Applied Welding Engineering

Applied Welding Engineering: Processes, Codes and Standards, Third Edition, provides expert advice on how to comply with international codes and work them into "day-to-day" design, construction and inspection. This new edition covers advances in automation and robotic welding in advanced manufacturing, the applications of friction stir welding, and standards and codes. The science of metallurgy, including Alloys, Physical Metallurgy, Structure of Materials, Non-Ferrous Materials, Mechanical Properties and Testing of Metals and Heal Treatment of Steels is also considered, as are Welding Metallurgy, Welding Processes, Nondestructive Testing and Codes and Standards. Case studies bridge the gap between theory and the world of welding engineering.

Other topics cover Mechanical Properties and Testing of Metals, Heat Treatment of Steels, Effect of Heat on Material During Welding, Stresses, Shrinkage and Distortion in Welding, Welding, Corrosion Resistant Alloys-Stainless Steel, Welding Defects and Inspection, Codes, Specifications and Standards.

Cover image
Title page
Table of Contents
Copyright
Dedication
Preface to the first edition
Preface to the second edition
Preface to the third edition
Acknowledgments
Section 1: Introduction to Basic Metallurgy
1: Introduction
Abstract
Pure metals and alloys
Smelting
Iron
2: Alloys
Abstract
Alloys
Effects of alloying elements
Alloy steels
The effect of alloying elements on ferrite
Effects of alloying elements on carbide
3: Physical metallurgy
Abstract
Crystal lattices
Crystal structure nomenclature
Solidification
Constitutional supercooling
Elementary theory of nucleation
Allotropy
Crystal imperfections
Grain size
4: Structure of materials
Abstract
Phase diagrams
Different types of phase diagrams
Iron-iron carbide phase diagram
Explanation of iron-carbon phase diagram
Rationale for letter designations in iron-iron carbide phase diagram
5: Production of steel
Abstract
Electric arc furnace (EAF) process
Furnace charging
Melting
Refining
Phosphorus removal
Sulfur removal
Nitrogen and hydrogen control
Deslagging
Tapping
Basic oxygen furnace (BOF)
Refining reactions
Carbon
Silicon
Manganese
Phosphorus
Sulfur removal
Deoxidation of steel
Deoxidation equilibria
Practical case emphasizing the importance of deoxidation of steel for critical welding applications
Iron-iron carbide phase diagram
6: Classification of steels
Abstract
Carbon steels
Low-carbon
Medium-carbon
High-carbon
Ultrahigh-carbon
High-strength low-alloy steels (HSLA)
Classification of high-strength low-alloy steels
Low-alloy steels
AISI series
Material classification through the processing methods
Recrystallization rolling
Dynamic recrystallization-controlled rolling
7: Cast iron and cast steel
Abstract
Types of cast iron
White cast iron
Malleable cast iron
Ferritic malleable iron
Pearlite malleable cast iron
Martensitic malleable iron
Gray cast iron
Castability of gray cast iron
Chilled cast iron
Nodular (spheroidal graphite) cast iron
Castability, solidification, and shrinkage
Alloy cast irons
Corrosion, wear, abrasion, and heat resistance of alloy cast irons
Classification of special high-alloy cast irons
Steel castings
ASTM A 781/A 781M: Castings, steel and alloy, common requirements for general industrial use
8: Stainless steels and other CRAs
Abstract
Stainless steel production
Fabrication of stainless steel
Welding and joining
Types of stainless steels
Classification of stainless steel
Martensitic stainless steels
Properties of martensitic stainless steel
Ferritic stainless steels
Pitting resistance equivalent
Austenitic stainless steels
Properties of austenitic stainless steel
Duplex stainless steels
Precipitation-hardening stainless steels
9: Nonferrous materials
Abstract
Copper and copper alloys
Aluminum and aluminum alloys
Physical metallurgy of aluminum
Effect of alloying elements on aluminum
Age-hardenable alloys
Nickel and nickel alloys
Titanium and titanium alloys
10: Working with metals
Abstract
Elastic limit
Plastic deformation
Fracture
Polycrystalline material
Cold-working
Stored energy
Restoring the lattice structure of metal after cold-work—Annealing
Grain growth
Hot-working
11: Mechanical properties and testing of metals
Abstract
Strength of materials
Elastic and plastic behavior
Ductile vs brittle behavior
Failure
Fracture
Fracture control
Crack growth and fracture
Failure analysis
Testing of metals
12: Heat treatment of steels
Abstract
TTT and CCT curves
Stress relief annealing
Normalizing
Annealing
Spheroidizing
Tempering
Austempering of steels
Hardening
Case hardening and carburizing
Process of quenching
Heat treatment of nonferrous material
Heat-treating furnaces
Liquid heating bath
Section 2: Welding Metallurgy and Welding Processes
1: Introduction
Abstract
Welding procedures
2: Physics of welding
Abstract
Heat
Heat in arc-welding processes
Heat in plasma arc cutting and welding
Heat in resistance welding
Heat in electroslag welding (ESW)
Heat in welding process using chemical sources
Heat generated by mechanical processes
Heat by focused sources
Laser-beam welding (LBW)
Electron-beam welding (EBW)
Other sources of heat in welding
Application of the principles of welding physics
Preheating
Postweld heat treatment (PWHT)
Heat and time in welding
Heat input
Energy distribution
Rate of heating
Maximum temperature
Heat generation and temperature distribution—Practical application
Time at temperature
Cooling rates
Base metal mass
3: Welding and joining processes
Abstract
Shielded metal arc welding (SMAW)
How the process works
Covered electrodes used in SMAW process
Joint design and preparation
Gas tungsten arc welding
Process advantages and limitations
Electrodes
Joint design
Gas metal arc welding
