AWS WHB-5 9-2015 Welding Handbook Volume 5 - MATERIALS AND APPLICATIONS Part 2.pdf

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1、i Welding Handbook Ninth Edition Volume 5 MATERIALS AND APPLICATIONS, PART 2 American Welding Societyii Welding Handbook, Ninth Edition Volume 1 Welding Science and Technology Volume 2 Welding Processes, Part 1 Volume 3 Welding Processes, Part 2 Volume 4 Materials and Applications, Part 1 Volume 5 M

2、aterials and Applications, Part 2iii Welding Handbook Ninth Edition Volume 5 MATERIALS AND APPLICATIONS, PART 2 Prepared under the direction of the Welding Handbook Committee Annette OBrien, Editor Kathy Sinnes, Associate Editor American Welding Society 8669 NW 36 St, # 130 Miami, FL 33126iv 2015 by

3、 American Welding Society All rights reserved No portion of this book may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, including mechanical, photocopying, recording, or otherwise, without the prior written permission of the copyright owner. Authorization t

4、o photocopy items for internal, personal, or educational classroom use only, or the internal, personal, or educational classroom use only of specific clients, is granted by the American Welding Society (AWS) provided the appropriate fee is paid to the Copyright Clearance Center, 222 Rosewood Drive,

5、Danvers, MA 01923; telephone: (978) 750-8400; Internet: . Library of Congress Control Number: 2001089999 ISBN: 978-0-87171-856-3 The Welding Handbook is the result of the collective effort of many volunteer technical specialists who provide infor- mation to assist with the design and application of

6、welding and allied processes. The information and data presented in the Welding Handbook are intended for informational purposes only. Reason- able care is exercised in the compilation and publication of the Welding Handbook to ensure the authenticity of the con- tents. However, no representation is

7、 made as to the accuracy, reliability, or completeness of this information, and an independent substantiating investigation of the information should be undertaken by the user. The information contained in the Welding Handbook shall not be construed as a grant of any right of manufacture, sale, use,

8、 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 such infringement. Whether the use of any information in the Welding Handbo

9、ok would result in an infringement of any patent, copyright, or trademark is a determination to be made by the user.v DEDICATION The Welding Handbook Committee dedicates this book jointly to Bernhard J. (Bernie) Bastian, long-term member of the Welding Handbook Committee, and Annette OBrien, Senior

10、Editor, in recognition of their contributions to the five volumes of the 9th edition of the Welding Handbook for the American Welding Society. B. J. Bastian, M.S., P.E., welding consultant, teacher, writer, mentor, and contributor to the technology of automo- tive welding, has generously shared the

11、expertise acquired during his 50-year career in the welding industry by serving on the Welding Handbook Committee. He has provided valuable guidance to the Committee on the orga- nization and technical content of the Welding Handbook, and was responsible for oversight and final reviews of various ch

12、apters of each of the five volumes of the 9th edition. Bernies career includes work with Ford Motor Company and Chrysler Corporation, not only in welding engineer- ing and management, but also as an instructor and coach for welders and technicians. He has a Bachelor of Science degree in mechanical e

13、ngineering and a Masters degree in metallurgical engineering from Rensselaer Polytechnic Institute. He added postgraduate studies at the University of Michigan. He taught welding and related courses at Henry Ford Community College for 17 years, and has written instructive articles for a number of te

14、chnical publi- cations. He is a Fellow of the American Welding Society and was also honored as a Life Member in recognition of his work as a volunteer with AWS. He is a past member of the AWS Board of Directors. Annette OBrien served as Editor for all five volumes of the Ninth Edition of the Welding

15、 Handbook. For more than 15 years she diligently and patiently guided the volumes, each containing over 700 pages, through many stages of editing, proofing, review, and final approval necessary to produce one of the finest series of reference books in the welding industry. Annette also served as Sec

16、retary to the Welding Handbook Committee, organizing meetings, preparing minutes, expediting and distributing chapters for peer reviews, and communicating the information necessary to keep the committee informed and on schedule. Her many years of commitment to the Welding Handbook have been invaluab

17、le to the American Welding Society. B. J. Bastian Annette OBrienvii CONTENTS DEDICATION v ACKNOWLEDGMENTS . x PREFACE. xi REVIEWERS. xii CONTRIBUTORS . xiii CHAPTER 1ALUMINUM AND ALUMINUM ALLOYS. 2 Introduction 2 Aluminum Product Forms . 3 Properties and Performance of Aluminum Weldments . 37 Arc We

18、lding of Aluminum. 48 High Energy Beam Welding Processes 86 Resistance Welding 93 Solid-State Welding 101 Oxyfuel Gas Welding. 106 Brazing 111 Soldering . 117 Adhesive Bonding 123 Joining Aluminum to Dissimilar Metals 124 Arc Cutting . 126 Applications 128 Safe Practices. 131 Bibliography 132 Supple

19、mentary Reading List 133 CHAPTER 2MAGNESIUM AND MAGNESIUM ALLOYS. 137 Introduction 138 Alloying Elements 140 Arc Welding. 148 Resistance Welding 165 High-Energy Beam Welding. 175 Solid-State Welding 179 Oxyfuel Gas Welding. 190 Brazing 192 Soldering . 196 Joining of Dissimilar Metals 198 Plasma Arc

