x Part 3 Gas Metal and Flux Cored Arc Welding . . . . . . . . .168 Chapter 7 GMAW and FCAW Equipment and Supplies . . . 169 7.1 Gas Metal Arc Welding (GMAW) and Flux Cored Arc Welding (FCAW) Welding Stations . . . . . . . . . . . . . . . . . . . . . . 169 7.2 Arc Welding Power Sources for GMAW and FCAW . . . . . . . . . . . . . . . . . 172 7.3 Wire Feeders Used with GMAW/FCAW . . 174 7.4 GMAW/FCAW Shielding Gases . . . . . . . . . 176 7.5 The GMAW/FCAW Welding Gun. . . . . . . . 180 7.6 GMAW and FCAW Electrode Wire. . . . . . . 185 7.7 Smoke Extracting Systems . . . . . . . . . . . . . . 191 7.8 Filter Lenses for Gas-Shielded Arc Welding. . 192 7.9 Protective Clothing . . . . . . . . . . . . . . . . . . . . 192 7.10 Safety Review. . . . . . . . . . . . . . . . . . . . . . . . . 192 Chapter 8 Gas Metal and Flux Cored Arc Welding . . . . . . . 195 8.1 Gas Metal Arc and Flux Cored Arc Welding Principles. . . . . . . . . . . . . . . . . 196 8.2 Metal Transfer . . . . . . . . . . . . . . . . . . . . . . . . 196 8.3 GMAW and FCAW Power Sources . . . . . . . 202 8.4 Setting Up the GMAW/FCAW Station . . . . 202 8.5 Preparing Metal for Welding . . . . . . . . . . . . 218 8.6 Electrode Extension. . . . . . . . . . . . . . . . . . . . 219 8.7 Welding Techniques . . . . . . . . . . . . . . . . . . . 220 8.8 Running a Bead . . . . . . . . . . . . . . . . . . . . . . . 221 8.9 Shutting Down the Station . . . . . . . . . . . . . . 224 8.10 Welding Joints in the Flat Welding Position . . . . . . . . . . . . . . . . . . 224 8.11 Welding Joints in the Horizontal Welding Position . . . . . . . . . . . . 226 8.12 Welding Joints in the Vertical Welding Position . . . . . . . . . . . . . . . 229 8.13 Welding Joints in the Overhead Welding Position . . . . . . . . . . . . . 231 8.14 Automatic GMAW and FCAW. . . . . . . . . . . 232 8.15 Gas Metal Arc Spot Welding . . . . . . . . . . . . 233 8.16 GMAW/FCAW Troubleshooting Guide . . . 233 8.17 GMAW and FCAW Safety . . . . . . . . . . . . . . 235 Part 4 Gas Tungsten Arc Welding . . . . . .240 Chapter 9 Gas Tungsten Arc Welding Equipment and Supplies. . . . . . . . . . . . . . . . . . . . 241 9.1 The Gas Tungsten Arc Welding Station . . . 241 9.2 Arc Welding Power Sources for GTAW . . . 242 9.3 Shielding Gases Used with GTAW . . . . . . . 246 9.4 Electrode Leads and Hoses Used for GTAW . . . . . . . . . . . . . . . . . 249 9.5 GTAW Torches . . . . . . . . . . . . . . . . . . . . . . . . 250 9.6 Tungsten Electrodes . . . . . . . . . . . . . . . . . . . 253 9.7 Filler Metals Used with GTAW . . . . . . . . . . 258 9.8 Filter Lenses for GTAW. . . . . . . . . . . . . . . . . 259 9.9 Protective Clothing . . . . . . . . . . . . . . . . . . . . 259 9.10 Safety Review. . . . . . . . . . . . . . . . . . . . . . . . . 260 Chapter 10 Gas Tungsten Arc Welding . . . . . . . . . . . . . . . . . . 263 10.1 Gas Tungsten Arc Welding Principles . . . . 264 10.2 GTAW Power Sources . . . . . . . . . . . . . . . . . . 268 10.3 Setting Up a GTAW Station . . . . . . . . . . . . . 269 10.4 Preparing Metal for Welding . . . . . . . . . . . . 281 10.5 Methods for Starting the Arc . . . . . . . . . . . . 282 10.6 Gas Tungsten Arc Welding Techniques . . . 283 10.7 Shutting Down the GTAW Station . . . . . . . 284 10.8 Welding Joints in the Flat Welding Position . . . . . . . . . . . . . . . . . . 284 10.9 Welding Joints in the Horizontal Welding Position . . . . . . . . . . . . 288 10.10 Welding Joints in the Vertical Welding Position . . . . . . . . . . . . . . . 290 10.11 Welding Joints in the Overhead Welding Position . . . . . . . . . . . . . 291 10.12 Welding Stainless Steel and Aluminum. . . 292 10.13 Semiautomatic Welding . . . . . . . . . . . . . . . . 294 10.14 Automatic and Mechanized GTAW . . . . . . 294 10.15 GTAW Troubleshooting Guide . . . . . . . . . . 295 10.16 GTAW Safety . . . . . . . . . . . . . . . . . . . . . . . . . 296 Part 5 Plasma Arc Cutting . . . . . . . . . . . . .300 Chapter 11 Plasma Arc Cutting . . . . . . . . . . . . . . . . . . . . . . . . . 301 11.1 Plasma Arc Cutting Principles. . . . . . . . . . . 301 11.2 Plasma Arc Cutting Equipment and Supplies. . . . . . . . . . . . . . . . 302 11.3 Plasma and Shielding Gases . . . . . . . . . . . . 305 11.4 Setting Up the PAC Station. . . . . . . . . . . . . . 308 11.5 Safety Equipment. . . . . . . . . . . . . . . . . . . . . . 308 11.6 PAC Cutting Procedures. . . . . . . . . . . . . . . . 310 11.7 Plasma Arc Gouging . . . . . . . . . . . . . . . . . . . 316 Part 6 Oxyfuel Gas Processes . . . . . . . . .320 Chapter 12 Oxyfuel Gas Welding Equipment and Supplies. . . 321 12.1 Complete Oxyfuel Gas Welding Outfi t. . . . 321 12.2 Oxygen Supply. . . . . . . . . . . . . . . . . . . . . . . . 322