Front Cover -- Applied Welding Engineering: Processes, Codes and Standards -- Copyright Page -- Contents -- Preface -- Acknowledgment -- 1. Introduction to Basic Metallurgy -- 1. Introduction -- Pure Metals and Alloys -- Smelting -- Iron -- Sponge Iron -- 2. Alloys -- Alloys -- Effects of Alloying Elements -- Carbon Steels -- Sulfur -- Manganese -- Phosphorus -- Silicon -- Alloy Steels -- The Effect of Alloying Elements on Ferrite -- Effects of Alloying Elements on Carbide -- 3. Physical Metallurgy -- Crystal Lattices -- Crystal Structure Nomenclature -- Solidification -- Lever Rule of Solidification -- Constitutional Supercooling -- Elementary Theory of Nucleation -- Allotropy -- Crystal Imperfections -- Grain Size -- 4. Structure of Materials -- Phase Diagrams -- Different Types of Phase Diagrams -- Iron-Iron Carbide Phase Diagram -- Explanation of the Iron-Carbon Phase Diagram -- Rationale for Letter Designations in the Iron-Iron Carbide Phase Diagram -- 5. Production of Steel -- The Electric Arc Furnace (EAF) Process -- Furnace Charging -- Melting -- Refining -- Phosphorus Removal -- Sulfur Removal -- Nitrogen and Hydrogen Control -- De-Slagging -- Tapping -- Basic Oxygen Furnace (BOF) -- Refining Reactions -- Carbon -- Silicon -- Manganese -- Phosphorus -- Sulfur Removal -- Deoxidation of Steel -- Rimmed Steel -- Capped Steel -- Semi-Killed Steel -- Killed Steel -- Deoxidation Equilibria -- The Iron-Iron Carbide Phase Diagram -- 6. Classification of Steels -- Carbon Steels -- Low-Carbon -- Medium-Carbon -- High-Carbon -- Ultrahigh-Carbon -- High-Strength Low-Alloy (HSLA) Steels -- Classification of HSLA -- Low-Alloy Steels -- Low-Carbon Quenched and Tempered Steels -- Medium-Carbon Ultrahigh-Strength Steels -- Bearing Steels -- Chromium-Molybdenum Heat-Resistant Steels -- AISI Series -- Some Examples AISI Classifications -- 7. Cast Iron.

Types of Cast Iron -- White Cast Iron -- Malleable Cast Iron -- Ferritic Malleable Iron -- White Heart Cast Iron -- Black Heart Cast Iron -- Pearlite Malleable Cast Iron -- Martensitic Malleable Iron -- Gray Cast Iron -- Castability of Gray Cast Iron -- Chilled Cast Iron -- Nodular (Spheroidal Graphite) Cast Iron -- Castability, Solidification and Shrinkage -- Alloy Cast Irons -- 8. Stainless Steels -- Stainless Steel Production -- Forming -- Heat Treatment -- Cutting Stainless Steel -- Finishing -- Fabrication of Stainless Steel -- Welding and Joining -- Types of Stainless Steels -- Classification of Stainless Steel -- Martensitic Stainless Steels -- Ferritic Stainless Steels -- Pitting Resistance Equivalent (PRE) -- Austenitic Stainless Steels -- Duplex Stainless Steels -- Precipitation-Hardening (PH) Stainless Steels -- 9. Non-Ferrous Materials -- Copper and Copper Alloys -- Aluminum and Aluminum Alloys -- Physical Metallurgy of Aluminum -- Effect of Alloying Elements on Aluminum -- Effect of Iron -- Effect of Silicon -- Effect of Manganese -- Effect of Magnesium -- Effect of Copper -- Effect of Zinc -- Effect of Chromium -- Effect of Zirconium -- Effect of Lithium -- Age Hardenable Alloys -- Nickel and Nickel Alloys -- Titanium and Titanium Alloys -- 10. Working With Metals -- Elastic Limit -- Plastic Deformation -- Fracture -- Polycrystalline Materials -- Cold Working -- Stored Energy -- Restoring the Lattice Structure of Metal after Cold Work - Annealing -- Grain Growth -- Hot Working -- 11. Mechanical Properties and Testing of Metals -- Strength of Materials -- Elastic and Plastic Behavior -- Ductile vs. Brittle Behavior -- Failure -- Fracture -- Fracture Control -- Crack Growth and Fracture -- Damage Tolerance -- Failure Analysis -- Testing of Metals -- Tensile Test -- Hardness Test -- Impact Test -- Creep Test -- Fatigue Test.

