xii Part 8 Special Processes. . . . . . . . . . . . . .534 Chapter 20 Special Welding Processes. . . . . . . . . . . . . . . . . . 535 20.1 Special Welding Processes . . . . . . . . . . . . . . 535 20.2 Arc Welding (AW) Processes . . . . . . . . . . . . 536 20.3 Solid-State Welding (SSW) Processes . . . . . 547 20.4 Other Welding Processes . . . . . . . . . . . . . . . 554 20.5 Review of Safety. . . . . . . . . . . . . . . . . . . . . . . 560 Chapter 21 Special Ferrous Welding Applications . . . . . . . . 563 21.1 Ferrous Metals and Alloys . . . . . . . . . . . . . . 563 21.2 Welding Medium- and High-Carbon Steels . . . . . . . . . . . . . . . . 564 21.3 Welding Steel Alloys . . . . . . . . . . . . . . . . . . . 565 21.4 Welding Chrome-Molybdenum Steels . . . . 568 21.5 Welding Precoated Steels . . . . . . . . . . . . . . . 568 21.6 Welding Maraging Steels . . . . . . . . . . . . . . . 569 21.7 Welding Stainless Steels . . . . . . . . . . . . . . . . 569 21.8 Welding Dissimilar Ferrous Metals . . . . . . 576 21.9 Welding Cast Iron . . . . . . . . . . . . . . . . . . . . . 577 Chapter 22 Special Nonferrous Welding Applications. . . . . 583 22.1 Nonferrous Metals and Alloys . . . . . . . . . . 583 22.2 Aluminum . . . . . . . . . . . . . . . . . . . . . . . . . . . 583 22.3 Welding Aluminum . . . . . . . . . . . . . . . . . . . 584 22.4 Welding Magnesium . . . . . . . . . . . . . . . . . . . 590 22.5 Welding Copper and Copper Alloys. . . . . . 591 22.6 Welding Titanium . . . . . . . . . . . . . . . . . . . . . 594 22.7 Welding Nickel-Based Alloys . . . . . . . . . . . 597 22.8 Welding Zirconium . . . . . . . . . . . . . . . . . . . . 598 22.9 Welding Beryllium . . . . . . . . . . . . . . . . . . . . 598 22.10 Welding Dissimilar Metals. . . . . . . . . . . . . . 598 22.11 Welding Plastics. . . . . . . . . . . . . . . . . . . . . . . 598 Chapter 23 Pipe and Tube Welding. . . . . . . . . . . . . . . . . . . . . . 603 23.1 Types of Pipe . . . . . . . . . . . . . . . . . . . . . . . . . 604 23.2 Types of Tubing . . . . . . . . . . . . . . . . . . . . . . . 610 23.3 Preparing Pipe Joints for Welding. . . . . . . . 611 23.4 Welding Pipe Joints with SMAW. . . . . . . . . 618 23.5 Welding Pipe Joints with GMAW and FCAW. . . . . . . . . . . . . . . . 623 23.6 Welding Pipe Joints with GTAW . . . . . . . . . 625 23.7 Welding Tube Joints with SMAW . . . . . . . . 629 23.8 Welding Tube Joints with GTAW and GMAW. . . . . . . . . . . . . . . . 630 23.9 Heat Treating Pipe and Tube Welded Joints . . . . . . . . . . . . . . . . 631 23.10 Inspecting Pipe and Tube Welds . . . . . . . . . 631 23.11 Code Requirements . . . . . . . . . . . . . . . . . . . . 632 23.12 Welding Plastic Pipe . . . . . . . . . . . . . . . . . . . 633 23.13 Review of Safety in Pipe and Tube Welding. . . . . . . . . . . . . . . . . 633 Chapter 24 Special Cutting Processes . . . . . . . . . . . . . . . . . . 637 24.1 Air Carbon Arc Cutting (CAC-A) . . . . . . . . 637 24.2 Exothermic Cutting . . . . . . . . . . . . . . . . . . . . 643 24.3 Oxygen Lance Cutting (OLC). . . . . . . . . . . . 649 24.4 Shielded Metal Arc Cutting and Gouging (SMAC) . . . . . . . . . . . 651 24.5 Laser Beam Cutting (LBC) . . . . . . . . . . . . . . 652 24.6 Water Jet Cutting . . . . . . . . . . . . . . . . . . . . . . 653 24.7 Safety Review. . . . . . . . . . . . . . . . . . . . . . . . . 653 Chapter 25 Underwater Welding and Cutting . . . . . . . . . . . . 657 25.1 Development of Underwater Welding . . . . 657 25.2 D3.6M Underwater Welding Code . . . . . . . 659 25.3 Welding Equipment for Underwater Welding. . . . . . . . . . . . . . . . 660 25.4 Wet Welding . . . . . . . . . . . . . . . . . . . . . . . . . . 661 25.5 Hyperbaric (Dry) Welding Underwater. . . . . . . . . . . . . . . . . . . 663 25.6 Crack Repairs . . . . . . . . . . . . . . . . . . . . . . . . . 666 25.7 Underwater Cutting . . . . . . . . . . . . . . . . . . . 666 25.8 Diving Operations . . . . . . . . . . . . . . . . . . . . . 671 25.9 Jobs in Underwater Welding . . . . . . . . . . . . 673 25.10 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 674 Chapter 26 Automatic and Robotic Welding. . . . . . . . . . . . . . 677 26.1 Advantages of Automatic Welding . . . . . . . 678 26.2 Feedback Controls . . . . . . . . . . . . . . . . . . . . . 678 26.3 Automatic Welding Processes . . . . . . . . . . . 683 26.4 Introduction to Robots . . . . . . . . . . . . . . . . . 684 26.5 Safety Practices in Automatic and Robotic Welding . . . . . . . . . 694 Chapter 27 Metal Surfacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 697 27.1 Principles of Surfacing . . . . . . . . . . . . . . . . . 698 27.2 Selection of a Surfacing Process. . . . . . . . . . 699 27.3 Principles of Flame Spraying . . . . . . . . . . . . 704 27.4 Electric Arc Spray Surfacing . . . . . . . . . . . . 710 27.5 Detonation Flame Spraying . . . . . . . . . . . . . 711 27.6 Plasma Arc Spraying Process. . . . . . . . . . . . 711 27.7 Surface Preparation . . . . . . . . . . . . . . . . . . . . 713 27.8 Selecting Thermal Spray Surfacing Material . . . . . . . . . . . . . . . . . . . . . 714 27.9 Testing and Inspecting Thermal Surfacings . . . . . . . . . . . . . . . . . . . . 714 27.10 Review of Surfacing Safety. . . . . . . . . . . . . . 715