welding

1

(Welding)208281 Workshop Practice Created by Prateep Chaisermtawan

2 3

1.

1,000 . 19

Edmund Davy

.. 2344 Sir Humphry Davy

()

Auguste de Meritens

.. 2424 Auguste de Meritens

.. 2428 Bernados N. Olszeweskis

3 ()

.. 2431 N.G. Slavianoff

.. 2435 C.L. Coffin

.. 2435 N.G. Slavianoff

()

.. 2455 Kjellberg

42. 2

()

.. 2473 2 Gobart Devers

.. 2485 The Linde Company GTAW (Gas Tungsten-Arc Welding) TIG 2

5 ()

GTAW

GTAW(TIG)

.. 2491 GMAW (Gas Metal-Arc Welding)

GMAW

GMAW(MIG)

6 ()

3.3.

(ASW) 50

()

(Oxyfuel Gas Welding : OFW)(Resistance Welding : RW)

(Arc Welding : AW)

(Solid-State Welding : SSW)

(Soldering : S)

(Brazing : B)

American Welding Society : AWS

7 ()

(Thermal Cutting :TC)

(Oxygen Cutting : OC)

(Arc Cutting : AC)

(Thermal Spraying : THSP)

(Adhesive Bonding : ABD)

AWS

()

(Bare Metal Arc Welding : BMAW) (Atomic Hydrogen Welding : AHW) (Carbon Arc Welding : CAW)

(Arc Welding : AW)

AWS

(Submerged Arc Welding : SAW) (Stud Arc Welding : SW) (Shield Metal Arc Welding : SMAW) (Plasma Arc Welding : PAW) (Gas Tungsten Arc Welding : GTAW) (Gas Metal Arc Welding : GMAW)

8 ()

- (Oxyacetylene Welding : OAW)- (Air Acetylene Welding : AAW)

(Oxyfuel Gas Welding : OFR)

AWS

(Pressure Gas Welding : PGW)-(Oxyhydrogen Welding : OHW)

()

(Roll Welding : ROW)(Hot Pressure Welding : HPW) (Ultrasonic Welding : USW)(Friction Welding : FRW)

(Solid-State Welding : SSW)

AWS

(Forge Welding : FOW) (Explosion Welding : EXW) (Diffusion Welding : DFW) (Cold Welding : CW)

9 ()

(HFRW) (PEW) (FW)

(Resistance Welding : RW)

AWS

(Upset Welding : UW) (Projection Welding : RPW) (Resistance Seam Welding : RSEW) (Resistance Spot Welding : RSW)

()

(Laser Beam Welding : LBW) (Thermit Welding : TW) (Induction Welding : IW)

AWS

(Electron Beam Welding : EBW) (Flow Welding : FLOW)

10

()

(Furnace Soldering : FS)(Induction Soldering : IS)(Infrared Soldering : IRS) (Dip Soldering : DS)

(Soldering : S)

AWS

(Resistance Soldering : RS) (Torch Soldering : TS) (Wave Soldering : WS) (Iron Soldering : INS)

()

(Induction Brazing : IB) (Infrared Brazing : IRB) (Resistance Brazing : RB) (Torch Brazing : TB)(Twin Carbon Arc Brazing : TCAB) (Furnace Brazing : FB)

(Brazing : B)

AWS

(Block Brazing : BB) (Diffusion Brazing : DFB) (Dip Brazing : DB) (Flow Brazing : FLB)

11

()

(Metal Powder Cutting : POC) (Oxygen Arc Cutting : AOC) (Chemical Flux Cutting : FOC) (Oxygen Lance Cutting : LOC)

(Oxygen Cutting : OC)

AWS

(Oxyfuel gas Cutting : OFC)- - (Oxyhydrogen Cutting : OFC-H)- - (Oxyacetylene Cutting : OFC-A)- - (Oxynatural Cutting : OFC-N)- - (Oxypropane gas Cutting : OFC-P)

()

(Carbon Arc Cutting : CAC)(Gas Meta Arc Cutting : GMAC)(Gas Tungsten Arc Cutting : GTAC)-(Air Carbon Arc Cutting : AAC)

(Arc Cutting : AC)

AWS

(Plasma Arc Cutting : PAC) (Metal Arc Cutting : MAC)(Shield Metal Arc Cutting : SMAC)

12

()

AWS

(Laser Beam Cutting : LBC)(Electron Beam Cutting : EBC)

()

(Thermal Spraying : THS)

AWS

(Flame Spraying : FLSP) (Plasma Spraying : PSP) (Electric Arc Spraying : EASP)

13

208281 Workshop Practice Created by Prateep Chaisermtawan

(Welding Processes) 40


Shield Metal Arc Welding:

SMAWSubmerged Arc Welding:

SAW

Gas Metal Arc Welding: GMAW

Gas Tungsten Arc Welding:GTAW

Plasma Arc Welding: PAW

Oxy-acetylene Welding: OAW

14


1.

