01 Welding

208281 Workshop Practice Created by Prateep Chaisermtawan
(Welding)
3
1.

1,000 .
19
Edmund Davy
.. 2344 Sir Humphry Davy
()

Auguste de Meritens
.. 2424 Auguste de Meritens
.. 2428 Bernados N. Olszeweskis

()
.. 2431 N.G. Slavianoff
.. 2435 C.L. Coffin
.. 2435 N.G. Slavianoff
()
.. 2455 Kjellberg

2.
2
()
.. 2473 2 Gobart Devers

.. 2485 The Linde Company
GTAW (Gas Tungsten-Arc Welding)
TIG 2

()
GTAW
GTAW(TIG)

.. 2491 GMAW (Gas

Metal-Arc Welding)
GMAW

GMAW(MIG)

()
3.

(ASW) 50
()
(Soldering : S)
(Brazing : B)
(Solid-State Welding : SSW)
(Arc Welding : AW)
(Oxyfuel Gas Welding : OFW)
(Resistance Welding : RW)
American Welding Society : AWS

()
(Adhesive Bonding : ABD)
(Thermal Spraying : THSP)
(Arc Cutting : AC)
(Thermal Cutting :TC)
(Oxygen Cutting : OC)
AWS
()
(Arc Welding : AW)

(Submerged Arc Welding : SAW)
(Stud Arc Welding : SW)
(Shield Metal Arc Welding : SMAW)

(Plasma Arc Welding : PAW)
(Gas Tungsten Arc Welding : GTAW)
(Gas Metal Arc Welding : GMAW)
(Bare Metal Arc Welding : BMAW)
(Atomic Hydrogen Welding : AHW)
(Carbon Arc Welding : CAW)
AWS

()
(Oxyfuel Gas Welding : OFR)
(Pressure Gas Welding : PGW)

-
(Oxyhydrogen Welding : OHW)
-
(Oxyacetylene Welding : OAW)
-
(Air Acetylene Welding : AAW)
AWS
()
(Solid-State Welding : SSW)
(Forge Welding : FOW)

(Explosion Welding : EXW)
(Diffusion Welding : DFW)
(Cold Welding : CW)
(Roll Welding : ROW)
(Hot Pressure Welding : HPW)
(Ultrasonic Welding : USW)
(Friction Welding : FRW)
AWS

()
(Resistance Welding : RW)
(Upset Welding : UW)

(Projection Welding : RPW)
(Resistance Seam Welding : RSEW)
(Resistance Spot Welding : RSW)
(HFRW)
(PEW)
(FW)
AWS
()
(Electron Beam Welding : EBW)

(Flow Welding : FLOW)
(Laser Beam Welding : LBW)

(Thermit Welding : TW)
(Induction Welding : IW)
AWS

()
(Soldering : S)
(Resistance Soldering : RS)

(Torch Soldering : TS)
(Wave Soldering : WS)
(Iron Soldering : INS)
(Furnace Soldering : FS)
(Induction Soldering : IS)
(Infrared Soldering : IRS)

(Dip Soldering : DS)
AWS
()
(Brazing : B)
(Block Brazing : BB)

(Diffusion Brazing : DFB)
(Dip Brazing : DB)
(Flow Brazing : FLB)
(Induction Brazing : IB)

(Infrared Brazing : IRB)
(Resistance Brazing : RB)
(Torch Brazing : TB)
(Twin Carbon Arc Brazing : TCAB)

(Furnace Brazing : FB)
AWS
10

()
(Oxygen Cutting : OC)
(Oxyfuel gas Cutting : OFC)

- - (Oxyhydrogen Cutting : OFC-H)
- - (Oxyacetylene Cutting : OFC-A)
- - (Oxynatural Cutting : OFC-N)
- - (Oxypropane gas Cutting : OFC-P)
(Metal Powder Cutting : POC)

(Oxygen Arc Cutting : AOC)
(Chemical Flux Cutting : FOC)
(Oxygen Lance Cutting : LOC)
AWS
()
(Arc Cutting : AC)

