David H. Phillips is a Professor of Practice in the Welding Engineering program at The Ohio State University, USA. Dr. Phillips earned his PhD in Welding Engineering and, alongside the prior edition of this book, has co-authored the textbook Resistance Spot Welding: Fundamentals and Applications for the Automotive Industry. He is a licensed Professional Engineer (PE) in Welding Engineering, an International Welding Engineer (IWE), and a Certified Welding Inspector (CWI) with more than 20 years’ experience in the field. Dr. Phillips is a recipient of both the Adams Memorial and the MacQuigg teaching excellence awards.

• Preface xiiiAbout the Companion Website xv1 What Is Welding Engineering? 11.1 Introduction to Welding Processes 12 Arc Welding Processes 32.1 Fundamentals and Principles of Arc Welding 32.1.1 Fundamentals of an Electric Arc 52.1.2 Arc Voltage 62.1.3 Polarity 72.1.4 Heat Input 92.1.5 Welding Position 102.1.6 Filler Metals and Electrodes 112.1.7 Shielding 112.1.7.1 Gas Shielding 112.1.7.2 Flux Shielding 122.1.8 Weld Joints and Weld Types for Arc Welding 132.1.9 Primary Operating Variables in Arc Welding 142.1.9.1 Voltage 142.1.9.2 Current 142.1.9.3 Electrode Feed Rate/Wire Feed Speed 152.1.9.4 Welding Travel Speed 152.1.10 Metal Transfer Mode 162.1.11 Arc Blow 162.1.12 Common Arc Welding Defects and Discontinuities 172.2 Arc Welding Power Supplies 172.2.1 Transformers 182.2.2 Generators 182.2.3 Important Electrical Elements in Arc Welding Power Supplies 202.2.4 Volt-Ampere Characteristic of Arc Welding Power Supplies 232.2.5 Duty Cycle 262.2.6 Modern Advanced Arc Welding Power Supplies 272.3 Shielded Metal Arc Welding 302.4 Gas Tungsten Arc Welding 362.5 Plasma Arc Welding 442.6 Gas Metal Arc Welding 472.7 Flux Cored Arc Welding 552.8 Submerged Arc Welding 582.9 Other Arc Welding Processes 632.9.1 Electrogas Welding 632.9.2 Electroslag Welding 632.9.3 Arc Stud Welding 652.10 Test Your Knowledge 683 Resistance Welding Processes 693.1 Fundamentals and Principles of Resistance Welding Processes 693.1.1 Resistance and Resistivity 693.1.2 Current Range and Lobe Curves 723.1.3 Modern Equipment and Power Supplies 743.2 Resistance Spot Welding 753.3 Resistance Seam Welding 793.4 Resistance Projection Welding 813.5 High Frequency Welding 833.6 Flash Welding 853.7 Test Your Knowledge 884 Solid-State Welding Processes 914.1 Fundamentals and Principles of Solid-State Welding 914.1.1 Solid-State Welding Theory 914.1.2 Roll Bonding Theory 924.2 Friction Welding Processes 934.2.1 Inertia Friction Welding 944.2.2 Continuous Drive Friction Welding 964.2.3 Linear Friction Welding 974.2.4 Friction Stir Welding 984.3 Other Solid-State Welding Processes 1014.3.1 Diffusion Welding 1014.3.2 Explosion Welding 1044.3.3 Ultrasonic Welding 1064.4 Test Your Knowledge 1105 High-Energy Density Welding Processes 1115.1 Fundamentals and Principles of High-Energy Density Welding 1115.1.1 Power Density 1115.1.2 Keyhole Mode Welding 1135.2 Laser Beam Welding 1135.3 Electron Beam Welding 1165.4 Test Your Knowledge 1186 Other Approaches to Welding and Joining 1216.1 Brazing and Soldering 1216.2 Welding of Plastics 1236.2.1 Hot Tool (Plate) Welding 1246.2.2 Hot Gas Welding 1256.2.3 Implant Induction Welding 1266.2.4 Ultrasonic Welding 1266.2.5 Vibration Welding 1276.3 Adhesive Bonding 1286.4 Novel and Hybrid Welding Processes 1286.5 Additive Manufacturing 1316.6 Oxyfuel Welding and Cutting 1326.7 Other Cutting Processes 1376.7.1 Plasma Cutting 1376.7.2 Laser Beam Cutting 1386.7.3 Air Carbon Arc Gouging 1386.8 Test Your Knowledge 1407 Design Considerations for Welding 1417.1 Introduction to Welding Design 1417.2 