the science and practice of...
TRANSCRIPT
The science and practice of welding
A. C. DAVIES
8.5< (Londoll H/,mS . • ,," Lj".'!'OOI). c.F.na·. M 11- I Frllow,,/rItt W<ld"" lIu,;,~"
SEVENT H EDITION
CA MBRIDGE UN I VERSITY PRESS CAM 8Rll) G I:
LONDON NEW VORK . ME L DO UItNF.
Contents
Preface
Preface to the sixth edition
The metric sySlem and the use of SI units
poge vii-vii i
ix-x
xi-xiii
W~kling sdence 1--62 Ileal p. 1. behaviour of metal~ under loads p. 21. chemistry applied 10 welding p. 33. fluxcs p. 55
2 Melallurgy 63-147 Production and propcrllcs of iron and steel p. 63, lhe effect of the addition of carbon 10 pure ITOn p. 79, carbon and alloy steels p. 82, the c:ffttt of heal on the structure of steel p. 91. the effect of welding on the SlI1lClure of Sleel p. 101, Ihe effect of deformation on Ihe propcnics of metals p. 113. non· ferrous metals p. 118, stresses and distortiun in welding p. 133
3 Oxy-acelylene welding 148-215 Principles and equipment p. 148. methods of welding p. 166, ca~1
iron welding p. 1711. braze welding and brontc wdding p. 1110. copper wddinJ!: p. 191. aluminium weldingp. 194. welding of IIIckc:l and nickel allo~s p. 199. hard surfaCing and stel1itmg p. 203. brazing p. 209, general preeautions p. 214
4 Basic electrical principles 21 ~292 Electrical technology p. 216. wc:lding generators p. 235, rc:cllficn. p. 252, alternating-current welding p. 269. earthing p. 29Cl
5 Manual metal arc welding 293-372 The electric arc p. 294. electrode classification p. 306, welders' accc:ssories p. 314. the practice of manual metal arc welding p. 322. welding of pipe lines p. 362. wc:lding of carbon and carbon-manganese and lo,,-ano~ steels p. 367
6 Tungsten electrode, inert gas shielded "'elding processes (TIG). and the plasma arc process 373-426 Technology and equipment p. 373, wc:lding techniques p. 394, automatic welding p. 410, plasma welding p. 414, plasma cutting. p. 420, plasma hot wire )urfacing p. 425
"j Cuntents
7 Gas shielded metal arc wdding 427-465 Metallic inom gas (MIG). CO. and mixed gas processes p. 427. technIques p. 448. CO. It.elu;ng of mild steel p. 456, automatic It.clding p. 458. pulsed arc It.cldmg p. 462
8 Resistance welding and nash bUll welding 466-486 Spot It.elding p. 466. electrodes p. 474. seam "'clding p. 478. projection "'eldmg p. 4111. resistance bun wcldlng p. 483, flash butt ",elding p. 484
9 Additional processes of welding 487-523 Submerged arc "'elding p. 487. clectr~lag It.·cluing p. 494, mechanized ""clding '" ith robots p. 498, atl)mi<: hydrogen an: ",elding p. 499. pressure wclding p. 502, friction wclding p. 503. electron bc;.Ol ",ddingp. 508 lascrbcuOl welding p. 5 10. stl)d "'dding p. 512. stud welding (capacitor dis.-:hargc) p. 5 IS. c~plosi"e welding p. 5 t7. gnwity wclding p. 520. thermit wclding p. 522
10 Cutting proct'sses 524-542 Gas cuuing of iron and ~tcel p. 524. oxygcn or thermic lancc p. 531. n~me gouging by the o~)·acet~lcne procc~s p_ 534. powder Injection culling p. 536. oxy-arc cutting process p. 540, arc·alr cull ing and gouging PnK'CSS p. 541
11 IlIsp«tion and testing of welds 543-584 Non-destruetl\e tests p. 545. dcstructh'c tcsts p. 558
12 Engineering drawing and It.-eldlng symbols Engineering drawing p. 585. ",eld,ng symbols p, 589
585-592
[J Metallic alloys and equilibrium diagrams 593-603 Metallic alloys p. 593. equilibrium uiagrams and their uscs p. 595
Appendix 604-618 Tables p. 604. selection of Bri ti sh Standards relating \0 welding p. 615
City and Guilds of London Institute examination questions 619-700 Related studies and technology p. 619, welding engineering (Tdft studies p. 651:1, f .. bri~·ation an,j welding engineering technieians-part I p. 674. fabrication and ",elding engineering teehniciaM- part 11 p. 679, dra""ing and de\'Clopment p. 697
Index 701
Index
Abnooon ~uTfllCing manual melal arc, 351-5 oXY'&«lylcne, 203--8
Acetyl~r>e
Ib$o<plion by aIXlune. 150 bum,n" 41 d,<IOIvcd. 150-1 ~nerlltor. medium J>n')!,UTf. 154 lmpuriuu in. 154 prep;lnlion. 44 pressure. 150. 154 purification. 154 .. fcly precautions. 152 OlIfely valve. 155. 158 $tunge.IS1 lest for kall-, 151 te~ for purit~ .. 154
Acid ~ttflm&bng. 69-70 Adbcl-iun. 165 Ad)u~lmenl switch (expans.on). 9 Age ILard.:ning. 130,602 Agglomeration of orc., 63 Allulru~ modificalion
of carbon, 45 of Iron, 49--S0