(Plasma Arc Cutting : PAC)
(Metal Arc Cutting : MAC)
(Shield Metal Arc Cutting : SMAC)
(Carbon Arc Cutting : CAC)
(Gas Meta Arc Cutting : GMAC)
(Gas Tungsten Arc Cutting : GTAC)

-
(Air Carbon Arc Cutting : AAC)
AWS
11

()
(Laser Beam Cutting : LBC)
(Electron Beam Cutting : EBC)
AWS
()
(Thermal Spraying : THS)
(Flame Spraying : FLSP)

(Plasma Spraying : PSP)
(Electric Arc Spraying : EASP)
AWS
12
(Welding Processes)

40
Gas Metal Arc Welding:

GMAW
Gas Tungsten Arc Welding:
GTAW
Plasma Arc Welding:

PAW
Shield Metal Arc Welding:
SMAW
Submerged Arc Welding:
SAW
Oxy-acetylene Welding:
OAW
13

1.
(Shield Metal Arc Welding Process : SMAW)

2.
(Submerged Arc Welding Process : SAW)

3.
(Gas Metal Arc Welding Process : GMAW)

4.
(Gas Tungsten Arc Welding)

5.
-
(The Oxy-acetylene Welding Process : OAW)
6.

(Electrode)
(Base Metal) ( 3,300 C 5,500C )

14

SMAW

1.

2.

3.

4.

5.
-
6.
15

(Flux
Hopper)

SAW
16

1.

2.

3.

4.

5.
-
6.

(MIG Metal Inert
Gas)

17

GMAW
(Shielding Gas) Ar, He, CO2

18

1.

2.

3.

4.

5.
-
6.

(TIG
Tungsten Inert Gas)
(Tungsten Electrode)

19

GMAW
(Shielding Gas) Ar, He
20

1.

2.

3.

4.

5.
-
6.
-

(O2) (C2H5)
( 3,100 C 3,500 C)

21
-
OAW

1.

2.

3.

4.

5.
-
6.
22

TIG
(Constricted Arc)
(Transferred
Arc)
(Constricting Orifice)
23
5 (5 Types of Joints)
1. Butt joint
2

5 ()
2. Corner joint
2

24
5 ()
3. Lap joint
2
5 ()
4. Tee joint
2
T
25
5 ()
5. Edge joint
2
(Types of Welds)
Fillet Weld 4
a.
b.
c. 2
d. T
26
()
Groove Weld 6
a. 1
b. 1
c. V 1
()
d. U 1
e. J 1
f. V 1
27
()
Spot Weld 2
2

(Butt Weld)
(PA Flat)
(PC Horizontal Vertical)

(PE Overhead)
28

(Butt Weld)
(PF Vertical Upwards)
(PG Vertical Downwards)

(Fillet Weld)
(PA Flat)
(PB Horizontal Vertical)
29

(Fillet Weld)
(PG Vertical Downwards)
(PF Vertical Upwards)
(PD Horizontal Overhead)
30
31

(Melting point)

1,482 C
(Weld ability)

()
(Fusibility)

(Volatility)

32
()
(Electrical conductivity)

(Electrical resistance)

()
(Thermal conductivity)

(Coefficient
of thermal expansion)

33
()
(Hot shortness)

(Overheating)

()
(Hot shortness)

(Overheating)

34

Shielded metal-arc-welding : SMAW

>>

6000 oF 9000 oF (3315 oC 4982 oC)
35
2
1.) (Resistance welding)
2.) (Arc welding)

10,000 12,000
3
(Cathode)
(Anode)
(Arc Plasma)
36
(Polarity)
>> DCPR DCSP
d.c. ()
>> A.C.
A B
(Welding Current) 2
(Alternating Current : AC)

-
50 Hz (1 50 )
(Direct Current : DC)

-
100 Hz
37
(Slag)

38
1) / (Type of Power Source)

2
1.1) (output slop)
39
1.2) 3
- -
-
-
-
-
>> -
-

-
- /
40
400
-

-
1.
2.
3.
/
4.