20、Cutting . 198 Applications 199 Safe Practices. 206 Bibliography 207 Supplementary Reading List 210 CHAPTER 3COPPER AND COPPER ALLOYS. 215 Introduction 216 Copper Alloys . 217 High-Copper Alloys 221 Welding and Joining Processes. 225 Filler Metals 229 Joint Designs for Copper Welds. 233 Welding Condi

21、tions. 233 Brazing 253 Soldering . 260 Applications 263 Safe Practices. 271viii Bibliography.272 Supplementary Reading List.272 CHAPTER 4NICKEL AND COBALT ALLOYS.275 Introduction.276 Physical and Mechanical Properties277 Alloy Groups278 Surface Preparation for Welding.289 Arc Welding .290 Other Weld

22、ing Processes 315 Fabrication for High-Temperature Service323 Weld Cladding .327 Brazing.338 Soldering342 Thermal Cutting.343 Applications.344 Safe Practices347 Bibliography.349 Supplementary Reading List.349 CHAPTER 5LEAD AND ZINC.351 Introduction.352 Welding of Lead .352 Lead Soldering .362 Weldin

23、g and Soldering of Zinc .367 Typical Applications for Lead 376 Typical Applications for Zinc.378 Safe Practices380 Bibliography.382 Supplementary Reading List.383 CHAPTER 6TITANIIUM AND TITANIUM ALLOYS.385 Introduction.386 Physical Metallurgy of Titanium 388 Welding Metallurgy of Titanium and Titani

24、um Alloys .400 Joint Processes for Titanium.415 Brazing.432 Thermal Cutting.434 Applications.435 Safe Practices444 Bibliography.445 Supplementary Reading List.445 CHAPTER 7REACTIVE, REFRACTORY, AND PRECIOUS METALS 449 Introduction.450 Reactive Metals450 Zirconium 451 Hafnium.463 Beryllium467 Berylli

25、um-Aluminum 470 Uranium .473 Refractory Metals 475 Tantalum475 Niobium.478 Molybdenum and Tungsten 483 Rhenium.488ix Precious Metals . 491 Gold 494 Silver 497 Platinum and Platinum Alloys 499 Palladium. 502 Iridium. 503 Osmium. 505 Rhodium 505 Ruthenium. 506 Applications 506 Safe Practices. 511 Bibl

26、iography 512 Supplementary Reading List 513 CHAPTER 8PLASTICS 517 Introduction 518 Welding Processes for Thermoplastics . 520 Weld Quality of Thermoplastics 557 Applications 558 Safe Practices. 564 Bibliography 565 Supplementary Reading List 566 CHAPTER 9CERAMICS 569 Introduction 570 Ceramic Materia

27、ls . 571 Welding and Joining Processes. 575 Applications 590 Safe Practices. 592 Bibliography 595 Supplementary Reading List 596 CHAPTER 10COMPOSITES 599 Introduction 600 Welding Polymeric Composites 603 Metal Matrix Composites . 613 Safe Practices. 638 Bibliography 639 Supplementary Reading List 64

28、2 APPENDIX ASAFETY CODES AND OTHER STANDARDS 643 Publishers of Safety Codes and Other Standards . 645 APPENDIX BWELDING HANDBOOK REFERENCE GUIDE. 649 MAJOR SUBJECT INDEX 667 Volumes 3 and 4, Eighth Edition . 667 Volumes 1, 2, 3, 4, and 5, Ninth Edition . 667 INDEX OF VOLUME 5, NINTH EDITION . 691x A

29、CKNOWLEDGMENTS The Welding Handbook Committee of the American Welding Society and the editors gratefully recognize the contri- butions of the volunteers who have created, developed, and documented the technology of welding and shared it in past editions of the Welding Handbook, beginning with the fi

30、rst edition published in 1938. The enthusiasm and meticulous dedication of the authors and technologists reflected in the previous eight editions of the Welding Handbook are continued in this volume of the Ninth Edition. This volume was compiled by the members the Welding Handbook Volume 5 Committee

31、 and the WH5 Chapter Committees, with oversight by the Welding Handbook Committee. Chapter committee chairs, chapter committee members, and oversight persons are recognized on the title pages of the chapters. The Welding Handbook Committee and the editors recognize and appreciate the AWS technical c

32、ommittees who developed the consensus standards that pertain to this volume, and acknowledge the work of the editors of the Eighth Edition of the Welding Handbook: L. P. Connor, Volume 1; R. L. OBrien, Volume 2; and W. R. Oates, Volumes 3 and 4. The Welding Handbook Committee is grateful to members

33、of the AWS Technical Activities Committee and the AWS Safety and Health Committee for their reviews of the chapters. The editors appreciate the AWS Technical Services staff for their assistance during the preparation of this volume. Welding Handbook Committee Chairs, 19382015 19381942 D. S. Jacobus