Mechanical Properties 1417.2.1 Yield Strength 1417.2.2 Tensile Strength 1427.2.3 Ductility 1427.2.4 Fatigue Strength 1427.2.5 Toughness 1427.2.6 Mechanical Properties—Effect of Temperature 1447.3 Physical Properties 1447.3.1 Thermal Conductivity 1447.3.2 Melting Temperature 1447.3.3 Coefficient of Thermal Expansion 1457.3.4 Electrical Conductivity 1457.4 Design Elements for Welded Connections 1457.4.1 Joint and Weld Types 1457.4.2 Joint and Weld Type Selection Considerations 1487.4.3 Weld Joint Nomenclature—Groove Welds 1507.4.4 Weld Joint Nomenclature—Fillet Welds 1517.4.5 Welding Positions 1517.5 Welding Symbols 1547.6 Weld Sizing 1597.7 Computational Modeling of Welds 1627.8 Test Your Knowledge 1648 Heat Flow, Residual Stress, and Distortion 1658.1 Heat Flow 1658.2 Fundamentals and Principles of Residual Stress and Distortion 1698.3 Approaches to Minimizing or Eliminating Distortion 1728.4 Test Your Knowledge 1769 Welding Metallurgy 1779.1 Introduction to Welding Metallurgy 1779.2 The Fusion Zone 1799.3 The Partially Melted Zone 1809.4 The Heat‐Affected Zone (HAZ) 1829.5 Introduction to Phase Diagrams 1839.6 Test Your Knowledge 18610 Welding Metallurgy of Carbon Steels 18710.1 Introduction to Steels 18710.2 Steel Microstructures and the Iron-Iron Carbide Diagram 18910.3 Continuous Cooling Transformation (CCT) Diagrams 19310.4 Hardness and Hardenability 19610.5 Hydrogen Cracking 19810.6 Heat-Affected Zone Microstructures in Steel 20010.7 Advanced High-Strength Steels 20210.8 Test Your Knowledge 20411 Welding Metallurgy of Stainless Steels 20711.1 Introduction to Stainless Steels 20711.2 Constitution Diagrams 20811.3 Martensitic Stainless Steels 21011.4 Ferritic Stainless Steels 21111.5 Austenitic Stainless Steels 21411.6 Duplex Stainless Steels 21811.7 Precipitation-Hardening Stainless Steels 22011.8 Test Your Knowledge 22012 Welding Metallurgy of Nonferrous Alloys 22312.1 Aluminum Alloys 22312.2 Nickel-Based Alloys 22712.3 Titanium Alloys 23112.4 Copper Alloys 23412.5 Magnesium Alloys 23512.6 Test Your Knowledge 23713 Weld Quality 23913.1 Weld Discontinuities and Defects 23913.2 Mechanical Testing of Weldments 24013.2.1 Tensile Testing 24013.2.2 Ductility Testing 24113.2.3 Toughness Testing 24313.2.4 Fatigue Testing 24413.3 Nondestructive Testing 24813.3.1 Visual Examination 24913.3.2 Liquid Penetrant Testing 24913.3.3 Magnetic Particle Testing 25013.3.4 Radiographic Testing 25213.3.5 Ultrasonic Testing 25413.4 Introduction to Fractography 25513.5 Test Your Knowledge 25814 Codes, Standards, and Welding Qualification 25914.1 Introduction to Standards 25914.2 AWS D1.1—“Structural Welding Code—Steel” 26514.2.1 Welding and Welder Qualification 26514.2.2 Fabrication and Inspection 27214.3 Test Your Knowledge 27215 Safe Practices in Welding 27515.1 Electrical Shock 27515.2 Radiation 27515.3 Burns 27515.4 Smoke and Fumes 27615.5 Welding in Confined Space 27615.6 Fire and Explosion Danger 27615.7 Compressed Gasses 27615.8 Hazardous Materials 27715.9 Test Your Knowledge 277Index 279

David H. Phillips is a Professor of Practice in the Welding Engineering program at The Ohio State University, USA. Dr. Phillips earned his PhD in Welding Engineering and, alongside the prior edition of this book, has co-authored the textbook Resistance Spot Welding: Fundamentals and Applications for the Automotive Industry. He is a licensed Professional Engineer (PE) in Welding Engineering, an International Welding Engineer (IWE), and a Certified Welding Inspector (CWI) with more than 20 years’ experience in the field. Dr. Phillips is a recipient of both the Adams Memorial and the MacQuigg teaching excellence awards.

