ISO 4063 : NOMENCLATURE OF WELDING AND ALLIED PROCESSES

Transcription

1 ISO 4063 : NOMENCLATURE OF WELDING AND ALLIED PROCESSES CHRONOLOGICAL OVERVIEW ( ) Stjepan Gangur Key words: welding and allied processes, nomenclature of processes 1-INTRODUCTION According to many, the basic grouping of welding processes is in two categories: fusion welding and welding with pressure. Although these two welding process' groups are detailed and separated in many literature, realistic look according to numbers and diversity of processes telling that is necessary to do more detailed separation and dividing of processes. Although there was earlier some standards that gave separations and reference numbers of welding processes, first real detail separation (together with nomenclature) was as standard ISO 4063 Welding, brazing, braze welding and soldering of metals ; List of processes for symbolic representation on drawings. This paper deals with chronological overview of separation and welding processes nomenclature from first edition of standard till fifth, and last edition 2011 (actually, there are just 4 editions of standard, the fifth is just correction of fourth edition in some few numerical designations). According to this standard, welding processes was originally divided into 5 basic groups, and later editions provided 6 groups of welding processes. Since the standard also separate and nomenclature allied processes to welding brazing, soldering, braze welding, cutting and gouging, that processes are also elaborated in this paper. 2- ARC WELDING Arc welding is fusion welding in which heat for welding is obtained from an electric arc or arcs. This group of welding was always most spreaded and most used, and processes from this group of welding are more and more developing all the time, and there are regulary modifications, semiautomatic or fully automatic types of some of these processes. Nomenclatured with basic number 1, first edition of standard ISO year, divide arc welding in 6 basic categories: Without gas protection: 111 Metal arc-welding with covered electrode 112 Gravity arc welding with covered electrode 113 Bare wire metal-arc welding 114 Flux cored metal-arc welding 115 Coated wire metal-arc welding 118 Firecracker welding 12 Submerged arc welding: 121 SAW with wire electrode 122 SAW with strip electrode 13 Gas-shielded metal-arc welding: 131 MIG welding 135 MAG welding; metal-arc welding with non-inert gas shield 136 Flux cored metal-arc welding with non-inert gas shield 14 Gas-shielded welding with non-consumable electrode: 141 TIG welding; Gas tungsten arc welding 149 Atomic-hydrogen welding 15 Plasma arc welding 18 Other arc welding processes: 181 Carbon-arc welding 185 Rotating arc welding CHRONOLOGICAL OVERVIEW ( ) 1

