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Welding - Brands Delmar - Cengage Learning

Welding Principles and Applications Fifth Edition Welding Principles and Applications Fifth Edition Larry Jeffus A u s t r a l i a C a n a d a M e x i c o S i n g a p o r e S p a i n U n i t e d K i n g d o m U n i t e d S t a t e s Welding Principles and Applications Fifth Edition Larry Jeffus Business Unit Director: Executive Marketing Manager: Project Editor: Alar Elken Maura Theriault Barbara L. Diaz Executive Editor: Channel Manager: Senior Art/Design Coordinator: Sandy Clark Fair Huntoon Mary Beth Vought Acquisitions Editor: Marketing Coordinator: Production Coordinator: Sanjeev Rao Sarena Douglass Sharon Popson Developmental Editor: Executive Production Manager: Editorial Assistant: Alison S.

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1 Welding Principles and Applications Fifth Edition Welding Principles and Applications Fifth Edition Larry Jeffus A u s t r a l i a C a n a d a M e x i c o S i n g a p o r e S p a i n U n i t e d K i n g d o m U n i t e d S t a t e s Welding Principles and Applications Fifth Edition Larry Jeffus Business Unit Director: Executive Marketing Manager: Project Editor: Alar Elken Maura Theriault Barbara L. Diaz Executive Editor: Channel Manager: Senior Art/Design Coordinator: Sandy Clark Fair Huntoon Mary Beth Vought Acquisitions Editor: Marketing Coordinator: Production Coordinator: Sanjeev Rao Sarena Douglass Sharon Popson Developmental Editor: Executive Production Manager: Editorial Assistant: Alison S.

2 Weintraub Mary Ellen Black Jill Carnahan COPYRIGHT 2004 by Delmar Learning , a ALL RIGHTS RESERVED. Certain portions of Library of Congress Cataloging-in- division of Thomson Learning , Inc. this work 1999, 1993, and 1988. No part Publication Data: Thomson Learning is a trademark used of this work covered by the copyright here- herein under license. on may be reproduced in any form or by Jeffus, Larry F. any means graphic, electronic, or Welding : principles and applications/. Cover: Courtesy Hornell, Inc. mechanical, including photocopying, Larry Jeffus. 5th ed. p. cm. Section Opener Photos 1 5 recording, taping, Web distribution, or Includes index.

3 And 7. Courtesy of Larry Jeffus information storage and retrieval systems ISBN 1-40181-046-2. Section Opener Photo 6. without the written permission of the 1. Welding . I. Title. Courtesy of Messer Eutectic publisher. TS227 .J418 2003. Printed in the United States of America For permission to use material from the text '2 dc21 2002031518. 1 2 3 4 5 XX 06 05 04 03 02 or product, contact us by Tel. (800) 730-2214. For more information contact Fax (800) 730-2215. Delmar Learning Executive Woods 5 Maxwell Drive, Box 8007, Clifton Park, NY 12065-8007. Or find us on the World Wide Web at NOTICE TO THE READER. Publisher does not warrant or guarantee any of the products described herein or perform any independent analysis in connec- tion with any of the product information contained herein.

4 Publisher does not assume, and expressly disclaims, any obligation to obtain and include information other than that provided to it by the manufacturer. The reader is expressly warned to consider and adopt all safety precautions that might be indicated by the activities herein and to avoid all potential hazards. By following the instructions contained herein, the reader willingly assumes all risks in con- nection with such instructions. The publisher makes no representation or warranties of any kind, including but not limited to, the warranties of fitness for particular purpose or merchantability, nor are any such representations implied with respect to the material set forth herein, and the publisher takes no responsibility with respect to such material.

5 The publisher shall not be liable for any special, conse- quential, or exemplary damages resulting, in whole or part, from the readers' use of, or reliance upon, this material. Contents Preface ..xi Features of the Text ..xiv SECTION 2. SHIELDED METAL ARC. About the Welding . Index of Experiments and Practices ..xviii Chapter 3 Shielded Metal Arc Equipment, Setup, and Operation SECTION 1 Welding INTRODUCTION Types of Welding Open Circuit Voltage ..52. Chapter 1 Introduction to Welding Operating Voltage ..52. Arc Blow ..52. Welding Types of Power Sources ..53. Uses of Generators and Welding Processes ..8 Rectifiers.

