion Brazing
  • Methods
  • Variables
  • Equipment and Tooling
  • Materials and Applications
  • Diffusion Soldering
  • Applications
  • Inspection of DFW and DFB Joints
  • Economics
  • Safe Practices
  • Conclusion
  • Bibliography
  • Supplementary Reading List

CHAPTER 13--ELECTRON BEAM WELDING

  • Introduction
  • Fundamentals
  • Equipment
  • Welding Procedures
  • Selection of Welding Variables
  • Applications
  • Weld Quality
  • Economics
  • Safe Practices
  • Conclusion
  • Bibliography
  • Supplementary Reading List

CHAPTER 14--LASER BEAM WELDING, CUTTING, AND ASSOCIATED PROCESSES

  • Introduction
  • Fundamentals of Laser Beam Welding and Cutting
  • Laser Beam Welding
  • Laser Beam Systems
  • Welding Techniques
  • Applications
  • Joint Design
  • Laser Beam Cutting
  • Principles of Cutting and Drilling
  • Equipment
  • Materials
  • Process Variables
  • Quality
  • Economics of Laser Beam Welding and Cutting
  • Safe Practices
  • Conclusion
  • Bibliography
  • Supplementary Reading List

CHAPTER 15--OTHER WELDING AND CUTTING PROCESSES

  • Introduction
  • Forge Welding
  • Early Arc Welding
  • Hot Pressure Welding
  • Thermite Welding
  • Cold Welding
  • Magnetic Pulse Welding
  • Electro-Spark Deposition
  • Percussion Welding
  • Water Jet Cutting
  • Conclusion
  • Bibliography
  • Supplementary Reading List

APPENDIX A–AMERICAN WELDING SOCIETY SAFETY AND HEALTH STANDARDS LIST
APPENDIX B–SAFETY CODES AND OTHER STANDARDS
APPENDIX C–CONVERSIONS FOR VARIOUS PRESSURE UNITS
MAJOR SUBJECT INDEX:
Volumes 1, 2, and 3–Ninth Edition, and Volumes 3 and 4–Eighth Edition
INDEX OF VOLUME 3, NINTH EDITION

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