Alloy lItcL "'"tiding of. 366-10 AII'J'IU!;l1Ion rigbl .. 'ard ,,"Cld,"g. 116_7 Ahe.nal1ng CUlTCnI general,on. 241--8
manual metal arc ,,"clding. 26\1 TlO wcldng. 375
Aluminium annealing. 130 bnlZlng. 211 - 13 toLd working. 118, 130 torr~n. 41. 129 filkr rods: (1)·aa:lyicne. 19S: manual
metll arc. 344 n1l1 for welding, 56-7. 60 hol wnrking, 118 manual ""'Ial arc wcldlng. 344--8
MIO ,,"'eld,"&- 451 oxidalion. 41. 1211, 194 oxy·ao;lykne welding. 194-9 product,nn, 128 properties. 128 no .... ddtng. 394"";
Alum,n,um dloys ciass,fW::1110n. I JO---l hut·\Tutahlc, 1:Kl mlnUlI met~l arc weldmg. 344--8 MIO ""'cld,,,g. 450-2 o.y·a~tylene wck!ing. 19~-'J TIG w~kling. 394""; .... ork hankning. 130
Alullllmum hronl<: cold wnrk.n" 116, 1111 nuus fnr ,,"cld.ng. 56 hut ",'o.klng. 118 manual IIKtal arc .. clding. HQ-I o"Y'KI;lylcnc ... ·clding. 190 T IO wcldlng, 401-8 I)p.: •. 118
AmllKler, 211
Am""'lcr <hunl. 221 Amorphous carbon. 45 Ampeu. ddin'lion of. 229 Annulong
aliummlum. 130 hru~, 124 copper, 120 pr~ss. 99 ~phcrolll, 99 slccl. !/7-8
Anodizmg. 129 AK-aIT CUlling and lOug.ng. 541-2 Arc. IIKIII
aitcrna11111 CurKnl, 294 bare "me, 294 blow, 297 ~harac1c.isllCS nf. 294~5
702 Index
Arc. metal - roll'. controt. typn or automatic. 4.J.0-6 din:ct curnnt. 29~ d,u.ribuuon or heat in. 294 deeme em:un of ,,-clding. 229-31 ~ner&y. 296 forces. 297.4211 MIG,428-30 pb.ma. 415-1 K ~hicldcd, 29~
~tnklng and maintaining. 324-~ n G. )75-<l Ir.mffr~1>Ct of ""'!BI. 296--7 ... ollage drop. 296
Arc "'~Idlng atomic h)·<Jrogen. 41)9-501 carbon. 342-3 ~leclrodes. ut Eleclro<.k horizonta~nlCal J4] uvclhelOd. 242 P'f'C lines. 362-<l <Ieel CI<IIng .. 372 Stell'l;ng. 356 studding. 3411-9 tabl~ of eleClrode .. 614
lipf>inglool '1"e1. 3SS ...,nkal. 339-41 wear and ahT1lloion resi~am surfaces.
3SI-5 Ht tmdu ,,,d,,,r.dulll ..... ,Q/s
Ar,on. 36 Arre)! point! .. 91-3 Arso;nit ,n OOpPCr. 119 Atmosphere
eompmllion or. 34-5 ~ff~ct On wtlding. 103-4
Atomic hydrogen arc we lding. 499-501 Atomk Structure. 1-4 Atomit ... e'ghIS. table ufo 604~ Austempenng. 96 Au'lemle.96 AuStennic $te~1$. S4-<l Automatit " 'eld;ng
MIC.4S8-6\ spot. 471_2 SClm.478 TIG.410
Back chipping. 4SJ Back purging. 399. 453 Back stepping. 137 Backfire. 16)-4
Bac:kinglnl. 399. 40~ Bac:k,n! mip, 396-7 Balnne.93 B.litl"ad load. 287 Ball d ay. 61 Bar. ddinilion of. 2J Baloic electro& mating. JOO-I Ba~ oxygrn sleel. 71-4 Bat«: slag. 70 Ba.k steel proce .... 69 Bauxite. 128 Ikh8,iuur of metals under load. 21 - 32 Rell.od Spigol joint. 36S Bell hale ... cldinj!.. 362 Bend test. ~70-2 Beryllium. welding of. 414 Blast furnace. 6-4 Bkw;k ","(Idmg. 174 Blowpipe. 1~9~1
can:. 163 cleaning. 164 cuUing. 524-<l gas velocity. 160 hi~h prc",ure. ]S9 "'w prn'lure. ]60 MUleS. 1~9. 161 o~Cfh<:ahng. 163
BUlhng point. 4 Boom I.m. 460 Boundary of crystal. 52 Ora~
alpha. ]2] _nnuhng. 124 bell. 121 cartridge. 121 cold working. 117 elasticity. 124 equilibrium diagrams. 600-1 nux for wdding. 56 h"h len,;Lo:. 12~ hot ",·ork'ng. 116 munnnr yellow. 121 OJ)'<I«t)"Lo:ne ... ·elding. 188 pn>pcme~ 122 lable of. 122 lemJKr.124 IYJKS. 121
Br.u "·eld'ng. 180 Bl1Iring. 209_] 3
aluminium. 21 ]-13
Bnncll tcS1 for hardnus. ~78-9 Brilish Standards. table of. 615-18
Index
Brittle fracture. 144-~ Bnttlenc$$. DOtCh. 145 Hronze
alumonium. 116-18. 350-1. 190 nux for .... cIding, 180 ptlosphor.l24 ty~s. 124 .. '~khng roch. 182
Bronl<: arc weiding. 34\1-51 Bron., "'cidmg
oly-acctylenc.I80-91 manual melal al'l;, 34'1-51
Hrushless I'!'nerators. 262-3 Bumt .teel. '19 8ut~nc. 44 Bun .... dding
CO.. 459 manU31 metal arc. 3JI MIO: aluminIum. 451; oopJICr. 452:
Statnle5SSleel4H-4; SOcUllron.455 oXY'Ketylenc: left ... nl. 166--a; nght·
w"d.168-70 resIStance. 483 submerged arc, 493 TlO: aluminium. 396; copper. 452; mag·
nUlum. 400; ruckd. 405; slalnle5S $Ie.:1.403
Cables CSP.223 current carrymg capacity. 224 I.ble of .ius, 224 .... cldin" 223-4
Calcium carhide. 44 Calcium carbonate. 61. 313 Cak1um oxidt. 59 CapKitancr.233 Capacitor, 231-4
in Mn •. e. circuit. 219 Cap,lhary attraction. 209 Carbon
arc, 21<,1 rompoun<ls of. 45--6 cffcclS in steel. 79-82. 102-3 fomo5 of. 45 pock-up. 112
Carbon diou<k propenin. 36-7 .... eiding (CO.). 456-9
Cuban equi~alcnt. 367 Carbon monoxide, 45 Carbon steel. 82--4
Carborundum,49 Carburwng name, 47
703
Case-h.rdemnl or pac:k-harderung. 99-100 Cast iron
alloys. 68 bronze .... elding: manual mCIl,1 .rc.
