AWS welding handbook VOL 2 9th ed (2004) welding processes part 1

Sách handbook (sách kinh điển) về hàn theo AWS, phần 1 các quá trình hàn theo tiêu chuẩn của hội hàn mỹ xuất bản lần thứ 9 vol 2 năm 2004. Chương 1 Các nguồn điện hàn, Chương 2 Hàn hồ quang tay Chương 3 Hàn hồ quang điện cực tungsten trong môi trường khí

Welding Handbook Ninth Edition Volume WELDING PROCESSES, PART Prepared under the direction of the Welding Handbook Committee Annette O’Brien Editor American Welding Society 550 N.W LeJeune Road Miami, FL 33126 02004 by American Welding Society All rights reserved No portion of this book may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, including mechanical, photocopying, recording, or otherwise, without the prior written permission of the copyright owner Authorization to photocopy items for internal, personal, or educational classroom use only, or the internal, personal, or educational classroom use only of specific clients, is granted by the American Welding Society (AWS)provided the appropriate fee is paid to the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923; telephone: (978) 750-8400; Internet: www.copyright.com Library of Congress Control Number: 2001089999 ISBN: 0-87171-729-8 The Welding Handbook is the result of the collective effort of many volunteer technical specialists who provide information to assist with the design and application of welding and allied processes The information and data presented in the Welding Handbook are intended for informational purposes only Reasonable care is exercised in the compilation and publication of the Welding Handbook to ensure the authenticity of the contents However, no representation is made as to the accuracy, reliability, or completeness of this information, and an independent substantiating investigation of the information should be undertaken by the user The information contained in the Welding Handbook shall not be construed as a grant of any right of manufacture, sale, use, or reproduction in connection with any method, process, apparatus, product, composition, or system, which is covered by patent, copyright, or trademark Also, it shall not be construed as a defense against any liability for such infringement Whether the use of any information in the Welding Handbook would result in an infringement of any patent, copyright, or trademark is a determination to be made by the user Printed in Canada PREFACE Welding Processes, Part is the second of the five volumes of the 9th edition of the Welding Handbook The fifteen chapters of this volume provide updated information on the arc welding and cutting processes, oxyfuel gas welding and cutting, brazing, and soldering Volume 3, Welding Processes, Part will cover resistance, solid state, and other welding and cutting processes Volumes and of the Welding Handbook will address welding materials and applications These volumes represent the practical application of the principles discussed in the chapters of Volume 1, Welding Science and Technology, published in 2001 This peer-reviewed volume of the Welding Handbook reflects a tremendous leap forward in welding technology While many basics of the welding processes have remained substantially the same, the precise control of welding parameters, advanced techniques, complex applications and new materials discussed in this updated volume are dramatically changed from those described in previous editions In particular, advancements in digital or computerized control of welding parameters have resulted in consistently high weld quality for manual and mechanized welding and the repeatability necessary for successful automated operations Chapter of Welding Processes, Part is a compilation of information on arc welding power sources Subsequent chapters present specific information on shielded metal arc welding, gas tungsten arc welding, gas metal arc welding, flux cored arc welding, submerged arc welding, plasma arc welding, electrogas welding, arc stud welding, electroslag welding, oxyfuel gas welding, brazing, soldering, oxygen cutting, and arc cutting and gouging Appendix A and B address safety issues Appendix A reproduces the American Welding Society Lens Shade Selector Appendix B is a list of national and international safety standards applicable to welding, cutting, and allied processes Although each chapter in this volume has a section on safe practices as they pertain to the specific process, readers should refer to Chapter 17, “Safe Practices,” of Volume and to the appropriate standards listed in Appendix B