Ramesh Singh - Arc Welding Processes Handbook

Figure 3.12.1 Five basic weld designs, (Courtesy of Indian Air force training manual “Basic Welding Technology”)

Figure 3.16.1 Copper and Aluminum welding leads: note the number of fine wires that compose a cable, and the rubber sheathing that covers them

Figure 3.16.2 Various types of cable connectors, and ground clamp. Pictures Curtsy of LENCO catalogue

Figure 3.25.9.3.1 Welder is tacking a pipe prior to welding

Figure 3.25.9.3.2 A nozzle is welded on a pipe header

Figure 3.25.10.2.1 Schaeffler diagram

Figure 3.25.10.2 DeLong diagram

Figure 4.3.1 Typical GMAW welding

Figure 4.4.1 A GMAW operator welding on an offshore pipeline

Figure 4.4.1.1 Short circuit transfer (arc-action and cycle)

Figure 4.4.1.2 Current voltage range for various transfer mode

Figure 4.11.1 Typical GMAW (MIG) welding set up with the external wire feed unit

Figure 4.12.1 A typical GMAW torch with trigger type on-off switch on the handle

Figure 4.12.2 Blow out of the GMAW torch that shows some of the components that make up a welding torch

Figure 4.12.3 The GMAW torch and the cable connector

Figure 4.12.1.4 Copper and aluminum welding leads: note the number of fine wires that compose a cable, and the rubber sheathing that covers them

Figure 4.13.8.1 (a) Contour of a weld bead in the flat position with the work horizontal; (b) welding slightly uphill; (c) welding slightly downhill

Figure 4.13.12.1 WRC diagram

Figure 5.3.1 FCAW-S self-shielding tubular wire process

Figure 5.3.2 FCAW-G, gas shielding solid wire process

Figure 5.4.1 Typical FCAW setup

Figure 5.5.1 FCAW electrode classification system

Figure 5.8.7.2.1 Shows the metal transfer through the arc with CO 2shielding on the left, and 75% Ar. + CO 2on the right

Figure 6.3.1 Schematic display of the SAW process

Figure 6.3.2 Shows the submerged arc welding of a plate

Figure 6.3.3 Shows the SAW of a pipe in a fabrication shop – note the arc and flux position as the pipe rotates

Figure 6.3.4 Shows the completed pipe weld

Figure 6.3.5 Higher deposition rate of SAW process

Figure 6.6.1 Showing SAW process in progress on a pipe weld

Figure 6.6.2 Shows the collected flus for cleaning and reusing

Figure 6.7.1 Multi-wire SAW system

Figure 6.7.3 Tandem head strip wire SAW process for cladding

Figure 7.1 Structure of the welding symbol

Figure 7.2 Welding symbol arrows

Figure 7.3 Welding symbol position of the arrows

Figure 7.4 Significance of the circle on the arrows

Figure 7.5 Symbols for type of welds

Figure 7.6 Symbol of a fillet weld

Figure 7.7 Shows the side of the metal where the fillet weld is required to be made

Figure 7.8 Graphic and as built depiction of welds – note the weld sizes shown in the symbol on left and its corresponding annotation on the actual weld

Figure 7.9 Shows the addition of the length of the weld to the symbol at the left, and what it means is shown in the as built figure on the right

Figure 7.10 Adding pitch of the weld

Figure 7.11 Symbols of various types of Groove Welds

Figure 7.12 Symbol of Sq. groove weld – note the annotation of root opening

Figure 7.13 Symbol and as built of V-groove welds, note how the root gap (opening) is shown

Figure 7.14 Shows the (1) depth of V groove on both sides of the weld, (2) shows the depth of the penetration desired of the weld

Figure 7.15 Shows the specific depth of the groove weld (effective throat) desired

Figure 7.16 Symbol of a bevel groove note which side of the plate is to be beveled and to what degree

Figure 7.17 Shows U-groove symbol

Figure 7.18 Shows the J-groove symbol and the weld. Note the indicated depth of the weld

Figure 7.19 Symbol of Flare-V groove weld and as built weld

Figure 7.20 Symbol of and as built flare bevel and the weld

Figure 7.21 Shows the melt-thru weld

Figure 7.22 Shows the supplementary symbol of backing bar for the weld

Figure 7.23 Symbol of a plug weld

Figure 7.24 Shows symbols of plug and slot welds, with weld sizes, spacing and depth of the weld

