Welding Handbook - 10th Edition, Volume 1
Welding and Cutting Science and Technology
Get an overview of the most recent research and engineering developments in the field of welding and cutting science and technology.
The seventeen chapters in this volume cover the fundamentals of welding, cutting, joining, and allied processes. The chapters discuss metallurgy, the physics of welding and cutting, heat flow in welding, and residual stress and distortion. Other important topics include engineering considerations of weld design, weldment tooling and positioning, automation, process monitoring and control, methods for the evaluation and testing of welds, weld quality, weld inspection and nondestructive examination, and the economics of welding.
Well-researched chapters on codes and other standards, the qualification and certification of welding techniques and personnel, the accurate communication of welding information, and safe practices are also included. The information in this volume is applicable to all categories of welding, from manual welding to the most sophisticated automated and robotic systems
Peer-reviewed for accuracy.
The peer-reviewed chapters in this volume are enhanced by the pertinent consensus standards that are referenced throughout. More than 700 drawings, schematics, and photographs illustrate the text. Approximately 170 tables provide categorized or comparative information. Explanatory information and sources are identified and referenced in footnotes.
This volume, like the others preceding it, is a voluntary effort by the members of the Welding Handbook Committee, the Welding Handbook Volume 1 Committee, and the Chapter Committees. Each chapter is reviewed by members of the American Welding Society’s Technical Activities Committee (TAC), Safety and Health Committee (SHC), and other specialists.
(Print - ISBN: 978-1-64322-014-7, PDF - ISBN: 978-1-64322-015-4)
Table of Contents
PART I — THE SCIENCE OF WELDING, CUTTING, AND ALLIED PROCESSES
CHAPTER 1 – SURVEY OF JOINING, CUTTING, AND ALLIED PROCESSES
- Introduction
- Joining Processes
- Resistance Welding
- Cutting Processes
- Thermal Spraying
- Conclusion
- Bibliography
- Supplementary Reading List
CHAPTER 2 – PHYSICS OF WELDING AND CUTTING
- Introduction
- Fusion and Solid-State Welding
- Energy Sources for Welding
- Arc Characteristics
- Metal Transfer
- Melting Rates
- Physical Properties of Metals and Shielding Gases
- Conclusion
- Bibliography
- Supplementary Reading List
CHAPTER 3 – HEAT FLOW IN WELDING
- Introduction
- Fundamentals of Heat Flow
- Quantitative Calculation of Heat Transfer in Fusion Welding
- Conduction of Heat during Fusion Welding
- Convective Heat Transfer in the Weld Pool
- Relative Importance of Conduction and Convection
- Heat Flow in Dissimilar Welding
- Heat Flow in Solid-State Welding
- Conclusion
- Bibliography
- Supplementary Reading List
CHAPTER 4 – WELDING METALLURGY
- Introduction
- Physical Metallurgy
- Metallurgy of Welding
- Weldability of Some Commercial Alloys
- The Brazed or Soldered Joint
- Corrosion in Weldments
- Conclusion
- Bibliography
- Supplementary Reading List
CHAPTER 5 – DESIGN FOR WELDING
- Introduction
- Connection Design
- Basics of Welded Connections
- Principles of Connection Design
- Economics of Welding
- Quality and Connection Design Detailing
- Detailing of Welds
- Sizing of Steel Welds
- Special Conditions
- Other Alloys
- Examples
- Conclusion
- Bibliography
PART II — DESIGN CONSIDERATIONS
CHAPTER 6 – SYMBOLS FOR JOINING AND INSPECTION
- Introduction
- Fundamentals
- Weld Symbols
- Welding Symbols
- Welding Symbols for Specific Weld Types
- Brazing Symbols
- Soldering Symbols
- Nondestructive Examination Symbols
- Conclusion
- Bibliography
- Supplementary Reading List
