welding principles and practices

Welding Principles and Practices by Edward R. Bohnart

Welding Principles and Practices (5th Edition) is a comprehensive test book for teaching purposes. The book is authored by Edward R. Bohnart. He designed the book as the main text to be taught in technical junior colleges, community technical colleges, career schools, secondary technical schools, and engineering schools. In addition, the book is helpful for apprenticeship programs and on-the-job training for students.

Besides this, the handbook serves as an additional source of information for the classes in metalworking, building construction, and industrial technology programs.

Welding Principles and Practices by Edward R. Bohnart

Table of Contents:

Unit I – Introduction to Welding and Oxyfuel

Chapter 1. History of Welding

  • Overview
  • The History of Metalworking
  • Welding as an Occupation
  • Industrial Welding Applications

Chapter 2. Industrial Welding

  • Fabrication
  • Maintenance and Repair
  • Industries

Chapter 3. Steel and Other Metals

  • History of Steel
  • Raw Materials for the Making of Steel
  • The Smelting of Iron
  • Steelmaking Processes
  • Metalworking Processes
  • Metal Internal Structures
  • Physical Properties of Metals
  • Effects of Common Elements on Steel
  • Types of Steel
  • SAE/AISI Steel Numbering System
  • ASTM Numbering System
  • Unified Numbering Designation
  • Types of Cast Iron
  • Aluminum-Making in the World
  • Titanium-Making in the United States
  • Unique Metals
  • Effects of Welding on Metal

Chapter 4. Basic Joints and Welds

  • Types of Joints
  • The Four Weld Types
  • Weld Size and Strength
  • Weld Positions
  • Strength of Welds
  • Common Weld and Weld-Related Discontinuities

Chapter 5. Gas Welding

  • Oxyacetylene Welding
  • Gases
  • General Cylinder Handling, Storage, and Operation Safety Concerns
  • Welding Equipment
  • Supporting Equipment
  • Safety Equipment
  • General Safety Operating Procedures

Chapter 6. Flame Cutting Principles

  • Oxyacetylene and Other Fuel Gas Cutting
  • Oxygen Lance Cutting

Chapter 7. Flame Cutting Practice (Jobs 7-J1–J3)

  • Review of Flame Cutting Principles
  • Cutting Different Metals
  • Cutting Technique
  • Surface Appearance of High-Quality Flame Cuts
  • Arc Cutting
  • Practice Jobs
  • Job 7-J1 Straight Line and Bevel Cutting
  • Job 7-J2 Laying Out and Cutting Odd Shapes
  • Job 7-J3 Cutting Cast Iron

Chapter 8. Gas Welding Practice (Jobs 8-J1–J38)

  • Sound Weld Characteristics
  • The Oxyacetylene Welding Flame
  • Setting Up the Equipment
  • Flame Adjustment
  • Closing Down the Equipment
  • Safety
  • Practice Jobs
  • Low Carbon Steel Plate
  • Heavy Steel Plate and Pipe

Chapter 9. Braze Welding and Advanced Gas Welding Practice (Jobs 9-J39–J49)

  • Braze Welding
  • Welding Cast Iron
  • Welding of Aluminum
  • Welding Other Metals with the Oxyacetylene Process
  • Hard Facing (Surfacing)

Chapter 10. Soldering and Brazing Principles and Practice (Jobs 10-J50–J51)

  • Soldering and Brazing Copper Tubing
  • Soldering
  • Practice Jobs: Soldering
  • Torch Brazing (TB)
  • Practice Jobs: Brazing

Unit II – Shielded Metal Arc Welding

Chapter 1. Shielded Metal Arc Welding Principles

  • Process Capability
  • Operating Principles
  • Welding Power Sources
  • Machines for Shielded Metal Arc Welding
  • Multiple-Operator Systems
  • Power Supply Ratings
  • Cables and Fasteners
  • Electrode Holders
  • Other Electric Arc Processes
  • Personal Safety Equipment

Chapter 12. Shielded Metal Arc Welding Electrodes

  • Introduction
  • Shielded Metal Arc Welding Electrodes
  • Functions of Electrode Coverings
  • Composition of Electrode Coverings
  • Identifying Electrodes
  • Electrode Selection
  • Specific Electrode Classifications
  • Packing and Protection of Electrodes

Chapter 13. Shielded Metal Arc Welding Practice (Jobs 13-J1-J25, Plate)