2 The second edition of standard which came introduced unnecessary reference number 101 Metal-arc welding. Another change was in splitting of two processes; plasma welding recieved the subprocess 151 Plasma MIG welding, and MIG welding process as itself was separated like MAG process in first edition; Metal-arc inert gas welding (131) and Flux-cored wire metal-arc welding with inert gas shield (137). The third edition of standard from finally officially introducing reference number for arc welding without gas protection (11), but still leaves unclear number 101. Since the some of arc welding processes in meantime became obsolete and became very rarely in use, 1998 nomenclature system retires folowing processes: 113 (Bare wire metal-arc welding), 115 (Coated wire metal-arc welding) and 118 (Firecracker welding). Submerged arc welding was now detailed into: 121 SAW with one wire electrode 122 SAW with strip electrode 123 SAW with multiple wire electrodes 124 SAW with metallic powder addition 125 SAW with tubular cored electrodes Sub-group 13 (Gas-shielded metal-arc welding) was intacted, and from sub-group 14 the process 149 (Atomic-hydrogen welding) was retaired. Plasma welding gets one more sub-group; 152 Powder plasma arc welding. From sub-group 18, 181 process (Carbon-arc welding) was retired because it was obsoleted in the meantime. It took 11 years for fourth edition of ISO 4063 standard, so it was published in year As some processes in meantime became more developed, especially TIG, plasma and MIG/MAG welding, it was expected for more detailed sub-grouping of this processes in this international standard. In edition the reference number 101 is finally retired, and also the reference number 123 (SAW with multiple wire electrode) is not valid anymore (see 10 Process variants). Flux-cored wire metalarc welding with inert gas shield is not anymore 137; now it is nomenclatured with 132. The arc welding processes sub-grouping, nomenclature and reference numbers from 2009 edition is same like in last (2011) edition of standard, and today it looks like this: 11 Metal arc welding without gas protection 111 Manual metal arc welding (metal arc welding with covered electrode); Shielded metal arc welding (USA) 112 Gravity (arc) welding with covered electrode; Gravity feed welding (USA) 114 Self-shielded tubular cored arc welding 12 Submerged arc welding (SAW) 121 SAW with solid wire electrode 122 SAW with strip electrode 124 SAW with metallic powder addition 125 SAW with tubular cored electrode 126 SAW with cored strip electrode 13 Gas-shielded metal arc welding; Gas metal arc welding (GMAW (USA)) 131 MIG welding with solid wire electrode; GMAW using inert gas and solid wire electrode (USA) 132 MIG welding with flux cored electrode; Flux cored arc welding (USA) 133 MIG welding with metal cored electrode; GMAW using inert gas and metal cored wire (USA) 135 MAG welding with solid wire electrode; GMAW using active gas with solid wire electrode (USA) 136 MAG welding with flux cored electrode; GMAW using active gas and flux cored electrode (USA) CHRONOLOGICAL OVERVIEW ( ) 2

3 138 MAG welding with metal cored electrode; GMAW welding using active gas and metal cored electrode (USA) 14 Gas-shielded arc welding with non-consumable tungsten electrode; Gas tungsten arc welding (USA) 141 TIG welding with solid filler naterial (wire/rod); Gas tungsten arc welding using inert gas and solid filler material (wire/rod) (USA) 142 Autogenous TIG welding; Autogenous gas tungsten arc welding using inert gas (USA) 143 TIG welding with tubular cored filler material (wire/rod); Gas tungsten arc welding using inert gas and tubular cored material (wire/rod) (USA) TIG welding using reducing gas and solid filler material (wire/rod); Gas tungsten arc welding using inert gas plus reducing gas additions and solid filler material (wire/rod) (USA) 146 TIG welding using reducing gas and tubular cored filler material (wire/rod); Gas tungsten arc welding using inert gas plus reducing gas additions and tubular cored filer material (wire/rod) 147 Gas-shielded arc welding with non-consumable tungsten electrode using active gas (TAG welding); Gas tungsten arc welding using active gas (USA) 15 Plasma arc welding 151 Plasma MIG welding 152 Powder plasma arc welding 153 Plasma arc welding with transferred arc 154 Plasma arc welding with non-transferred arc 155 Plasma arc welding with semi-transferred arc 18 Other arc welding processes 185 Magnetically impelled arc welding 3- RESISTANCE WELDING Nomenclatured with reference number 2, resistance welding is welding with pressure in which the heat necessary for welding is produced by resistance to an electrical current flowing through the welding zone. First edition of standard ISO 4063:1978, as resistance welding processes specifying: 21 Spot welding 22 Seam welding 221 Lap seam welding 225 Seam welding with strip 23 Projection welding 24 Flash welding 25 Resistance butt welding 29 Other resistance welding processes 291 HF resistance welding The only change in second edition of standard (1990) is sub-grouping of Seam welding into Lap seam welding (221), Mash seam welding (222) and Seam welding with strip (225). The third edition of standard in year 1998 introducing more detailed sub-grouping of resistance welding. Spot welding is divided on Indirect (211) and Direct (212) spot welding. Seam welding now have more two more sub-groups: Mash seam welding (222) and Foil butt-seam welding (225). The process that had reference number in earlier editions, now gets new reference number 226 Seam welding with strip. As spot welding, Projection welding also is now divided on Indirect (231) and CHRONOLOGICAL OVERVIEW ( ) 3

