1、MATERIALS AND APPLICATIONS - PART 1 EIGHTH EDITIONWELDING HANDBOOK Eighth Edition Volume 3 MATERIALS AND APPLICATIONS - PART 1The Four Volumes of the Welding Handbook, Eighth Edition 1) WELDING TECHNOLOGY 2) WELDING PROCESSES 3) MATERIALS AND APPLICATIONS - PART 1 4) MATERIALS AND APPLICATIONS - PAR
2、T 2WELDING HANDBOOK Eighth Edition Volume 3 MATERIALS AND APPLICATIONS PART1 William R. Oates Editor AMERICAN WELDING SOCIETY 550 N.W. LEJEUNE ROAD MIAMI, FL 33126Library of Congress Number: 96-083169 International Standard Book Number: 0-87171-470-1 American Welding Society, 550 N.W. Lejeune Road,
3、Miami, FL 33126 1996 by American Welding Society. All rights reserved. THE WELDING HANDBOOK is a collective effort of many volunteer technical specialists to provide information to assist with the design and application of welding and allied processes. Reasonable care is taken in the compilation and
4、 publication of the Welding Handbook to insure authenticity of the contents. However, no representation is made as to the accuracy or reliability of this information, and an independent, substantiating investigation should be undertaken by any user. The information contained in the Welding Handbook
5、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 su
6、ch infringement. Whether or not use of any information in the Handbook would result in an infringement of any patent, copyright, or trademark is a determination to be made by the user. Printed in the United States of AmericaCONTENTS WELDING HANDBOOK COMMITTEE ix PREFACE xi CHAPTER 1, ALUMINUM AND AL
7、UMINUM ALLOYS 1 INTRODUCTION 2 SAFE PRACTICES 28 ARC WELDING 30 STUD WELDING 52 ELECTRON BEAM WELDING 64 LASER BEAM WELDING 71 RESISTANCE WELDING 72 SOLID-STATE WELDING 80 OXYFUEL GAS WELDING 81 WELDING ALUMINUM CASTINGS 83 BRAZING 85 SOLDERING 90 ADHESIVE BONDING 95 JOINING TO OTHER METALS 97 ARC C
8、UTTING 98 PROPERTIES AND PERFORMANCE OF WELDMENTS 100 APPLICATIONS 111 SUPPLEMENTARY READING LIST 117 CHAPTER 2, MAGNESIUM AND MAGNESIUM ALLOYS 121 INTRODUCTION 122 ALLOYS 123 SURFACE PREPARATION 129 ARC WELDING 130 RESISTANCE WELDING 145 OXYFUEL GAS WELDING 152 OTHER WELDING PROCESSES 152 BRAZING 1
9、54 SOLDERING 155 PLASMA ARC CUTTING 156 SAFE PRACTICES 157 APPLICATIONS 158 SUPPLEMENTARY READING LIST 162CONTENTS CHAPTER 3f COPPER AND COPPER ALLOYS ies INTRODUCTION 164 ALLOYS 164 JOINING PROCESS SELECTION 172 WELDING 175 BRAZING 197 SOLDERING 204 APPLICATIONS 208 SUPPLEMENTARY READING LIST 215 C
10、HAPTER 4, NICKEL AND COBALT ALLOYS 217 INTRODUCTION 218 METAL CHARACTERISTICS 219 ALLOY GROUPS 224 SURFACE PREPARATION 229 ARC WELDING 230 DISSIMILAR METALS 250 OXYACETYLENE WELDING 264 RESISTANCE WELDING 265 ELECTRON BEAM WELDING 271 LASER BEAM WELDING 272 FABRICATION FOR HIGH-TEMPERATURE SERVICE 2
11、72 BRAZING 276 SOLDERING 279 THERMAL CUTTING 280 SAFE PRACTICES 281 APPLICATIONS 282 SUPPLEMENTARY READING LIST 287 CHAPTER 5, LEAD AND ZINC 289 WELDING AND SOLDERING OF LEAD 290 WELDING AND SOLDERING OFZINC 304 SAFETY AND HEALTH 311 APPLICATIONS 312 SUPPLEMENTARY READING LIST 316 CHAPTER 6, PLASTIC
12、S 319 INTRODUCTION 320 WELDING METHODS FOR THERMOPLASTICS 321 WELD QUALITY ASSESSMENT 344CONTENTS HEALTH AND SAFETY ISSUES 346 APPLICATIONS 347 SUPPLEMENTARY READING LIST 350 CHAPTER 7, COMPOSITES 353 WELDING OF POLYMERIC COMPOSITES 354 APPLICATIONS OF POLYMERIC COMPOSITES 364 WELDING OF METAL-MATRI
13、X COMPOSITES 365 APPLICATIONS OF METAL-MATRIX COMPOSITES 385 HEALTH AND SAFETY ISSUES 386 SUPPLEMENTARY READING LIST 387 CHAPTER 8, CERAMICS 389 INTRODUCTION 390 CERAMIC MATERIALS 391 JOINING PROCESSES 394 SAFETY AND HEALTH CONSIDERATIONS 409 INDUSTRY NEEDS 410 APPLICATIONS 411 SUPPLEMENTARY READING
