You are on page 1of 47

PowerPoint to accompany

Welding
Principles and Practices
4th edition
Edward R. Bohnart

History of
Welding

Chapter 1

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


2

Overview
• Welding is joining two pieces of metal by:
– Heating to temperature high enough to cause
WELDING: Principles and Practices, 4e

softening or melting
– With or without application of pressure
– With or without use of filler metal
• Melting point same as metals being joined or melting point
below metals but about 800ºF

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


3

Overview

• New methods,
WELDING: Principles and Practices, 4e

applications and
systems
– Tremendous progress
in short time
• Usually best method
to use when fastening
metal
© David H. Wells/The Image Works

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


4

History of Metalworking
• Began when people found they could shape
rocks by chipping them with other rocks
WELDING: Principles and Practices, 4e

• Copper probably first metal to be worked


– Ductile (easily hammered, bent or drawn)
– In Egypt as early as 4000 B.C. and USA before
2000 B.C.
• Welding began more than 3000 years ago
– Hot or cold metals hammered to obtain forge weld
– Forged metals, bronze and iron mentioned in Old
Testament

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


5

History of Metalworking
• Bronze developed between 3000 and 2000
B.C.
WELDING: Principles and Practices, 4e

• Iron became known to Europe about 1000 B.C.


– Philistines had four iron furnaces about 1300 B.C.
• Produced swords, chisels, daggers, and spearheads
– Egyptians began making iron tools during period of
900 to 850 B.C.
– Replaced bronze as metal used in manufacture of
utensils, armor and other applications after 800 B.C.

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


6

History of Metalworking
• Famous Damascus swords and daggers made
in Syria about 1300 B.C.
WELDING: Principles and Practices, 4e

– Sought because of their strength and toughness


– Made by forge-welding iron bars of different degrees
of hardness, drawing them down, and repeating
process many times
• Working of metals followed one another in
great ancient civilizations
– Copper, bronze, silver, gold, and iron

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


7

History of Metalworking
• Time of Roman Empire
– Iron use common in Europe, Near East and Far
WELDING: Principles and Practices, 4e

East
• Chinese developed ability to make steel from
wrought iron in 589 A.D.
• Belgians responsible for progress with steel in
Europe
• Japan manufactured steel by repeated welding
and forging and controlling amount of carbon
by use of fluxes
– Produced famous Samurai sword

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


8

History of Metalworking
• Blast furnace developed for melting iron about
1000 to 1200 A.D.
WELDING: Principles and Practices, 4e

• Fourteenth and fifteenth centuries saw great


improvements in design of blast furnaces
• First cast iron cannon produced in early 1600s
• Industrial Revolution in the middle of the
eighteenth century brought many
improvements

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


9

History of Metalworking
• Present factory system of mass production
introduced
WELDING: Principles and Practices, 4e

– American, Eli Whitney, developed idea of


interchanging parts in manufacture of arms
• Working of dyes and molds became
commonplace by beginning of nineteenth
century
• Henry Ford involved in developing
assembly line method for manufacturing
automobiles early in twentieth century
© 2012 The McGraw-Hill Companies, Inc. All rights reserved.
10

Early Developments in Welding

• Edmund Davy discovered acetylene at


beginning of nineteenth century
WELDING: Principles and Practices, 4e

• Sir Humphrey Davy discovered the electric arc


in 1801
– Concerned with use of arc for illumination
These inventions were forerunner of
– Demonstrated
present arcpossible
weldingto process.
maintain high
voltage arc for varying periods of time by 1809
• Workable electrical generating devices
invented and developed on practical basis by
1850
© 2012 The McGraw-Hill Companies, Inc. All rights reserved.
11

History of Fusion Welding


• First documented instance done by
Auguste de Meritens in 1881
WELDING: Principles and Practices, 4e

– Welded lead battery plates together with


carbon electrode
• Two of Auguste’s pupils, N. Benardos and
S. Olszewski, continued work and issued
patent for welding process using carbon
electrodes and electric power source four
years later
– Primary goal was repair welding