Appendix C is a list of American Welding Society filler metal specifications and related documents An index of this volume and a major subject index of previous volumes are included This volume was compiled by the members the Welding Handbook Volume Committee and the Chapter Committees, with oversight by the Welding Handbook Committee Chapter committee chairs, chapter committee members, and oversight persons are recognized on the title pages of the chapters An important contribution to this volume is the review of each chapter provided by members of the Technical Activities Committee and the Safety and Health Committee of the American Welding Society The Welding Handbook Committee welcomes your comments and suggestions Please address them to the Editor, Welding Handbook, American Welding Society, 550 N.W LeJeune Road, Miami, Florida 33126 Harvey R Castner, Chair Welding Handbook Committee Ian D Harris, Chair Volume Committee Annette O’Brien, Editor Welding Handbook xiii ACKNOWLEGMENTS xii PREFACE xlii REVIEWERS xiv CONTRIBUTORS xv CHAPTER A R C POWER SOURCES Introduction Fundamentals Principles of Operation Volt-Ampere Characteristics .12 Duty Cycle .16 Open-Circuit Voltage .17 NEMA Power Source Requirements 19 Alternating-Current Power Sources .20 Direct-Current Power Sources 30 Economics 42 Safe Practices .44 Conclusion .48 Bibliography 48 CHAPTER 2-SHIELDED METAL ARC WELDING 51 Introduction 52 Fundamentals 52 Equipment 60 Materials 68 Applications 80 Joint Design and Preparation 82 Welding Variables 85 Weld Quality 96 Economics 98 Safe Practices 99 Conclusion 101 Bibliography 101 CHAPTER - G A S TUNGSTEN ARC WELDING 103 Introduction 104 Fundamentals 104 Applications 107 Equipment .109 Techniques .128 Materials 135 Joint Design 139 Weld Quality 140 Economics 142 Safe Practices 142 Conclusion 144 Bibliography 144 CHAPTER &GAS METAL ARC WELDING 147 Introduction 148 vii Fundamentals .148 Principles of Operation 150 Equipment 160 Materials and Consumables 171 Process Variables 178 Weld Joint Designs 188 Inspection and Weld Quality 189 Troubleshooting 195 Economics 199 Safe Practices 201 Conclusion 203 Bibliography .204 CHAPTER !%-FLUX CORED ARC WELDING 209 Introduction .-210 Fundamentals -210 Applications 211 Equipment 215 Materials -219 Process Control 237 Joint Designs and Welding Procedures 241 Weld Quality 247 Troubleshooting 247 Economics -247 Safe Practices 250 Conclusion -252 Bibliography 252 CHAPTER SUBMERGED ARC WELDING 255 Introduction 256 Fundamentals 256 Equipment -258 Materials 268 Process Variables -278 Operating Procedures 282 Process Variations and Techniques .287 Applications 294 Weld Quality 297 Economics -299 Safe Practices 299 Conclusion 300 Bibliography 300 CHAPTER 7-PLASMA ARC WELDING 303 Introduction 304 Fundamentals 305 Equipment 310 Materials 319 Application Methods 324 Process Variations 326 Welding Procedures 332 Weld Quality 332 Economics 332 Safe Practices 334 Conclusion 335 Bibliography 33.5 CHAPTER 8-ELECTROGAS WELDING 337 Introduction 338 Fundamentals 338 Equipment 343 Materials 348 Process Variables 350 Applications 366 Joint Design 367 Inspection and Weld Quality .369 Economics 387 Safe Practices 387 Conclusion 390 390 Bibliography CHAPTER 9A RC STUD WELDING 393 Introduction 394 Fundamentals 394 Applications 395 Equipment and Technology 398 406 Designing for Arc Stud Welding Special Process Techniques 416 Capacitor Discharge Stud Welding 417 Stud Welding Process Selection 423 427 Weld Quality, Inspection, and Testing Economics 430 432 Safe Practices Conclusion 433 433 Bibliography CHAPTER 10-ELECTROSLAG WELDING 435 Introduction 436 Fundamentals Equipment 441 444 Materials Welding Variables 446 Welding Procedures 448 Applications 455 Inspection and Quality Control 457 Weld Quality 459 Economics 460 Safe Practices .463 Conclusion 464 464 Bibliography CHAPTER 11 X Y F U E L GAS WELDING 467 468 Introduction Fundamentals of Oxyfuel Gas Welding 468 471 Materials Oxyfuel Gas Welding Equipment 479 Process Variables and Operating Procedures 489 Applications .491 Weld Quality 494 Welding with Other Fuel Gases 495 Economics -495 Safe Practices 495 Conclusion 498 Bibliography .498 CHAPTER 12-BRAZING 501 Introduction .502 Fundamentals .502 Applications 503 Principles of Operation 503 Processes, Equipment, and Techniques 504 Automation 515 Materials 517 Joint Design 532 Procedures 541 Inspection 544 Troubleshooting 546 Braze Welding 546 Economics 550 Safe Practices 550 Conclusion 555 Bibliography 555 CHAPTER 13.4 OLDERING 559 Introduction 560 Fundamentals 560 Applications 