Welding PDF
Welding PDF
Welding PDF
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 27-4
Oxyacetylene Flames Used in Welding
Figure 27.1 Three basic types of oxyacetylene flames used in oxyfuel-gas welding and cutting
operations: (a) neutral flame; (b) oxidizing flame; (c) carburizing, or reducing, flame. The gas
mixture in (a) is basically equal volumes of oxygen and acetylene.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 27-3
Shielded Metal-Arc-Welding Process
FIGURE 12.2 (a) Schematic illustration of the shielded metal-arc-welding process. About
50% of all large-scale industrial welding operations use this process. (b) Schematic
illustration of the shielded metal-arc-welding operation, also known as stick welding,
because the electrode is in the shape of a stick.
FIGURE 12.6 Schematic illustration of the flux-cored arc-welding process. This operation
is similar to gas metal-arc welding, shown in Fig. 12.5.
FIGURE 12.5 (a) Gas metal-arc-welding process, formerly known as MIG welding (for
metal inert gas). (b) Basic equipment used in gas metal-arc-welding operations.
FIGURE 12.9 (a) Gas tungsten-arc-welding process, formerly known as TIG welding (for
tungsten inert gas). (b) Equipment for gas tungsten-arc-welding operations.
FIGURE 12.3 A weld zone showing the build-up sequence of individual weld beads in
deep welds.
FIGURE 12.11 Comparison of the size of weld beads in (a) electron-beam or laser-beam
welding with that in (b) conventional (tungsten-arc) welding. Source: American Welding
Society, Welding Handbook, 8th ed., 1991.
FIGURE 12.14 Grain structure in (a) deep weld and (b) a shallow weld. Note that the grains in the
solidified weld metal arc perpendicular to their interface with the base metal are perpendicular to their
interface with the base metal. In a good weld, the solidification line at the center in the deep weld shown
in (a) has grain migration, thus developing uniform strength in the weld bead.
FIGURE 12.17 Intergranular corrosion of a weld in ferritic stainless-steel welded tube after
exposure to a caustic solution. The weld line is at the center of the photograph. Scanning
electron micrograph at 20X. Source: Courtesy of B, R, Jack, Allegheny Ludlum Steel Corp.
FIGURE 12.15 (a) Weld bead on a cold-rolled nickel strip produced by a laser beam. (b)
Microhardness profile across the weld bead. Note the softer condition of the weld bead
compared with the base metal. Source: IIT Research Institute.
FIGURE 12.20 Types of cracks in welded joints. The cracks re caused by thermal stresses
that develop during solidification and contraction of the weld bead and the welded structure:
(a) crater cracks; (b) various types of cracks in butt and T joints.
FIGURE 12.23 Residual stresses developed in a straight butt joint. Source: Courtesy of the
American Welding Society.
FIGURE 12.22 Distortion of parts after welding: (a) butt joints and (b) fillet welds. Distortion is caused
by differential thermal expansion and contraction of different parts of the welded assembly. Warping can
be reduced or eliminated by proper weld design and part fixturing prior to welding.
FIGURE 12.53 Design guidelines for welding. Source: J. G. Bralla (ed.), Handbook of
Product Design for Manufacturing. Copyright © 1986, McGraw-Hill Publishing Company.
Reproduced by permission of the McGraw-Hill Companies.
FIGURE 12.39 (a) Sequence of operations in diffusion bonding and superplatic forming of
a structure with three flat sheets. Source: After D. Stephen and S, J. Swadling. (b) Typical
structures fabricated. Source: Rockwell International Corp.