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


12

Bare Metal Electrode Welding

• Introduced in 1888 by N. G. Slavianoff


(Russian)
WELDING: Principles and Practices, 4e

– Discovery first recognized in western Europe


in 1892
• C. L. Coffin was pioneer of welding
industry in United States
– 1889 received patent on equipment and
process for flash-butt welding

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


13

Bare Metal Electrode Welding

– 1890 received additional patents for spot


welding
WELDING: Principles and Practices, 4e

– 1892 received patent for bare metal electrode


arc welding process
• Without knowledge of Slavianoff’s work

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


14

History of Metalworking
• Foresche and Picard developed first
commercial oxyacetylene welding torch at
WELDING: Principles and Practices, 4e

turn of the 20th century


• Electric arc welding method used in US
until about 1920
– Handicapped because of welds produced by
these electrodes not as strong as metal being
welded
• Welding arc very unstable

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


15

History of Metalworking
• In 1907 Kjellberg (Swedish engineer) received
patent covering electrode-coating process
WELDING: Principles and Practices, 4e

– Coating thin and acted only as stabilizer of arc


– Produced welds little better than bare
electrodes
• In 1912 Kjellberg received another patent
for electrode with heavier coating made of
asbestos with binder of sodium silicate
• In 1908, Benardos patented electroslag
process of welding thick plates in one pass
© 2012 The McGraw-Hill Companies, Inc. All rights reserved.
16

History of Metalworking
• Technology of welding progressed slowly
until World War I
WELDING: Principles and Practices, 4e

– Demands of war called for improved methods


of fabrication
– End of war, welding widely accepted
• Research on coated electrodes through
1920s resulted in electrode coatings and
improved core wire

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


17

Multipass Welds
Pass 1

Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
WELDING: Principles and Practices, 4e

Ability to make multipass welds Pass 2


such as this one, on plate and pipe,
led to growth of industry. Welds are
sound and have uniform appearance.

Pass 3

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


18

History of Metalworking
• Stick welding process
– Advanced rapidly due to electrode coatings
WELDING: Principles and Practices, 4e

and improved core wire


– Now called shielded metal arc welding
(SMAW)
• X-ray development
– Possible to examine internal soundness of
welded joints

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


19

Shipbuilding

• 5,171 vessels constructed to American


Bureau of Shipping standard
WELDING: Principles and Practices, 4e

– Through 1945
– During Maritime Commission wartime
shipbuilding program
• Welding was replacing riveting as main
method of assembly

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


20

Development of Modern Welding

• Design of welding machines changed very


little during postwar period
WELDING: Principles and Practices, 4e

– Done with d.c. current from batteries


• Use of a.c. welding machines occurred in
late 1920 and increased in the early 1930s
– First high frequency a.c. industrial machine
introduced in 1936 by Miller Electric
Manufacturing Company
– High rate of metal deposition and absence of
arc blow

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


21

Inert Gas Welding


• World War II spurred development
• Possible to produce welds of high purity
WELDING: Principles and Practices, 4e

and critical application


• Patent issued in 1930 to Hobart and
Devers for use of electric arc within inert
gas atmosphere
– Not well received because high cost of argon
and helium and lack of suitable torch
equipment

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


22

GTAW Welding
• Tungsten electrode replace magnesium
procedure
WELDING: Principles and Practices, 4e

– Patent issue in 1942


• Linde Company developed gas tungsten
arc welding (GTAW)
– Also called tungsten inert gas (TIG) process or
HELIARC
– Perfected water-cooled torch capable of high
amperage

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


23

Tungsten Inert Gas (TIG) Process

Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
WELDING: Principles and Practices, 4e

An aluminum weld made using


the TIG process. The welding
of aluminum is no longer a
problem and can be done with
the same ease as that of steel.

