Welding Handbook Seventh Edition, Volume 2 Welding Processes- Arc and Gas Welding and Cutting, Brazing, and Soldering The Five Volumes of the Welding Handbook, Seventh Edition 1 Fundamentals of Welding 2 Welding Processes- Arc and Gas Welding and Cutting, Brazing, and Soldering 3 Welding Processes- Resistance and Solid State Welding and Other Joining Processes 4 Engineering Applications-Materials 5 Engineering Applications-Design Welding Handbook Seventh Edition, Volume 2 Welding Processes- Arc and Gas Welding and Cutting, Brazing, and Soldering W.H. Kearns, Editor AMERICAN WELDING SOCIETY 2501 Northwest 7th Street Miami, Florida 33125 Macmillan Education Published in the U.K. and distributed in Europe 1978 by THE MACMILLAN PRESS LTD London and Basingstoke ISBN 978-1-349-04295-1 ISBN 978-1-349-04293-7 (eBook) DOI 10.1007/978-1-349-04293-7 American Welding Society, 2501 N.W. 7th Street, Miami, FL 33125 ©1978 by American Welding Society. Softcover reprint of the hardcover 7th edition 1978 978-0-333-25666-4 All rights reserved. Note: By publication of this handbook, the American Welding Society does not insure anyone utilizing this handbook against liability arising from the use of such handbook. A publication of a handbook by the American Welding Society does not carry with it the right to make, use, or sell patented items. Each prospective user should make an independent investigation. Contents Welding Handbook Committee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix Preface.............................................................. xi Chapter 1, Arc Welding Power Sources .. , ............................... . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Open-Circuit Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 NEMA Power Source Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Alternating Current Power Sources, Constant Current . . . . . . . . . . . . . . . . . . . . . 16 Direct Current Power Sources, Constant Current . . . . . . . . . . . . . . . . . . . . . . . . . 23 Direct Current Power Sources, Constant Voltage . . . . . . . . . . . . . . . . . . . . . . . . . 29 Special Power Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Solid State Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Supplementary Reading List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Chapter 2, Shielded Metal Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Fundamentals of the Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Joint Design and Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Welding Procedures ................. : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Quality of the Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 4 Supplementary Reading List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Chapter 3, Gas Tungsten Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Fundamentals of the Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 General Process Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Process Variables .................................................. 104 Welding Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7 Weld Quality ..................................................... 110 Supplementary Reading List ......................................... 112 v CONTENTS Chapter 4, Gas Metal Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Fundamentals of the Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Equipment ....................................................... 120 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Process Variables .................................................. 137 Welding Procedures ................................................ 143 Weld Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Process Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Gas Metal Arc Spot Welding ......................................... 149 Narrow Gap Welding ............................................... 151 Supplementary Reading List ......................................... 152 Chapter 5, Flux Cored Arc Welding ...................................... 153 Fundamentals of the Process ......................................... 154 Equipment ....................................................... 157 Materials ........................................................ 161 Process Control ................................................... 169 Joint Designs and Welding Procedures ................................. 174 Weld Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186 Supplementary Reading List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 Chapter 6, Submerged Arc Welding ..................................... 189 Fundamentals of the Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 General Process Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 Operating Variables ................................................ 202 Types of Welds .................................................... 209 Welding Procedures ................................................ 213 Weld Quality ..................................................... 222 Supplementary Reading List ......................................... 223 Chapter 7, Electroslag and Electrogas Welding ............................. 225 Introduction ...................................................... 226 Electroslag Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226 Electrogas Welding ................................................ 248 Supplementary Reading List ......................................... 260 Chapter 8, Stud Welding ............................................... 261 Introduction ............................................· . . . . . . . . . . 262 Process Capabilities and Limitations ................................... 263 Arc Stud Welding .................................................. 264 Capacitor Discharge Stud Welding .................................... 282 Process Selections and Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291 Supplementary Reading List ......................................... 294 vi Contents Chapter 9, Plasma Arc Welding ......................................... 295 FundwmentdsofthePTocess ......................................... 296 Equipment ....................................................... 302 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310 General Process Applications .............•.......................... 314 Advantages and Limitations .......................................... 315 Joint Designs ..................................................... 316 Welding Procedures ................................................ 317 Welding Conditions ................................................ 324 Weld Quality ..................................................... 328 Safety Recommendations ............................................ 329 Supplementary Reading List ......................................... 330 Chapter 10, Oxyfuel Gas Welding ....................................... 331 Fundwmentals of the Process ......................................... 332 Characteristics of Fuel Gases ......................................... 333 Oxyfuel Gas Welding Equipment ..................................... 341 Applications of Oxyfuel Gas Welding .................................. 356 Welding Procedures ................................................ 362 Welding with Other Fuel Gases ....................................... 366 Supplementary Reading List ......................................... 367 Chapter 11, Brazing ................................................... 369 Fundwmentds ..................................................... 370 Brazing Processes ................................................. 371 Base Metals ...................................................... 376 Brazing Filler Metals ............................................... 387 Fluxes and Atmospheres ............................................ 397 Joint Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407 Brazing Equipment and Techniques .................................... 421 Brazing Procedures ................................................ 428 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430 Safe Practices in Brazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433 Braze Welding .................................................... 434 Supplementary Reading List ......................................... 438 Chapter 12, Soldering ................................................. 439 Fundwmentals of the Process ......................................... 440 Solders .......................................................... 442 Fluxes ........................................................... 448 Joint Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449 Precleaning and Surface Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451 Soldering Methods and Equipment .................................... 452 Flux Residue Theatment ............................................. 457 Supplementary Reading List ......................................... 458 vii CONTENTS Chapter 13, Arc and Oxygen Cutting ..................................... 459 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460 Oxyfuel Gas Cutting ............................................... 460 Arc Cutting ...................................................... 499 Supplementary Reading List ......................................... 515 Chapter 14, Surfacing ................................................. 517 Fundamentals of the Process ......................................... 518 Special Considerations .............................................. 524 Surfacing Methods ................................................. 530 Base Metals for Hardfacing Overlays .................................. 550 Metallurgy of Surfacing Alloys ....................................... 551 Surfacing Filler Metals .............................................. 553 Supplementary Reading List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 562 Index of Major Subjects ................................................ 563 Index ............................................................... 575 viii Welding Handbook Committee A.W. Pense, Chairman Lehigh University W. L. Wilcox, Vice-Chairman Gilbert-Commonwealth W.H. Kearns, Secretary American Welding Society /.G. Betz Department of the Army J.R. Condra E. I. DuPont de Nemours & Co. R .L. Frohlich Westinghouse Electric Corp. A.F.Manz Union Carbide Corp. L.J. Privoznik Westinghouse Electric Corp. R.E. Somers Bethlehem Steel Corp. l.L. Stern American Bureau of Shipping R.T. Telford* Union Carbide Corp. S. Weiss* University of Wisconsin-Milwaukee *Membership expired May 31, 1977 ix