561 Process Variations 563 Equipment 570 Materials 571 Procedures 584 Process Variables -588 Inspection and Testing 590 Economics 592 Safe Practices 593 Conclusion 594 Bibliography 594 CHAPTER 1&OXYGEN CUTTING 597 Introduction 598 Fundamentals of Oxygen Cutting 598 Oxyfuel Gas Cutting -599 Equipment -602 Gases 608 Operating Procedures 612 Process Variations 617 Appllcatlons 620 Quality 626 Oxygen Arc Cutting 630 Oxygen Lance Cutting 630 Metal Powder Cutting 631 632 Flux Cutting Economics 632 633 Safe Practices Conclusion 635 Bibliography 635 CHAPTER 15-ARC CUTTING AND GOUGING 637 Introduction 638 Plasma Arc Cutting 638 Plasma Arc Gouging 648 Air Carbon Arc Cutting 651 Other Arc Cutting Processes 659 Economics 662 Safe Practices 665 Conclusion 669 Bibliography 670 APPENDIX A-LENS SHADE SELECTOR 673 APPENDIX B-HEALTH AND SAFETY CODES AND OTHER STANDARDS 675 APPENDIX C-FILLER METAL SPECIFICATIONS 679 INDEX OF MAJOR SUBJECTS: 681 Eighth Edition and Ninth Edition Volume and Volume INDEX OF NINTH EDITION Volume 699 CHAPTER ARC WELDING POWER SOURCES Prepared by the Welding Handbook Chapter Committee on Arc Welding Power Sources: S P Moran, Chair Miller Electric Manufacturing Company D J Erbe Panasonic Factory Automation W, E Herwig Miller Electric Manufacturing Company W E Hoffman ESA B Welding and Cutting Products C Hsu The Lincoln Electric Company J 0.Reynolds Miller Electric Manufacturing Company Welding Handbook Committee Member: C E Pepper ENGlobal Engineering Contents Introduction Fundamentals Principles of Operation Volt-Ampere Characteristics Duty Cycle Open-Circuit Voltage NEMA Power Source Requirements Alternating-Current Power Sources Direct-Current Power Sources Economics Safe Practices Conclusion Bibliography Supplementary Reading List CHAPTER1 ARC WELDING POWER SOURCES CHAPTER ARC WELD1NG POWER SOURCES INTRODUCTION This chapter presents a general overview of the electrical power sources used for arc welding It explores the many types of welding power sources available to meet the electrical requirements of the various arc welding processes Welding has a long and rich history Commercial arc welding is over a hundred years old, and scores of processes and variations have been developed Over the years, power sources have been developed or modified by equipment manufacturers in response to the changes and improvements in these processes As welding processes continue to evolve, power sources continue to provide the means of controlling the welding current, voltage, and power This chapter provides updated information on the basic electrical technologies, circuits, and functions designed into frequently used welding power sources Topics covered in this chapter include the following: The volt-ampere (V-A) characteristics required for common welding processes, Basic electrical technologies and terminology used in power sources, Simplified explanations of commonly used power source circuits, and An introduction to useful national and international standards A basic knowledge of electrical power sources will provide the background for a more complete understanding of the welding processes presented in the other chapters of this book FUNDAMENTALS This section introduces the fundamental functions of welding power sources and the concepts of constant- voltage (CV) and constant-current (CC) characteristics required for welding processes The voltage supplied by power companies for industrial purposes-120 volts (V), 230 V, 380 V, or 480 Vis too high for use in arc welding Therefore, the first function of an arc welding power source is to reduce the high input or line voltage to a suitable output voltage range, 20 V to 80 V A transformer, a solid-state inverter, or an electric motor-generator can be used to reduce the utility power to terminal or open-circuit voltage appropriate for arc welding Alternatively, a power source for arc welding may derive its power from a prime mover such as an internal combustion engine The rotating power from an internal combustion engine is used to rotate a generator or an alternator for the source of electrical current Welding transformers, inverters, or generator/ alternators provide high-amperage welding current, generally ranging from 30 amperes (A) to 1500 A The output of a power source may be alternating current (ac), direct current (dc) or both It may be constant current, constant voltage, or both Welding power sources may also provide pulsed output of voltage or current Some power source configurations deliver only certain types of current For