>>
41
>>
a.c. d.c.
>> -

1)
2)
3)
4)
--
42
>>
-
- 1/120
>>
>> ( 0.01 .)
>>
>>
>> (0.01 . 20 )
>>

43
Laser
Competing Process
Advantages of Laser Welding
Gas Metal Arc
1 2
Submerged Arc
Resistance Welding

on-line processing
radiation shielding
Electron Beam
Robot9 Axis Arc Welding
RobotTwin Weld Gun Cell

robotic welding and cutting systems
44
2) (Electrode holders)
-
-
-

-

-
400
200

2 4148 oC
45
-
3)

-
-

()
100
150
200
250
300
350
400
450
500
50
75
100
125
150
175
200
2
2
2
2
1
1/0
1/0
2/0
3/0
2
2
1
1/0
2/0
3/0
3/0
3/0
4/0
2
1
1/0
2/0
3/0
4/0
4/0
2
1/0
2/0
3/0
4/0
1
2/0
3/0
4/0
1/0
2/0
4/0
1/0
3/0
4/0
46
-
4)
(Cable Lugs and Ground Clamps)
-
-

-
-
5)
>>
>> 2
1) 2)
>>
47

>>
>>
>>
>>
>>
- /
48

>>
>>
>>
>>
>>
>>
49
-
-
-
50
6
1.
2.
3.
4.
(Correct Electrode)
(Welding Position)
(Correct Current)
(Correct Arc Length or
Voltage)
5. (Correct Electrode Angle)
6. (CorrectTravel Speed)
1. (Correct Electrode

>>
>> =>
>> =>
>> =>
>> =>
>>
>>
51
>>
>>
>>
>>
>>
: (Preheating)
(psi)
(psi)
50 60,000
38 45,000
60 75,000
45 60,000
55 70,000
30 32,000
(% 2 )
5.0 10.0
20.0 40.0
30.0 40.0
(%)
10.0 20.0
35.0 60.0
(%)
8.0 20.0
35.0 65.0
60.0 70.0
(gm/cm3)
(psi)
ft./ib
7.5 7.7
7.80 7.85
7.85
12 18,000
26 30,000
26 30,000
5-15
40-70
50 - 80
52

E 4 5
E XX X X
/
1
2
3
100
psi ( 2 3 5 )
AWS
E 6010
E 6011
E 6012
DCRP
DCRP a.c.
DCSP a.c.
E 6013
E 7014
DCSP, DCRP a.c.

DCSP, DCRP a.c.
E 7015
DCRP
(30%)
E 7016
E 7018
DCRP a.c.
DCRP a.c.
E 7020
DCSP,DCRP a.c.
(25%)
E 7024
E 6027
E 7028
DCSP,DCRP a.c.
DCSP,DCRP a.c.
DCRP a.c.
/ 50%
/ (50%)
/ (50%)
53
E 6010
E
60
1
0

60,000 psi

DCRP
2. (Welding Position)
>>
>>
>>
>> => =>
54
E XX20, E XX24,
E XX27, E XX28
E XX15, E XX16,
E XX18, E XX12,
E XX13, E XX20,
E XX24, E XX27,
E XX28
E 6012

E XX10()
E XX11, E XX16,
E XX18
E 6010
E 6011 E 6010
E XX12, E XX13,
(
)
3. (Correct Current)
-
>>
>>
>>
55
Undercut
Undercut
No Overlap
Overlap
Overlap
()
()
E6010,
E6011DC+
E6012
E6013
E6020
E6027
E7014
E7015,
E7016
E7018
E7024,E
7028
1/16
5/64
3/32
40 - 80
20-40
25-60
35-85
20-40
25-60
45-90
80-125
65-110
70-100
100-145*
1/8
5/32
3/16
75125
110170
140-215
80-140
110-190
140-240
80-130
105-180
150-230
100-150
130-190
175-250
125-185
160-240
210-300
110-160
150-210
200-275
100-150
140-200
180-255
115-165
150-220
200-275
140-190
180-250
230-305
7/32
1/4
5/16
170-250
210-320
275-425
200-300
250-400
300-500
210-300
250-350
320-430
225-310
275-375
340-450
250-350
300-420
375-475
260-340
330-415
390-500
240-320
300-390
375-475
260-340
315-400
375-470
275-365
335-430
400-525*
56
4. (Correct Arc Length or

