INTRODUCTION

Althouse, Andrew R, et. al., Modern Welding,

Welding The Goodheart-

Willcox Company, Inc., Illinois, 1988.

ASME, 1998 ASME Boiler & Pressure Vessel Code, Section IX

- Welding and Brazing Qualification,

Qualification The American Society of
Mechanical Engineers, New York, 2000.

AWS, AWS D1.1: 2002, Structural Welding Code - Steel,

Steel

American Welding Society, Miami, 2002.

AWS, Certification Manual for Welding Inspectors,

Inspectors American

Welding Society, Miami, 4th Edition, 2000.

REFERENCES
AWS, ANSI/AWS A3.0-94, Standard Welding Terms and

Definitions,
Definitions American Welding Society, Miami, 1994.

AWS, Welding Inspection Handbook,

Handbook American Welding

Society, Miami, 3rd Edition, 2000.

Jeffus, Larry, Welding - Principles and Applications,

Applications Delmar

Publishers Inc., Albany, 3,d Edition, 1993.

Jenney, Cynthia L., and Annette O'Brien, Welding Handbook,

Volume 1 - Welding Science and Technology,

Technology American
Welding Society, Miami, 9th Edition, 2001.

NONMANDATORY REFERENCES
O'Brien, R.L., Welding Handbook, Volume 2 - Welding

Processes,
Processes American Welding Society, Miami, 8th Edition,
1991.

Oates, William R., Welding Handbook, Volume 3 - Materials &

Applications Part l,
l American Welding Society, Miami, 8th
Edition, 1996.

Oates, William R., and Alexander M. Saitta, Welding

Handbook, Volume 3 Materials & Applications Part 2,

2
American Welding Society, Miami, 8th Edition, 1998.

MANDATORY REFERENCES
Wiryosumarto, Harsono, dan Toshie
Okumura, Teknologi Pengelasan
Logam, Pradnya Paramita, Jakarta,
Cetakan Kedelapan, 2000.

JOINING METHOD CHART

Early metal-joining methods included such processes as forming

a sand mold on top of a piece of metal and casting the desired
shape directly on the base metal, Figure 1-1

Another metal-joining method used in early years was to place

two pieces of metal close together and pour molten metal
between them. When the edges of the base metal melted, the
flow of metal was then dammed and allowed to harden. Figure 12.

The Industrial Revolution, from

1750 to 1850, introduced a
method of joining pieces of iron
together known as forge
welding or hammer welding.
welding

This process involved the use of a

forge to heat the metal to a soft,
plastic temperature. The ends of the
iron were then placed together and
hammered until fusion took place.

Forge welding remained as the primary welding method until Elihu

Thomson,
Thomson in the year 1886, developed the resistance welding
technique.
technique This technique provided a more reliable and faster way
of joining metal than did previous methods.
As techniques were further developed, riveting was replaced in the
United States and Europe by fusion welding to repair ships at the
end of World War I. At that time the welding process was considered
to be vital to military security. Repairs to the ships damaged during
World War I were done in great secrecy. Even today some aspects of
welding are closely guarded secrets.
Since the end of World War I, many welding methods have been
developed for joining metals. These various welding methods are
playing an important role in the expansion and production of the
welding industry. Welding has become a dependable, efficient, and
economical method for joining metal.

WELDING DEFINED
A weld is defined by the American Welding Society (AWS) as "a

localized coalescence (the fusion or growing together of the grain

structure of the materials being welded) of metals or nonmetals
produced either by heating the materials to the required welding
temperatures, with or without the application of pressure, or by the
application of pressure alone, and with or without the use of filler
materials."

Welding is defined as "a joining process that produces

coalescence of materials by heating them to the welding

temperature, with or without the application of pressure or by the
application of pressure alone, and with or without the use of filler
metal."