  • Introduction
  • Approach to the Job
  • Learning Welding Skills
  • Practice Jobs
  • Job 13-J1 Striking the Arc and Short
  • Stringer Beading
  • Job 13-J2 Stringer Beading
  • Job 13-J3 Weaved Beading
  • Job 13-J4 Stringer Beading
  • Job 13-J5 Weaved Beading
  • Job 13-J6 Welding an Edge Joint
  • Job 13-J7 Welding an Edge Joint
  • Job 13-J8 Welding a Lap Joint
  • Job 13-J9 Welding a Lap Joint
  • Job 13-J10 Stringer Beading
  • Job 13-J11 Stringer Beading
  • Job 13-J12 Welding a Lap Joint
  • Job 13-J13 Welding a Lap Joint
  • Job 13-J14 Welding a T-Joint
  • Job 13-J15 Welding a T-Joint
  • Job 13-J16 Welding a T-Joint
  • Job 13-J17 Welding a T-Joint
  • Job 13-J18 Stringer Beading
  • Job 13-J19 Weaved Beading
  • Job 13-J20 Weaved Beading
  • Job 13-J21 Welding a Lap Joint
  • Job 13-J22 Welding a T-Joint
  • Job 13-J23 Welding a T-Joint
  • Job 13-J24 Welding a T-Joint
  • Job 13-J25 Welding a T-Joint

Chapter 14. Shielded Metal Arc Welding Practice (Jobs 14-J26-J42, Plate)

  • Introduction
  • Practice Jobs
  • Job 14-J26 Stringer Beading
  • Job 14-J27 Weave Beads
  • Job 14-J28 Welding a Single-V Butt Joint (Backing Bar Construction)
  • Job 14-J29 Welding a T-Joint
  • Job 14-J30 Welding a Single-V Butt Joint (Backing Bar Construction)
  • Job 14-J31 Welding a Square Butt Joint
  • Job 14-J32 Welding an Outside Corner Joint
  • Job 14-J33 Welding a Single-V Butt Joint
  • Job 14-J34 Welding a T-Joint
  • Job 14-J35 Welding a T-Joint
  • Job 14-J36 Welding a T-Joint
  • Job 14-J37 Welding a T-Joint
  • Job 14-J38 Welding a Single-V Butt Joint (Backing Bar Construction)
  • Job 14-J39 Welding a Square Butt Joint
  • Job 14-J40 Welding an Outside Corner Joint
  • Job 14-J41 Welding a T-Joint
  • Job 14-J42 Welding a Single-V Butt Joint (Backing Bar Construction)

Chapter 15. Shielded Metal Arc Welding Practice (Jobs 15-J43–J55 (Plate)

  • Introduction
  • Practice Jobs
  • Job 15-J43 Welding a Single-V Butt Joint
  • Job 15-J44 Welding a T-Joint
  • Job 15-J45 Welding a T-Joint
  • Job 15-J46 Welding a Lap Joint
  • Job 15-J47 Welding a Lap Joint
  • Job 15-J48 Welding a Single-V Butt Joint
  • Job 15-J49 Welding a T-Joint
  • Job 15-J50 Welding a T-Joint
  • Job 15-J51 Welding a Single-V Butt Joint
  • Job 15-J52 Welding a Coupling to a Flat Plate
  • Job 15-J53 Welding a Coupling to a Flat Plate
  • Job 15-J54 Welding a Single-V Butt Joint (Backing Bar Construction)
  • Job 15-J55 Welding a Single-V Butt Joint
  • Tests

Chapter 16. Pipe Welding and Shielded Metal Arc Welding Practice (Jobs 16-J1–J17 (Pipe)

  • Introduction
  • Shielded Metal Arc Welding of Pipe
  • Joint Design
  • Codes and Standards
  • Practice Jobs
  • Tools for Pipe Fabrication

Unit III – Arc Cutting and Gas Tungsten Arc Welding

Chapter 17. Arc Cutting Principles and Arc Cutting Practice (Jobs 17-J1–J7)

  • Arc Cutting
  • Learning Arc Cutting Skills
  • Practice Jobs
  • Job 17-J1 Square Cutting with PAC
  • Job 17-J2 Bevel Cutting with PAC
  • Job 17-J3 Gouging with PAC
  • Job 17-J4 Hole Piercing
  • Job 17-J5 Shape Cutting with PAC
  • Job 17-J6 Gouging with CAC-A
  • Job 17-J7 Weld Removal with CAC-A