CHAPTER 7 – RESIDUAL STRESS AND DISTORTION
- Introduction
- Fundamentals
- Nature and Causes of Residual Stress
- Effects of Residual Stress
- Measurement of Residual Stress in Weldments
- Residual Stress Distribution Patterns in Typical Welds
- Effects of Welding Sequence on Residual Stress
- Residual Stress and Distortion in Welds Made with Different Welding Processes
- Computational Weld Modeling
- Weld Distortion
- Reducing or Controlling Residual Stress and Distortion
- Conclusion
- Bibliography
- Supplementary Reading List
CHAPTER 8 – ECONOMICS OF WELDING AND CUTTING
- Introduction
- The Cost Estimate
- Economics of Welding
- Automated and Robotic Systems
- Economics of Resistance Spot Welding
- Capital Investment in Welding Automation and Robotics
- Control of Welding Costs
- Economics of Brazing and Soldering
- Economics of Thermal Cutting
- Conclusion
- Bibliography
- Supplementary Reading List
PART III — AUTOMATION OF JOINING PROCESSES
CHAPTER 9 – MECHANIZED, AUTOMATED, AND ROBOTIC WELDING
- Introduction
- Mechanized Welding and Cutting
- Automated Welding
- Robotic Welding
- Planning for Automated and Robotic Welding
- Conclusion
- Bibliography
- Supplementary Reading List
CHAPTER 10 – WELDMENT TOOLING AND POSITIONING
- Introduction
- Fixtures
- Positioners
- Conclusion
- Bibliography
- Supplementary Reading List
CHAPTER 11 – MONITORING AND CONTROL OF WELDING AND JOINING PROCESSES
- Introduction
- Principles of Monitoring and Control
- Sensing Devices
- Process Instrumentation
- Process Monitoring Systems
- Process Control Systems
- Monitoring and Control Systems
- Conclusion
- Bibliography
- Supplementary Reading List
PART IV — QUALITY, TESTING STANDARDS, AND METHODS
CHAPTER 12 – WELD QUALITY
- Introduction
- Defining Weld Quality
- Overview of Weld Discontinuities
- Discontinuities Associated with Fusion Welding
- Discontinuities Associated with Resistance Welding
- Discontinuities Associated with the Solid-State Welding Processes
- Discontinuities in Brazed and Soldered Joints
- Significance of Weld Discontinuities
- Conclusion
- Bibliography
- Supplementary Reading List
CHAPTER 13 – TEST METHODS FOR EVALUATING WELDED JOINTS
- Introduction
- Testing for Strength
- Hardness Testing
- Bend Testing
- Fracture Toughness Testing
- Fatigue Testing
- Corrosion Testing
- Creep and Rupture Testing
- Testing of Thermal Spray Applications
- Weldability Testing
- Conclusion
- Bibliography
- Supplementary Reading List
CHAPTER 14 – WELDING INSPECTION AND NONDESTRUCTIVE EXAMINATION
- Introduction
- Personnel Qualifications
- The Inspection Plan
- Nondestructive Examination
- Metallographic Examination Methods
- Inspection of Brazed and Soldered Joints
- Conclusion
- Bibliography
- Supplementary Reading List
CHAPTER 15 – PERSONNEL QUALIFICATION AND CERTIFICATION
- Introduction
- Welding and Brazing Procedure Specifications
- Qualification of Welding and Brazing Procedures
- Performance Qualification
- Standardization of Qualification Requirements
- Conclusion
- Bibliography
- Supplementary Reading List
CHAPTER 16 – CODES AND OTHER STANDARDS
- Introduction
- Types of Regulatory Documents
- Standards-Developing Organizations and Welding-Related Publications
- Guidelines for Participating in International Standards Activities
- Conclusion
- Supplementary Reading List
PART V — SAFETY AND HEALTH
CHAPTER 17 – SAFE PRACTICES
- Introduction
- Safety Management
- Protection of the Work Area
- Personal Protective Equipment
- Protection against Fumes and Gases
- Safe Handling of Compressed Gases
- Protection against Electromagnetic Radiation
- Electrical Safety
- Fire Prevention and Protection
- Explosion Prevention
- Process-Specific Safety Considerations
- Safety in Robotic Operations
- Conclusion
- Bibliography
- Supplementary Reading List