example, transformer power sources deliver ac only Transformer-rectifier power sources can deliver either alternating or direct current, as selected by the operator Electric motor-generator power sources usually deliver dc output A motoralternator delivers ac, or when equipped with rectifiers, dc Power sources can also be classified into subcategories For example, a gas tungsten arc welding power source might be identified as transformer-rectifier, constant-current, ac/dc A complete description of any power source should include welding current rating, duty cycle rating, service classification, and input power MAJOR SUBJECT INDEX Ninth Edition Volume Chapter 689 Eighth Edition Volume Chapter 4 10 18 14 1 1 16 2 15 1, 2, 1, 4 10 1, 3, 1, 2, 4, 5, 10 2 4 1 10 29 14 10 17 1, 3, 5, 10 12 P Painted steel Palladium Percussion welding (PEW) Performance qualification Performance qualification, brazers and brazing operators Performance qualification, nondestructive examination (NDE) personnel Performance qualification, thermal spray operators Performance qualification, welders and welding operators Personal protective equipment (PPE) Phase transformations Physical properties of metals and gases Physics of welding and cutting Plasma arc cutting (PAC) Plasma arc spraying (PSP) Plasma arc surfacing Plasma arc welding (PAW) Plastics Platinum Polymeric composites Porosity Positioners Power sources, arc welding Power sources, special Precious metals and alloys Precipitation-hardening stainless steels Pressure gas welding (PGW) Preventive maintenance Procedure qualification, brazing Procedure qualification, welding Procedure specifications Procedure specifications, arc welding processes Procedure specifications, brazing Procedure specifications, oxyfuel gas welding Procedure specifications, resistance welding Procurement scheduling Projection welding (RPW) Proof testing 1 15 15 15 15 1 1 15 17 2 15 2 7 1 2 13 1 1 1 1 1 15 15 15 15 15 15 15 12 14 690 MAJOR SUBJECT INDEX Ninth Edition Volume Chapter Eighth Edition Volume Chapter 1 1 17 17 17 1 1 16 16 16 1 1 15 15 12, 13 13 13, 14 1 14 14 1 11 14 Radiographic examination Reactive metals and alloys Reconditioned materials and methods Refractory metals and alloys Reheat cracking of steel Repair welding Residual stress Residual stress, effects of Residual stress, control and reduction of Residual stress, nature and causes of Residual stress, measurement of Resistance brazing (RB) Resistance implant welding Resistance projection welding (PW) Resistance seam welding (RSEW) Resistance spot welding (RSW) Resistance weld discontinuities Resistance welding (RW) 1 14 4 1 1 7 7 12 4 4 1 1 12 10 10 7 7 1 13 1, 2, 10, 13, 15 2 1 Resistance welding automation Resistance welding electrodes Resistance welding equipment Resistance weld strength tests Rhenium Rhodium Robotic welding Robots, arc welding 11 2 12 17 17 17 11 19 1, 2, 4, 5, 1, 2, 3, 4, 8, 9, 10 10 19 19 4 10 10 10 Properties, mechanical Properties of metals Protective clothing Protective eyewear Protective footwear Q Qualification and certification Qualification, personnel Quality, cost of Quality, terminology related to Quality control Quenched and tempered steels R 1 11 11 MAJOR SUBJECT INDEX Robots, resistance welding Rockwell hardness test (HR) Ruthenium Ninth Edition Volume Chapter 1 11 691 Eighth Edition Volume Chapter 10 1 1 16 1–6, 8, 10 1–10 16 16 16 16 16 10, 16 16 16 5, 16 4 4 3 1 1 2 5, 6, 17 2, 3, 1, 3, 5, 1, 3, 4, 10 1–10 17, 18, 23–26 10 11 13 1, 2, 3, 4, 3, 5, 8, 10 16 13 13 S Safe practices 17 Safe practices, arc welding and cutting Safe practices, brazing and soldering Safe practices, electron beam welding Safe practices, laser beam welding and cutting Safe practices, oxyfuel gas welding and cutting Safe practices, plasma arc welding and cutting 1 1 1 1 1 1 17 17 17 17 17 17 7, 15 14 17 17 17 1, 11 17 2–15 17 Safe practices, radiographic examination Safe practices, resistance welding Safe practices, robotic operations Safe practices, thermal spraying Safety and health Safety considerations, processes-specific Safety management Schaeffler constitution diagram Seam welding Shielded metal arc welding (SMAW) 2 Shielding gas moisture content Short-circuiting transfer Silicon bronze Solid-state welding Silver 1, 2, 13 12, 13 Sizing steel welds Soldered joints, discontinuities in Soldering 1 13 1, Soldering economics Soldering metallurgy Soldering safety 1 12 17 Soldering symbols Solders 1 692 MAJOR SUBJECT INDEX Ninth Edition Volume Chapter Solid-state circuitry, power source Solid-state welding 1 Solid-state