4 Direct (232) projection welding. Flash welding is divided in two sub-groups: with (241) and without preheating (242). The fourth edition of standard removes HF resistance welding from Other resistance welding processes and nomenclature it with number 27. Seam welding is again much more detailed, and Resistance stud welding is not anymore in Other welding processes (782 see chapter 7 Other welding processes) than it's in (this) Resistance welding processes group. The resistance welding processes sub-grouping, nomenclature and reference numbers from 2009 edition is also same like in last (2011) edition of standard, and today it looks like this: 21 Resistance spot welding, Spot welding (USA) 221 Indirect spot welding 222 Direct spot welding 22 Resistance seam welding; Seam welding (USA) 221 Lap seam welding 222 Mash seam welding 223 Prep-lap seam welding 224 Wire seam welding 225 Foil butt-seam welding 226 Seam welding with strip 23 Projection welding 231 Indirect projection welding 232 Direct projection welding 24 Flash welding 241 Flash welding with preheating 242 Flash welding without preheating 25 Resistance butt welding; Upset welding (USA) 26 Resistance stud welding 27 High-frequency resistance welding; High-frequency upset welding (USA) 29 Other resistance welding processes. 4. GAS WELDING The main reference number which represent gas welding is number 3. Gas welding is fusion welding, with or without filler metal, in which the heat for welding is produced by the combustion of the fuel gas or gases with an admixture of oxygen. First nomenclature of gas welding in divided gas welding in two main groups: 31 Oxy-fuel gas welding 311 Oxy-acetilene welding 312 Oxy-propane welding 313 Oxy-hydrogen welding 32 Air-fuel gas welding 321 Air-acetilene welding 322 Air-propane welding In the third edition of standard (1990) group 32 is not anymore in nomenclature system because that kind of gas welding is obsolete. And sub-grouping of sub-group 31 remains same until today, and it looks loke this: 31 Oxy-fuel gas welding 311 Oxy-acetilene welding 312 Oxy-propane welding 313 Oxy-hydrogen welding CHRONOLOGICAL OVERVIEW ( ) 4

5 5. WELDING WITH PRESSURE According to many definitions, the main separation of welding processes is fusion welding and welding with pressure. From it's first edition, standard ISO 4063 separates some welding processes with pressure as one separated group. The basic definition of welding with pressure is that is the welding in which sufficient outer force is applied to cause more or less plastic deformation of both the faying surfaces, generally without the addition of filler metal. Usually, but not necessarily, the faying surfaces are heated in order to permit or to facilitate unifying. The first edition of standard (1978) gives main reference number 4 to this processes, and separatate it into: 41 Ultrasonic welding 42 Friction welding 43 Forge welding 44 Welding by high mechanical energy 441 Explosive welding 45 Diffusion welding 47 Gas pressure welding 48 Cold welding The second edition of standard does make no changes, and in third edition (1990) Forge welding (43) is retired as obsolated process. The fourth edition of standard (2009) brings some changes and introducing some new processes, and nomenclature and reference numbers from that edition are still valid today: 41 Ultrasonic welding 42 Friction welding 421 Direct drive friction welding 422 Inertia friction welding 423 Friction stud welding 43 Friction stir welding 44 Welding by high mechanical energy 441 Explosion welding 442 Magnetic pulse welding 45 Diffusion welding 47 Oxyfuel gas pressure welding; Pressure gas welding (USA) 48 Cold pressure welding, Cold welding (USA) 49 Hot pressure welding 6. BEAM WELDING Beam welding are fusion welding processes using a focused beam of high energy radiation. This welding processes were in first two editions of standard ISO 4063 classified under the other welding processes (see part 7). As beam welding were developing, it was expected for this processes to have it's own standalone separated nomenclature order and to be seperated as separated welding processes group, what was happened in the third edition ISO Since that edition, beam welding are nomenclatured with main reference number 5, and it have two main sub-groups: 51 Electron beam welding 511 Electron beam welding in vacuum 512 Electron beam welding in atmosphere 52 Laser welding 521 Solid state laser wedling 522 Gas laser welding The fourth edition of standard adds two new processes, and since the last edition (2011) haven't changed anything, nomenclature system of beam welding today is: CHRONOLOGICAL OVERVIEW ( ) 5