Voltage)
>>
>>
>>
>>
(
) (Arc blow)
: Arc Blow
57
5. (Correct Electrode Angle)

>> =>
>> =>
6. (CorrectTravel
Speed)
>>
>> /
58

1)
2)
3)
4)
5)
6)
7)
59

:
>>
>> (
:
>> 90 0
100 200
>> Arc blow
>>
>>

(
)
60
:
>>
>>
>>
B
C
61
590
:
>>
>>
>>
>>
62
DCSP A,C,
63
:
>> 900
>> 300
>>
>>
DCRP A.C.
:
>>
>> 300
>>
>> /
64
:
>> (d.c. 120 -170 a.c.
130 190 )
>> 900
50 -150
>>
65
DCRP A.C.

>>
>>
: V
>>
>> 900 100 200
>>
66
V DCRP A.C.
(Underwater welding)
>>
>>
>>
()
>> /
67
68
3
1. Drag or self-consuming technique
2. Oscillation technique
3. Step-back technique
Drag or self-consuming technique
Oscillation technique
>>
>>
>>
/
Step-back technique
>> - (
2-3 )
>>
69

- 15o 45o
self-consuming Technique
(General Shop Precautions)

1.
2. , , ,
3.
4.
70
5.
6.

7.
8.
9.

(Safety in Arc
Welding)
1.
>>
>>

71
2.

2
2.1 (Ultra-Violet Radiation)
>>

Arc eye
>> 6
12-24
>>
2.2 (Infrared Radiation)
>> (Filter lens)

>> , ,
,
72
3.
>>
>>
>>
>>

1.
2.
3.
(filter lens)
4.

73
5.
6.

7.
8.
9.
10.
11.

74
Jig & Figture
75
Jig & Figture
76
77
78
79
80
81

(
)
82
83
Q&A
(Metal Inert Gas Welding :

MIG)
84
()
()
85
()
()
86
()

1.
>> ,
2. >>
3.
4. DIN JIS .
87
AWS5.18 AWS5.28
ER XX S X
x 1,000 psi
()
ER 70S 6 Mild Steel Electrodes

ER =
70 = 70,000 psi
S =
6 =
88
()
ER 80S B2L Low Alloy Steel Electrodes

ER =
80 = 80,000 psi
S =
B2 =
L =
()
ER316 L Stainless Steel Electrodes

ER =
316 =
L =
89
()
90
0.13 0.4
1.6
(.)
3.2 4.8 6.4 10 12.7 19
25
91
()
92

1.

()
2.

93
()
3.
()
4.
94
()
5.

95
()
60%
()
85%
96
97
()
()
98
()
Q&A
99
(Welding) (3/4)
(Tungsten Inert Gas Welding : TIG)

(Spot Welding/Resistance Welding)
(Resistance Seam Welding)
(Robotic Welding)
100
(Tungsten Inert Gas Welding :

TIG)
()
101
()
3,410 C
(WIG)
()
102
()
()
103
()
()
104
()
()
105
(Plasma Arc Welding :

PAW)
20,000 C
()
106
()
()
107
()
()
108
()
()
109
(Spot Welding/Resistance
Welding)

(Mass production)

~10,000
()
110
(Spot Welding
Cycle)
()

(1)
(2)
(3)
(4)
(5)
111
()
(
)
()
( 1 )
112
(Resistance Seam
Welding)

(Mass production)
()
113
()
(Robotic Welding)
(Mass production)

114
()
2
1. Rectilinear robots
x y z

()
2. Articulating robots

115
Q&A
116
(Welding) (4/4)
117
()

()

118
DIN JIS .
1.5 2 .
()
119
1.5 .

28%
120

1.
2.
2.1
2.2
3.
4.
121
()
1. (.)
= (.) x (./.) x
(./.) x (./.)
2.
2.1 (.)
= (.) x (./.) x (./.)

