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Sarjana Teknik Perkapalan ITS 1994 (welding) Master of Engineering, MUN Canada 1999 (nondestructive engineering) ASNT NDT Level II, MT, PT, UT, RT

Session II, NACE International Coating Inspector Training, Orlando - Florida, USA 1999 Welding Inspector Course, Politeknik Perkapalan, angkatan V, 1995

WELDING TECHNOLOGY Teknik Las

INTRODUCTION

NONMANDATORY REFERENCES

Althouse, Andrew R, et. al., Modern Welding, The GoodheartWillcox Company, Inc., Illinois, 1988. ASME, 1998 ASME Boiler & Pressure Vessel Code, Section IX Welding and Brazing Qualification, The American Society of Mechanical Engineers, New York, 2000. AWS, AWS D1.1: 2002, Structural Welding Code - Steel, American Welding Society, Miami, 2002. AWS, Certification Manual for Welding Inspectors, American Welding Society, Miami, 4th Edition, 2000.

NONMANDATORY REFERENCES

AWS, ANSI/AWS A3.0-94, Standard Welding Terms and Definitions, American Welding Society, Miami, 1994. AWS, Welding Inspection Handbook, American Welding Society, Miami, 3rd Edition, 2000.

Jeffus, Larry, Welding - Principles and Applications, Delmar Publishers Inc., Albany, 3,d Edition, 1993.
Jenney, Cynthia L., and Annette O'Brien, Welding Handbook, Volume 1 - Welding Science and Technology, American Welding Society, Miami, 9th Edition, 2001.

NONMANDATORY REFERENCES

O'Brien, R.L., Welding Handbook, Volume 2 - Welding Processes, American Welding Society, Miami, 8th Edition, 1991. Oates, William R., Welding Handbook, Volume 3 - Materials & Applications Part l, American Welding Society, Miami, 8th Edition, 1996.

Oates, William R., and Alexander M. Saitta, Welding Handbook, Volume 3 Materials & Applications Part 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 1-2.

The Industrial Revolution, from 1750 to 1850, introduced a method of joining pieces of iron together known as forge welding or hammer

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, in the year 1886, developed the resistance welding 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."

In less technical language, a weld is made when separate pieces of material to be joined combine and form one piece when heated to a temperature high enough to cause softening or melting and flow together. Pressure may or may not be used to force the pieces together. In some instances, pressure alone may be sufficient to force the separate pieces of material to combine and form one piece. Filler material is added when needed to form a completed weld in the joint.

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, 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. 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.