• Preface xiiiAbout the Companion Website xv1 What Is Welding Engineering? 11.1 Introduction to Welding Processes 12 Arc Welding Processes 32.1 Fundamentals and Principles of Arc Welding 32.1.1 Fundamentals of an Electric Arc 52.1.2 Arc Voltage 62.1.3 Polarity 72.1.4 Heat Input 92.1.5 Welding Position 102.1.6 Filler Metals and Electrodes 112.1.7 Shielding 112.1.7.1 Gas Shielding 112.1.7.2 Flux Shielding 122.1.8 Weld Joints and Weld Types for Arc Welding 132.1.9 Primary Operating Variables in Arc Welding 142.1.9.1 Voltage 142.1.9.2 Current 142.1.9.3 Electrode Feed Rate/Wire Feed Speed 152.1.9.4 Welding Travel Speed 152.1.10 Metal Transfer Mode 162.1.11 Arc Blow 162.1.12 Common Arc Welding Defects and Discontinuities 172.2 Arc Welding Power Supplies 172.2.1 Transformers 182.2.2 Generators 182.2.3 Important Electrical Elements in Arc Welding Power Supplies 202.2.4 Volt-Ampere Characteristic of Arc Welding Power Supplies 232.2.5 Duty Cycle 262.2.6 Modern Advanced Arc Welding Power Supplies 272.3 Shielded Metal Arc Welding 302.4 Gas Tungsten Arc Welding 362.5 Plasma Arc Welding 442.6 Gas Metal Arc Welding 472.7 Flux Cored Arc Welding 552.8 Submerged Arc Welding 582.9 Other Arc Welding Processes 632.9.1 Electrogas Welding 632.9.2 Electroslag Welding 632.9.3 Arc Stud Welding 652.10 Test Your Knowledge 683 Resistance Welding Processes 693.1 Fundamentals and Principles of Resistance Welding Processes 693.1.1 Resistance and Resistivity 693.1.2 Current Range and Lobe Curves 723.1.3 Modern Equipment and Power Supplies 743.2 Resistance Spot Welding 753.3 Resistance Seam Welding 793.4 Resistance Projection Welding 813.5 High Frequency Welding 833.6 Flash Welding 853.7 Test Your Knowledge 884 Solid-State Welding Processes 914.1 Fundamentals and Principles of Solid-State Welding 914.1.1 Solid-State Welding Theory 914.1.2 Roll Bonding Theory 924.2 Friction Welding Processes 934.2.1 Inertia Friction Welding 944.2.2 Continuous Drive Friction Welding 964.2.3 Linear Friction Welding 974.2.4 Friction Stir Welding 984.3 Other Solid-State Welding Processes 1014.3.1 Diffusion Welding 1014.3.2 Explosion Welding 1044.3.3 Ultrasonic Welding 1064.4 Test Your Knowledge 1105 High-Energy Density Welding Processes 1115.1 Fundamentals and Principles of High-Energy Density Welding 1115.1.1 Power Density 1115.1.2 Keyhole Mode Welding 1135.2 Laser Beam Welding 1135.3 Electron Beam Welding 1165.4 Test Your Knowledge 1186 Other Approaches to Welding and Joining 1216.1 Brazing and Soldering 1216.2 Welding of Plastics 1236.2.1 Hot Tool (Plate) Welding 1246.2.2 Hot Gas Welding 1256.2.3 Implant Induction Welding 1266.2.4 Ultrasonic Welding 1266.2.5 Vibration Welding 1276.3 Adhesive Bonding 1286.4 Novel and Hybrid Welding Processes 1286.5 Additive Manufacturing 1316.6 Oxyfuel Welding and Cutting 1326.7 Other Cutting Processes 1376.7.1 Plasma Cutting 1376.7.2 Laser Beam Cutting 1386.7.3 Air Carbon Arc Gouging 1386.8 Test Your Knowledge 1407 Design Considerations for Welding 1417.1 Introduction to Welding Design 1417.2 Mechanical Properties 1417.2.1 Yield Strength 1417.2.2 Tensile Strength 1427.2.3 Ductility 1427.2.4 Fatigue Strength 1427.2.5 Toughness 1427.2.6 Mechanical Properties—Effect of Temperature 1447.3 Physical Properties 1447.3.1 Thermal Conductivity 1447.3.2 Melting Temperature 1447.3.3 Coefficient of Thermal Expansion 