6 51 Electron beam welding 511 Electron beam welding in vacuum 512 Electron beam welding in atmosphere 513 Electron beam welding with addition of shielding gases 52 Laser welding; Laser beam welding (USA) 521 Solid state laser welding 522 Gas laser welding 523 Diode laser welding; Semi-conductor laser welding (USA) 7. OTHER WELDING PROCESSES There are certain welding processes which are hard to put in some specific group, so these processes in nomenclature system are sorted out from the other groups and nomenclatured with reference number 7. Some of these processes are fusion processes, some are processes with pressure, or both. In this group are also some of the stud welding processes. Some of other welding processes are became more developed with time, so that processes are lately removed from this group and separated into their own group (beam welding). First system that divided the other welding processes, in ISO 4063:1978, classified here: 71 Thermit welding 72 Electroslag welding 73 Electrogas welding 74 Induction welding 75 Light radiation welding 751 Laser welding 752 Arc image welding 753 Infrared welding 76 Electron beam welding 77 Percussion welding 78 Stud welding 781 Arc stud welding 782 Resistance stud welding The second edition of standard didn't changed anything, and in the third edition of standard Beam welding becomes their own welding group, so Laser welding process have new reference number 52, and Electon beam welding process have reference number 51. The unique reference number for arc stud welding (781) don't exist anymore because arc stud welding is now splitted into 5 different processes: Drawn arc stud welding with ceramic ferrule or shielding gas (783), Short-cycle drawn arc stud welding (784), Capacitor discharge drawn arc stud welding (785), Capacitor discharge stud welding with tip ignition (786) and Drawn arc stud welding with fusible collar (787). Third edition also introducing Friction stud welding (788). In the sub-group of Light radiation welding the only process that left is Infrared welding (753), and Arc image welding is removed from nomenclature system as obsolated process. Induction welding is splitted into Butt (741) and Seam (742) welding. The fourth edition of standard, 2009., removes Percussion welding (77) as obsolated. Resistance stud welding (782) is removed into Resistance welding group and now it's nomenclatured with number 26, and also Friction stud welding (788) is removed into the Welding with pressure group and now it have reference number 423. Electroslag welding is now divided in two sub-groups, and Induction welding gets one more sub-group. As in fifth edition of standard nothing has been changed here that has been changed in fourth edition, the nomenclature of other welding processes nowdays is: CHRONOLOGICAL OVERVIEW ( ) 6

7 71 Aluminothermic welding; Thermite welding (USA) 72 Electroslag welding 721 Electroslag welding with strip electrode 722 Electroslag welding with wire electrode 73 Electrogas welding 74 Induction welding 741 Induction butt welding; Induction upset welding (USA) 742 Induction seam welding 743 Induction HF welding 75 Light radiation welding 753 Infrared welding 78 Arc stud welding 783 Drawn arc stud welding with ceramic ferrule or shielding gas; Arc stud welding (USA) 784 Short-cycle drawn arc stud welding; Arc stud welding (USA) 785 Capacitor discharge drawn arc stud welding; Arc stud welding (USA) 786 Capacitor discharge stud welding with tip ignition; Arc stud welding (USA) 787 Drawn arc stud welding with fusible collar 8. CUTTING AND GOUGING Cutting and gouging are processes allied with welding. Thermal cuttings including processes which are intended to separating or gouging, i.e. creating of groove half round or similiar cross section on material, by applying thermal energy without mechanical cutting tools. Gouging is forming of a groove by means of thermal cutting through melting or burning. The third edition of standard 1998 introducing nomenclature system for these processes. The main reference number for it is number 8, and detailed, first dividing was: 81 Flame cutting 82 Arc cutting 821 Air arc cutting 822 Oxygen arc cutting 83 Plasma cutting 84 Laser cutting 86 Flame gouging 87 Arc gouging 871 Air arc gouging 872 Oxygen arc gouging 88 Plasma gouging The fourth edition of standard gave some details to plasma cutting, and as fifth edition remains the same, today sub-grouping of these processes is: 81 Flame cutting; Oxygen cutting, Oxyfuel cutting (USA) 82 Arc cutting 821 Air arc cutting; Air carbon arc cutting (USA) 822 Oxygen arc cutting 83 Plasma cutting; Plasma arc cutting (USA) 831 Plasma cutting with oxidising gas 832 Plasma cutting without oxidising gas 833 Air plasma cutting 834 High-tolerance plasma cutting CHRONOLOGICAL OVERVIEW ( ) 7