(Shield Metal Arc Welding Process : SMAW)2.

(Submerged Arc Welding Process : SAW)3.

(Gas Metal Arc Welding Process : GMAW)4.

(Gas Tungsten Arc Welding)5. -

(The Oxy-acetylene Welding Process : OAW)6.

(Plasma Arc Welding : PAW)


(Electrode) (Base Metal) ( 3,300 C 5,500C )

(Shield Metal Arc Welding Process : SMAW)

15

208281 Workshop Practice Created by Prateep Chaisermtawan (Shield Metal Arc Welding Process : SMAW)

SMAW


1.







16

208281 Workshop Practice Created by Prateep Chaisermtawan (Submerged Arc Welding Process : SAW)

(FluxHopper)

208281 Workshop Practice Created by Prateep Chaisermtawan (Submerged Arc Welding Process : SAW)

SAW

17


1.







208281 Workshop Practice Created by Prateep Chaisermtawan(Gas Metal Arc Welding Process : GMAW)

(MIG Metal Inert Gas)

18


GMAW

(Gas Metal Arc Welding Process : GMAW)

(Shielding Gas) Ar, He, CO2

208281 Workshop Practice Created by Prateep Chaisermtawan(Gas Metal Arc Welding Process : GMAW)

19


1.







208281 Workshop Practice Created by Prateep Chaisermtawan(Gas Tungsten Arc Welding : GTAW)

(TIG Tungsten Inert Gas) (Tungsten Electrode)

20

208281 Workshop Practice Created by Prateep Chaisermtawan(Gas Tungsten Arc Welding : GTAW)


GMAW

(Shielding Gas) Ar, He

(Gas Tungsten Arc Welding : GTAW)

21


1.







208281 Workshop Practice Created by Prateep Chaisermtawan- (The Oxy-acetylene Welding Process : OAW)

(O2) (C2H5) ( 3,100 C 3,500 C)

22


OAW

- (The Oxy-acetylene Welding Process : OAW)


1.







23

208281 Workshop Practice Created by Prateep Chaisermtawan(Plasma Arc Welding : PAW)

TIG (Constricted Arc) (Transferred Arc) (Constricting Orifice)

208281 Workshop Practice Created by Prateep Chaisermtawan(Plasma Arc Welding : PAW)

24

5 (5 Types of Joints)1. Butt joint 2

5 ()2. Corner joint 2

25

5 ()3. Lap joint 2

5 ()4. Tee joint 2 T

26

5 ()5. Edge joint 2

(Types of Welds)Fillet Weld 4 a. b. c. 2 d. T

27

()Groove Weld 6 a. 1 b. 1 c. V 1

()d. U 1 e. J 1 f. V 1

28

()Spot Weld 2 2

(PA Flat) (PC Horizontal Vertical)

(Butt Weld)

(PE Overhead)

29

(Butt Weld)

(PF Vertical Upwards)

(PG Vertical Downwards)

(PA Flat)

(PB Horizontal Vertical)

(Fillet Weld)

30

(Fillet Weld)

(PG Vertical Downwards)

(PF Vertical Upwards)

(PD Horizontal Overhead)

32

(Melting point) 1,482 C

(Weld ability)

()

(Fusibility)

(Volatility)

33

()

(Electrical conductivity)

(Electrical resistance)

()

(Thermal conductivity)

(Coefficient of thermal expansion)

34

()

(Hot shortness)

(Overheating)

()

(Hot shortness)

(Overheating)

35

Shielded metal-arc-welding : SMAW

>>

6000 oF 9000 oF (3315 oC 4982 oC)

36

2 1.) (Resistance welding) 2.) (Arc welding)

10,000 12,000 3

(Cathode) (Anode) (Arc Plasma)

37

(Polarity)>> DCPR DCSP

d.c. () >> A.C.

