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Welding: Principles and Applications

By Larry Jeffus

9th Edition © 2021
Discipline:Trades
Course:Welding
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This proven guide provides students with the knowledge and skills they need to complete AWS SENSE Level I and Level II programs, create Workmanship Qualification Specimens, and earn professional certification. Advancing rapidly from basic concepts and processes to today’s most complex, cutting-edge welding technologies and practices, this comprehensive text features valuable information on topics such as welding metallurgy, metal fabrication, weld testing and inspection, joint design, job costing, and environmental and conservation tips. The author opens each section by introducing students to the materials, equipment, setup procedures, and critical safety information they need to execute a specific process successfully, while subsequent chapters focus on individual welding tasks leading to SENSE certification. In addition to hundreds of new photos showcasing current welding tools and techniques, the Ninth Edition includes new and updated information on GTAW cup walking, induction welding machine operations, innovations in PAC equipment, and other industry advances relevant to today’s welding professionals. Available to complement the text and enhance learning, online MindTap® resources include useful skills simulations and up-to-date welding videos.

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About this product

This proven guide provides students with the knowledge and skills they need to complete AWS SENSE Level I and Level II programs, create Workmanship Qualification Specimens, and earn professional certification. Advancing rapidly from basic concepts and processes to today’s most complex, cutting-edge welding technologies and practices, this comprehensive text features valuable information on topics such as welding metallurgy, metal fabrication, weld testing and inspection, joint design, job costing, and environmental and conservation tips. The author opens each section by introducing students to the materials, equipment, setup procedures, and critical safety information they need to execute a specific process successfully, while subsequent chapters focus on individual welding tasks leading to SENSE certification. In addition to hundreds of new photos showcasing current welding tools and techniques, the Ninth Edition includes new and updated information on GTAW cup walking, induction welding machine operations, innovations in PAC equipment, and other industry advances relevant to today’s welding professionals. Available to complement the text and enhance learning, online MindTap® resources include useful skills simulations and up-to-date welding videos.

The text content is designed to prepare students for certification based on the widely recognized Schools Excelling through National Skills Education (SENSE) Level I standards published by the American Welding Society.

In addition to maintaining and actively working in a fully equipped welding shop, the author has over five decades of welding experience in a wide variety of industries and applications, including structural steel, petrochemical, agricultural, food processing, mineral exploration, and transportation (automotive, trucking, aviation, rail, and shipping). He draws on this vast and ongoing experience, as well as many years of teaching and writing, to provide a wealth of practical tips and real-world examples to bridge the gap between theory and practice.

To prepare students for success in the dynamic field of modern welding, the text covers a broad range of current welding technologies and practices, as well as providing a solid foundation in key topics such as welding metallurgy, metal fabrication, weld testing and inspection, joint design, and job costing.

A robust study guide and lab manual help students gain hands-on welding practice, while PowerPoint® presentations containing all chapter art and additional graphics and photographs help illustrate important concepts.

Table of contents

Chapters

Cover Page
Title Page
Copyright Page
Dedication
Preface
Features of the Text
Acknowledgments
About the Author
Section 1. Introduction
Section 2. Shielded Metal Arc Welding
Section 3. Cutting and Gouging
Section 4. Gas Shielded Welding
Section 5. Related Technologies
Section 6. Oxyfuel Processes
Appendix I. Student Welding Report
Appendix II. Time Sheet, Bill of Materials, and Hot Work Permit Instructions
Appendix III. AWS Sense Forms
Appendix IV. Conversion of Decimal-Inches to Millimeters and Fractional Inches to Decimal-Inches and Millimeters
Appendix V. Conversion Factors: U.S. Customary (Standard) Units and Metric Units (SI)
Appendix VI. Abbreviations and Symbols
Appendix VII. Metric Conversion Approximations
Appendix VIII. Pressure Conversion
Appendix IX. Welding Codes and Specifications
Appendix X. Welding Associations and Organizations
Show more

Section 1. Introduction

Chapter 1. Introduction to Welding
Preview this section ↗
Introduction ↗
Welding Terminology ↗
Welding Defined ↗
Uses of Welding ↗
Welding and Cutting Processes ↗
Welding Processes ↗
Oxyacetylene Welding, Brazing, and Cutting ↗
Shielded Metal Arc Welding (SMAW) ↗
Gas Tungsten Arc Welding (GTAW) ↗
Gas Metal Arc Welding (GMAW) ↗
Flux Cored Arc Welding (FCAW) ↗
Thermal Cutting Processes ↗
Oxyfuel Gas Cutting ↗
Plasma Arc Cutting ↗
Selection of the Joining Process ↗
Occupational Opportunities in Welding ↗
Training for Welding Occupations ↗
Job-Related Skills ↗
Beginning a Welding Career ↗
Job Prospects ↗
Job-Related Personal Skills ↗
Teamwork ↗
Communication ↗
Problem Solving ↗
Reading and Understanding Text ↗
Punctuality ↗
Missing Work ↗
Continued Education ↗
AWS SENSE Welder Certification ↗
Level I Qualification Procedures ↗
Practical Knowledge Qualification—Written Test ↗
Performance Qualification—Workmanship Samples and Test Plates ↗
Thermal Cutting Principles and Practices ↗
Welding Inspection and Testing Principles and Practices ↗
Level II Advanced Welder Qualification ↗
SkillsUSA ↗
Experiments and Practices ↗
Welding Video Series ↗
Metric Units ↗
Summary ↗
Review ↗
Chapter 2. Safety in Welding
Introduction
Burn Classification
First-Degree Burns
Second-Degree Burns
Third-Degree Burns
Burns Caused by Light
Personal Protection Equipment (PPE)
General Work Clothing
Special Protective Clothing
Face and Eye Protection
Goggles
Full Face Shield
Welding Helmets
Auto Darkening Welding Helmets
Shop Noise
Respiratory Protection
Hazardous Gases
Ventilation
Safety Data Sheets (SDSs)
Handling and Storing Cylinders
Securing Gas Cylinders
Storage Areas
Cylinders with Valve Protection Caps
General Precautions
Acetylene
Caution
Fire Protection
Fire Watch
Fire Extinguishers
Location of Fire Extinguishers
Using Fire Extinguishers
Equipment Maintenance
Hoses
Work Area Cleaning
Hand Tools
Hand Tool Safety
Hammer Safety
Electrical Safety
Electrical Safety Systems
Voltage Warnings
Extension Cords
Safety Rules for Portable Electric Tools
Power Tools
Grinders
Drills
Metal Cutting Machines
Material Handling
Lifting
Hoists or Cranes
Ladder Safety
Types of Ladders
Ladder Inspection
Rules for Ladder Use
Summary
Review

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