welds, discontinuities in Solidification rates Specifications for steel buildings Specifications, qualification of Specifications, sources of 1 1 13 15 15 Spot welding, gas metal arc Spot welding, resistance Spot welds, testing of Sprayed zinc coating Spraying, thermal Stainless steel cladding, heat treatment of Stainless steels Standardization of qualification Standards, sources of Steel Steel, infiltration of, by copper Stress-corrosion cracking Stress-relief cracking of steel Stress-rupture cracking of steel Stress in surfacing, thermal Stress, residual Structural tubular connections Stud welding 6 1 15 16 4, 4, 1 1 1 1 1 Submerged arc welding (SAW) Superaustenitic stainless steels Superferritic stainless steels Surfacing Surfacing metals Surfacing processes Survey of joining, cutting, and allied processes Symbols for joining and inspection Symbols for welding, brazing, and nondestructive examination Eighth Edition Volume Chapter 2 1 1, 18, 23–26 11 1 2 14 13 1, 2, 3, 1–10 17 8 4 1 4 4 4 1 4 4 4 1 28 14 13 1, 2, 3, 4, 5, 1 7 1, 2, 1–10 5 7 6 4 4 10 10 12 T Tacking fixtures Tantalum Tantalum alloys Tensile properties of welded joints MAJOR SUBJECT INDEX Tension tests Terneplate Testing, mechanical Testing of welded joints Testing, weldability Thermal cutting (TC) Thermal cutting economics Thermal spray operator qualification Thermal spraying (THSP) Thermal spray surfacing Thermal spray testing Thermal treatments of weldments Thermite welding (TW) Thermite welding of cast irons Thermoplastics, welding of Tin-plated steel Titanium Titanium alloys Tool and die steels Torch brazing (TB) Torch soldering (TS) Toughness, fracture Tubular connections, structural Tungsten carbide Turning rolls Turntables Ninth Edition Volume Chapter 1 6 1 15 1, 1 1 4 2 1 12 13 1 9 14 13 Eighth Edition Volume Chapter 1 1 1 4 4 2 1 1 12 12 14–16 14 28 12 29 9 12 13 7 9 12 4 3 4 25 3, 6, 10 10 10 4, 5, 17 1, 3, 10 12 9, 10 U Ultra-high-strength steels Ultrasonic examination Ultrasonic soldering (USS) Ultrasonic welding (USW) Underbead cracking in steel Underwater cutting Underwater welding Unified numbering system, SAE-ASTM Upset welding (UW) 13 15 12 Uranium V Vacuum brazing Vacuum-purge welding chamber 693 694 MAJOR SUBJECT INDEX Vacuum soldering Ventilation Vibration welding Visual examination Ninth Edition Volume Chapter 13 17 13, 14 1 1 1 1 13 13 7, 13 13 6 1 1 1 1 1 1 1 6 6, 13 15 17 2–11 11 16 12 14 1 15 1 4, 1 4 1 4 Eighth Edition Volume Chapter 16 15 2 1 1 1 1 1 1 16 13 11 11 4 12 12 12 12 12 12 1 1 1 1 14 16 1–10 10 13 15 1 3 14 4 4 4 3 10 W Water jet cutting Wave soldering (WS) Weld discontinuities, significance of Weld distortion Weld quality Weld thermal cycles, typical Weldability of commercial alloys Weldability testing Welded joints, corrosion testing for Welded joints, design of Welded joints, elevated-temperature behavior Welded joint evaluation, test methods for Welded joints, fatigue properties Welded joints, performance of Welded joints, tensile properties Welded joint, the Welding performance qualification Welding, physics of Welding, safe practices in Welding applications Welding automation Welding codes Welding costs Welding design Welding fixtures Welding inspection and nondestructive examination Welding inspector qualification Welding metallurgy Welding of ceramics Welding of composites Welding of metals Aluminum and aluminum alloys Austenitic manganese steel Austenitic (Cr-Ni) stainless steels Beryllium Carbon steels Cast iron Chromium (4 to 10%)-molybdenum steels Chromium stainless steels Cobalt alloys Copper and copper alloys MAJOR SUBJECT INDEX Gold Hafnium Iron Lead Low-alloy steels Magnesium and magnesium alloys Molybdenum Nickel and nickel alloys Niobium Palladium Platinum Precious metals Reactive metals Refractory metals Silver Steel Tantalum Titanium and titanium alloys Tungsten Uranium Wrought iron Zinc Zinc-coated steel Zirconium Welding of plastics Welding procedure specifications (WPS) Welding processes Atomic hydrogen welding (AHW) Bare metal arc welding (BMAW) Braze welding (WB) Carbon arc welding (CAW) Cold welding (CW) Diffusion welding (DFW) Electrogas welding Electron beam welding (EBW) Electroslag welding (ESW) Explosion welding (EXW) Flash welding (FW) Flux cored arc welding (FCAW) Forge welding (FOW) Friction welding (FRW) Gas metal arc welding (GMAW) Gas tungsten arc welding (GTAW) Hot-pressure welding (HPW) Laser beam welding (LBW) Oxyfuel gas welding (OFW) Percussion welding (PEW) Plasma arc welding (PAW) Projection welding (RPW) Ninth Edition Volume Chapter 