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


24

GTAW Welding
• First done with rotating d.c. welding machines
• Later a.c. units developed
WELDING: Principles and Practices, 4e

• In 1950s
– Selenium rectifier type d.c. welding machines
– a.c.-d.c. rectifier welding machines with built-in
high frequency for GTAW welding became
available
• Miller Electric Manufacturing Company
developed Miller controlled-wave a.c. welder for
critical welds on aircraft and missiles

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


25

Development of Modern Welding

• Use of aluminum and magnesium increased


– Development of GTAW welding
WELDING: Principles and Practices, 4e

– Desirable characteristics of reduced weight and


resistance to corrosion
• Thicker materials in construction, which
required preheating using GTAW welding
• U.S. patent issued in 1948 for gas metal arc
welding (GMAW) process
– Superseded earlier terms of metal inert gas (MIG)
and metal active gas (MAG)

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


26

GMAW Process
• Concentrates high heat at a focal point
• Produces This and similar
WELDING: Principles and Practices, 4e

– Small heat-affected zone processes


are responsible for over
– Narrow bead width
70 percent of welds
– Deep penetration being performed today.
– Faster welding
speed
• Now used in all
industries
St Louis Car. Co.
Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display.

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


27

FCAW Process
• Tubular wire filled with flux: outside acts as electrical
conducting sheath and provides bulk of weld bead; core
WELDING: Principles and Practices, 4e

contains scavengers and deoxidizers


• Some flux cored electrodes generate sufficient gas
shielding; referred to as self-shielding (FCAW-S)
• Other flux cored electrodes require an external shielding
gas (FCAW-G)
• Flux cored wire welding high-deposition process is fast
and economical
• Slag that retards cooling rate and supports molten weld
pool allowing certain electrodes to weld in all positions

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


28

Development of Modern Welding

• Rapid changes occurred in 1980s and


continuing today
WELDING: Principles and Practices, 4e

– Exotic multiple gas mixes


– State-of-art electrodes
– Onboard computers
– Robotic welding
– Hybrid process
• Methods developing that may change way
welds made in future
© 2012 The McGraw-Hill Companies, Inc. All rights reserved.
Processes and Applications 29

Involving Use of the Electric Arc


• Arc spot welding
• Atomic-hydrogen welding
WELDING: Principles and Practices, 4e

• Electrogas
• Plasma arc welding
• Stud welding
• Submerged arc welding
• Underwater arc welding

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


Other Specialized Processes 30

Include
• Cold welding • Laser welding
• Electron beam welding • Oxyhydrogen
WELDING: Principles and Practices, 4e

• Explosive welding welding


• Force welding • Thermit welding
• Friction welding • Ultrasonic welding
• Friction stir welding • Welding of plastics

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


31

Industry Demand
• Over 90 welding processes defined
• Force new and improved developments in
WELDING: Principles and Practices, 4e

machines, gases, torches, electrodes,


procedures, and technology
• Constant research for new metals done by
shipbuilding, space and nuclear industries
– Spurs research in welding

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


32

Welding Associations
• American National Standards Institute
(ANSI)
WELDING: Principles and Practices, 4e

• American Petroleum Institute (API)


• American Society of Mechanical Engineers
(ASME)
• American Welding Society (AWS)
• American Bureau of Shipping (ABS)
Provide guidance and standards relating
to the welding industry.

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


33

Welding as an Occupation
• Can be certified by AWS, ASME and API
– Tests difficult and require many hours of
WELDING: Principles and Practices, 4e

practice
• Key positions in major industries
– Important to economic welfare of country
• Gender friendly
• Done in every civilized country in the world
• Offer prestige and security
• Chances for advancement excellent

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


34

Industrial Welding Applications

• More than 90 different welding processes


• Divided into three major types
WELDING: Principles and Practices, 4e

– Arc
– Gas
– Resistance
• Number of other types used to lesser
extent
– Induction, forge, thermit, flow, and brazing

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


35

Resistance Welding

• Includes spot welding, seam welding, flash


welding, projection welding, and other
WELDING: Principles and Practices, 4e

similar processes performed on machines


• Operators usually taught on job
– Semiskilled workers do not need specific
hands-on-welding skills

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


36

Arc and Gas Welding


• Focus of this text
• Combine art and science
WELDING: Principles and Practices, 4e

• Welders have almost complete control of


the process
– Must know properties of metals to weld; which
weld process to use; and how to plan,
measure, and fabricate

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


37

Welding Positions

Vertical Overhead
WELDING: Principles and Practices, 4e

Miller Electric Mfg. Co.

