Welding Essentials:
Questions & Answers
Second Edition
William L. Galvery, Jr. Professor of Welding Technology American Welding Society QC-1, CWI, CWE Orange Coast College Costa Mesa, California and Frank M. Marlow, PE Illustrations by Pamela Tallman & Lawrence Smith
Industrial Press Inc.
STATEMENT OF NON-LIABILITY
The process of welding is inherently hazardous. Welding is often used to assemble buildings, structures, vehicles, and devices whose failure can lead to embarrassment, property damage, injury, or death. The authors have carefully checked the information in this book, have had others with professional welding experience and credentials review it as well and believe that it is correct and in agreement with welding industry practices and standards. However, the authors cannot provide for every possibility, contingency, and the actions of others. If you decide to apply the information, procedures, and advice in this book, the authors refuse to be held responsible for your actions. If you decide to perform welding, use common sense, have a competent person check your designs, the welding processes, and the completed welds themselves. Seek the help of people with professional welding inspection credentials to check critical welds until you gain experience. Do not attempt life-critical welds without competent on-the-spot assistance. Copyright © 2006 All rights reserved. With the exception of quoting brief passages, no part of this publication may be reproduced, or transmitted in any form without written permission from the copyright owner. ISBN 978-0-8311-9046-0 Manufactured in the U.S.A. Visit us at our website: 10 9 8 7 6 5 4 3 2 1 I dedicate this work to my wife Kathleen because of her patience and understanding support in all my endeavors and special thanks to her for her love. W.L.G.
To Charlotte Woodruff Mattia and Ralph Francis Mattia and also to Squeaker and Gray.
F.M.M. William L. Galvery graduated from California State University, Long Beach with a Bachelor of Vocational Engineering, has more than 30 years of industrial welding experience, and is an American Welding Society (AWS) Certified Welding Inspector and a Certified Welding Educator. In 2003 the AWS presented him with its prestigious national teaching award, the Howard E. Adkins Memorial Instructor Award, and for the second time he was chosen AWS District 21 Educator of the Year. In the same year he was also presented with an Excellence in Education Award by the University of Texas, Austin. Bill has served as an officer for the AWS Long Beach/Orange County Section and is currently Professor of Welding Technology and Welding Department coordinator at Orange Coast College in Costa Mesa, California. Frank B. Marlow is a Registered Professional Engineer and holds a BA and BSEE from Lehigh University, an MSEE from Northeastern University and an MBA from the University of Arizona. With a background in electronic circuit design, industrial power supplies, and electrical safety, he has worked for Avco, Boeing, Raytheon, DuPont, and Emerson Electric. Frank has served as both Secretary and Treasurer of the AWS Long Beach/Orange County Section and is author of Welding Fabrication and Repair: Questions and Answers (Industrial Press) and Machine Shop Essentials: Questions and Answers (Metal Arts Press).
Contents
CHAPTER 4COMMON WELDING ELEMENTS
CHAPTER 5SHIELDED METAL ARC WELDING
CHAPTER 6WIRE FEED WELDING PROCESSES — GMAW & FCAW
CHAPTER 7NON-CONSUMABLE ELECTRODE WELDING PROCESSES GTAW & PAW
CHAPTER 8SURVEY OF OTHER WELDING METHODS
CHAPTER 9CONTROLLING DISTORTION
CHAPTER 10WELDING SYMBOLS
CHAPTER 11INSPECTION & DISCONTINUITIES
CHAPTER 12WELDING METALLURGY
CHAPTER 13POWER SUPPLIES & ELECTRICAL SAFETY
CHAPTER 14QUALIFICATION & CERTIFICATION
CHAPTER 15FABRICATION & REPAIR TIPS
Appendix
A: ENGLISH-METRIC CONVERSION FACTORS
B: PROPERTIES OF ELEMENTS & IMPORTANT COMPOSITIONS
C: AWS DESIGNATIONS FOR WELDING & ALLIED PROCESSES
Glossary