USES OF WELDING

WELDING PROCESSES
The number of different welding processes has grown in recent
years. These processes differ greatly in the manner in which heat,
pressure, or both heat and pressure are applied, and in the type of
equipment used.
Figure 10.1 lists various welding methods. Certain methods listed
in the figure require hammering, pressing, or rolling to effect the
coalescence in the weld joint. Other methods bring the metal to a
fluid state, and the edges flow together.

The most popular processes are oxyacetylene welding

(OAW), shielded metal arc welding (SMAW) which
often called stick welding,
welding gas tungsten arc welding
(GTAW), gas metal arc welding (GMAW), flux cored
arc welding (FCAW), and submerge arc welding
(SAW).

Oxyacetylene is one part of the larger group of processes known as oxyfuel

gas (OF). This group of processes can be used for welding (OFW), cutting
(OFC), and brazing (TB). This group is one of the most versatile of the welding
processes. The equipment required is comparatively inexpensive, and the cost of
operation is low, Figure 1-7.

Shielded metal arc welding (SMAW) is the most common method of joining
metal. High-quality welds can be made rapidly and with excellent uniformity. A
variety of metal types and metal thicknesses can be joined with one machine,
Figure 1-8.

Gas tungsten arc welding (GTAW) is easily performed on almost any

metal. Its clean, high-quality welds often require little or no postweld
finishing, Figure 1-9.

Gas metal arc welding (GMAW) is extremely fast and economical.

This process is easily used for welding on thin-gauge metal as well as on
heavy plate. The high welding rate and reduced postweld cleanup are
making gas metal arc welding an outstanding welding process, Figure 110.

Flux cored arc welding (FCAW) uses the same type of equipment that
is used for the gas metal arc welding process. A major advantage of this
process is that with the addition of flux to the center of the filler wire the
weld's properties can be changed. Although welds must be cleaned after
completion, the improved quality, flexibility, and welding speed offset this
requirement.

Selection of the Joining Process

The selection of the joining process for a particular job depends upon many
factors. No one specific rule controls the welding process to be selected
for a certain job. A few of the factors that must be considered when choosing
a joining process include:

Availability of equipment - The types, capacity, and condition of

equipment that can be used to make the welds.

Repetitiveness of the operation - How many of the welds will be

required to complete the job, and are they all the same?

Quality requirements - Is this weld going to be used on a piece of

furniture, to repair a piece of equipment, or to join a pipeline?

Location of work - Will the weld be in a shop or on a remote job site?

Materials to be joined - Are the parts made out of a standard metal or

some exotic alloy?

Appearance of the finished product - Will this be a weldment that is

only needed to test an idea, or will it be a permanent structure?

Size of the parts to be joined - Are the parts small, large, or different
sizes, and can they be moved or must they be welded in place?

Time available for work - Is this a rush job needing a fast repair, or is
there time to allow for pre and postweld cleanup?

Skill or experience of workers - Do the welders have the ability to do

the job?

Cost of materials - Will the weldment be worth the expense of special

equipment materials or finishing time?

Code or specification requirements - Often the selection of the

process is dictated by the governing agency, codes, or standards.

The welding engineer and/or the welder must not only decide on the welding
process but must also select the method of applying it.
it The following
methods are used to perform welding, cutting, or brazing operations.

Manual - The welder is required to manipulate the entire process.

Semiautomatic - The filler metal is added automatically, and all
other manipulation is done manually by the welder.

Machine - Operations are done mechanically under the observation

and correction of a welding operator.

Automatic - Operations are performed repeatedly by a machine that

has been programmed to do an entire operation without interaction of
the operator.

Automated - Operations are performed repeatedly by a robot or

other machine that is programmed flexibly to do a variety of processes.

Welding Occupation

Welder
Welding foreman
Welding supervisor
Welding inspector
Welding technician
Welding instructor
Welding engineer
Welding sales representative
Welding service representative

QUALIFICATION & CERTIFICATION

Qualification
is the ability of an individual to perform a job according to a
required standard.

Certification
is a written statement attesting to the fact the welder has been
able to produce welds meeting a prescribed standard.