34、Circa 1950 H. L. Boardman 19561958 F. L. Plummer 19581960 R. D. Stout 19601962 J. F. Randall 19621965 G. E. Claussen 19651966 H. Schwartzbart 19661967 A. Lesnewich 19671968 W. L. Burch 19681969 L. F. Lockwood 19691970 P. W. Ramsey 19701971 D. V. Wilcox 19711972 C. E. Jackson 19721975 S. Weiss 197519

35、78 A. W. Pense 19781981 W. L. Wilcox 19811984 J. R. Condra 19841987 J. R. Hannahs 19871990 M. J. Tomsic 19901992 C. W. Case 19921996 B. R. Somers 19961999 P. I. Temple 19992004 H. R. Castner 20042007 P. I. Temple 20072009 C. E. Pepper 20092014 Wangen Lin 20150000 D. D. Kautzxi PREFACE This is Volume

36、 5, the last in the series of the Ninth Edition of the Welding Handbook. It is Materials and Applications, Part 2, presented in ten peer-reviewed chapters covering the welding of nonferrous metals and materials. The titles of the chapters in this book indicate the variety of challenges presented to

37、welders, designers, welding engineers, and others in the welding workplace. The scientists who examine the microstructures of metals and other materials, identify constituents, and determine how the properties of these materials can be used and controlled during welding have contributed to the expan

38、ded information in this book. Some of the best scientists in the welding industry from universities, government and pri- vate research laboratories, metals-producing companies, fabricators, consulting firms, and testing facilities have stepped forward as volunteers to update this volume. They are re

39、cognized on the title pages of their respective chapters. This volume covers the technicalities of joining aluminum; magnesium; copper; nickel and cobalt; lead and zinc; titanium; reactive, refractory, and precious metals; plastics; ceramics; and composites. Each chapter includes a thorough explanat

40、ion of the metal or other material, details of the welding processes used to join it, and a compre- hensive bibliography. A section on safe practices pertinent to the specific metal or material is included in each chapter. Two appendices provide supplemental information. Appendix A is a list of sour

41、ces of safety codes and standards, with contact information of the publishers. Appendix B is a reference guide to Ninth Edition Volumes 1, 2, 3, and 4, included to accommodate the frequent references to the chapters of these books. This volume concludes the Ninth edition of the Welding Handbook, fol

42、lowing the four published volumes: Volume 1, Welding Science and Technology, which provides the foundation for successful welding and allied processes; Volume 2, Welding Processes, Part 1, which contains the technical details of arc welding and cutting, the gas processes, brazing, and soldering; Vol

43、ume 3, Welding Processes, Part 2, comprised of the resistance, solid-state, and other welding processes; and Volume 4, Materials and Applications, Part 1, which covers the ferrous metals. Volume 5, Materials and Applications, Part 2, covers nonferrous metals and materials, including ceramics, plasti

44、cs, and composites. These five books, all peer-reviewed, are made up of 67 chapters; overall, they represent the collaborative work of a total of 428 volunteers who generously spent many hours of personal time to provide authentic technical informa- tion from their specific areas of expertise. The W

45、elding Handbook Committee extends its gratitude to each of these volunteers. The Welding Handbook Committee welcomes your comments and suggestions. Please address them to the Editor, Welding Handbook, American Welding Society, 8669 NW 36 St, # 130, Miami, FL 33126. Wangen Lin, Past Chair Douglas D.

46、Kautz, Chair Welding Handbook Committee Welding Handbook Committee and Volume 5 Committee Welding Handbook Annette OBrien, Senior Editor Kathy Sinnes, Associate Editorxii REVIEWERS AMERICAN WELDING SOCIETY SAFETY AND HEALTH COMMITTEE AND TECHNICAL ACTIVITIES COMMITTEE D. E. Clark Idaho National Labo

47、ratory, Ret. D. A. Fink The Lincoln Electric Company S. R. Fiore Hobart Brothers Company W. A. Komlos Arc Tech, LLC D. J. Landon Vermeer Corporation K. A. Lyttle Praxair Inc. D. D. Rager Rager Consulting, Incorporated A. W. Sindel Alstom Power, Incorporated W. J. Sperko Sperko Engineering Servicesxi

48、ii CONTRIBUTORS WELDING HANDBOOK COMMITTEE Wangen Lin, Chair Pratt & Whitney R. W. Warke, 1st Vice Chair Stress Engineering Services D. D. Kautz, 2nd Vice Chair Los Alamos National Laboratory A. OBrien, Secretary American Welding Society B. J. Bastian Benmar Associates H. R. Castner EWI M. D. Hayes

49、Acute Technological Services S. P. Moran Weir American Hydro J. H. Myers Welding Inspection & Consulting Services T. A. Palmer Pennsylvania State University J. J. Perdomo ExxonMobile Research and Engineering Co. C. E Pepper Ford, Bacon & Davis P. I. Temple eNergyWise Consulting, LLC G. A. Young Consultant WELDING HANDBOOK VOLUME 4 COMMITTEE D. D. Kautz, Chair Los Alamos National Laboratory R. W. Warke, Vice Chair Stress Engineering Services A. OBrien, Secretary American Welding Society B. J. Bastian Benmar Associates H. R. Cas