As well as flat
and vertical
Miller Electric Mfg. Co. Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display.

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


Qualifications and Personal 38

Characteristics
• Welders certified for ability to do work and
work is inspected
WELDING: Principles and Practices, 4e

• Required to pass periodic qualification


tests
• Certifications issued according to kind and
gauge of metal and specific welding
process
• Can hold several different certifications
simultaneously
© 2012 The McGraw-Hill Companies, Inc. All rights reserved.
Example of Magnetic-particle 39

Testing in Building
WELDING: Principles and Practices, 4e

Weld testing and


inspection give
proof of the
soundness of welds.

Circlesafe Aerosol/Circle Systems, Inc.


Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display.

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


40

Basic Tasks
• Gas weld
– Attaching proper tip and adjusting welding
WELDING: Principles and Practices, 4e

regulators for proper volume and gas


pressures
• Electric arc welding
– Regulate welding machine for proper welding
current, select proper electrode size and type,
and right shielding gas
• Need steady hand and have good
visualization skills

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


Master Welder Job 41

Examples
WELDING: Principles and Practices, 4e

Welds in these tanks must


meet X-ray requirements
and pass a dye penetrant
test. Tanks are often lined
with a very thin layer of
pure silver.
AP Photo/U.S. Department of Energy, The Monroe Evening News

Creating Art!
Enrique Vega
Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display.

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


42

Master Welder
• Master craftsperson
• Able to weld all steels and alloys
WELDING: Principles and Practices, 4e

– Plus nickel, aluminum, tantalum, titanium,


zirconium, and their alloys and claddings
• Welds of highest quality
• Welds meet requirement of job
– Delicate welding of silver and gold
– Heavy pressure vessels requiring 4-inch plate

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


Welding Occupations Requiring 43

a High School Education


• Welding operator • Welding superintendent
• Welding fitter • Equipment sales
WELDING: Principles and Practices, 4e

• Combination welder • Sales demonstrator


• Master welder • Sales troubleshooter
• Welding supervisor • Welding instructor
• Welding analyst • Robotics welder
• Inspector operator
• Welding foreman • Job or fabrication shop
owner

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


Welding Occupations Requiring 44

a High School Education


• Welding engineer • Technical editor
(metallurgical) • Welding professor
WELDING: Principles and Practices, 4e

• Welding development • Certified welding


engineer inspector (AWS/CWI)
• Welding research • Corporation executive
engineer • Owner of welding
• Welding engineer business
• Sales engineer

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


45

Safety and Working Conditions

• Indoors or outdoors
• Noisy
WELDING: Principles and Practices, 4e

– Hearing protection
needed
• Awkward positions
• Spacious surroundings
or cramped quarters
• High off ground in
scaffolds with safety © Vicki Silbert/PhotoEdit

harness
© 2012 The McGraw-Hill Companies, Inc. All rights reserved.
46

Job Hazards
• Fire danger
• Burns (including “sunburn” from electric
WELDING: Principles and Practices, 4e

arcs)
• Noxious fumes from materials vaporized at
high temperatures
• Eyestrain Hazards can be minimized
or eliminated by use
• Welders flash
of proper protective
• Electric shock clothing and equipment.

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.


47

Ways to Stay Current


1. Read trade journals, service manuals,
textbooks, and trade catalogs.
WELDING: Principles and Practices, 4e

2. Join associations such as the American


Welding Society.
3. Research topics on the Internet.
4. Trade trips with your peers.

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

You might also like