1457.3.4 Electrical Conductivity 1457.4 Design Elements for Welded Connections 1457.4.1 Joint and Weld Types 1457.4.2 Joint and Weld Type Selection Considerations 1487.4.3 Weld Joint Nomenclature—Groove Welds 1507.4.4 Weld Joint Nomenclature—Fillet Welds 1517.4.5 Welding Positions 1517.5 Welding Symbols 1547.6 Weld Sizing 1597.7 Computational Modeling of Welds 1627.8 Test Your Knowledge 1648 Heat Flow, Residual Stress, and Distortion 1658.1 Heat Flow 1658.2 Fundamentals and Principles of Residual Stress and Distortion 1698.3 Approaches to Minimizing or Eliminating Distortion 1728.4 Test Your Knowledge 1769 Welding Metallurgy 1779.1 Introduction to Welding Metallurgy 1779.2 The Fusion Zone 1799.3 The Partially Melted Zone 1809.4 The Heat‐Affected Zone (HAZ) 1829.5 Introduction to Phase Diagrams 1839.6 Test Your Knowledge 18610 Welding Metallurgy of Carbon Steels 18710.1 Introduction to Steels 18710.2 Steel Microstructures and the Iron-Iron Carbide Diagram 18910.3 Continuous Cooling Transformation (CCT) Diagrams 19310.4 Hardness and Hardenability 19610.5 Hydrogen Cracking 19810.6 Heat-Affected Zone Microstructures in Steel 20010.7 Advanced High-Strength Steels 20210.8 Test Your Knowledge 20411 Welding Metallurgy of Stainless Steels 20711.1 Introduction to Stainless Steels 20711.2 Constitution Diagrams 20811.3 Martensitic Stainless Steels 21011.4 Ferritic Stainless Steels 21111.5 Austenitic Stainless Steels 21411.6 Duplex Stainless Steels 21811.7 Precipitation-Hardening Stainless Steels 22011.8 Test Your Knowledge 22012 Welding Metallurgy of Nonferrous Alloys 22312.1 Aluminum Alloys 22312.2 Nickel-Based Alloys 22712.3 Titanium Alloys 23112.4 Copper Alloys 23412.5 Magnesium Alloys 23512.6 Test Your Knowledge 23713 Weld Quality 23913.1 Weld Discontinuities and Defects 23913.2 Mechanical Testing of Weldments 24013.2.1 Tensile Testing 24013.2.2 Ductility Testing 24113.2.3 Toughness Testing 24313.2.4 Fatigue Testing 24413.3 Nondestructive Testing 24813.3.1 Visual Examination 24913.3.2 Liquid Penetrant Testing 24913.3.3 Magnetic Particle Testing 25013.3.4 Radiographic Testing 25213.3.5 Ultrasonic Testing 25413.4 Introduction to Fractography 25513.5 Test Your Knowledge 25814 Codes, Standards, and Welding Qualification 25914.1 Introduction to Standards 25914.2 AWS D1.1—“Structural Welding Code—Steel” 26514.2.1 Welding and Welder Qualification 26514.2.2 Fabrication and Inspection 27214.3 Test Your Knowledge 27215 Safe Practices in Welding 27515.1 Electrical Shock 27515.2 Radiation 27515.3 Burns 27515.4 Smoke and Fumes 27615.5 Welding in Confined Space 27615.6 Fire and Explosion Danger 27615.7 Compressed Gasses 27615.8 Hazardous Materials 27715.9 Test Your Knowledge 277Index 279

David H. Phillips is a Professor of Practice in the Welding Engineering program at The Ohio State University, USA. Dr. Phillips earned his PhD in Welding Engineering and, alongside the prior edition of this book, has co-authored the textbook Resistance Spot Welding: Fundamentals and Applications for the Automotive Industry. He is a licensed Professional Engineer (PE) in Welding Engineering, an International Welding Engineer (IWE), and a Certified Welding Inspector (CWI) with more than 20 years’ experience in the field. Dr. Phillips is a recipient of both the Adams Memorial and the MacQuigg teaching excellence awards.