(./.) x (%)
= (.) x (./.)
()
(%)
10 20 30 40 50 60 70 80 90 100
122
()
2.2. (.)
= () x () x (.) x (./. - .)
(%)
3. (.)
= +
( )
()

(.)

2,400
2,400
8.5
400
600
200
2,400
2,400
3,600
123
()

Q&A
124

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
1.
2.
3.
125

3
1) >>
2) >>
3) >> /
(Nondestructive Testing)
(Magnetic Particle Testing)

(Radiographic)
(Penetrant Inspection)
(Red Dye Penetrant)
(Ultrasonic Inspecton)
(Eddy Current Testing)
(Leak Testing)
(Hardness Testing)
126
(WPS)
127

, ,
, 2529
, ,
,2524
End of Welding
128

01 Welding

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01 Welding

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208281 Workshop Practice Created by Prateep Chaisermtawan

.. 2344 Sir Humphry Davy

.. 2428 Bernados N. Olszeweskis

.. 2431 N.G. Slavianoff

.. 2435 C.L. Coffin

.. 2435 N.G. Slavianoff

.. 2473 2 Gobart Devers

.. 2491 GMAW (Gas

(Solid-State Welding : SSW)

(Arc Welding : AW)

(Oxyfuel Gas Welding : OFW)

(Resistance Welding : RW)

American Welding Society : AWS

(Adhesive Bonding : ABD)

(Thermal Spraying : THSP)

(Arc Cutting : AC)

(Thermal Cutting :TC)

(Oxygen Cutting : OC)

(Arc Welding : AW)

(Shield Metal Arc Welding : SMAW)

(Gas Tungsten Arc Welding : GTAW)

(Gas Metal Arc Welding : GMAW)

(Bare Metal Arc Welding : BMAW)

(Atomic Hydrogen Welding : AHW)

(Carbon Arc Welding : CAW)

(Oxyfuel Gas Welding : OFR)

(Pressure Gas Welding : PGW)

(Solid-State Welding : SSW)

(Forge Welding : FOW)

(Roll Welding : ROW)

(Hot Pressure Welding : HPW)

(Ultrasonic Welding : USW)

(Friction Welding : FRW)

(Resistance Welding : RW)

(Upset Welding : UW)

(Electron Beam Welding : EBW)

(Laser Beam Welding : LBW)

(Resistance Soldering : RS)

(Furnace Soldering : FS)

(Induction Soldering : IS)

(Infrared Soldering : IRS)

(Block Brazing : BB)

(Induction Brazing : IB)

(Twin Carbon Arc Brazing : TCAB)

(Oxygen Cutting : OC)

(Oxyfuel gas Cutting : OFC)

(Metal Powder Cutting : POC)

(Arc Cutting : AC)

(Shield Metal Arc Cutting : SMAC)

(Carbon Arc Cutting : CAC)

(Gas Meta Arc Cutting : GMAC)

(Gas Tungsten Arc Cutting : GTAC)

(Laser Beam Cutting : LBC)

(Electron Beam Cutting : EBC)

(Thermal Spraying : THS)

(Flame Spraying : FLSP)

208281 Workshop Practice Created by Prateep Chaisermtawan

208281 Workshop Practice Created by Prateep Chaisermtawan

Gas Metal Arc Welding:

Plasma Arc Welding:

208281 Workshop Practice Created by Prateep Chaisermtawan

(Shield Metal Arc Welding Process : SMAW)

(Submerged Arc Welding Process : SAW)

(Gas Metal Arc Welding Process : GMAW)