Volume 06 - Welding, Brazing and Soldering Part 12 pdf

References cited in this section Welding of Aluminum Alloys Paul B.. Dickerson, Aluminum Company of America retired Welding Processes The GTAW The ac-GTAW process... Dickerson, Alumi

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FIG 11 METHODS APPLIED TO THE OFW PROCESS TO DEPOSIT FILLER METAL WITH MINIMUM WELD STRESS

(A) BLOCK SEQUENCE (B) CASCADE SEQUENCE

Flame spraying

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Welding of Cast Irons *

Roger A Bushey, The ESAB Group, Inc

Arc-Welding Processes

Shielded Metal Arc Welding

Cast iron electrodes

Steel electrodes

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Stainless steel electrodes

Nickel-base electrodes

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Nickel-Iron-Manganese Electrodes.

Nickel-copper electrodes

Copper-base electrodes

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The globular transfer mode

The short-circuiting transfer mode

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Choosing the Right Transfer Mode.

Consumable Electrodes

Steel Electrodes

Nickel-base electrodes

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Nickel-iron electrodes

Nickel-lron-Manganese Electrodes

Copper-Base Electrodes

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Flux-Cored Arc Welding

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Submerged Arc Welding

Surfacing and Overlaying

Oxyfuel gas welding

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Cast iron alloys

Reference cited in this section

Welding of Cast Irons *

Roger A Bushey, The ESAB Group, Inc

References

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Welding of Aluminum Alloys

Paul B Dickerson, Aluminum Company of America (retired)

Introduction

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Forms of Aluminum.

Filler Alloy Selection Criteria

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FIG 2 EFFECT OF ALLOYING ADDITIONS ON SOLIDIFICATION CRACK SENSITIVITY OF SELECTED ALUMINUM

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ALLOY SYSTEMS (A) LITHIUM (B) SILICON (C) COPPER (D) MAGNESIUM (E) ALUMINUM-MAGNESIUM SILICIDE SOURCE: REF 1, 3, 4, 5, AND 6

ALUMINUM-Groove weld strength

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FIG 3 PHOTOMICROGRAPHS SHOWING HAZ MICROSTRUCTURES OF A SINGLE-PASS GAS-METAL ARC WELD

ON 6.35 MM (0.25 IN.) THICK 5083-H116 ALLOY KELLER'S REAGENT USED AS ETCHANT

FIG 4 PHOTOMICROGRAPHS SHOWING HAZ MICROSTRUCTURES OF A SINGLE-PASS GAS-METAL ARC WELD

ON 6.35 MM (0.25 IN.) THICK 6061-T6 ALLOY KELLER'S REAGENT USED AS ETCHANT

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xxx

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Fillet weld strength

The ductility

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xxx

Temperature Versus Performance

xxx xxx

xxx

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xxx

FIG 5 TYPICAL ROOM-TEMPERATURE AND LOW-TEMPERATURE TENSILE PROPERTIES OF 5083-O BASE ALLOY

PLATE WELDED WITH 5183 ALLOY FILLER

Corrosion resistance

xxx

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FIG 6 PLOT OF SOLUTION POTENTIAL AND HARDNESS VERSUS DISTANCE FROM WELD CENTERLINE TO

SHOW EFFECT OF THE HEAT OF WELDING ON METALLURGICAL CHANGES IN SELECTED ALUMINUM ALLOYS (A) 5456-H321 BASE ALLOY WELDED WITH 5556 ALLOY FILLER GMAW-DCEP, THREE PASSES (B) 2219-T87 BASE ALLOY WELDED WITH 2319 ALLOY FILLER GTAW-DCEN, TWO PASSES (C) 7039-T651 BASE ALLOY WELDED WITH 5183 ALLOY FILLER GTAW-DCEN, TWO PASSES

N

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xxx xxx xxx

xxx

Weld and Base Metal Color Match

FIG 7 CLEAR ANODIC COATING ON 6063 WELDS MADE WITH ALUMINUM-MAGNESIUM (5356) AND

ALUMINUM-SILICON (4043) FILLERS

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Filler Alloy Choices.

