Volume 06 - Welding, Brazing and Soldering Part 5 doc

TABLE 1 STUD-WELDING PROCESS SELECTIONCAPACITOR DISCHARGE STUD WELDING WELDING GAP AND CONTACT METHODS DRAWN ARC METHOD STUD SHAPE... TABLE 2 GAS FLOW RATES FOR ALUMINUM STUD ARC WELDING

TABLE 1 STUD-WELDING PROCESS SELECTION

CAPACITOR DISCHARGE STUD WELDING

WELDING

GAP AND CONTACT METHODS

DRAWN ARC METHOD

STUD SHAPE

STUD DIAMETER OR AREA

STUD METAL

BASE METAL

BASE-METAL THICKNESS

STRENGTH CRITERIA

TABLE 2 GAS FLOW RATES FOR ALUMINUM STUD ARC WELDINGSTUD WELD BASE DIAMETER SHIELDING GAS FLOW(A)

TABLE 3 TYPICAL STUD WELDING SETTINGS

s cycl es

m m

in m m in.

CURRE

NT, A

s cycl es

m m

in m m in.

CURRE

NT, A

s cycl es

m m

in m m in.

STEEL AND STAINLESS STEEL

ALUMINUM(A)

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TABLE 4 DIMENSIONS FOR COUNTERBORE AND COUNTERSINK WELD FLASH CLEARANCE

COUNTERBORE 90° COUNTERSINK STUD BASE DIAMETER

TABLE 5 RECOMMENDED BASE METAL THICKNESSES FOR STUD ARC WELDING

STUD BASE

TABLE 6 TYPICAL COMBINATIONS OF BASE AND STUD METALS FOR STUD ARC WELDING

TABLE 7 MECHANICAL PROPERTIES OF LOW-CARBON STEEL STUD ARC WELDED FASTENERS

MEAN EFFECTIVE THREAD AREA (B)

YIELD TENSILE LOAD (C)

ULTIMATE TENSILE LOAD

YIELD TORQUE (D)

ULTIMATE TORQUE

ULTIMATE SHEAR LOAD (E)

TABLE 8 MECHANICAL PROPERTIES OF STAINLESS STEEL STUD ARC WELDED FASTENERS

MEAN EFFECTIVE THREAD AREA (B)

YIELD TENSILE LOAD (C)

ULTIMATE TENSILE LOAD

YIELD TORQUE (D)

ULTIMATE TORQUE

ULTIMATE SHEAR LOAD (E)

STUD

THREAD

DIAMETER (A)

TABLE 9 MECHANICAL PROPERTIES OF ALUMINUM STUD ARC WELDED FASTENERS

MEAN EFFECTIVE THREAD AREA (B)

YIELD TENSILE LOAD (C)

ULTIMATE TENSILE LOAD

YIELD TORQUE (D)

ULTIMATE TORQUE

ULTIMATE SHEAR LOAD (E)

STUD THREAD

DIAMETER (A)

mm2 in.2 kn lbf kn lbf j ft · lbf j ft · lbf kn lbf

≤ ≤

TABLE 1 STANDARD CAPACITOR DISCHARGE STUD FASTENER LOAD STRENGTHS

MAXIMUM FASTENING

ULTIMATE TENSILE LOAD

MAXIMUM SHEAR LOAD

SIZE

TABLE 2 WELDING CAPABILITIES OF CAPACITOR DISCHARGE STUD FASTENERS

STUD MATERIAL BASE MATERIAL

MILD STEEL (TYPES 1008, 1010)

STAINLESS STEEL (TYPES 304, 305)

ALUMINUM (5356, 6061)

BRASS (70-30, 65-35)

Equipment

TABLE 1 COMPARISON OF FILLER WIRE MELTING RATES FOR PLASMA-MIG WELDING WITH AND WITHOUT THE GMAW ARC

DIAMETER OF FILLER WIRE

MELTING RATE OF FILLER WIRE

PLASMA ARC

CURRENT, A

PLASMA ARC VOLTAGE, V

FILLER WIRE CURRENT, A

MIG-ARC VOLTAGE, V

mm in g/min oz/min

TABLE 2 COMPARISON OF WELDING SPEEDS FOR GMAW AND PLASMA-MIG WELDING OF ALUMINUM AND STEEL

PLASMA-MIG

TABLE 3 WELD SURFACING PARAMETERS FOR STAINLESS STEEL DEPOSITS ON MILD STEEL USING PLASMA-MIG WITH FLUX-CORED WIRES

WELDING SPEED

DEPOSITIO

N RATE

INNER WIRE STICK- OUT

MIG WELDIN

G CURREN

T, A

MIG WELDIN

G VOLTAG

E, V

PLASMA WELDIN

G CURREN

T, A

PLASMA WELDIN

G VOLTAG

E, V mm/

mi

in./mi n

kg/

h

lb/h m m in.

DILUTIO

N, %

FERRIT

E NO.

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(EQ 1)

(EQ 2)

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TABLE 1 PROJECTION AND DIE GEOMETRIES FOR WELDING A RANGE OF HEAVY-GAGE STEELS

PROJECTION PUNCH DIE MATERIAL

HEIGHT

(P),

±2%

HOLE DIAMETER

(D), ±0.1

MM (±0.005 IN.)