349-51: oxy-a«lylenc. 180--91 romposilion of. 68 dcflDllion of. 68 grey. 68, 80 manuat mellt arc .. -dding. 346-9 MIO ,,·cldlng. 455 "~)'lIoCctylcne weld,ng. 178-80 prc·hcating. 119 production. 6R propefllC<' 68 spl"oerOldalgrapl"oite (SG). 68 .. h.ne. 68. 80-1
Ceb,us, 6 Cementite. 79 CharKtcri~tlCS of welding power un ilS
manual metal arc. 256--64. 287-9 no. 382-7 MIO.43~
Charpy tnl. S14-io
C""mical CC!>!. fOI weld ""'tal 563 Chill cauing. 178 Cbill •• 121 Choke. 274-5 Chromium and nickel s=ls. 84~
manual mc tat arc wclding. 357--11 MIO welding. 453 no welding. 402
Chromium carbide:. 86 Cluom,um steels. 84~ Clad stcel nickel and ",link .. s« Nockel
dad ncci. and Slainle ... ceel CO, .. ekhng. 456-9 CoOah. 554-5 Codfocicnl of cxpamion
cubICal. 12-13 linear. 11-12
Cold .Ilnrtne". 82 C"ld working. 113-]4 C"lour rode cyltfldr,n, IS3 Columbium, I« Niobium Column" Q)'51als. 52 Combu§toon. t""of)' of. 46 Commutalor. 248 Comp;.ri50nof I.C. and d.c. welding. 269-70 Compounds. 33
of carbon. 45-6
704 Index
Compre:l6I"( .. 'us and strain. 29 Conduc1l0n of heat. 18 CondlllCt"'IIy
effect on .... cldln" 111-20 therml~ 19
CondlllClol') of ~Jcclncity. 221 Cono:t., t~mpcr. .. urt. 6 COn>iumablc ,u>de .. dding (electroslad.
495-7 Contact rc,islancc. 23 I COntaclOr. nH. 388 Contraction. 9
cffect in ,,·elding. 10 Controllcd thc:rmal ... ~crit)· Icst (CfS). 369 ConV«lIon, 2()-1 Copper
aUoy filt('~: TIG. 407-9; MIG. 4H annubn .. 120 arxnic in, 1111 bllstcr. 118 bronze .. cldin&: by manual metal an:.
)49-51; by oly·acetylene. 180-91 cleaning. 120 cold working. 117 corrosion. 41 deolidiud. 119 effecI of huttn" 193 nUl for " 'cldin" 57--.8. 193 ,rack" 121 ,nun siu. 120-1 hoI working. 117 mlnual metllln: ,,·clding. 349 Mla .. 'dd,n" 452 olid,lion.41 uly·-.cet)'lcnc .. ·.Idrng. 191-4 olygcn in. 118 production. 118 proptrtiu, 120 temptr. 120 TIG w(ldlng. 407--.8. 452
Coppcr-;tluminium (aluminium bronze) na .. cidlng. 407-8
Coppcr-fllCkclllloys. 125 rold workina. 117 hoI workin" 117 Mla ""CldlO,. ",52-3 TIG ""tldlO" 408
Copptr pyrit(s, 118 Coppcr-tillicon alloy.
manual me tal ne wclding, 350 Tla .. ddin&. 407
COpptr-l1O IlIoys. 124
Coppcr-lJlICaUo)'s, 121-2 Conn .. 5117 COflOSlOll of .... kIs in .. ec~ 54-5 COrlos .. ·• actiOn of nu.., ... 57 Crack,n,1O Sletl
....,Id. 113 hol. 112
CrackIng I .... 583-4 Crack .. dCICCItOn of. 545. 546. 558 Crayon~. temperatu ... 6 Creep. 32 C"'~j>"ru"'tint .. eel. 32 Cm",.! cooLtn, ,ates, 93 Cfllleal point .. 91-2 Crou ",n: w"'ding. 483 Cr)")lal ,ro,,"'. 52 Cry .. al
allo).54 boundary. 52 chill. 52 columnar. 52 <.kndruic. 52 cff~~t of cold work on. 52 cquiaxed. 52 fllCton innUCDCing g'""tl>. 54 formallon of metanic. 49-54
('uppon, te~l. 584 Cupro·n",kd •• 125
M1G " 'clding. 452 '-10 ,,"(Idin&. 408
CUp'o"" o~wk. 119 Cur.e. ~5~ Current
.!tcrnat,ng. 241--.8 dir(ct.248-51 shon circuit. 267
CUrrenl carrying capacity o f .. c Idong ~able ..