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Note:

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WELD J.,

MET PROG.,

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WELD J.,

Z ANORG CHEM.,

Preparation for Welding

Joint Designs

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FIG 8 TYPICAL JOINT GEOMETRIES USED FOR AC-GTAW AND GMAW OF ALUMINUM COMPONENTS LETTERS

CORRESPOND TO EDGE PREPARATIONS IN TABLES 15, 17, AND 18 SOURCE: AMERICAN WELDING SOCIETY

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A W

FIG 9 EXTENDED-LAND BEVEL USED TO WELD ALUMINUM PIPE (A) TYPICAL MULTIPLE-PASS WELD USED TO

JOIN PIPE WITH EXTENDED-LAND BEVEL (B) RECOMMENDED EXTENDED-LAND BEVEL SPECIFICATIONS FOR 3.2 TO 305 MM ( TO 12 IN.) DIAM PIPE WITH 7.01 TO 12.7 MM (0.276 TO 0.500 IN.) WALL THICKNESS SOURCE: AMERICAN WELDING SOCIETY

R

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FIG 10 EFFECT OF PHYSICAL STRETCHING ON ROOT FUSION (A) ORIGINAL OXIDE SURFACES (B)

INCOMPLETE (POOR) ROOT FUSION (C) COMPLETE (PROPER) ROOT FUSION

t

Surface Preparation

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References cited in this section

Welding Processes

The GTAW

The ac-GTAW process

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The dc-GTAW Process.

Variable Polarity PAW

GMAW

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XXX, XXX, XXX

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XXX XXX XXX

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Other arc welding processes

The oxyfuel gas welding (OFW)

Electron-beam welding (EBW)

xxx

Laser-beam welding (LBW)

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Reference cited in this section

Joining Aluminum to Other Metals

WELD J.,

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Welding of Nickel Alloys

Revised by E.B Hinshaw, Inco Alloys International, Inc

Introduction

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Heat Treatment of Nickel Alloys

Preweld Heating and Heat Treating

Postweld Treatment

Cleaning of Workpieces

Surface Engineering, ASM Handbook.

Joint Design

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T

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FIG 1 TYPICAL JOINT CONFIGURATIONS AND DIMENSIONS FOR GTAW, GMAW, AND SMAW APPLICATIONS

DIMENSIONS IN SCHEMATIC GIVEN IN INCHES

Beveled Joints

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Corner and lap joints

Design Considerations

Welding Fixtures

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FIG 2 GROOVE CONFIGURATIONS FOR BACKING BARS (A) STANDARD GROOVE FOR USE WITHOUT A

BACKING GAS (B) SQUARE-CORNER GROOVE EMPLOYED WITH BACKING GAS (GROOVE DEPTH DEPENDS ON GAS FLOW REQUIRED AND LENGTH OF BAR) DIMENSIONS GIVEN IN INCHES

Welding of Precipitation-Hardenable Alloys

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Preweld and Postweld Treatments.

General Welding Procedures

Welding of Cast Nickel Alloys

Gas-Tungsten Arc Welding

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Shielding Gas.

• IMPROVED SOUNDNESS:

• INCREASED WELDING SPEED:

• DECREASED ARC STABILITY:

Electrodes

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Filler Metals.

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Joint Design.

Welding Techniques

Gas-Metal Arc Welding

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Plasma Arc Welding

References cited in this section

WELD ENG.,

ET AL., WELD J.,

Electrodes

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Welding Current.

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FIG 3 JOINT CONFIGURATIONS FOR WELDING 13 MM ( IN.) NICKEL 200 AND SUBSEQUENT CRACK IN

WELD METAL CAUSED BY EXCESSIVE HEAT INPUT DIMENSIONS GIVEN IN INCHES

Cleaning the Weld Bead

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Joint Design.

FIG 4 TYPICAL DIMENSIONS FOR SAW OF NICKEL ALLOYS BACKING STRIPS ARE OPTIONAL WITH ZERO

ROOT OPENINGS DIMENSIONS GIVEN IN INCHES

Electrodes

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S

β

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Welding Current

Bead Deposition

Minimizing Weld Defects

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Stress-Corrosion Cracking

Effect of Slag on Weld Metal

Joining of Dissimilar Metals

•

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Dilution of Weld Metal.