1 12, 13 1 1 1 2, 2, 4 1 1 1 4 12, 13 4, 2, 4 4 1 14 12 10 2 11 Eighth Edition Volume Chapter 4 4 4 4 4 4 4 4 4 4 1 2 10 10 10 10 10 10 10 10 10 10 1–5 10 10 10 10 14 29 29 2 2 2 2 2 2 2 2 2 29 29 26 21 24 18, 19 29 23 29 22 11 18 10 17, 19 695 696 MAJOR SUBJECT INDEX Ninth Edition Volume Resistance seam welding (RSEW) Resistance spot welding (RSW) Resistance welding (RW) Shielded metal arc welding (SMAW) Stud welding Submerged arc welding (SAW) Thermite welding (TW) Torch brazing (TB) Ultrasonic welding (USW) Upset welding (UW) Welding safety Welding specifications Welding standards Welding symbols Weld joint tests Weldment design considerations Weldments, corrosion in Weldment tooling and positioning Weld metal Weld quality Weld type, selection of White cast iron WRC-1992 constitution diagram Wrought iron, weldability of Chapter 2 2 12 1 1 1 1 1 17 15 16 4, 13 Eighth Edition Volume Chapter 2 2 2 17, 19 17, 19 17, 19 29 2 1 1 25 18, 19 16 14 13 4 5, 6, 4 4 3 10 10 Z Zinc-aluminum coated steel Zinc-rich painted steel Zinc, welding of Zirconium Zirconium alloys LENS SHADE SELECTOR APPENDIX A 673 Appendix A LENS SHADE SELECTOR Shade numbers are given as a guide only and may be varied to suit individual needs Electrode Size in (mm) Arc Current (Amperes) Minimum Protective Shade Suggested* Shade No (Comfort) Less than 2.4 (3/32) 2.4–4.0 (3/32–5/32) 4.0–6.4 (5/32–1/4)0 More than 6.4 (1/4) Less than 60 60–160 160–250 250–550 10 11 — 10 12 14 Gas Metal Arc Welding (GMAW) and Flux Cored Arc Welding (FCAW) Less than 60 60–160 160–250 250–500 10 10 10 — 11 12 14 Gas Tungsten Arc Welding (GTAW) Less than 50 50–150 150–500 8 10 10 12 14 Less than 500 500–1000 10 11 12 14 Plasma Arc Welding (PAW) Less than 20 20–100 100–400 400–800 10 11 6–8 10 12 14 Plasma Arc Cutting (PAC) Less than 20 20–40 40–60 60–80 80–300 300–400 400–800 8 10 12 14 Torch Brazing (TB) — — or Torch Soldering (TS) — — — — 14 Process Shielded Metal Arc Welding (SMAW) Air Carbon Arc Cutting (CAC-A) (Light) (Heavy) Carbon Arc Welding (CAW) Plate Thickness Oxyfuel Gas Welding (OFW) Light Medium Heavy Oxygen Cutting (OC) Light Medium Heavy mm in Suggested* Shade No (Comfort) Under 3 to 13 Over 13 Under 1/8 1/8 to 1/2 Over 1/2 or 5 or 6 or Under 25 25 to 150 Over 150 Under 1 to Over or 4 or 5 or *As a general rule for selecting the correct lens shade, the welder should start with a shade that is too dark to see the weld zone, then go to a lighter shade which gives sufficient view of the weld zone without going below the minimum In oxyfuel gas welding, cutting, or brazing where the torch or the flux, or both, produces a high yellow light, it is desirable to use a filter lens that absorbs the yellow or sodium line of the visible light spectrum Source: Adapted from American Welding Society (AWS) Committee on Safety and Health and Subcommittee on Labeling and Safe Practices, F2.2:2001 Lens Shade Selector (Chart), Miami: American Welding Society HEALTH AND SAFETY CODES AND OTHER STANDARDS APPENDIX B 675 Appendix B HEALTH AND SAFETY CODES AND OTHER STANDARDS Appendix B is excerpted from Annex B of Safety in Welding, Cutting, and Allied Processes, ANSI Z49.1:1999,1,TT2 It is not a part of that standard, but is included for information The following codes, standards, specifications, pamphlets, and books contain information that may be useful in meeting the safety and health requirements of welding, cutting, and allied processes The names of the standards organizations and their letter designations are also listed in this appendix Inquiries as to the availability and cost of any of these publications should be addressed directly to the publishers ACGIH Threshold Limit Values (TLV®) for Chemical Substances and Physical Agents in the Workroom Environment Industrial Ventilation Manual AGA Purging Principles and Practices ANSI API A13.1 Scheme for the Identification of Piping Systems B11.1 Safety Requirements for Construction, Care and Use of Mechanical Power Presses B15.1 Safety Standard for Mechanical Power Transmission Apparatus (with ASME) B31.1 Power Piping (with ASME) Z535.4 Standard for Product Safety Signs and Labels Z87.1 Practice for Occupational and Educational Eye and Face Protection Z88.2 Respiratory Protection Z89.1 Protective Headwear for Industrial Workers 1104 Standard for Welding Pipelines and Related Facilities PUBL 2009 Safe Welding and Cutting Practices in Refineries, Gasoline Plants, and Petrochemical Plants PUBL 2013 Cleaning Mobile Tanks in Flammable or Combustible Liquid Service STD 2015 Safe Entry and Cleaning of Petroleum