12. Heat Treatment of Steels -- TTT and CCT Curves -- Isothermal-Transformation (IT) or (TTT) Diagrams -- Cooling Curves -- Cooling-Transformation (C-T) Diagrams -- Stress Relief Annealing -- Normalizing -- Annealing -- Spheroidizing -- Tempering -- Austempering of Steels -- Martempering -- Hardening -- Hardening by Martensite Transformation -- Case Hardening and Carburizing -- Process of Quenching -- Heat Treatment of Non-Ferrous Material -- Heat Treatment of Copper and Copper Alloys -- Heat Treating Aluminum and its Alloys -- Heat-Treating Furnaces -- Liquid Heating Baths -- 2. Welding Metallurgy and Welding Processes -- 1. Introduction -- Welding Procedures -- 2. Physics of Welding -- Heat -- Details of the Heat-Flow in Welding -- Heat in Arc Welding Processes -- Heat in Plasma Arc Cutting and Welding -- Heat in Resistance Welding -- Heat in Electroslag Welding (ESW) -- Heat in Welding Processes using Chemical Sources -- Thermit Welding -- Heat Generated by Mechanical Processes -- Friction Welding -- Ultrasonic Welding -- Explosion Welding -- Heat by Focused Sources -- Laser Beam Welding (LBW) -- Electron Beam Welding (EBW) -- Other Sources of Heat in Welding -- Application of the Principles of Welding Physics -- Pre-Heating -- Determining the Need for Pre-Heat and the Temperature -- Post-Weld Heat Treatment (PWHT) -- Heat and Time in Welding -- Heat Input -- Energy Distribution -- Rate of Heating -- Maximum Temperature -- Heat Generation and Temperature Distribution - Practical Application -- Time at Temperature -- Cooling Rates -- Base Metal Mass -- 3. Welding and Joining Processes -- Shielded Metal Arc Welding (SMAW): Process Fundamentals -- How the Process Works -- Covered Electrodes Used in the SMAW Process -- Joint Design and Preparation -- Gas Tungsten Arc Welding (GTAW): Process Description -- Process Advantages and Limitations.

Electrodes -- Joint Design -- Gas Metal Arc Welding (GMAW) -- Process Description -- Electrode Selection -- Joint Design -- Flux Cored Arc Welding (FCAW) -- Process Fundamentals -- Principal Applications of FCAW -- Shielding Gases -- Electrodes -- Submerged Arc Welding (SAW) -- Process Description -- Materials -- Other Common Joining and Welding Processes -- Electroslag Welding (ESW) -- Plasma Arc Welding (PAW) -- Stud Welding -- Oxy-fuel Gas Welding (OFW) -- Brazing and Soldering -- Arc-Welding Power Sources -- Constant Voltage Power Source -- Constant-Current Power Source -- Transformers -- Thyristor-Silicon Controlled Rectifiers (SCR) -- Generators -- Alternators -- 4. Physical Effect of Heat on Material During Welding -- The Molten Metal -- The Welded Plate -- Influence of Cooling Rate -- 5. Stresses, Shrinkage and Distortion in Weldments -- Stresses in Weldments -- Definitions of Terms -- Development of Stresses -- Moving a Localized Heat Source -- Distribution of Stress in a Simple Weld -- Residual Stresses -- Shrinkages -- Shrinkage Transverse to a Butt Weld -- Shrinkage Longitudinal to a Butt Weld -- Distortion in Weldments -- General Description -- Angular Distortion -- Longitudinal Bowing -- Buckling -- Corrective Measures -- Thermal Straightening -- Designing Weld Joints -- Assessing the Strength of Welds -- Throat of a Weld -- Sizing a Fillet Weld -- Stress Causing Fatigue in Weld -- Weld Size and Cost Control -- Control of Welding Stresses to Minimize Through-Thickness Failures -- 6. Welding Corrosion Resistant Alloys - Stainless Steel -- Corrosion Resistant Alloys (CRAs) -- Stainless Steel -- Welding Stainless Steel -- General Welding Characteristics -- Welding Processes -- Protection against Oxidation -- Welding Hygiene -- Austenitic Stainless Steels -- Metallurgical Concerns Associated with Welding Austenitic Stainless Steels.

Mechanical Properties of Stainless Steels -- Welding of Austenitic Stainless Steels -- Superaustenitic Stainless Steels -- Material Properties and Applications -- Welding and Joining of Superaustenitic Stainless Steels -- Difficulties Associated with Welding Stainless Steel -- Martensitic Stainless Steels -- Properties and Application -- Welding Martensitic Stainless Steels -- Ferritic Stainless Steels -- Properties and Application -- Welding Ferritic Steel -- Precipitation Hardened Stainless Steels -- Properties and Application of Precipitation Hardened Steels -- Welding Precipitation Hardened (PH) Steels -- Duplex Stainless Steels -- Mechanical Properties -- Heat Treatment -- Welding and Fabrication -- 7. Welding Non-Ferrous Metals and Alloys -- Aluminum and its Alloys -- The Confusing Thing about Aluminum -- Weld Hygiene -- Preheating -- The Conductivity of Heat -- Welding Filler Metals -- Welding Aluminum with the Shield Metal Arc Welding (SMAW) process -- Welding Aluminum with the Gas Tungsten Arc Welding (GTAW) process -- Type of Current and Electrode -- Grinding the Tip of the Electrodes -- Welding Aluminum with the Gas Metal Arc Welding (GMAW) Process -- Power Source -- Wire Feeder -- Welding Guns -- Welding Technique -- The Push Technique -- Travel Speed -- Shielding Gas -- Welding Wire -- Friction Stir Welding (FSW) -- Nickel Alloys -- Heat Treatment -- Mechanical Properties -- Fabrication -- Precipitation Hardenable Nickel-Based Alloys -- Heat Treatment of PH Nickel Alloys -- Mechanical Properties -- Welding -- Titanium Alloys -- Heat Treatment -- Alpha (α) Titanium -- Alpha/beta (α-β) Titanium -- Beta (β) Titanium -- 8. Weld Defects and Inspection -- Weld Quality -- Acceptance Standards -- Discontinuities in Fusion Welded Joints -- Classification of Weld Joint Discontinuities -- Typical Weld Defects -- Porosity -- Inclusions.

Incomplete Fusion.