Filler Metals/Welding Electrodes

•

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Example 1: Elimination of Weld Cracking and Distortion

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FIG 5 FLUORINE-GENERATOR COVER MADE BY SMAW OF SIMILAR (ALLOY 400 TO ALLOY 400) AND

DISSIMILAR (ALLOY 400 TO LOW-CARBON STEEL) MATERIALS (ASTM A 285) BOTH WELDS USED NICKEL ALLOY FILLER METAL A CORNER JOINT AND DOUBLE FILLET WELD WAS UTILIZED TO JOIN THE SIMILAR ALLOYS A T-JOINT AND DOUBLE FILLET WELD WAS UTILIZED TO JOIN THE DISSIMILAR MATERIALS PARAMETERS COMMON TO BOTH SETUPS: POWER SUPPLY, 400 A (DC); STRESS RELIEF, 1 H AT 620 ± 14 °C (1150 ± 25 °F)

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References

WELD ENG.,

ET AL., WELD J.,

Selected References

Welding of Copper Alloys

Revised by M Ned Rogers, Batesville Casket Company

Introduction

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Alloy Metallurgy and Weldability

• COPPERS,

• HIGH-COPPER ALLOYS,

• COPPER-ZINC ALLOYS (BRASSES),

• COPPER-TIN ALLOYS (PHOSPHOR BRONZES),

• COPPER-ALUMINUM ALLOYS (ALUMINUM BRONZES),

• COPPER-SILICON ALLOYS (SILICON BRONZES),

• COPPER-NICKEL ALLOYS,

• COPPER-ZINC-NICKEL ALLOYS (NICKEL SILVERS),

• SPECIAL ALLOYS,

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Tin

Beryllium, aluminum, and nickel

Silicon

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Factors Affecting Weldability

Effect of Thermal Conductivity

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Arc Welding Processes

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Plasma Arc Welding

Filler Metals

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Copper Filler Metals.

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Copper-Zinc Filler Metals.

Copper-Tin Filler Metals

Copper-Silicon Filler Metals

Copper-Aluminum Filler Metals

Copper-Nickel Filler Metals

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Welding of Coppers

ASM Handbook.

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Effect of Cuprous Oxide.

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FIG 1 CONDITIONS FOR GTAW OF A NUCLEAR FUEL CONTAINER DISTORTION IN WELDING WAS MINIMIZED

BY INCREASING THE MASS OF THE FIXTURE TO INCREASE HEAT WITHDRAWAL AND BY CHAMFERING JOINT EDGES TO PERMIT REDUCTION OF WELDING CURRENT

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Oxygen-Free and ETP Coppers.

Example 2: Automatic GTAW of Joints between Alloy C11000 Bar and Tubing

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FIG 2 CONDITIONS FOR AUTOMATIC GTAW OF ALLOY C11000 TUBING AND BAR INDUCTOR COILS THE

POSITIONS OF THE ASSEMBLY, GUIDE ROLLS, AND TORCH DURING WELDING ARE SHOWN

Nominal Conditions

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Filler Metals (Electrode Wires).

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Welding of High-Strength Beryllium Coppers

ASM Handbook.

Nominal Conditions

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Example 3: Gas-Tungsten Arc Welding of High-Strength Beryllium Coppers in an Alloy C17000 Pressure Vessel

Example 4: Gas-Tungsten Arc Welding of High-Strength Beryllium Copper in a Cylindrical Generator Liner

Example 5: Gas-Tungsten Arc Welding of High-Strength Beryllium Copper in a to-Housing Weldment

Cover-Gas-Metal Arc Welding

Nominal Conditions

Welding of High-Conductivity Beryllium Copper

ASM Handbook.

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Preheating and Postweld Aging.

Properties of Weldments

Welding of Cadmium and Chromium Coppers

Welding of Copper-Zinc Alloys

ASM Handbook.

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Welding of Phosphor Bronzes

ASM Handbook.

Nominal Conditions

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Welding of Aluminum Bronzes

ASM Handbook.

Nominal Conditions

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FIG 3 CONDITIONS FOR GTAW OF A PROPELLER HOUSING THE WELDMENT REPLACED A SINGLE-PIECE

CASTING, THEREBY REDUCING COST AND IMPROVING SERVICEABILITY

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Welding of Silicon Bronzes

ASM Handbook.

Nominal Conditions

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Welding of Copper-Nickel Alloys

ASM Handbook.

Nominal Conditions

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Preheating and Postheating.

Welding of Dissimilar Metals

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