Process description
Electrode selection
Joint design
Gas metal arc welding: Newer variants
The pulse arc systems
Flux cored arc welding (FCAW)
Principal applications of FCAW
Shielding gases
Electrodes
Submerged arc welding (SAW)
Materials
Other common joining and welding processes
Plasma arc welding
Stud welding
Oxyfuel gas welding
Brazing and soldering
Hyperbaric welding
Arc-welding power sources
Development of square wave AC power sources
4: Welding automation
Abstract
Mechanized and automatic welding
Welding automation and robots
5: Physical effect of heat on material during welding
Abstract
The molten metal
The welded plate
Influence of cooling rate
6: Stresses, shrinkage, and distortion in weldments
Abstract
Stresses in weldments
Development of stresses
Distribution of stress in a simple weld
Residual stresses
Shrinkages
Shrinkage longitudinal to a butt weld
Distortion in weldments
Corrective measures
Thermal straightening
Designing weld joints
Welding of carbon steel and low alloys
Welding challenges associated with reducing environment
Welding and fabrication of low-alloy steels
Challenges of 9-chrome-moly and microalloyed 9-chrome steel
Properties of 9Cr-1Mo steels’ alloy that contributed to its use
Quality assurance
Selection of weld consumable and postweld heat-treatment temperatures
Intercritical region and tempering
Phenomena of over- and undertempering
Hardness testing
Determining creep damage of in-service equipment
Fabrication and weldability of HSLA steel
Welding high strength steels
Forming and working with HSLA steel
Welding HSLA steel
Typical filler metal selection
Filler metal selection
Heat input control
Corrosion
7: Welding, corrosion-resistant alloys—Stainless steel
Abstract
Corrosion-resistant alloys (CRAs)
Stainless steel
Welding stainless steel
Welding processes
Protection against oxidation
Welding hygiene
Filler metals
Austenitic stainless steels
Superaustenitic stainless steels
Martensitic stainless steels
Ferritic stainless steels
Precipitation hardening stainless steels
Duplex stainless steels
Welding and fabrication
8: Welding nonferrous metals and alloys
Abstract
Aluminum and alloys
Confusing things about aluminum
Weld hygiene
Preheating
Welding aluminum with shield metal arc welding (SMAW) process
Welding aluminum with gas tungsten arc welding process
Welding aluminum with gas-metal-arc-welding process
Welding technique
Shielding gas
Welding wire
Friction stir welding
Nickel alloys
Titanium alloys
9: Weld defects and inspection
Abstract
Weld quality
Classification of weld joint discontinuities
Typical weld defects
Base metal discontinuities
Designing weld joints
Welding and quality assurance
Section 3: Nondestructive Testing
1: Introduction
Abstract
2: Visual inspection (VT)
Abstract
Advantages of visual inspection
3: Radiography
Abstract
Source of radiation
X-ray
Film
Radiographic exposure techniques
Radiographic image quality
Image quality indicator (IQI) or penetrameter
Radiation safety
4: Magnetic particle testing
Abstract
Principles of magnetic particle testing
Calculating magnetizing current
Type of magnetizing current
Drying after preparation
Application of the current
Alternating current
Direct current
Continuous or residual application of current
5: Penetrant testing
Abstract
General procedure
Drying after preparation
Techniques
Interpretation
Evaluation
6: Ultrasonic testing
Abstract
An introduction to the world of sound
Theory of sound wave and propagation
Theory of sound
Piezoelectricity
Sound beam reflection
Sound beam frequencies
Sound beam velocities
Snell's law of reflection and refraction
Selection of test equipment
Testing procedure
Automization of ultrasonic testing systems
The recording system
Mapping (TOFD)
7: Eddy current testing
Abstract
Method
Advantages and disadvantages of eddy current inspection system
8: Acoustic emission testing (AET)
Abstract
Ongoing developments in AET field
Future of AET
9: Ferrite testing
Abstract
Effect of ferrite in austenitic welds
10: Pressure testing
Abstract
Purpose
Method
Test medium
Sensitivity of the test
Proof testing
Practical application of hydrostatic testing
Critical flaw size
Section 4: Codes and Standards
1: Introduction
Abstract
2: Codes, specifications, and standards
Abstract
American Society of Mechanical Engineers (ASME)
American Petroleum Institute
American Society for Testing Materials (ASTM)
Det Norske Veritas (DNV)
Canadian Standards Association (CSA)
Welding-related specifications from European norm and International Standards Organization
EN ISO 15607, specification and qualification of welding procedures for metallic materials—General rules
EN ISO 15608, welding—Guidelines for a metallic materials grouping system
EN ISO 15610, specification and qualification of welding procedures for metallic materials—Qualification based on tested welding consumables
EN ISO 15611, specification and qualification of welding procedures for metallic materials—Qualification based on previous welding experience
EN ISO 15612, specification and qualification of welding procedures for metallic materials—Qualification by adoption of a standard welding procedure
EN ISO 15613, specification and qualification of welding procedures for metallic materials—Qualification based on preproduction welding test
EN ISO 15614, specification and qualification of welding procedures for metallic materials—Welding procedure test—Part 1: Arc and gas welding of steels and arc welding of nickel and nickel alloys
EN ISO 9606 (five parts) welder approval testing
Index

Life Sciences

Physical Sciences & Engineering

Social Sciences & Humanities

Health

Applied Welding Engineering

Processes, Codes, and Standards

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Ramesh Singh