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Sheet Metal Welding Guide, 3rd Edition, 2007
- FOREWORD
- WELDING TASK FORCE
- NOTICE TO USERS OF THIS PUBLICATION
- TABLE OF CONTENTS
- CHAPTER 1 INTRODUCTION [Go to Page]
- 1.1 BACKGROUND
- 1.2 CODE WELDING
- 1.3 CONTENTS OF THIS MANUAL
- CHAPTER 2 WELDING AND CUTTING PROCESSES [Go to Page]
- 2.1 PROCESSES
- 2.2 CARBON ARC WELDING (CAW)
- 2.3 SHIELDED METAL ARC WELDING (SMAW)
- 2.4 GAS TUNGSTEN ARC WELDING (GTAW)
- 2.5 GAS METAL ARC WELDING (GMAW)
- 2.6 FLUX CORED ARC WELDING (FCAW)
- 2.7 METAL CORED WELDING
- 2.8 PLASMA ARC WELDING (PAW)
- 2.9 SUBMERGED ARC WELDING (SAW)
- 2.10 LASER BEAM WELDING (LBW)
- 2.11 RESISTANCE WELDING (RW)
- 2.12 OXY-FUEL CUTTING (OFC)
- 2.13 PLASMA ARC CUTTING (PAC)
- 2.14 PLASMA ARC GOUGING
- 2.15 AIR CARBON ARC GOUGING
- Table 2-1 Welding Processes
- Table 2-2 SMAW Performance Characteristics of Covered Carbon Steel Electrodes
- Table 2-3 SMAW Welding Variables for Carbon Steel
- Table 2-4 SMAW Welding Variables for Galvanized Steel
- Table 2-5 SMAW Electrodes for Welding Stainless Steels
- Table 2-5 SMAW Electrodes for Welding Stainless Steels (Continued)
- Table 2-6 SMAW Welding Variables for Austenitic Stainless Steel
- Table 2-7 GTAW Tungsten Electrodes
- Table 2-8 GTAW Procedure for Carbon Steel
- Table 2-9 GTAW Welding Variables for Carbon Steel
- Table 2-10 GTAW Welding Variables for Galvanized Steel
- Table 2-11 GTAW Procedure for Stainless Steel
- Table 2-12 GTAW Welding Variables for Austenitic Stainless Steel
- Table 2-13 GTAW Welding Variables for Aluminum
- Table 2-14 GTAW Welding Current Selections
- Table 2-15 GTAW Current Ranges for Tungsten Electrodes
- Table 2-16 GTAW Shielding Gas Selections
- Table 2-17 GMAW Welding Variables for Carbon Steel
- Table 2-18 GMAW Welding Variables for Galvanized Steel
- Table 2-19 GMAW Welding Variables for Stainless Steel
- Table 2-20 GMAW Welding Variables for Aluminum
- Table 2-21 GMAW Filler Metals
- Table 2-21 GMAW Filler Metals (Continued)
- Table 2-22 GMAW Shielding Gas Selections, Spray Transfer
- Table 2-23 GMAW Shielding Gas Selections, Short Circuit Transfer
- Table 2-24 FCAW Welding Electrodes and Related Variables
- Table 2-25 SMAW / FCAW Electrode Equivalents
- Table 2-26 FCAW Electrodes for Stainless Steel
- FIGURE 2-1 CARBON ARC WELDING AND BRAZING PROCESS
- FIGURE 2-2 CARBON ARC WELDING AND BRAZING EQUIPMENT
- FIGURE 2-3 SHIELDED METAL ARC WELDING PROCESS
- FIGURE 2-4 SHIELDED METAL ARC WELDING EQUIPMENT
- FIGURE 2-5 GAS TUNGSTEN ARC WELDING PROCESS
- FIGURE 2-6 GAS TUNGSTEN ARC WELDING EQUIPMENT
- FIGURE 2-7 GRINDING OF TUNGSTEN ELECTRODES
- FIGURE 2-8 GAS METAL ARC WELDING PROCESS
- FIGURE 2-9 GAS METAL ARC WELDING EQUIPMENT
- FIGURE 2-10 FLUX CORED ARC WELDING PROCESS
- FIGURE 2-11 GUN POSITIONS FOR FCAW
- FIGURE 2-12 FLUX-CORED WELDING EQUIPMENT
- FIGURE 2-13 PLASMA WELDING PROCESS
- FIGURE 2-14 PLASMA ARC WELDING MODES
- FIGURE 2-15 PLASMA ARC WELDING EQUIPMENT
- FIGURE 2-16 SUBMERGED ARC WELDING PROCESS
- FIGURE 2-17 OXY-FUEL CUTTING
- FIGURE 2-18 OXYFUEL CUTTING EQUIPMENT
- FIGURE 2-19 PLASMA CUTTER
- CHAPTER 3 WELDING EQUIPMENT [Go to Page]
- 3.1 TYPES OF EQUIPMENT
- 3.2 POWER SOURCES, APPLICATIONS AND LIMITATIONS
- 3.3 WELDING CABLES
- 3.4 WIRE FEEDERS FOR GMAW AND FCAW
- 3.5 BOOMS FOR GMAW AND FCAW PROCESS
- 3.6 WELDING GUNS FOR GMAW AND FCAW
- 3.7 TORCHES FOR GTAW
- 3.8 SEAM WELDING MACHINES
- 3.9 TURNING ROLLS
- 3.10 WELDING POSITIONERS, TAIL STOCKS, TURN TABLES, MANIPULATORS, ETC.