A B

(Welding Current) 2 (Alternating Current : AC)- 50 Hz (1 50 )

1

(Direct Current : DC)- -100 Hz

38

(Slag)

39

-

/

- 1) / (Type of Power Source) 2

1.1) (output slop)

40

1.2) 3 - - - -

-

-

>> - - - - / -

41

400

- -1. 2.

3.

/ 4.

>>

42

>> a.c. d.c.

-

-

>> -

--

1) 2) 3) 4)

43

>> - - 1/120 -

>> >> ( 0.01 .) >> >>>> (0.01 . 20 )>>

44

Laser

- - on-line processing- -

radiation shielding

Electron Beam

- - -

Resistance Welding

- - -

Submerged Arc

- - - - 1 2

Gas Metal Arc

Advantages of Laser WeldingCompeting Process

Robot9 Axis Arc Welding RobotTwin Weld Gun Cell

robotic welding and cutting systems

45

- 2) 2) ( (Electrode holders)Electrode holders)

- - -

-

- 400 200

2 4148 oC

46

-

3)

- -

4/03/05003/02/0450

4/03/01/04004/03/01/0350

4/03/02/013004/03/02/01/02250

4/04/03/02/01/0122003/02/02/01/01221501/01/012222100

2001751501251007550

()

47

-

4) (Cable Lugs and Ground Clamps)- - -

-

5) 5) >> >> 2

1) 2) >>

48

>> >> >> >> >>

- / -

-

49

>> >> >> >> >> >>

-

50

- - -

51

6

1. (Correct Electrode)2. (Welding Position)3. (Correct Current)4. (Correct Arc Length or

Voltage)5. (Correct Electrode Angle)6. (CorrectTravel Speed)

1. (Correct Electrode >> >> => >> =>

>> =>

>> =>

>> >>

52

>>

>> >> >> >>

: (Preheating)

50 - 8040-705-15 ft./ib

26 30,00026 30,00012 18,000 (psi)

7.857.80 7.857.5 7.7 (gm/cm3)

60.0 70.035.0 65.08.0 20.0 (%)

35.0 60.010.0 20.0 (%)

30.0 40.020.0 40.05.0 10.0 (% 2 )

30 32,00045 60,00038 45,000 (psi)55 70,00060 75,00050 60,000 (psi)

53

E 4 5

E XX X X /

E

1 2 3

100 psi ( 2 3 5 )

/ 50% / (50%) / (50%)

DCSP,DCRP a.c.DCSP,DCRP a.c.DCRP a.c.

E 7024E 6027E 7028

(25%)

DCRP a.c.DCRP a.c.

DCSP,DCRP a.c.

E 7016E 7018

E 7020

(30%)

DCSP, DCRP a.c.DCSP, DCRP a.c.

DCRP

E 6013E 7014

E 7015

DCRP DCRP a.c.DCSP a.c.

E 6010E 6011E 6012

AWS

54

E 6010E 60 60,000 psi1 0 DCRP

>> >> >> >> => =>

2. (Welding Position)

55

E 6011 E 6010

E 6010

E 6012

()

E XX12, E XX13, 4

E XX10()E XX11, E XX16, E XX18

3

E XX15, E XX16, E XX18, E XX12, E XX13, E XX20, E XX24, E XX27,E XX28

2

E XX20, E XX24, E XX27, E XX28

1

3. (Correct Current)->> >> >>

56

Undercut

Overlap

No Overlap

Undercut

Overlap

275-365335-430400-525*

260-340315-400375-470

240-320300-390375-475

260-340330-415390-500

250-350300-420375-475

225-310275-375340-450

210-300250-350320-430

200-300250-400300-500

170-250210-320275-425

7/321/45/16

140-190180-250230-305

115-165150-220200-275

100-150140-200180-255

110-160150-210200-275

125-185160-240210-300

100-150130-190175-250

80-130105-180150-230

80-140110-190140-240

75125110170140-215

1/85/323/16

--

100-145*

--

70-100

--

65-110

--

80-125

---

---

20-4025-6045-90

20-4025-6035-85

--

40 - 80

1/165/643/32

E7024,E7028

E7018E7015,E7016

E7014E6027E6020E6013E6012E6010,E6011DC+

()

()

57

4. (Correct Arc Length or Voltage)

>> >>

>>

>>

( ) (Arc blow)

: Arc Blow

58

5. (Correct Electrode Angle) >> => >> =>

6. (CorrectTravelSpeed)

>>

>> /

59

/

1) 2) 3) 4) 5) 6) 7)

60

:

>> >> (

2

: >> 90 0 100 200

>> Arc blow>> >>

()

61

: >> >> >>

A

B C

62

590

: >> >> >> >>

63

DCSP A,C,

64

: >> 900 >> 300 >>

>>

DCRP A.C.