8 84 Laser cutting; Laser beam cutting (USA) 86 Flame gouging; Thermal gouging (USA) 87 Arc gouging 871 Air arc gouging; Air carbon arc cutting (USA) 872 Oxygen arc gouging; Oxygen gouging (USA) 88 Plasma gouging 9. BRAZING, SOLDERING AND BRAZE WELDING Brazing and soldering are processes of joining metals using a metled filler metal with a lower melting point than the parent metal, and which is wetting the surface of heated parent metal and which is, during of after heating, drawn into (or if it's setted before) retained in the narrowed gap between the components to be joined. Soldering is using filler metal with maximum melting point of 450 C, and brazing is using filler metal with melting point above 450 C, but in both cases, always below the melting temperature of parent material. Braze welding is joining of metals using a technique similar to fusion welding and a filler metal with a lower melting point than the parent metal, but neither using capillary action as in brazing nor intentionally melting the parent metal. The first edition of standard (1978. Year) gives this process main number 9, and dividing was: 91 Brazing 911 Infrared 912 Flame 913 Furnace 914 Dip 915 Salt bath 916 Induction 917 Ultrasonic 918 Resistance 919 Diffusion 923 Fricton 924 Vacuum 93 Other brazing processes 94 Soldering 941 Infrared 942 Flame 943 Furnace 944 Dip 945 Salt bath 946 Induction 947 Ultrasonic 948 Resistance 949 Diffusion 951 Flow 952 With soldering iron 953 Friction 954 Vacuum 96 Other soldering processes 97 Braze welding 971 Gas 972 Arc The second edition of standard from didn't change anything in brazing or braze welding. In soldering designation 953 becoming abrasion soldering, and there is new number 956 for drag soldering. In the third edition of standard, three processes are withdrawned as obsolated: ultrasonic brazing (917), friction brazing (923) and abrasion soldering (953). The fourth edition of standard from Introducing new processes, withdrawning obsolated processses and brings considerable changes in nomenclaturing of this processes. Brazing and soldering are divided into two main groups: with local heating and with global heating. Also, braze welding is richer with 5 new processes, and just nomenclaturing of that 5 processes, accidentaly or with purpose, was nomenlatured "wrong and that was the reason for revision of 4th edition, and publishing of final edition ISO With explanations of differences in editions from and 2011., the nomenclature of this processes today looks like this: CHRONOLOGICAL OVERVIEW ( ) 8