Storage Tanks, Planning and Managing Tank Entry from Decommissioning through Recommissioning PUBL 2201 Procedures for Welding or Hot Tapping on Equipment in Service AVS Vacuum Hazards Manual American National Standards Institute (ANSI) Committee Z49, 1999, Safety in Welding, Cutting, and Allied Processes, ANSI Z49.1:1999, American Welding Society At the time of preparation of this appendix, the codes and other standards were valid, however, as codes and standards undergo frequent revision, the reader is advised to consult the most recent edition 676 APPENDIX B CGA HEALTH AND SAFETY CODES AND OTHER STANDARDS C4 Method of Marking Portable Compressed Gas Cylinders to Identify the Material Contained E1 Regulator Connection Standards E2 Standard Hose Connection Specification G 7.1 Commodity Specification for Air P1 Safe Handling of Compressed Gas Cylinders V1 Compressed Gas Cylinder Valve Outlet and Inlet Connections NEMA EW1 Electric Arc Welding Power Sources NFPA 50 Bulk Oxygen Systems at Consumer Sites 51 Standard for the Design of Oxygen-Fuel Gas Systems for Welding and Cutting, and Allied Processes 51B Standard for Fire Prevention in Use of Cutting and Welding Processes 70 National Electrical Code® 79 Electrical Standard for Industrial Machinery 306 Control of Gas Hazards on Vessels 327 Standard Procedures for Cleaning or Safeguarding Small Tanks and Containers Without Entry 701 Standard for Flame-Resistant Textiles and Films NIOSH 78 138 80 144 NSC Safety and Health in Arc Welding and Gas Welding and Cutting Certified Equipment List (with Supplements) Accident Prevention Manual for Industrial Operations Fundamentals of Industrial Hygiene OSHA Occupational Safety and Health Standards for General Industry (29 CFR Part 1910, Subpart Q) Occupational Safety and Health Standards for Construction (29 CFR Part 1926, Subpart J) RMA IP RWMA UL Specification for Rubber Welding Hose Resistance Welding Machine Standards 252 Regulators 551 Transformer-Type Arc Welding Machines HEALTH AND SAFETY CODES AND OTHER STANDARDS APPENDIX B PUBLISHERS OF SAFETY CODES AND OTHER STANDARDS ACGIH American Conference of Governmental Industrial Hygienists 6500 Glenway Avenue, Building D Cincinnati, OH 45211-4438 www.acgih.org AGA American Gas Association 1515 Wilson Boulevard Arlington, VA 22209 www.aga.com ANSI American National Standards Institute 11 West 42nd Street, 13th Floor New York, NY 10036-8002 www.ansi.org API American Petroleum Institute 1220 L Street NW Washington, DC 20005 www.api.org ASME American Society of Mechanical Engineers 345 East 47th Street New York, NY 10017-2392 www.asme.org ASTM ASTM 1916 Race Street Philadelphia, PA 19103 www.astm.org AVS American Vacuum Society 120 Wall Street, 32nd Floor New York, NY 10005 www.avs.org AWS American Welding Society 550 N.W LeJeune Road Miami, FL 33126 www.aws.org CGA Compressed Gas Association 1725 Jefferson Davis Highway, Suite 1004 Arlington, VA 22202-4102 www.cganet.com MSHA Mine Safety and Health Administration 4015 Wilson Boulevard Arlington, VA 22203 www.msha.gov NEMA National Electrical Manufacturers Association 2101 L Street NW Washington, DC 20037 www.nema.org 677 678 APPENDIX B NFPA National Fire Protection Association One Batterymarch Park Quincy, MA 02269-9101 www.nfpa.org www.sparky.org NIOSH National Institute for Occupational Safety and Health 4676 Columbia Parkway Cincinnati, OH 45226 www.cdc.gov/niosh/homepage/html NSC National Safety Council 1121 Spring Lake Drive Itasca, IL 60143-3201 www.nsc.org OSHA Occupational Safety and Health Administration 200 Constitution Avenue NW Washington, DC 20210 www.osha.gov RWMA Resistance Welder Manufacturers Association 1900 Arch Street Philadelphia, PA 19103 www.rwma.org RMA Rubber Manufacturers Association 1400 K Street NW Washington, DC 20005 www.rma.org UL Underwriters Laboratories, Incorporated 333 Pfingsten Road Northbrook, IL 60062 www.ul.com U.S Government Printing Office Superintendent of Documents P.O Box 371954 Pittsburgh, PA 15250-7954 www/access/gpo.gov HEALTH AND SAFETY CODES AND OTHER STANDARDS FILLER METAL SPECIFICATIONS APPENDIX C 679 Appendix C FILLER METAL SPECIFICATIONS Compiled by the American Welding Society Committee on Filler Metals and Allied Products.1, AWS Filler Metal Specifications by Material and Welding Process OFW SMAW GTAW GMAW PAW Carbon Steel A5.20 A5.10 A5.18 A5.20 A5.17 A5.25 A5.26 A5.8, A5.31 Low-Alloy Steel A5.20 A5.50 A5.28 A5.29 A5.23 A5.25 A5.26 A5.8, A5.31 A5.40 A5.9, A5.22 A5.22 A5.90 A5.90 A5.90 A5.8, A5.31 A5.15 A5.15 A5.15 Nickel Alloys A5.11 A5.14 