- 3.11 ELECTRODE OVENS
- 3.12 MISCELLANEOUS EQUIPMENT
- 3.13 SAFETY AND PROTECTIVE EQUIPMENT
- Table 3-1 Suggested Copper Cable Sizes
- FIGURE 3-1 POWER SOURCE
- FIGURE 3-2 PORTABLE WELDING MACHINE
- FIGURE 3-3 WELDING CABLE CONSTRUCTION
- FIGURE 3-4 SPOOL-ON-GUN WIRE FEEDER
- FIGURE 3-5 PORTABLE GUN ASSEMBLY
- FIGURE 3-6 BOOM CART
- FIGURE 3-7 FCAW / GMAW GUNS
- FIGURE 3-8 TORCHES FOR GTAW
- FIGURE 3-9 EXTERNAL SEAM WELDER
- FIGURE 3-10 INTERNAL SEAM WELDER
- FIGURE 3-11 POWER TURNING ROLL AND WELDHEAD POSITIONER
- FIGURE 3-12 ELECTRIC DRYING OVEN
- FIGURE 3-13 HAND-HELD BEVELER
- FIGURE 3-14 POWER NIBBLER
- CHAPTER 4 SAFETY [Go to Page]
- 4.1 MANAGEMENT RESPONSIBILITIES
- 4.2 AIR CONTAMINATION
- 4.3 ARC RADIATION
- 4.4 ELECTRICAL SHOCK
- 4.5 FIRE AND EXPLOSION
- 4.6 COMPRESSED GASES
- 4.7 HEAT
- 4.8 NOISE
- 4.9 BASIC DOCUMENT REFERENCES
- 4.10 SAFETY PROCEDURES
- 4.11 SMACNA'S SAFETY AND HEALTH DEPARTMENT
- Table 4-1 Control of Welding Hazards
- CHAPTER 5 WELDED JOINT DESIGN [Go to Page]
- 5.1 BASIC DESIGN CONSIDERATIONS
- 5.2 WELDING SYMBOLS AND TYPES OF WELDS
- 5.3 WELDING POSITIONS
- 5.4 TYPES OF JOINTS AND EDGE PREPARATION
- 5.5 WELD STRENGTH
- FIGURE 5-1 STANDARD LOCATION OF ELEMENTS OF A WELDING SYMBOL
- FIGURE 5-2 SUPPLEMENTARY SYMBOLS
- FIGURE 5-3 TYPICAL WELD SYMBOLS USED FOR SHEET METAL AND LIGHT PLATE
- FIGURE 5-4 THE FIVE BASIC TYPES OF GROOVE WELDS
- FIGURE 5-5 WELDING SYMBOLS FOR FILLET WELDS
- FIGURE 5-6 WELDING SYMBOLS FOR INTERMITTENT FILLET WELDS
- FIGURE 5-7 WELDING SYMBOLS FOR EDGE FLANGE WELDS
- FIGURE 5-8 WELDING SYMBOLS FOR CORNER FLANGE WELDS
- FIGURE 5-9 BASIC WELDING POSITIONS
- FIGURE 5-10 BASIC WELDING JOINTS
- FIGURE 5-10A JOINTS, WELDS, AND GROOVES
- FIGURE 5-11 WELDED JOINT DESIGNS - BUTT JOINTS (B)
- FIGURE 5-12 WELDED JOINT DESIGNS - CORNER AND TEE JOINTS (C AND T)
- CHAPTER 6 STANDARDS, CODES & SPECIFICATIONS [Go to Page]
- 6.1 HISTORY
- 6.2 DEVELOPING A WELDING PROCEDURE SPECIFICATION
- 6.3 WELDING PROCEDURE QUALIFICATION
- 6.4 WELDER QUALIFICATION
- FIGURE 6-1
- FIGURE 6-1A
- FIGURE 6-2
- FIGURE 6-2A
- FIGURE 6-3
- FIGURE 6-3A
- CHAPTER 7 WELD QUALITY [Go to Page]