• Preface xiiiAbout the Companion Website xv1 What Is Welding Engineering? 11.1 Introduction to Welding Processes 12 Arc Welding Processes 32.1 Fundamentals and Principles of Arc Welding 32.1.1 Fundamentals of an Electric Arc 52.1.2 Arc Voltage 62.1.3 Polarity 72.1.4 Heat Input 92.1.5 Welding Position 102.1.6 Filler Metals and Electrodes 112.1.7 Shielding 112.1.7.1 Gas Shielding 112.1.7.2 Flux Shielding 122.1.8 Weld Joints and Weld Types for Arc Welding 132.1.9 Primary Operating Variables in Arc Welding 142.1.9.1 Voltage 142.1.9.2 Current 142.1.9.3 Electrode Feed Rate/Wire Feed Speed 152.1.9.4 Welding Travel Speed 152.1.10 Metal Transfer Mode 162.1.11 Arc Blow 162.1.12 Common Arc Welding Defects and Discontinuities 172.2 Arc Welding Power Supplies 172.2.1 Transformers 182.2.2 Generators 182.2.3 Important Electrical Elements in Arc Welding Power Supplies 202.2.4 Volt-Ampere Characteristic of Arc Welding Power Supplies 232.2.5 Duty Cycle 262.2.6 Modern Advanced Arc Welding Power Supplies 272.3 Shielded Metal Arc Welding 302.4 Gas Tungsten Arc Welding 362.5 Plasma Arc Welding 442.6 Gas Metal Arc Welding 472.7 Flux Cored Arc Welding 552.8 Submerged Arc Welding 582.9 Other Arc Welding Processes 632.9.1 Electrogas Welding 632.9.2 Electroslag Welding 632.9.3 Arc Stud Welding 652.10 Test Your Knowledge 683 Resistance Welding Processes 693.1 Fundamentals and Principles of Resistance Welding Processes 693.1.1 Resistance and Resistivity 693.1.2 Current Range and Lobe Curves 723.1.3 Modern Equipment and Power Supplies 743.2 Resistance Spot Welding 753.3 Resistance Seam Welding 793.4 Resistance Projection Welding 813.5 High Frequency Welding 833.6 Flash Welding 853.7 Test Your Knowledge 884 Solid-State Welding Processes 914.1 Fundamentals and Principles of Solid-State Welding 914.1.1 Solid-State Welding Theory 914.1.2 Roll Bonding Theory 924.2 Friction Welding Processes 934.2.1 Inertia Friction Welding 944.2.2 Continuous Drive Friction Welding 964.2.3 Linear Friction Welding 974.2.4 Friction Stir Welding 984.3 Other Solid-State Welding Processes 1014.3.1 Diffusion Welding 1014.3.2 Explosion Welding 1044.3.3 Ultrasonic Welding 1064.4 Test Your Knowledge 1105 High-Energy Density Welding Processes 1115.1 Fundamentals and Principles of High-Energy Density Welding 1115.1.1 Power Density 1115.1.2 Keyhole Mode Welding 1135.2 Laser Beam Welding 1135.3 Electron Beam Welding 1165.4 Test Your Knowledge 1186 Other Approaches to Welding and Joining 1216.1 Brazing and Soldering 1216.2 Welding of Plastics 1236.2.1 Hot Tool (Plate) Welding 1246.2.2 Hot Gas Welding 1256.2.3 Implant Induction Welding 1266.2.4 Ultrasonic Welding 1266.2.5 Vibration Welding 1276.3 Adhesive Bonding 1286.4 Novel and Hybrid Welding Processes 1286.5 Additive Manufacturing 1316.6 Oxyfuel Welding and Cutting 1326.7 Other Cutting Processes 1376.7.1 Plasma Cutting 1376.7.2 Laser Beam Cutting 1386.7.3 Air Carbon Arc Gouging 1386.8 Test Your Knowledge 1407 Design Considerations for Welding 1417.1 Introduction to Welding Design 1417.2 