LIMITED OFFER
Save 50% on book bundles
Immediately download your ebook while waiting for your print delivery. No promo code needed.
Applied Welding Engineering
Processes, Codes, and Standards
- 3rd Edition - June 2, 2020
- Author: Ramesh Singh
- Language: English
- Paperback ISBN:9 7 8 - 0 - 1 2 - 8 2 1 3 4 8 - 3
- eBook ISBN:9 7 8 - 0 - 1 2 - 8 2 2 3 9 9 - 4
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-d… Read more
Purchase options
Institutional subscription on ScienceDirect
Request a sales quoteApplied 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.
- Includes the very latest on automation and robotic welding in advanced manufacturing environments
- Explains how to weld a range of common metals, also including technical instructions
- Provides coverage of international codes and standards relevant to welding
- Addresses a wide range of practical welding themes, including stresses and distortion, corrosion, weld defects and nondestructive testing
Researchers, students and practitioners working in fields related to welding technology
- 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
- No. of pages: 442
- Language: English
- Edition: 3
- Published: June 2, 2020
- Imprint: Butterworth-Heinemann
- Paperback ISBN: 9780128213483
- eBook ISBN: 9780128223994
RS
Ramesh Singh
Ramesh Singh, MS, IEng, MWeldI, is registered as Incorporated Engineer with British Engineering Council UK and a Member of The Welding Institute, UK. He worked as engineer for various operating and EPC organizations in Middle East, Canada and US. Most recently, he worked for 10 years with Gulf Interstate Engineering, Houston, TX. He is now consulting in the fields of pipeline integrity and related materials and corrosion topics. Ramesh is a graduate from Indian Air Force Technical Academy, with diplomas in Structural Fabrication Engineering and Welding Technology. He has been member and officer of the Canadian Standard Association and NACE and serves on several technical committees. He has worked in industries spanning over aeronautical, alloy steel castings, fabrication, machining, welding engineering, petrochemical, and oil and gas. He has written several technical papers and published articles in leading industry magazines, addressing the practical aspects of welding, construction and corrosion issues relating to structures, equipment and pipelines.
Affiliations and expertise
Senior Principal Engineer (Materials, Welding and Corrosion) for Gulf Interstate Engineering and Consultant, Management of Welding, Materials, and Corrosion, Nadoi Management, Inc.Read Applied Welding Engineering on ScienceDirect