'" Currenl COnt'"~ 327 CUt and !hut ~nd. 261. 274..J} Cutlin, po"occsos
alloy l>I(d. 5J9-40 arc .. ir. 541 ~2 camon arc. J4J caSl Iron. S33 dfcct on ilcel ~30-1 m:,och,lICl, B2 0.)·lICClykne.524-31 oxy·arc. 5"'0-1 oxy·hydrogcn. 527 o""'nalu,al ga .. 527 Ox)·propane. 527
lndel:
pI:uma. 420--2 po"'du inJecuon cUlling. 536-9~
alummium. 540; cut iron. 539-40; copper. 540~ lIigh-aUoy $ted. 539; DlCleJ and nICkel alloys. 540; "'.nl<:!4
""cL S39 CUlling lools. I.pplng
manual meral an:. 355 u.)-acetylenc.205-6
Cycle:. 244. 471 C)'Clc an: "ddi"" 462 Cyllll<kn. 151-3
Decalc~~. 91 DHp penetraliQn dectrode. 302 Odo.mation
of. beam. 570-1 dfect on propertic:$of merals. ID-14 e~ic. 21-7 pI:utic. 21-7
Dcg.eas",g. 46, 450 DeiQnlZed water, 422-3 Dcnd.itic cry".I •. 52 DeMlty (specifIC g.av,ty)
aluminium and alloys., 128 b.1UIo, 122 ..... ppc •• 120 iron. 49 magnesium alloys. 132
Deoxidation. Sff rcdt.ICtion DeoIidizcd copper, 119 Dcoulizcn. 446 Desut.lClivc tuts. 558-84 Dctector. magnetic: crack. 446 D",kctric.231 D,lution. III J)irntnsion. of I .. cid. gauge for. 544 Dip !fander. 429-30 Direct cur",nt IC'ncrltlOn. 248-51
.... eldinggene ... tor. 256 D,,,,,, redt.ICtiun of iron ore. 66 D'S$Qlvcd a«lyknc, I SO-I Distortion
facton affcctin, ,n .. "Iding, 133 "",(hods of rcdllCmg. D6-8
Dolomite, 69 Droopng clutrac;terislie, 259,432 Ducrilc-bnulc t ... nsitlon. 145-7 DllCliJity. 30 Duplc~ copper llloys. 121 Duty cycle, 223-4
!'..aRhing. 29'0-1 Elastic deformwtion. 21-7 Elaslic limn. 25 Elasticity. modulus of. 24
705
Ekctnc ",rcult of the ""idm,lrc. 229-31
Elennc fu.n~ an:. 74-6 indoct;"n. n-4J; high f.cqocIK'Y, 78
Elect.O<k dHSif"'~tK)n of. J06....8 compositIOn uf coa.llna. 312-13 dttp penetration. 302 dr)"ng of. 304-5 eccenlricity of core """c. 298-9 efficiency. 300 nux cored, 446
bydrogi:n controlled. 300-1 b)·dr"lC'n releasin" 304 manuII metal ate ... ·cldin .. ~. 360-2.
'" MIG ... clding. 446-8 'torage. 3()4 TIG ... ddmg. 392
EIenT<><lc holder. 314 Elcaroiym.. effect 'n wcklm" 54-$ I:.lectromlgneti<;: ,ndt.ICoon, 277-9 EI«-tromoll~e fora:, 217 Electron. 1 Electron boeam welding. 508-9 Elcctru!>l~g wcldong, 494-5
consumable gu,dc. 495-7 Elcmenu .. 33
lable of,6()4-7 Encrgy, unn of electrical, 226 Equalizu bar. 264 Equiax~d cry~(als. 53. 97-100 E'Iuilibflum di~gr.m .. 91-2. 5\15-603 Enduen te~l. 584 Etching >olullons. 560-1 EutC<'lic. 598-9 Eutcctmd.602_3 Exci'"r.2511-61 Expan~iQn. 9
coefflC,ent: or cubical. 12-13; of liDCar, 11-12
cffC<'\ on ... 'dd,"" 134 ,able or coefficient$., 12
ExotbcrmlC reliction. 39 Eyes. pro'ection uf
manual metal an: .... elding. 316 MIG ""cldin .. 448
706 Index
Ey", prolection of - W1II. ol)'-ao::tykne _Idln" 214 T IG .. ..,Idiog, 3'13
Fatigue. 32- 3 IUI.581 - 3
Fault, in a weld. 333 Fct.par.61 Ferric carbide. 79 Feme o~ide. 63 FUl"lle.79 Ferromangane.." 10 Fcrrosilicate. 60 FCrr05ilioon. 70 Fillet wdo
manual melal arc. 336-9 M1G. 445. 459 oxy_ao::tyknc.I1S-4i TIG, 399, 402
Filttr$, eye. sn Eyes Fistures. 316-17 R.~
adJu~tment for wcldmg. 161-2 carburizing, 47 cutting. S21 gouging, 534-5 osidizing. 162 ",Ktion'! in osy-acctykM. 47-8 temperatures. 47
A.ill, 163 a~Sler. ]64
Aaill bun welding. 4M4-S Fleming'. right hano rule, 242 Fluoride .. 56 Floonpar.61 R~
manual metal arc, S8-60 OS)·-ao::lyle ... : alumimum and alloys., 56;
bra5lCs and bron"'s. S6. 180; Cl" iron. 57; ropper. 57
Flu~ <;Qred >emi·~ul ... malic and aUlomalic wclding, 45S~1
Flux lealr.age control. 275 Free HiJ,b1 transfer. 428-9 Freezing point, 5-14 Frequency, 244 Frio;tion ",..,Idiog, 503-1 Fumace
ekctric arc, 14-0 induetion. 77-8: hIgh frequency. 78 open heanh. 69
FlISion. ~pecif"1C lalent heat of, 17-111
GalvllllUd articles manual metal arc .. ..,Iding, 349 O,y-a«I)lene ",·tlding, 186
(jamma iron, 92 Gamma ray lesling, 544-1 On
poiwnous.. irrilanl and •• phyxlunt. 46 pressurc of a«lykne. 1 50. ] 54 table e>f colour rodeo for romprc!o5Cd. 153 labk for MIG .. clding, 443 T IG. 394. 399. 402. 403. 401 velocity. 16
Gas shiclded metal art ",..,lding. 421-4i5 Gauge for ",elds. 544 Gauge length. 567 GeI\Cralion
alternalln, current, 24\-8 dirctl CUffent. 248-51 principles of, 241
Genentor aoelykne medium pre .. u..,. 154 ~ Iectric: brmhkss. 262-3. ,·h~l1Ictc""ict..