Mechanical Properties 1417.2.1 Yield Strength 1417.2.2 Tensile Strength 1427.2.3 Ductility 1427.2.4 Fatigue Strength 1427.2.5 Toughness 1427.2.6 Mechanical Properties—Effect of Temperature 1447.3 Physical Properties 1447.3.1 Thermal Conductivity 1447.3.2 Melting Temperature 1447.3.3 Coefficient of Thermal Expansion 1457.3.4 Electrical Conductivity 1457.4 Design Elements for Welded Connections 1457.4.1 Joint and Weld Types 1457.4.2 Joint and Weld Type Selection Considerations 1487.4.3 Weld Joint Nomenclature—Groove Welds 1507.4.4 Weld Joint Nomenclature—Fillet Welds 1517.4.5 Welding Positions 1517.5 Welding Symbols 1547.6 Weld Sizing 1597.7 Computational Modeling of Welds 1627.8 Test Your Knowledge 1648 Heat Flow, Residual Stress, and Distortion 1658.1 Heat Flow 1658.2 Fundamentals and Principles of Residual Stress and Distortion 1698.3 Approaches to Minimizing or Eliminating Distortion 1728.4 Test Your Knowledge 1769 Welding Metallurgy 1779.1 Introduction to Welding Metallurgy 1779.2 The Fusion Zone 1799.3 The Partially Melted Zone 1809.4 The Heat‐Affected Zone (HAZ) 1829.5 Introduction to Phase Diagrams 1839.6 Test Your Knowledge 18610 Welding Metallurgy of Carbon Steels 18710.1 Introduction to Steels 18710.2 Steel Microstructures and the Iron-Iron Carbide Diagram 18910.3 Continuous Cooling Transformation (CCT) Diagrams 19310.4 Hardness and Hardenability 19610.5 Hydrogen Cracking 19810.6 Heat-Affected Zone Microstructures in Steel 20010.7 Advanced High-Strength Steels 20210.8 Test Your Knowledge 20411 Welding Metallurgy of Stainless Steels 20711.1 Introduction to Stainless Steels 20711.2 Constitution Diagrams 20811.3 Martensitic Stainless Steels 21011.4 Ferritic Stainless Steels 21111.5 Austenitic Stainless Steels 21411.6 Duplex Stainless Steels 21811.7 Precipitation-Hardening Stainless Steels 22011.8 Test Your Knowledge 22012 Welding Metallurgy of Nonferrous Alloys 22312.1 Aluminum Alloys 22312.2 Nickel-Based Alloys 22712.3 Titanium Alloys 23112.4 Copper Alloys 23412.5 Magnesium Alloys 23512.6 Test Your Knowledge 23713 Weld Quality 23913.1 Weld Discontinuities and Defects 23913.2 Mechanical Testing of Weldments 24013.2.1 Tensile Testing 24013.2.2 Ductility Testing 24113.2.3 Toughness Testing 24313.2.4 Fatigue Testing 24413.3 Nondestructive Testing 24813.3.1 Visual Examination 24913.3.2 Liquid Penetrant Testing 24913.3.3 Magnetic Particle Testing 25013.3.4 Radiographic Testing 25213.3.5 Ultrasonic Testing 25413.4 Introduction to Fractography 25513.5 Test Your Knowledge 25814 Codes, Standards, and Welding Qualification 25914.1 Introduction to Standards 25914.2 AWS D1.1—“Structural Welding Code—Steel” 26514.2.1 Welding and Welder Qualification 26514.2.2 Fabrication and Inspection 27214.3 Test Your Knowledge 27215 Safe Practices in Welding 27515.1 Electrical Shock 27515.2 Radiation 27515.3 Burns 27515.4 Smoke and Fumes 27615.5 Welding in Confined Space 27615.6 Fire and Explosion Danger 27615.7 Compressed Gasses 27615.8 Hazardous Materials 27715.9 Test Your Knowledge 277Index 279