14、 LIST 415 CHAPTER 9, MAINTENANCE AND REPAIR WELDING 417 INTRODUCTION 418 A SYSTEMATIC APPROACH TO MAINTENANCE AND REPAIR WELDING 419 APPLICATIONS 430 SUPPLEMENTARY READING LIST 444 CHAPTER 10, UNDERWATER WELDING AND CUTTING 445 INTRODUCTION 446 SAFETY IN UNDERWATER WELDING AND CUTTING 449 UNDERWATER
15、 WELDING 453 UNDERWATER WELDING SPECIFICATIONS 485 UNDERWATER INSPECTION 487 UNDERWATER THERMAL CUTTING 489 APPLICATIONS 495 SUPPLEMENTARY READING LIST 499 WELDING HANDBOOK INDEX OF MAJOR SUBJECTS 501 INDEX 513WELDING HANDBOOK COMMITTEE May 31, 1992 C. W. Case, Chairman D. R. Amos, 1st Vice Chairman
16、 B. R. Somers, 2nd Vice Chairman W. R. Oates, Secretary J. R. Condra J. G. Feldstein J. M. Gerken K. F.Graff L Heckendorn J. C. Papritan P. I. Temple M. J. Tomsic R. M. Walkosak Inco Alloys International Westinghouse Turbine Plant Consultant American Welding Society E. I. duPontde Nemours and Compan
17、y Teledyne McKay Consultant Edison Welding Institute Consultant Ohio State University Detroit Edison Plastronic, Incorporated Westinghouse Electric Corporation WELDING HANDBOOK COMMITTEE May 31, 1993 B. R. Somers, Chairman W. R. Oates, Secretary H. R. Castner J. G. Feldstein J. M. Gerken L Heckendor
18、n S D. Kiser J. C. Papritan P. I. Temple M. J. Tomsic R. M. Walkosak Lehigh University American Welding Society Edison Welding Institute Foster Wheeler Energy Corporation Consultant Consultant Inco Alloys International Ohio State University Detroit Edison Plastronic, Incorporated Westinghouse Electr
19、ic CorporationWELDING HANDBOOK COMMITTEE May 31, 1994 B. R. Somers, Chairman P. I. Temple, 1st Vice Chairman Ft. M. Walkosak, 2nd Vice Chairman W. R. Oates, Secretary H. R. Castner J. G. Feldstein J. M. Gerken L Heckendorn S. D. Kiser J. C. Papritan M. J. Tomsic Lehigh University Detroit Edison West
20、inghouse Electric Corporation American Welding Society Edison Welding Institute Foster Wheeler Energy Corporation Consultant lntechR&D,USA Inco Alloys International Ohio State University Plastronic, Incorporated WELDING HANDBOOK COMMITTEE May 31, 1995 B. R. Somers, Chairman P. I. Temple, 1st Vice Ch
21、airman R. M. Walkosak, 2nd Vice Chairman W. R. Oates, Secretary B. J. Bastian H. R. Castner D. J. Corrigall J. G. Feldstein J. M. Gerken L Heckendorn S. D. Kiser J. C. Papritan D. V. Rypien R. P. Schuster M. J. Tomsic C. L Tsai Lehigh University Detroit Edison Westinghouse Electric Corporation Ameri
22、can Welding Society Benmar Associates Edison Welding Institute Miller Electric Company Foster Wheeler Energy Corporation Consultant lntechR&D,USA Inco Alloys International Ohio State University American Bureau of Shipping Hamischfeger Industries, Inc. Plastronic, Incorporated Ohio State UniversityPR
23、EFACE This is Volume Three of the Eighth Edition of the Welding Handbook. The title of this third volume, Materials and ApplicationsPart 1, suggests correctly that the Eighth Edition will have a fourth volume, Materials and ApplicationsPart 2. Volume Three begins the process of updating and substant
24、ially expanding the material previously presented in Volume Four of the Seventh Edition and Volume 5 of the Sixth Edition. Originally, the Welding Handbook Committee had planned to publish the Materials and Applications title as a single publication. However, as the Committee began to compile the te
25、xt, it became apparent that the material was too voluminous to be contained in a single text. Therefore, it was necessary to separate Materials and Applications into two volumes. Unfortunately, this decision was made after the first two volumes of the Eighth Edition had been published, and so the fr