6 57. Occupational Opportunities in Welding ..12 Duty Cycle ..58. Training for Welding Occupations ..14 Welding Experiments and Electrode Holders ..60. Welding Video Work Metric Units ..16 Setup ..61. Welding at the Bottom of the World ..19 Experienced Welders Make a Difficult Offshore Weld Run Smoothly ..63. Chapter 2 Safety in Welding Chapter 4 Shielded Metal Arc Welding Eye and Ear Protection ..24 of Plate Respiratory Protection ..28 Ventilation ..30 Effect of Too High or Too Low Current Material Specification Data Sheets (MSDS) ..30 Settings ..67. Waste Material Disposal ..30 Electrode Size and Heat ..69. Electrical Arc Length.

7 69. General Work Clothing ..31 Electrode Special Protective Electrode Manipulation ..73. Handling and Storing Cylinders ..34 Positioning of the Welder and the Plate ..75. Fire Protection ..36 Practice Welds ..75. Equipment Stringer Beads ..76. Work Square Butt Hand Tools ..38 Edge Power Tools ..39 Outside Corner Joint ..86. Metal Cutting Machines ..40 Lap Joint ..89. Material Handling ..41 Tee Heads Up on Safety: Use Proper Head Keeping Shipshape through Underwater and Eye Protection ..43 v vi Contents Chapter 5 Shielded Metal Arc Welding of Pipe Oxygen Cutting ..176. Pipe and Preparation and Chapter 8 Plasma Arc Cutting Practice Welds.

8 106 1G Horizontal Rolled 2G Vertical Fixed Arc Plasma ..179. 5G Horizontal Fixed Position ..115 Plasma Torch ..180. 6G 45 Inclined Power and Gas Cables ..182. Power Orbital Welding Helps NASA's X-34 Heat Rocket Soar ..119 Applications ..185. Chapter 6 Advanced Shielded Metal Arc Machine Cutting ..190. Welding Manual Plasma Arc Gouging ..191. Root Hot Pass ..127 Filler Weld Shop Keeps Coast Guard Ready ..197. Cover Plate Preparing Specimens for Testing ..134. Restarting a Weld Bead ..135 Chapter 9 Related Cutting Processes Preheating and Postheating ..135 Poor Fit ..143 Laser Beam Cutting (LBC) and Laser Beam Drilling (LBD).

9 201. Artists Honored at International Institute Lasers ..201. of Welding (IIW) Assembly ..145 Applications ..203. Laser Beam Laser Beam Drilling ..204. Laser SECTION 3 Air Carbon Arc Cutting ..204. Manual Torch Design ..205. CUTTING AND GOUGING. Oxygen Lance Cutting ..211. Chapter 7 Flame Cutting Applications ..211. Water Jet Metals Cut by the Oxyfuel Applications ..212. Eye Protection for Flame Cutting Torches ..151. Lasers: The New Wave in Ship Cutting Oxyfuel Cutting, Setup, and Hand Cutting ..159. Layout ..163. Selecting the Correct Tip and Setting SECTION 4. the GAS SHIELDED Welding . The Chemistry of a Cut.

10 165. The Physics of a Cut ..166 Chapter 10 Gas Metal Arc Welding Equipment, Plate Cutting ..168 Setup, and Operation Cutting Table ..168 Torch Guides ..169 Metal Filler Metal Specifications ..225. Cutting Wire Melting and Deposition Pipe Welding Power Molten Weld Pool Control ..228. Contents vii Equipment ..231 Spot Welding ..236 Welding Lends Architectural Flair to Airport Simple Steps to Achieving Better Gas Metal Arc Welding ..239. Chapter 14 Other Constant-potential Welding Processes Chapter 11 Gas Metal Arc Welding Submerged Arc Welding (SAW)..336. Setup ..242 Weld Travel ..336. Gas Density and Flow Rates.


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