262. 26~; diffe,",nlia! compound, 260; high [r~qu.ncy. 378-9; magnClil: field. 2~8: in parallel 264-S; o;c!f-cxcited. 260: ..,paralcly ucitcd. 260: shunt, 260; variation 01 Curt~nl.nd votlap' in, l67
Gou"n" S34-4i, 541-2 Gram ,ro"lh. 52 Onphite. 79410, 82, 1711 Grey caSt iron. 68. 110 Guoset bend. 364
11 bar. tkfinition of. 23 Haemame. 63 Haigh f~tiguc test, 5S\-3 !lard $Urla.ci.ng
manual mclal arc, 351-4 ptalillla. 425~ ,"y-~telylcne. 203-7 spray fu~. 207-8
Hardentng ~tummlum alto) .. 129 bn.~. 124 ropper. 120 steet,93-S
111«1110" 31 leM'.578-81
Heal. dfect 01 On rold "'orked metals. \14-15 on pro""ni •• of nKtals, 30
Index
on MrUO;H'fC of SI~t~ 91-3 Iranden,:rw;e, 18-21
Htll trt:luncPt IlwRlmum. 1l0-2 tu rtheve JlruscJ, 14()....3 stet'l. !H-IOO
Heatm, dfect of a cUIT~nt. 2211--9 Helium. 36 H~rtl, 244 I!i,h tcn,il~ bra"" 125 Ilook~'s UtW, 22, 25 Hu!Oei. 159 Hurirontal-verticll welding
man ..... 1 metal arc. 341-2 oxy-a.:etykr>e:, 171
Hot cn.ckin&. 367 Hot ptI .. 36<1-5 Hoc shonneos, 82 HyciroF"
oompuunds ... ·lih carbon. 45 oonlfolkd e1e"J"OOks. 300-1 dfecI un wdd, 301-2 solubility in weld melal, 301
1",;lion, 2~6 of hllh frt:'1""1IC)' ~rc. 378--9
Ilmeo,le.61 ImptlCi lest
ChIrpy, 574-6 1.00, S7H
Impedanoe, 281-2 impunlies m stcel, 82 Inspeellon and I."ung of ... ..,1<1$, 543-84 Insulallon reS'5tlrlCe. 228 Insulatori. 221-2 Imcrmo;lIlli.; cumpound, S99"'()OO. 6tJ2 Interpolcs. 261 lon,41S Iridium. 554-5 Iron
~Ipha. 50,91 ca!>!,68 delta. 50 ",mma. 50. 92 malleable. 78-9, 185 ort:i. 63 p'g, 64 po ... der electrodes. 300 production. 64-5 prupmil!), 68 rU5tmg, 40-1 wrousht, 68-9
Iron arbi<.k. 79 Iron ntlfide, 101-2 Iron o.\ide, 63 lsolopes. SS4 lzod lest. S7H
J'gi. 316-17 Joints
bUII,330, 493 fillet, ))0. 493 jUllilcd lap, 330 open corner, 330. 493
Juule. 13
Ke)hok: ",ckiins. 419 K,Io""1 hour. 227
umo;llar Inrins. 371 Lam,natiom. IH. 273 Lap Jomt. 330 Luer beam "clding. 510-12 Lattice, 49-~0 Lcft ... ard "clding. 166-11 Lenses for ",clding. fU Eye. Limit of proportionality. 15 \.imunit(, 63 Lmdc ... ddins. 17.1--4 Liqllld p~s. 149 Lil.juidus. 595-6 titre, )'ui
707
Load. bchil,iotIr of melals under. 21-32 Lo .... ·alloy stcel, .. ckiin« ol 366-70
MacrO'K<lpic tCst. 561 Magne!oium alloys
prup,"rtiel, 132~3 filled wirc, 401-2 rlO ... eldins. 399-4()()
Magnetic cract <.ktcctor. 546 MagnetIC r",1d
lluc 10 • current, 237 of a ",,,.,fltor, 258-64 of a transJormcr. 270-4
MagnetIC 'nduclion. 277 M~gneUle, 63 Malleability. JO Mallublc 'T<ln, 78-9. 185
compoliJlJon, 78-9 oxy·~t)le..., ""clding., 1115 properticl, 711
Manllunuc, 84. 90 weldinl of ~tcd, comaining. 352-J
708 Index
M.np....,$!: bron~. 122. 125 Manp~ .!.Icd. 510 Man,pulator.317 t>hnu.al m(lal In: "clding, 293-372
hard .urfaon" 351-1 horizonlaJ-\I(rticll. 341 -2 overheltd. 342 "'kly pr~uulion .. 323
Mart(mperina. 95-6 Marl (nsil(. 93-6 M~r!~nsil ic SI.,nlc,"" ~lcd. 85 MeWr. 227-a Meltm, poml
dcrtlUlion of. 14-15 dfc~ ...... carbon. 174 by mc.hod of cuoling. 1S-17 P'I u'On. 611. 174 Ilbkl of. 6().1-6 Sleel 174
Mc.alhc !!-.er! aa~ "'clding (MIG). 421-65 vertical. 449 1«1 umkr mdwidUill _'flU
Mclh~ne. 4S. 47 MClrica.iQn eleclrode. 322 Metric system, Ji Mica. 62 MicroK'OpM; le)'. SS9--tl 1
e"I\inl ~a8"nt .. 560 Ilull) in " 'ekk indicatcd by. 560-1
MIld .!.Ieel ~Id,n, CO .. 465-11 manu.al m~t" Irc, 324-12 MIG ... elding. 446 Ol)'-aoetyIeM. 166-77
Modulus of elaslicll y. 24 Molcculu. 1.34 Mol~bdcnum Ilcd. 89 MOMI
composition. 199 ,,"'cid in. of. Itt Nichl alloys
Neulral flame. 162 Neutron. I Nc""on, 23 Ne ... ,on·s La ... of Gr.~itation, 23 Nickel