Chapter 18. Gas Tungsten Arc and Plasma Arc Welding Principles

  • Gas Shielded Arc Welding Processes
  • Gas Tungsten Arc Welding
  • TIG Hot Wire Welding

Chapter 19. Gas Tungsten Arc Welding Practice (Jobs 19-J1-J19 (Plate)

  • Gas Tungsten Arc Welding of Various Metals
  • Joint Design and Practices
  • Setting Up the Equipment
  • Safe Practices
  • Arc Starting
  • Welding Technique
  • Practice Jobs

Chapter 20. Gas Tungsten Arc Welding Practice (Jobs 20-J1-J17 (Pipe)

  • Joint Design
  • Porosity in Gas Tungsten Arc Welds
  • Practice Jobs

Unit IV – Gas Metal Arc, Flux Cored Arc, and Submerged Arc Welding

Chapter 21. Gas Metal Arc and Flux Cored Arc Welding Principles

  • Overview
  • GMAW/FCAW Welding Equipment
  • Summary

Chapter 22. Gas Metal Arc Welding Practice with Solid and Metal Core Wire (Jobs 22-J1-J23 (Plate)

  • Operating Variables that Affect Weld Formation
  • Weld Defects
  • Safe Practices
  • Welding Technique
  • Process and Equipment Problems
  • Practice Jobs
  • Gas Metal Arc Welding of Other Metals

Chapter 23. Flux Cored Arc Welding Practice (Plate), Submerged Arc Welding, and Related Processes: FCAW-G Jobs 23-J1–J11, FCAW-S Jobs 23-J1–J12; SAW Job 23-J1

  • Flux Cored Wire Welding
  • Flux Cored Arc Welding-Gas Shielded
  • Practice Jobs
  • Flux Cored Arc Welding-Self-Shielded
  • Flux Cored Arc Welding-Self-Shielded
  • Practice Jobs
  • Automatic or Mechanized
  • Welding Applications
  • Submerged Arc Welding Semiautomatic Practice Job
  • Choice of Welding Process

Chapter 24. Gas Metal Arc Welding Practice (Jobs 24-J1-J15 (Pipe)

  • Industrial Applications of GMAW Pipe Welding
  • Use of Equipment and Supplies
  • Welding Operations
  • Practice Jobs

Unit V – High Energy Beams, Automation, Robotics, and Weld Shop Management

Chapter 25. High Energy Beams and Related Welding and Cutting Process Principles

  • Introduction
  • High Energy Beam Processes
  • Summary

Chapter 26. General Equipment for Welding Shops

  • Screens and Booths
  • Work-Holding Devices
  • Preheating and Annealing Equipment
  • Sandblasting Equipment
  • Spot Welder
  • Hydraulic Tools
  • Power Squaring Shears
  • Small Hand Tools
  • Portable Power Tools
  • Machine Tools

Chapter 27. Automatic and Robotic Arc Welding Equipment

  • Arc Control Devices
  • Arc Monitoring
  • Controller Communication
  • Robotic Arc Welding Systems
  • Robot Ratings
  • Robot Programming
  • Training, Qualification and Certification
  • Conclusion

Chapter 28. Joint Design, Testing, and Inspection

  • Joint Design
  • Code Welding
  • Nondestructive Testing (NDT)
  • Destructive Testing
  • Visual Inspection
  • Summary

Chapter 29. Reading Shop Drawings

  • Introduction
  • Standard Drawing Techniques
  • Types of Views

Chapter 30. Welding Symbols

  • Fillet Welds and Symbol
  • Weld-All-Around Symbol
  • Groove Welds
  • Edge Welds
  • Combination Symbols
  • Contour Symbol
  • Applications of Welding Symbols

Chapter 31. Welding and Bonding of Plastics

  • Know Your Plastics
  • Characteristics of Plastics
  • Welding as a Method of Joining Plastics
  • Inspection and Testing
  • Practice Jobs
  • Tack Welding

Chapter 32. Safety

  • Safety Practices: Electric Welding Processes
  • Safety Practices: Oxyacetylene Welding and Cutting

Thus, Welding Principles and Practices (5th Edition) is an extensive book designed for welding schools, colleges, tech centers, etc.

Related: Other Important Welding Handbooks

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