RECESS RADIUS

TABLE 2 PROCESS REQUIREMENTS FOR PROJECTION WELDING OF A RANGE OF HEAVY-GAGE LOW-CARBON STEELS

PROJECTION SIZE MINIMUM THICKNESS

(A)(B)

DIAMETER HEIGHT MINIMUM

SPACING, CENTERLINE

TO CENTERLINE

MINIMUM CONTACT OVERLAP

ELECTRODE FORCE WELD

ELECTRODE FORCE FORGE

SHEAR STRENGTH (F)

WELD- TIME (D) , CYCLES

WELDING CURRENT (C) , A

mpa ksi

SCHEDULE A: WELDING NORMAL-SIZED WELDS

SCHEDULE B: WELDING SMALL-SIZED WELDS

TABLE 3 PROJECTION AND DIE GEOMETRIES FOR WELDING A RANGE OF INTERMEDIATE-GAGE STEELS TO MAKE SPHERICAL PROJECTIONS

POINT RADIUS

(R ), ±0.05

MM (±0.002 IN.)

HOLE DIAMETER

(B ), ±0.1

MM (±0.005 IN.)

CHAMBER DIAMETER

(D)

USS

GAGE

NO.

mm in mm in mm in mm in mm in mm in mm in.

TABLE 4 PROCESS REQUIREMENTS FOR PROJECTION WELDING OF A RANGE OF GAGE LOW-CARBON STEELS

INTERMEDIATE-PROJECTION SIZE MATERIAL

THICKNESS DIAMETER HEIGHT

MINIMUM SPACING CENTERLINE TO CENTERLINE

MINIMUM CONTACT OVERLAP

CONFIGURATION USS

GAGE NO.

WELDING SCHEDULE B (FOR 1-3 PROJECTIONS), EACH PROJECTION(G)

WELDING SCHEDULE C (FOR [GES]3 PROJECTIONS), EACH PROJECTION(H)

TABLE 5 PROJECTION DESIGNS AND PROCESS REQUIREMENTS FOR ANNULAR PROJECTION WELDING OF THIN-GAGE LOW-CARBON STEEL

TENSILE-SHEAR STRENGTH EACH PROJECTION (F)

THICKNESS (A)(B

)

MINIMUM SPACING CENTERLIN

E TO CENTERLIN E

MINIMUM CONTACT OVERLAP

WELDING CURRENT (E) , A

mp a

ksi mp a ksi

TABLE 6 PROCESS REQUIREMENTS FOR CROSS-WIRE WELDING OF HOT- AND COLD-DRAWN STEEL WIRES IN A RANGE OF THICKNESSES

COLD-DRAWN WIRE HOT-DRAWN WIRE

WIRE

DIAMETE

R

WELD FORCE

WELD STRENGTH

WELD FORCE

WELD STRENGT H

, A

mpa ksi

WELD TIME (A)

, CYCLE S

kn lbf

WELDING CURRENT (B )

, A

mpa ksi

15% SETDOWN

30% SETDOWN

50% SETDOWN

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WELDING HANDBOOK

EQUIPMENT SPECIFICATIONS AND WELDING PARAMETERS

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(EQ 1)

L, N

(EQ 7)

(EQ 8)

(EQ 9)

(EQ 10)

TABLE 1 THEORETICAL PARAMETERS FOR LAP SEAM WELDING OF TWO EQUAL SHEETS OF MILD STEEL (PER EQ 2, 3, 4, 5, 6, 7, 8, 9, 10)

COATED OR UNCOATED (A)

UNCOATED (A), ONE SPOT UNDER WHEEL (N

IMPULSED CURRENT (I)

STACKUP

(SMIN )

WELD ZONE LENGTH

(L)

TRAVEL SPEED

(V)

STACKUP

(SMIN )

WELD ZONE LENGTH

(L)

TRAVEL SPEED

(V)

STACKUP

(SMIN )

WELD ZONE LENGTH

(L)

TRAVEL SPEED

s

in./mi n

s in./mi n

(EQ 11)

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TABLE 1 ENERGY CONSUMPTION AND EFFICIENCY OF LBW RELATIVE TO OTHER SELECTED WELDING PROCESSES

INTENSITY OF ENERGY SOURCE WELDING PROCESS

w/cm2 w/in.3

JOINING EFFICIENCY,

FUSION ZONE PROFILE

TABLE 2 PARAMETERS FOR SELECTED PULSED AND CONTINUOUS WAVE LASERS USED FOR LBW APPLICATIONS

MAXIMUM WELD

WELDING SPEED

LENGTH, MS

PULSE ENERGY, J

PEAK POWER,

PULSED

CONTINUOUS WAVE

PULSED CONTINUOUS WAVE

TABLE 3 PARAMETERS FOR HIGH-POWER LBW RELATIVE TO ALLOY TYPE FOR BEAD-ON-PLATE JOINTS

THICKNESS

LASER POWER, KW

μ μ

PR PR

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TABLE 4 TYPICAL OUTPUT POWER OF COMMERCIALLY AVAILABLE CW CO 2 LASERS

PER CAVITY LENGTH FLOW CONFIGURATION TYPE

ELECTRIC EXCITATION DISCHARGE(A) w/m w/ft

TABLE 1 ENERGY BALANCE IN THE SLAG PHASE OF ELECTROSLAG WELDING

EFFECT OF WELDING PARAMETERS ON WELD METAL POOL SHAPE

EFFECT OF PARAMETER INCREASE ON WELD-METAL

(F = W/H)

(EQ 1)

π

=

I V W

R

(EQ 3)

−

=

CONSTITUENT CONTENT, WT%

CONSTITUENT CONTENT, WT%

→ (EQ 5)

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