Welding engineering is a subject that applies the fundamental ideas of materials science, mechanical engineering, structural engineering, and electrical engineering to the development and implementation of joining technology. It is a crucial construction process that involves applying heat to bind materials together. Advances in the technology of these processes have made it possible to join a wide range of materials, including metals, ceramics, polymers, composites, and electronic materials, in ways that maximise reliability while minimising cost. Welding is now widely used for the fabrication of a wide range of components, including critical structures such as boilers and pressure vessels, ships, off-shore structures, bridges, storage tanks and spheres, pipelines, railway coaches, anchor chains, missile and rocket parts, nuclear reactors, fertiliser and chemical plants, structural, earth moving equipment, plate and box girders, and missile and rocket parts.
This book provides comprehensive insights into the field of welding engineering and technology. It discusses in detail some of the essential application and techniques for this subject. This book attempts to understand the multiple branches that fall under this discipline and how such concepts have practical applications. It deals with arc welding processes, resistance welding process, welding positions and weld joints. The book has been written primarily to meet the requirements of welding engineering professionals and students. It also describes high energy density welding process, design consideration for welding, welding metallurgy, safety and standards of welding. Such selected concepts that redefine this area have been presented in the book. It is meant for students who are looking for an elaborate reference on welding engineering.
Preface ix
1. What is Welding Engineering? 1
1. Introduction 1
2. Welding Engineers 3
3. Characteristics of a Welder 6
4. Welding Processes 7
5. Conclusion 17
References 18
MCQs 18
Answers 19
2. Arc Welding Processes 20
1. Introduction 20
2. Fundamentals of Arc Welding 20
3. Arc Welding Power supplies 21
4. Circuit diagram of Arc Welding 23
5. Types of arc welding 24
6. Consumable Electrode Methods 25
7. Non-consumable Electrode Methods 39
8. Other Types of Arc Welding 42
9. Basic Welding Circuit 44
10. Arc Shielding 44
11. Nature of the Arc 45
12. Polarity in Welding 46
13. Conclusion 49
References 50
MCQs 50
Answers 51
3. Welding Positions and Weld Joints 52
1. Introduction 52
2. Types of Welds 75
3. Mechanical Properties of Welded Joints 79
4. Factors affecting on Welded Joints 80
vi Welding Engineering and Technology
5. Conclusion 81
References 82
MCQs 82
Answers 84
4. Resistance Welding Process 85
1. Introduction 85
2. Resistance welding processes 86
3. Parameters in resistance welding 88
4. Working Principle of Resistance Welding 93
5. Types of Resistance Welding 94
6. Resistance Spot Welding 95
7. Resistance Seam Welding 101
8. Projection Welding 104
9. Flash butt Welding 108
10. Upset Welding 110
11. High-frequency resistance welding (HFRW) 112
12. Electrode degradation and tip dressing 112
13. Conclusion 114
References 114
MCQs 115
Answers 116
5. Solid State Welding Process 117
1. Introduction 117
2. Solid-State Welding Processes 118
3. Conclusion 149
References 149
MCQS 150
Answers 151
6. High Energy Density Welding Process 152
1. Introduction 152
2. Effect of power density 152
3. Conduction Mode Welding 155
4. Keyhole Mode Welding 157
5. Laser beam welding (LBW) 160
6. Electron beam Welding 169
7. Conclusion 178
References 178
MCQS 179
Answers 181
vii
Contents
7. Design Consideration for Welding 182
1. Introduction to Welding Designs 182
2. Design aspects of weld joint 183
3. Design of Weld Joints for fatigue loading 183
4. Fatigue design rules in welding 185
5. Influence of residual stress 185
6. Factors Influencing Fatigue Behavior 186
7. Effect of welding process 188
8. Conclusion 199
References 200
MCQS 200
Answers 202
8. Welding Metallurgy 203
1. Introduction 203
2. Conclusion 212
References 214
MCQs 215
Answers 215
9. Welding Metallurgy of Steels and Non-ferrous Alloys 216
1. Introduction 216
2. Welding metallurgy of carbon steels 216
3. Rapid Cooling Martensitic Grades 223
4. Other Martensitic Grades 225
5. Precipitation Hardened (PH) Stainless Steel 226
6. Conclusion 233
References 234
MCQS 234
Answers 235
10. Safety and Standards of Welding 236
1. Introduction 236
2. American Society Of Mechanical Engineers (ASME) 245
3. Conclusion 253
References 254
MCQs 255
Answers 256
Index 257
Michelina Sykes is a Senior Science Research Specialist at Technical Institute, Quebec. She earned her Ph.D. in Welding Engineering & Metallurgy from Public State University, Tucson. Her scholarly interests lie in machining, welding methodology & aspects of welding. Sykes has authored and edited numerous articles, journal papers, and book chapters, which have been published worldwide. She has also been an invited speaker at various national and international conferences.