26、ont matter in Volumes One and Two indicate Volume Three to be the Materials and Applications material in its entirety. Volume Three, Materials and ApplicationsPart 1, covers many nonferrous metals, plastics, composites, ceramics, and new specialized topics: maintenance and repair welding and underwa
27、ter welding and cutting. Volume Four, Materials and ApplicationsPart 2, will contain information mostly on ferrous materials, but it also will cover titanium, clad and dissimilar metals, tube-to- tubesheet welding, and the reactive, refractory, and precious metals and alloys. Volume Four, Materials
28、and ApplicationsPart 2, is scheduled to be published two years following the publication of Volume Three, Materials and ApplicationsPart 1. This volume represents a considerable expansion of the information on these topics contained in previous editions. As with the first two volumes of this Eighth
29、Edition, practical application data and color illustrations have been added. This volume, like the others, was a voluntary effort by the Welding Handbook Committee and the Chapter Committees. The Chapter Committee Members and the Welding Handbook Committee Member responsible for each chapter are rec
30、ognized on the title page of that chapter. Other individuals also contributed in a variety of ways, particularly in chapter reviews. All participants contributed generously of their time and talent, and the American Welding Society expresses its sincere appreciation to them and to their employers fo
31、r supporting this work. The Welding Handbook Committee expresses its appreciation to the AWS staff members who assisted with this volume, especially the Technical Division staff engineers for technical assistance, Deborah Givens for editorial assistance, and Doreen Kubish for editorial and productio
32、n assistance with text, graphics, and layout. The Welding Handbook Committee welcomes your comments on the Welding Handbook as well as your potential interest in contributing to future volumes. Communications may be addressed to the Editor, Welding Handbook, American Welding Society, 550 N. W. Lejeu
33、ne Road, Miami, Florida, 33126. B. R. Somers, Chairman W. R. Oates, Editor Welding Handbook Committee Welding Handbook 1992-1996 xiCHAPTER 1 ALUMINUM AND ALUMINUM ALLOYS Introduction 2 Welding Aluminum Castings Safe Practices 28 Brazing Arc Welding 30 Soldering Stud Welding 52 Adhesive Bonding Elect
34、ron Beam Welding 64 Joining to Other Metals Laser Beam Welding 71 Arc Cutting Resistance Welding Properties and Performance 72 ofWeidments Solid-State Welding 80 Applications Oxyfuel Gas Welding 81 Supplementary Reading List 83 85 90 95 97 98 100 111 PREPARED BY A COMMITEE CONSISTING OF: W. H. Kielh
35、orn, Chairman LeTourneau University F. Armao Aluminum Company of America H. A. Chambers TRW Nelson Stud Welding Division P. Dent Grumman Aircraft Systems P. B. Dickerson Consultant R. Donnelly Vertex Communications S. E. Gingrich Grove Worldwide D. R. Hill Alumatech L. S. Kramer Martin Marietta J. M
36、urphy Consultant J. R. Pickens Martin Marietta J. Schuster Omni Technologies Corporation J. Stokes Consultant A. Szabo Martin Marietta WELDING HANDBOOK COMMITTEE MEMBER: P. I. Temple Detroit Edison Company 1172 ALUMINUM AND ALUMINUM ALLOYS CHAPTER 1 ALUMINUM AND ALUMINUM ALLOYS INTRODUCTION ALUMINUM
37、 IS JOINED with most of the known joining processes. It is readily joined by welding, braz- ing, soldering, adhesive bonding, or mechanical fasten- ing. In many instances, aluminum is joined by the conventional equipment and techniques used with other metals. Occasionally, specialized equipment or t
38、echniques, or both, are required. The alloy, joint con- figuration, strength requirement, appearance, and cost are factors that dictate the choice of joining process. Each process for joining aluminum has certain advan- tages and limitations. GENERAL CHARACTERISTICS OF ALUMINUM ALUMINUM IS LIGHT in
