Handbook. Gas Tungsten Arc Welding. Sixth Edition. William H. Minnick Mark A. Prosser. Welding/Fabrication Instructor. Janesville, Wisconsin

Transcription

1 Gas Tungsten Arc Welding Handbook Sixth Edition William H. Minnick Mark A. Prosser Welding/Fabrication Instructor Black hawk Technical College Janesville, Wisconsin

2 6 Gas Tungsten Arc Welding Handbook Table of Contents Chapter 1 Gas Tungsten Arc Welding History and Safety History 12 GTAW Hazards 13 Safety in the Shop 16 Chapter 2 Power Sources Power Source Basics 30 Types of Power Sources 38 Power Source Controls.45 Power Source Selection 47 Power Source Installation 47 Power Source Maintenance 47 Chapter 3 Auxiliary Equipment and Systems Auxiliary High-Frequency Generators 52 Pulsers 53 Slope Controllers 54 Timers 55 Remote Controls 55 GTAW Torches 56 Gas Lens 59 Cables, Hoses, Connectors, and Valves 59 Electrodes 64 Chapter 4 GTAW Shielding Gases and Filler Metals 71 Shielding Gases 72 Shielding Gas Purity 74 Shielding Gas Supply 74 Shielding Gas Storage 75 Shielding Gas Distribution 75 Shielding Gas Safety 79 Filler Metals 71 80

3 Table of Contents 7 Chapter 5 Weld Joints and Weld Types Weld Types 88 Welding Terms and Symbols 93 Design Considerations 96 Welding Positions 102 Chapter 6 Tooling 105 Design Concepts 106 Types of Tools Application and Operation of Tooling 107 Tooling Materials, 107 Backing Bar Design. 108 Hold-Down Bar Design Tooling Maintenance Test Tooling Auxiliary Tooling Ill Ill Ill Chapter 7 Weld Preparation and Equipment Setup Welding Procedure Specifications 117 Job and Equipment Considerations 118 Preweld Cleaning 119 Equipment and Welding Machine Setup 122 Chapter 8 Manual Welding Techniques Base Materials (Steel) 128 Filler Metals 129 Joint Preparation 131 Torch Angles and Bead Placement 131 Types of Beads/Passes 134 Welding Steels Using DCEN (Straight) Polarity 135 Welding Procedure Specifications (WPS) 136 Reading the Weld Pool 145 Postweld Treatment 151

4 8 Gas Tungsten Arc Welding Handbook Chapter 9 Manual Welding of Aluminum Base Materials 154 Filler Metals 156 Joint Preparation for Welding Aluminum 156 Welding Aluminum Using AC High-Frequency (ACHF) Polarity 159 Welding Aluminum Using DCEN (Straight) Polarity 162 Welding Aluminum Using DCEP (Reverse) Polarity 165 Welding Procedures 166 Chapter 10 Manual Welding of Stainless Steel Base Materials 172 Material Problems Associated with Stainless Steel : 175 Filler Metals 175 Preparation of Stainless Steel 177 Welding Stainless Steel Using DCEN (Straight) Polarity 180 Procedure for Welding Stainless Steel 180 Postweld Heat Treatment 182 Chapter 11 Manual Welding of Magnesium Base Materials 186 Filler Metals : 186 Weld Joint Design 187 Welding Magnesium Using AC High-Frequency (ACHF) Polarity 188 Welding Magnesium Using DCEN (Straight) Polarity. 190 Welding Magnesium Using DCEP (Reverse) Polarity 190 / Chapter 12 Manual Welding of Copper and Copper Alloys Base Materials 194 Filler Metals 194 Weld Joint Design and Fitup 194 Welding Copper Using DCEN (Straight) Polarity 197 Welding Castings of Copper 199 Postweld Treatment of Castings 199

5 Table of Contents 9 Chapter 13 Manual Welding of Nickel, Nickel Alloys, and Cobalt Alloys Base Materials 202 Material Problems Associated with Nickel and Cobalt Alloys 202 Filler Metals 202 Weld Preparation 204 Welding Nickel, Nickel Alloys, and Cobalt Alloys Using DCEN (Straight) Polarity 205 Procedure for Welding Nickel and Cobalt 206 Chapter 14 Manual Welding of Titanium Base Material 210 Filler Metals '. 210 Preweld Preparation 211 Welding Titanium Using DCEN (Straight) Polarity 214 Techniques for Welding Titanium and Titanium Alloys 215 Sources of Contamination 215 Chapter 15 Manual Welding of Dissimilar Metals Material Combinations/Applications 218 Filler Metals 221 Joint Preparation 221 Joint Cleaning 225 Welding 226 Chapter 16 Manual Welding of Pipe Joint Designs 230 Joint Preparation 230 Pipe Purging 234 Fitup and Tack Welding 237 Welding Techniques 238 Chapter 17 Semiautomatic and Automatic Welding Semiautomatic Welding 246 Welding Schedules 257 Automatic Welding 261

6 10 Gas Tungsten Arc Welding Handbook Chapter 18 Weld Inspection and Repair Inspection Areas 266 Types of Inspection 266 Weld Repair 276 Chapter 19 Qualification, Certification, and Employment Specifications and Codes 284 Careers 285 Workplace Skills 287 Estimating Costs 287 Maintaining the Workplace 290 Equipment Inspection 290 AWS (SENSE) Welder Certification Program 290 Reference Section 292 Glossary of Welding Terms 308 Index 315