alloyt, 84-6 effect In Sled. 84-8 manual metal arc ",(lding. 358-60 MIG ... elding. 454_5 o~y-lCClylcnc welding. 199-201 TlO .... cldin&. 402-4
Nickel clad SICel manu.almcuI an: ""cldin" 361-2 OJ)-3ott1)knc " 'clding. 199-201
N,trard,nl (n,uiding). 100 Nnndc Mcdlcs, 102 Nitrogen
effect on ""dd. 103-1 liqu,d. \49 o~,dcs of. 46 r'op"rtiu, 15-6
Non-dc>tructivc I(Sling. 545-5ti Normahzmg. 98-9 NOlel\ brinkrw:.u.. 14S-1. 573 Sucleu .. I
Ohm. 225 Otun's La .... 2l4-6 Ohmm(t(l. 227 Open hearth f ... rnltt. 69 O.b,ut! p'pe ""clding. 410 Ovcr-ageing. 602 Overhead weldinl
manual mClal ~rc. 342 MIG.449 OJ,-acctyknr.l77
O.'erhutcd Mecl 99 O.'e rlo~ protection. 229 Oxidlltion, 39
aluminium, 41. 128_ 194 roppcr. ~I "",in bnundancs. 99 ,'ed. 42
Oudmnl agcnls, table: 01, 43 O,iditing flame. 162 Oxy-Ie<,:tylcne f1amc
adJ ... stm~nl. Ibl-l r(lOtllon ,no 47-8 tcmper~ture, 47
OJY-lCCtylellC "eldin. ,U-I'O'"IOII rilht ... ard. 176-7 aluminium bruing. 211-12 block. 174 blo .. p'pe, JS9--tl1 blUe ... eld,ng. 180 double operalor .'~rtical. 172 (ilkt .. 17S-6 general prccalllions. 214-15 Incone!. 199 left ..... rd. 166-8 Lm<le .... dding. 173-4
Index
Moncl ..,rfacinc. 199 ow=.head.I12-3 rilhtward, 168-70 5tdlitinc. 203-7 tablt of finc. rods. 612-13 tank!, 214 t«hnil.!"". 164-5 ut IUtJu ",di~jJuoI m~,ab
OKY'I~ cUlling. 540-1 Ol)lOl'n
In copper. "I cyhnders, 148 effect of combinallon wIth mctMI .. sa
o. idauo n effccl on a weld, 41 liquid. 1"9-50 prOl'p"ratlon. 38 pruptrUH, 39-40 ucclln&tln&. 70-3 leM for Itat, 1"9
O.y,.:o I~. 531-2 Ol.One. 46
Paddin" 333-5 PalOlI, Icmptnllure. 6 Parallel
dtctrical oonneIions lB. 220 ,c"",ralon in. 264-5 lra ... lo"""" in. 289-90
Pearlile, 79-S0, 92-3. % Pecning, 139-40 I'e.ctcctic reaction. 600 Ptnodic claS&i(lCation. 2 Pl\asc (,dds, 594- 5 Phn: of current and ,"uhast, 279-30 PIwot di~rlllm. 281 PhoISCM. "6 Pho!.phor bron:rx:. 124 Phosphorus in steel. 82 Pi, i.on production , 64-5 Pip!' hne welding, 362--() Pitch of copper. 118-19 Pl~srn.
cUllln&. 420-4 surfacinJ, 425-.0 wdding, "1"-20
Pl.~ic lkfnrmation. 25 Plaslicity, 30 Polarity. effect on welding
manual melal arc. 329 MIG,375
p.,., geMrlIO •• 257 Law of Magnetic. 2J5
Palinj of copper. 118 Polishing of mkrosections, 560 P O.UIO"",n, ) 17-18 Patennal dlfful:lI('.OI', 2]8 Po,,-de. inJtctlOn culling. B6-\I
.Iunnnlum and allo)"S, 50W
709
ca'" Iron ami high-aUoy steels. 539-40 nlCkl:l and alloys. 540 "a'nkSJ ~tttl. 539
Powder surfacing. 207-8 Pawl:r
definItIOn af, 226 eicctrlCal, 226 un't of, 226
POVfl:r 'fOetor. 283-4 P,,",pltatlOn harden.n,. 131. "09 Pre»urt .<:,ul"or, 154-8 Prcw;ure "·l:ld'n&. S02
cold. SO) Projection
first anale, 585-.0 third Ingk. 585--()
Pro]Cction weld,n&. 481-3 P ...... f mess. 27-8 Prop"M. 44. 527 Protoo,1 Puddhng procc~. 61 PulSl:d currcnt ... dding
MIG.462-5 T1G.411_12
Pyromcter optic.~ 8 plallnum rt~anoe. 6---7 radiation. 7 IhefTT'lO-CO<lpk.7
Qucnclling. dfcet (ln alumIDlum. 130 bra~ 124 copper. 124 slcel.9)
Q""ochlnt ItIedJa. 9S
RadiatlOtl pmml rl). 5S4 helt.21 X-ray. 547-8
Radiography. la X-ray tests RuctQr, mduchw=. Srt choke
710 Index
Recaleso:ntt,91 Rem"ery rat~. 299 R(try~al1iz.ation. 17.50-2 R((·tor"'"tio"
fun·,,",e.255 half·"avc.255
Recufier ""<cnploon. 252 o;clen,um. 252--6
<cmH:<>nductn •. 2~2~ <tlimn. 252--6
Reduction of a", ... 27. 42-3 In a bla<l furnact. 64-S
Rent t~st, 5!!3-4 Regulator. o~}·act t )'lcn. p.CSilurc. 154--11 K~Infu=mcnl of a "cid. 168.333 Relay. 23S---9 Rnl<lual .1r~,"",5.. methods of rditvin~
I ~9-40 W(<.J<lanc<:.
