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Sheet Metal Welding Guide, 3rd Edition, 2007

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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]

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Sheet Metal Welding Guide, 3rd Edition, 2007