39、weight, yet some of its alloys have strengths exceeding mild steel. It retains good ductility at subzero temperatures, has high resis- tance to corrosion, and is not toxic. Aluminum has good electrical and thermal conductivity as well as high reflectivity to both heat and light. It is nonsparking an
40、d nonmagnetic. Aluminum is easy to fabricate. It can be cast, rolled, stamped, drawn, spun, stretched, or roll-formed. It can also be hammered, forged, or extruded into a wide vari- ety of shapes. Machining ease and speed are important factors in using aluminum parts. Aluminum can be given a wide va
41、riety of mechanical, electromechanical, chemical, or paint finishes. Pure aluminum melts at 1220 F (660 C). Alumi- num alloys have an approximate melting range of from 900 to 1220 F (482 to 660 C), depending upon the alloy. There is no color change in aluminum when heated to the welding or brazing t
42、emperature range. This necessitates a welder assuming a position where the melting of the base and filler metals under the arc or flame can be witnessed. High thermal conductivity (as compared to steel) necessitates a high rate of heat input for fusion welding. Thick sections may require preheating.
43、 When resistance spot welding, aluminums high thermal and electrical conductivities require higher current, shorter weld time, and more precise control of the welding variables than when welding steel. Since aluminum is nonmagnetic and no arc blow is experienced when welding with direct current, alu
44、mi- num is being used for backing and fixtures in welding. Aluminum and its alloys rapidly develop a tenacious, refractory oxide film when exposed to air. This naturalALUMINUM AND ALUMINUM ALLOYS oxide film can be removed using either a protective atmosphere or fluxes suitable during arc welding, br
45、az- ing, or soldering. Exposure to the elevated temperatures of thermal treatments or exposure to moist environ- ments cause the aluminum oxide film to markedly thicken, necessitating removal prior to joining. Heat-treated aluminum can have an exceptionally thick aluminum oxide film that causes poor
46、 wetting and flow of filler metal. Aluminum oxide melts at about 3700 F (2037 C) and should be removed by chemical or mechanical means prior to welding. The composition and melting range of an aluminum alloy are the pri- mary considerations for selection of the joining process. Anodic electrolytic t
47、reatments applied to aluminum result in forming thick, dense oxide coatings that must be removed prior to fusion welding, brazing or solder- ing. The anodic coatings can resist 400 volts or more, so welding arcs cannot be initiated. This oxide must be removed not only from the joint but also at the
48、location of the work lead when arc welding. The properties and performances of aluminum parts are influenced by microstructural changes that occur during any elevated-temperature joining process. The strength, fatigue life, ductility, and formability originally in the parts are changed depending upo
49、n the amount of annealing, overaging, and formation of cast structure occurring during the joining process. The results of these changes are presented in subsequent sections of this chapter devoted to specific joining processes. ALUMINUM FORMS PURE ALUMINUM IS readily alloyed with many other metals to produce a wide range of physical and mechanical properties. Table 1.1 lists the major alloy- ing elements in the wrought aluminum alloys. The means by which the alloying elements strengthen aluminum are used as the basis to classify aluminum alloys into two categories: nonheat-trea
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