hUll "cldin,. 4RJ
ronlacl.1JI In~ulalion. 22K un;1 of. 225
WC<O<lanc<: "cld;ng. 466-86 Rcu~lI~Ily. 222 Reustor.217 Rllhl ... ud ... -.. Id;n," 1611-70
In·]lO>Ilion. 176-7 RMS. 'aluc (H.). 246-8 Robot we lding. 498-9 Rod\\dl hardne", 1nl. 579-l11 won ",dJ'n];. 362 RustIng of iron. 40-1 Ruule.6CJ.---I
Safel)' p",caution, manual ""'tal arc ... ·dd'" ... 323 MIG ..... K o~y·ltttt)lcne ",clJ,"g. 214-18 t"nh.2\4 T IG.39.1-4 ,n u<c of eomJ'l"u>cJ ga>c5.. 151-2
Sail ,n .t"""pM,,,, dfcel OIl ,.,tlde<. S5. 563 Salunlbl( "'''''tor. 277-9 S-,uratioo. ma&n<'tlc. 277 S<;ale.
dra"'n~ 588 \empcnlture.6
Schlernsropc hard",,\< te<l. ~81 Sl:am ".Iding. 47H S<;ctl(lnlo. 588-9
$.,m • ...-anducton. 222-3 Sen •.••• I«mal conn~~ioM ,n, 220 Shadflcr'~ diagram. 89 Shafts. r.:bu;IJing
munual m~lal arc ,,·.Iding. 136. 333_5 o~)'·a«I)'lcnc ,,·elding. 136. 214
St.."Prinl SI"'''' and stIllin. 29 Sh",ld. hand and head. 314-1 ~ Sh",kkd ltrc, prlne.pIc of. 295 Shun O:-Orcull transfer . .In' d,p tran,fn Shunl. $" ParaUel Shunl ~neIlltor. 260 SKkritc.63 S'lma php!o/:, H7
Silical." ~'HiO Silicon, 4S---9
effect in ca" iroo. 178 steel. 178 .... klIO' rods (oxY-"",",I)IcM). 179
S,loron dioxide (.ihca), 48-',1 SlOu~Klal "aV<' form. 244-6 SkIp ",'ddlO&- 138 Sing basicl\). 492
chemistry of formation. ~~ Slope (..,ntrolled reclifler. 432. 4JS Sod,um alginate. 62 Solenoid. principle of. 238-9 So1i1ls. I SoIKlus. 596 Salk, flOCk. 61 Soluu"n treatmenl. 13U Space lallke. 4. 49 Spatter,2!1K Spec,f", t..,,~t ca"",e;I)'. 14 SpttlflC lalent lira\. 17-18 Sphcroldal ,111phite (SG) CIIst ,.Oft. 68. ,0-,
""cldinl of. 4S5 Spot "cldin" 466----77
M IG.461-2 '1'[0.412-13
Spray fuse hard surfacing. 207-8 Spray nunsfer. 428-9 Sllblhzc:d ~tain"ss "ee!. 86 St.ck CUI\tn" 533 SU,nk: ... iron. 203 Slalnk:" ~t«1
tu"'''_ H4-6 ,,'.Id,ng: manual mClal an:. )57-8: MIG.
453-4, oxy-actty1cfl<. 201-3; TIG. <0,
Smun, 22
Ind",
Slruc(u~cllangc ohlee!l" .... cldin&. 101-3 Surface ICR5M>n, 209-10. 296
Tabk, aluminium ~UoY" 132 alumInIum IiUer md., O~y·~I~k:"".
191; TIG. 398 coefficient of Linear upansion, 12
oon"er>ion.611 clements. 604--t.
magnc,,;um alloy filkr rods. TlG. ] 33, 401-2
ilKn and mIXed g~st's fn. MIG .. -clding. .., melting point of metals. 604--.6 man""'] metal arc electr<>dn. 614 MIG lille .... ·ires' alumLni"m. 132;
copper. 4~J; 5la,nl\:14 Sleel. 454 O~idi7jng agem .. 43 oxy·acel)-knc filler rock. 612-13 Reduclnl agents. 4) SI unll<o. J<ii_xiii
specific heal capacity. 14 "peClflC lalcnt beat. If! lemlle: strength. 26 thermal ooodllC\,,-ily. 19 'rIG fillu ... iTCS: ~luminium alloys.