Aluminum Alloys A5.30 A5.10 A5.8, A5.31 Copper Alloys A5.60 A5.70 A5.8, A5.31 Titanium Alloys A5.16 A5.8, A5.31 Zirconium Alloys A5.24 A5.8, A5.31 Magnesium Alloys A5.19 A5.8, A5.31 Tungsten Electrodes A5.12 Stainless Steel Cast Iron A5.15 FCAW SAW ESW EGW Brazing A5.8, A5.31 A5.14 A5.8, A5.31 Brazing Alloys and Fluxes Surfacing Alloys A5.8, A5.31 A5.21 A5.13 A5.21 Consumable Inserts A5.30 Shielding Gases A5.32 A5.21 A5.32 A5.21 A5.32 American Welding Society (AWS) Committee on Filler Metals and Allied Products At the time of preparation of this appendix the referenced codes and standards were valid However, as codes and standards undergo frequent revision, the reader is advised to consult the most recent edition 680 APPENDIX C FILLER METAL SPECIFICATIONS AWS Filler Metal Specifications and Related Documents Designation Title FMC Filler Metal Comparison Charts UGFM User’s Guide to Filler Metals A4.2M/A4.2 Standard Procedures for Calibrating Magnetic Instruments to Measure the Delta Ferrite Content Austenitic and Duplex Ferritic-Austenitic Stainless Steel Weld Metal A4.3 Standard Methods for Determination of the Diffusible Hydrogen Content of Martensitic, Bainitic, and Ferritic Steel Weld Metal Produced by Arc Welding A4.4M Standard Procedures for Determination of Moisture Content of Welding Fluxes and Welding Electrode Flux Coverings A5.01 Filler Metal Procurement Guidelines A5.1 Specification for Carbon Steel Electrodes for Shielded Metal Arc Welding A5.2 Specification for Carbon and Low Alloy Steel Rods for Oxyfuel Gas Welding A5.3/A5.3M Specification for Aluminum and Aluminum-Alloy Electrodes for Shielded Metal Arc Welding A5.4 Specification for Stainless Steel Electrodes for Shielded Metal Arc Welding A5.5 Specification for Low-Alloy Steel Electrodes for Shielded Metal Arc Welding A5.6 Specification for Covered Copper and Copper Alloy Arc Welding Electrodes A5.7 Specification for Copper and Copper Alloy Bare Welding Rods and Electrodes A5.8 Specification for Filler Metals for Brazing and Braze Welding A5.9 Specification for Bare Stainless Steel Welding Electrodes and Rods A5.10/A5.10M Specification for Bare Aluminum and Aluminum-Alloy Welding Electrodes and Rods A5.11/A5.11M Specification for Nickel and Nickel-Alloy Welding Electrodes for Shielded Metal Arc Welding A5.12/A5.12M Specification for Tungsten and Tungsten-Alloy Electrodes for Arc Welding and Cutting A5.13 Specification for Surfacing Electrodes for Shielded Metal Arc Welding A5.14/A5.14M Specification for Nickel and Nickel-Alloy Bare Welding Electrodes and Rods A5.15 Specification for Welding Electrodes and Rods for Cast Iron A5.16/A5.16M Specification for Titanium and Titanium Alloy Welding Electrodes and Rods A5.17/A5.17M Specification for Carbon Steel Electrodes and Fluxes for Submerged Arc Welding A5.18/A5.18M Specification for Carbon Steel Electrodes and Rods for Gas Shielded Arc Welding A5.19 Specification for Magnesium Alloy Welding Electrodes and Rods A5.20 Specification for Carbon Steel Electrodes for Flux Cored Arc Welding A5.21 Specification for Bare Electrodes and Rods for Surfacing A5.22 Specification for Stainless Steel Electrodes for Flux Cored Arc Welding and Stainless Steel Flux Cored Rods for Gas Tungsten Arc Welding A5.23/A5.23M Specification for Low-Alloy Steel Electrodes and Fluxes for Submerged Arc Welding A5.24 Specification for Zirconium and Zirconium Alloy Welding Electrodes and Rods A5.25/A5.25M Specification for Carbon and Low-Alloy Steel Electrodes and Fluxes for Electroslag Welding A5.26/A5.26M Specification for Carbon and Low-Alloy Steel Electrodes for Electrogas Welding A5.28 Specification for Low-Alloy Steel Electrodes and Rods for Gas Shielded Arc Welding A5.29 Specification for Low-Alloy Steel Electrodes for Flux Cored Arc Welding A5.30 Specification for Consumable Inserts A5.31 Specification for Fluxes for Brazing and Braze Welding A5.32/A5.32M Specification for Welding Shielding Gases ... Currents for Arc Welding Power Sources (Amperes) Class I Class II Class 11 1 200 250 300 400 500 600 800 10 00 12 00 15 00 15 0 17 5 200 225 250 300 350 18 0-2 30 23 5-2 95 Source: Adapted with permission... designed to provide either constant-voltage or constant-current outputs from single LIVE GRAPH A - Click here to view C 10 I I I 250 300 350 - I 0 50 I 10 0 15 0 15 200 CURRENT, A Figure 1. I5-Volt-Ampere... generator arc welding power source is operating at maximum-rated no-load speed, the open-circuit voltages are limited to the levels shown in Table 1. 2 11 2 NEMA Class I and Class I1 power sources