: >> >> 300 >> >> /

65

: >> (d.c. 120 -170 a.c.

130 190 ) >> 900

50 -150 >>

66

>> >>

DCRP A.C.

: V >> >> 900 100 200

>>

V

67

V DCRP A.C.

(Underwater welding)

>>

>> >>

()

>> /

69

3 1. Drag or self-consuming technique2. Oscillation technique3. Step-back technique

Drag or self-consuming technique

Oscillation technique

Step-back technique

>>

>> >>

/

>> - ( 2-3 )

>>

70

- 15o 45o self-consuming Technique

(General Shop Precautions)1. 2. , , ,

3.

4.

71

5.

6.

7.

8.

9.

(Safety in Arc Welding)

1. >>

>>

72

2.

2 2.1 (Ultra-Violet Radiation)

>> Arc eye

>> 6 12-24

>>

2.2 (Infrared Radiation)

>> (Filter lens)

>> , , ,

73

3. >> >> >> >>

1.

2.

3.

(filter lens) 4.

74

5. 6.

7. 8. 9.

10. 11.

/

75

Jig & Figture

76

Jig & Figture

82

()

84

Q & A

(Metal Inert Gas Welding : MIG)

85

()

()

86

()

()

87

()

1.

>> , 2. >> 3. 4. DIN JIS .

88

AWS5.18 AWS5.28

ER XX S X

x 1,000 psi

() ER 70S 6 Mild Steel Electrodes ER = 70 = 70,000 psi S = 6 =

89

() ER 80S B2L Low Alloy Steel Electrodes ER = 80 = 80,000 psi S = B2 = L =

() ER316 L Stainless Steel Electrodes ER = 316 = L =

90

-

()

--

---

91

251912.7106.44.83.21.60.40.13 (.)

92

()

93

1.

()2.

94

()3.

()4.

/

95

()5.

96

() 60%

() 85%

98

()

()

99

()

Q & A

100

(Welding) (3/4)

(Tungsten Inert Gas Welding : TIG) (Plasma Arc Welding : PAW) (Spot Welding/Resistance Welding) (Resistance Seam Welding) (Robotic Welding)

101

(Tungsten Inert Gas Welding : TIG)

()

102

() 3,410 C (WIG)

()

103

()

()

104

()

()

105

()

()

106


20,000 C

()

107

()

()

108

()

()

109

()

()

110

(Spot Welding/Resistance Welding)

2

(Mass production)

~10,000

()

111

(Spot Welding Cycle)

() (1) (2) (3) (4) (5)

112

() (

)

() ( 1 )

113

(Resistance Seam Welding)

2

(Mass production)

()

114

()

(Robotic Welding) (Mass production)

115

() 2 1. Rectilinear robots

x y z

()2. Articulating robots

116

Q & A

117

(Welding) (4/4)

118

() ()

119

DIN JIS . 1.5 2 .

()

120

1.5 .

28%

121

1. 2.

2.1 2.2

3. 4.

122

()1. (.)

2. 2.1 (.)

= (.) x (./.) x (./.) x (./.)

= (.) x (./.) x (./.) (./.) x (%)

= (.) x (./.)

()

100908070605040302010

(%)

123

()2.2. (.)

3. (.)

4 ( )

= () x () x (.) x (./. - .) (%)

= +

()

2006004008.5

2,4002,400

3,600

2,4002,400

(.)

124

()

Q & A

125

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

1.

2.

3.

126

3

1) >>

2) >>

3) >> /

(Nondestructive Testing)

(Magnetic Particle Testing) (Radiographic) (Penetrant Inspection) (Red Dye Penetrant) (Ultrasonic Inspecton) (Eddy Current Testing) (Leak Testing) (Hardness Testing)

127

(WPS)

128

, , , 2529

, ,,2524

End of Welding

welding

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