298-9; copper and aJIo~ 409; magnesium .110"" 4.0 \-2; nickel and allO)'o
"" Zinc roppe r alloys.. 122 Tack ,,"clding. 13b-7. 332
10 prevent distoruon. 136-7 Tantalum. wcLding of. 414 Tanks. preclIution< in welding. 214_15 Tee joint$, S" Fillets T~mp .. bra~ 124 copper, 120
Temptr hardening, 602 Temptring $teel. 95-7 T~m~ratutc of fbme ... 47 T~m~t1Iture "",asurement
con.." 6 craYOM.6 paints, 6 p)·mmctc ..... ft-Cj
t~rmo""'lers. 5 st~el by colour. 96-7
T~nac;ty, 31 Tcrn;;1c strength, 31
lahie: of, 26
Tt_ung macl1inc
hardne~ S71H11 Impact, 57241 tensile strength. S64--'J
Testing of wcllls, 543-84 acwunic. 547 application of load, 558 Noo,570-2 Charpy. H4-6 chemical. 56.1-4 corn>SI'..,. 56J...4 m.ck,n&- 583-4 falig"".581-2 gamma ray. 5S4-8 /l algh. 582-3 hardness. 571-111 h)drlulic. SS8 Impact, 572--8 lrod.57641 mllCfoscup!<:.561 magnetIC. 545-6 microocopic.559-til nkk b"nd. 558-9 pc""lrant fluioJ. 545 Ree"".583-4 Rock,.dL 579-111 SchIcTOSCO~. S81 search roil. 546-7 sulphur print. 561-3 IC~Ic. 564--9 tOr!iion. 569-70 ultra<onk.551-3 Vickers (pyramid diamond). 581 ~~al. 543 WUhJcr. S83 ,.orbhop. 5S8--'J X·ray.547-51
TlIermal C<mdUCII~lty. 18 effect on wcJdin&- ]8-19 lable of compariti,..,. 19
T~nnlc lance. HI Tl"Icrmit
chemical rUClion,43 "'·eld,ng. 522-3
Thermn-.:ouplc. 7 Th<.:rmom~ICrs. 5-6 Thn:c·pha>c ,,-,,1\.1;"1 ~upply. 2M
ThY"Slor. 256 Threshold Imm VII ... (TI..V). 21S
7!1
1'10 wclding.slt tungsten ine" gas welding Tin bronze. oxy-acctylc"" welding. 190 Tipp.ng 1001 . ":d. 205-6. 355
712 Index
Titanium in "ain~ .. st~~I, 86 o.i<.le. 312 "clding. 413
Torch. JU !>Io"'pipt Transf~r~nce
of hem. 18 of mclalll<:ro .. an, gap. 2~
Transformer advanta8C_ and di~d,'anla8CS for ",·cld·
ing. 270 air coo~d. 273 oonncxions. 2~6 currenl oontrol of. 274 dflCi~ncy, 273 magn~tic fields in. 270-4 muhi...,pcralor, 288 oil immersed. 273 optT3tion in parall~l. 2R9-90 prin<:iple of. 270-4 'ingl~ nptl'3lor. 272 .ingJ~·pha..,. 2M7 'lep-<iown.272 ' Iep-up. 272 thru-pha..,.287 ,'ariation ohupply voliage in. 273
Trkhlorocth~lcn<:. 46 Triple d~oxidizcd "cld,ng wirc. 446 Tungsl~n arc. 375- 7 Tungsten carbide. 204--5. 352 Tungslen ckclro<.lC. 392
Ihorislcd. 392 zirconisled. 392
Tungst~n inert gas welding(T10). 373426 aUlomalic. 410 corrosion and Ileat rcsistant "eels. 402-3 ,~ 'mh, ,"<livid",,/ ",nal,
Tung"~n 'lc~1. 90
Ultimate lensile slrenglh (me .. ). 25 Ultra ..... nic le'ling. 551 Ultrasonic w~lding. 503 UnilS
curr~nt. 217. 229 enugy. 13. 226 10rce..23 i'>csl. 13 pow~r. 226 quantity of heat. 14 resiswnce. 229 SI .• ii--xHi voltago, 218. 229 work. 226
Vacuum in.ulat~d ~vaporator. 149- 50 Vacuum rcrming. 77 Vanadium stec1. YO Vaporization .• pccirlC latent heat. 17 Venical welding
manual metal arc. 339-41 MIG.449 ox~acclykne. 205-6 T[G.396
Vickers pyramid diamund hardnn .• le".
'" Volt. d~finition of. 229 Voh-ampere curves
manual ,""Ial arc weLding. 265 11.110.430
Voltage control in CO, ,,·clding. 456
of wcl<.ling generator. 258-60. 267 Vohago drop. 218- 19
in arc. 2[9. 296 MIG.435 open circuit. 217. 296 re..,rve. 435
Vohmcler. 218
Walt,226 Wear r~,i'tanl surfaces. building up
manual metal arc welding. 351 - 5 O.)·acely~ne wclding. 203-4 'pray fu..,. 207-8 T[G.425-6
Wca~ing. 328-9 W~ld
dcea)'.86-7 defccc .. 333 ....,fT".ion. ~4_S
eff~ct of' hy<.lrogcn. 104; nitrogen. 101 - 3; oxnen. 101_3
fealure> of. 800d w~ld. 333 ins""clion and te.ting. 543-84 rotation, 302-4 slope. 302
Weld melal ,nalysis of. 101 prep.a.r.tiun of tC'1 piece; impact. 577;
tensile. 566-7 Wcldmg
,trc_s ..,t up in. 133-40 st,octural changu in ste~l, 101-8
While ca" iron. 68. 178 Wohlcr fatigue test. SR3 Wroughl iron. 61>
Index
X-ray !CSlS. S47-S0
Y~1d point. 14--S Youn"~ mod"lus, H
Zint SQlubili!y ill coppe r. 121 coppcraUoys. 121-4
Z"conil,lm oxide.. 392 ZlfCon,l,Im "",,,,,,,Ioll,lm alloys. 399
713