9 91 Brazing with local heating 911 Infrared brazing 912 Flame brazing; Torch brazing (USA) 913 Laser beam brazing 914 Electron beam brazing 916 Induction brazing 918 Resistance brazing 919 Diffusion brazing 92 Brazing with global heating 921 Furnace brazing 922 Vacuum brazing 923 Dip-bath brazing 924 Salt-bath brazing 925 Flux-bath brazing 926 Immersion brazing 93 Other brazing processes 94 Soldering with local heating 941 Infrared soldering 942 Flame soldering; Torch soldering (USA) 943 Soldering with soldering iron 944 Drag soldering 945 Laser soldering 946 Induction soldering 947 Ultrasonic soldering 948 Resistance soldering 949 Diffusion soldering 95 Soldering with global heating 951 Wave soldering 953 Furnace soldering 954 Vacuum soldering 955 Dip soldering 957 Salt-bath soldering 96 Other soldering processes 97 Weld brazing; Braze welding (USA) 971 Gas weld brazing; Gas braze welding (USA) 972 Arc weld brazing; Arc braze welding (USA) 973 Gas metal arc weld brazing; Gas metal arc braze welding (USA) Gas tungsten arc weld brazing; Gas tungsten arc braze welding (USA) Plasma arc weld brazing; Plasma arc braze welding (USA) Laser weld brazing; Laser braze welding (USA) Electron beam weld brazing; Electron beam braze welding (USA) 1 1 In fourth edition of ISO 4063, five new braze welding processes was nomenclatured with numbers 983,984,985,986 i 987, but in fifth edition that was revised in above mentioned reference numbers (so, the problem was in number 8). 10. ADITIONAL DESIGNATION As some of the processes was developed (i.e. parallel using of two different filler materials), and since it was obvious that some things should be better explained (f.e. transfer modes), it was neccessary to define additional designation in nomenclature system of ISO That was defined CHRONOLOGICAL OVERVIEW ( ) 9

10 just in fourth edition from 2009., although before that it was in wide using. As additional designation, the 4 items was defined Transfer modes For welding processes where different transfer modes are possible, the transfer mode may be indicated in accordance with following designation: D short-circuit transfer G globular transfer S spray transfer P pulsed transfer F.e. : MIG welding with solid wire electrode using short-circuiting transfer is designated as: ISO D 10.2 Number of electrodes If more than one electrode is used, it may be indicated by number. F.e. : MIG welding with two solid electrodes is designated as: ISO Additional filler material If additional filler material is used, it's indicated in accordance with following designation: C cold wire H hot wire F.e. : Submerged arc welding with a single wire electrode and additional cold wire is designated as: ISO C 10.4 Hybrid welding processes When more than one welding process is used simultaneously in one process area, the processes may be describes using the designation for each process separated by a plus symbol ("+") I.e.: The use of laser and plasma welding together would be designated as : ISO 4063: CONCLUSION This article describes, by cronological order, the designation, changes, adding or removing of processes through 4 (i.e. 5) edition of nomenclature system ISO So what can we expect in some of upcoming edition of this standard? Before all, there is nowhere in nomenclature system splitting of automatized or automatic welding from manual welding; neither by numbers neither by additional designation. Nowhere is mentioned neither orbital welding, neither CMT welding, neither some new variants of TIG process (TOP TIG or TIP TIG), nowhere is mentioned many new varaints of MIG/MAG processes, robot welding processes The stud welding processes are totally scattered and probably the good idea would be to think of separately nomenclaturing of this group of processes. Maybe also it should be defined at least additional designation for overlay welding, cladding, underwater welding Because a lot of that in this system of nomenclaturing is pretty undefined! 12. BIBLIOGRAPHY [1] ISO 4063 : 1978 Welding, brazing and soldering of metals; List of processes for symbolic representation on drawings [2] ISO 4063 : 1990 Welding, brazing, soldering and braze welding of metals Nomenclature of processes and reference numbers for symbolic representation on drawings [3] ISO 4063 : 1998 Welding and allied processes Nomenclature of processes and reference numbers [4] ISO 4063 : 2009 Welding and allied processes Nomenclature of processes and reference numbers [5] ISO 4063 : 2011 Welding and allied processes Nomenclature of processes and reference numbers [6] BS : 2009 Welding terms and symbols Part 1 : Glossary for welding, brazing and thermal Cutting [7] Slobodan Kralj i Šimun Andrić Osnove zavarivačkih i srodnih postupaka, 1992 CHRONOLOGICAL OVERVIEW ( ) 10