- 7.1 QUALITY OF WELDS
- 7.2 PRE-WELD CONSIDERATION
- 7.3 WELD INSPECTION
- 7.4 TROUBLE-SHOOTING WELD QUALITY
- Table 7-1 SMAW Troubleshooting Guide
- Table 7-2 GMAW Troubleshooting Guide
- Table 7-2 GMAW Troubleshooting Guide (Continued)
- Table 7-3 GTAW Troubleshooting Guide
- FIGURE 7-1 EXAMPLES OF GOOD AND BAD WELDS
- CHAPTER 8 ESTIMATING WELDING COSTS [Go to Page]
- 8.1 INTRODUCTION
- 8.2 COST CONSIDERATIONS
- 8.3 ADDITIONAL COST CONSIDERATIONS
- 8.4 FACTORS
- 8.5 BASIC COST EQUATIONS
- 8.6 COST COMPUTATIONS
- 8.7 REDUCING WELDING COSTS
- 8.8 QUICK METHOD FOR ESTIMATING WELD COSTS
- Table 8-1 Sheet Metal Welding Parameters (IP)
- Table 8-1M Sheet Metal Welding Parameters (SI)
- Table 8-2 Conversion Table, Inches of Wire per Pound
- Table 8-2M Conversion Table, Meters of Wire per Kilogram
- Table 8-3 SMAW Welding Parameters " Butt Welds
- Table 8-4 SMAW Welding Parameters " Edge Welds
- Table 8-5 SMAW Welding Parameters " Fillet Welds
- Table 8-6 SMAW Welding Parameters " Lap Welds
- Table 8-7 SMAW Welding Parameters " Corner Welds
- Table 8-8 SMAW AC Arc Speed (in./min.) Data - Corner Welds
- Table of Useful Conversions (I-P to SI)
- CHAPTER 9 TRAINING OF WELDERS [Go to Page]
- 9.1 IMPORTANCE OF TRAINING
- 9.2 RESOURCES FOR TRAINING
- 9.3 TRAINING FOR QUALIFICATION
- 9.4 RE-QUALIFICATION REQUIREMENTS
- 9.5 REFERENCES
- 9.6 SUPPLEMENTAL TRAINING
- 9.7 WELDER CERTIFICATION
- CHAPTER 10 HIRIING OF WELDERS [Go to Page]
- 10.1 CHECK LIST FOR HIRING WELDERS
- 10.2 GENERAL KNOWLEDGE TEST
- Table 10-1 Welder Qualification Test Options
- APPENDIX A RECOMMENDED FILLER METALS [Go to Page]
- Table A-1 F Number Grouping of Welding Electrodes and Rods
- Table A-1 F Number Grouping of Welding Electrodes and Rods (Continued)
- APPENDIX B REFERENCED DOCUMENTS AND OTHER RESOURCES [Go to Page]
- B.1 CHAPTER 2 " ELECTRIC ARC WELDING PROCESSES
- B.2 CHAPTER 4 " SAFETY
- B.3 REFERENCED ASSOCIATIONS
- B.4 CHAPTER 5 " WELD JOINT DESIGN
- B.5 LIST OF WELDING TRAINING FACILITIES (OTHER THAN ITI SUPPORTED UNITS)
- GLOSSARY WELDING TERMS AND DEFINITIIONS [Go to Page]
- Figure G-1 Parts of a Weld
- INDEX [Go to Page]