Table 1.1 Welding and joining processes, type of energy used, and their abbreviations as defined by the American Welding Society

Table 1.2 Arc efficiency by welding process

Table 1.3 Shows the arc efficiency factors for various commonly used arc welding processes

Table 1.4 Indicates general limits of joining/welding processes that apply to the material listed in left column

Table 1.5 Arc efficiency factor

Table 2.8.3.1 Welding lead and their capacity

Table 2.9.1 Welding lens shades

Table 2.9.2 Helmets with auto adjusting lenses

Table 2.10.1 Electrode classification and A-numbers

Table 2.10.2 Shielded arc welding electrodes

Table 2.11.10 Common SMAW process anomalies and their suggested causes and corrections

Table 2.11.12 Weld defects and suggested changes that can correct them

Table 2.12.1 Aluminum alloy designation system

Table 2.12.5 Cast aluminum designation and numbering system

Table 2.12.6 Temper designation letters and meaning

Table 2.12.23 Stainless steel welding electrodes and heat treatments

Table 2.13 Nominal compositions of some of duplex steels

Table 2.13.1 Nominal mechanical properties of duplex stainless steels

Table 3.10.1 Basic matching guide for electrode size and nozzle

Table 3.11.1 Tungsten electrode tips

Table 3.11.2 Tungsten electrode tips

Table 3.11.3 Types of Tungsten electrode and their identification

Table 3.16.1 Welding cable current carrying capacity

Table 3.17.1 Details the NEMA rating and corresponding current output capacity

Table 3.21.1 Aluminum alloy designation system

Table 3.22.1 Cast aluminum designation and numbering system

Table 3.24.1 Aluminum welding procedures using AC high frequency stabilized arc

Table 3.24.2 GTAW stainless steel welding procedures

Table 3.25.1 Nominal compositions of some of duplex steels

Table 3.25.8 Stainless steel welding wire rod and heat treatments

Table 3.6.2 Nominal mechanical properties of duplex stainless steels

Table 3.29.1 Advantages and limitations of PAW process

Table 4.4.1 Deposition rate of various GMAW metal transfer mode

Table 4.4.1.1 WPS for carbon steel and low alloy steels with short circuit transfer mode

Table 4.4.1.2 Aluminum WPS for short circuit

Table 4.4.1.3 The transition current for spray transfer currents

Table 4.4.1.4.1 Carbon steel – Basic training WPS for spray transfer welding

Table 4.4.1.4.2 Aluminum – Basic training WPS for spray transfer welding

Table 4.5.1 Details the current and the shielding gas type used in spray transfer mode of some of the common materials

Table 4.5.5.1 Gas selection guide

Table 4.12.1.4 Welding lead current carrying capacity

Table 5.5.1 Carbon steel electrodes their use descriptions

Table 5.6.6.1 Impact of shielding gases on the mechanical properties of weld metal

Table 6.10.7 Indicates the basicity of various fluxes

Table 6.11 Common welding electrodes for SAW process

Table 7.1 Pipe schedule

Table 7.2 Terms and abbreviations relating to welding and construction

Table 7.3 F-Number, ASME specification and AWS classification

Table 7.4 P-number, group number, and type of material

Table 7.5 Qualification of metals based on the procedure qualification

Table 7.6 Temperature conversion

Table 7.7 Temperature and pressure

The book, “Arc Welding Processes Handbook”, brings together salient knowledge of arc welding methods used primarily in the industry and especially in the oil patch. The information presented about the welding process is usable and emulates the presence of your own welding engineer. Covering such welding methods as SMAW, GTAW, GMAW, FCAW and SAW with details in materials and techniques. This book is useful to both new welders as well as experienced welders. In the book, Ramesh covers these welding processes, how they work, and dives into the electrical side of welding. Welding machines, Transformers, Generators, Invertors, AC, DC, Sq. wave, Sine wave currents, Rectifiers, SCRs, Diodes, etc., as current control methods, all these are presented in a way that is easy to understand the functions of various welding machines. Most common weldable materials are discussed with welding guidance given that includes Aluminum, Nickel, Carbon steels, Stainless steels, Precipitation Hardened steels, Duplex Stainless steels, and others. The book is super comprehensive, easy to follow, and a welcome addition to any welding engineer’s bookcase. It is a truly great guide for any budding engineer or welder to help them master their skills.