Surfacing and Additive Technologies in Welded Fabrication: International Welding Engineers Textbook Series Under the Editorship of Borys Paton

Description

This book provides a comprehensive overview of a wide range of surfacing methods, detailing their physical basics and technologies. Each section of the book provides information on the formation of the structure and properties of the deposited metal, the reasons for the formation of defects, and directions for prevention. The book also covers the certification of surfacing procedures, adhering to international standards. With a focus on practical applications, the book is an essential reference for anyone working in the field of welding and related technologies. It includes detailed illustrations and diagrams, making it easy to understand and follow the concepts. Foreword Introduction Contents About the Authors 1 Definition and Classification of Surfacing Processes 2 Electric Arc Surfacing 2.1 Physical Principles of Electric Arc Surfacing 2.2 Manual Metal Arc Surfacing 2.3 Automated Submerged Arc Surfacing 2.3.1 Automated Submerged Arc Surfacing with Solid Wire or Strip 2.3.2 Automated Submerged Arc Surfacing with Solid or Flux-Cored Strip 2.4 Automated and Mechanized Gas Shielded Surfacing 2.5 Vibro-Arc Surfacing 2.6 CMT Surfacing 2.7 Features of Physical and Metallurgical Processes in Electric Arc Surfacing 2.7.1 Methods of Alloying of Deposited Metal 2.7.2 Effect of Electric Arc Surfacing Parameters on Chemical Composition of the Deposited Metal 2.8 Materials for Electric Arc Surfacing 2.8.1 Coated Electrodes 2.8.2 Solid Wires 2.8.3 Flux-Cored Wires 2.8.4 Cold-Rolled, Flux-Cored and Sintered Strips 2.8.5 Fluxes 2.8.6 Protective Gases 2.9 Electric Arc Surfacing Procedures 2.9.1 Parameters of Electric Arc Surfacing 2.9.2 Electric Arc Surfacing of Rotating Bodies 2.9.3 Electric Arc Surfacing of Flat Parts 2.9.4 Electric Arc Surfacing of Complex-Shaped Parts References 3 Plasma Surfacing 3.1 Physical Phenomena of Plasma Surfacing Process 3.2 Methods of Plasma Surfacing 3.2.1 Plasma Jet Surfacing with Current-Carrying Filler Wire 3.2.2 Plasma Arc Surfacing with Electrically Neutral Filler Wire 3.2.3 Plasma Arc Surfacing with Current-Carrying Filler Wire 3.2.4 Plasma Arc Surfacing with Two Current-Carrying Filler Wires Fed into the Arc 3.2.5 Plasma Arc Surfacing with Two Current-Carrying Filler Wires Fed to the Surfacing Pool 3.2.6 Plasma Surfacing with Consumable Electrode 3.2.7 Plasma-Powder Surfacing 3.2.8 Plasma Surfacing on a Fixed Additive 3.3 Materials for Plasma Surfacing 3.4 Procedures of Plasma Surfacing References 4 Electroslag Surfacing 4.1 Physical Phenomena of Electroslag Surfacing 4.2 Methods of Electroslag Surfacing 4.2.1 Classification of Methods of Electroslag Surfacing 4.2.2 Electroslag Surfacing with Electrode Wires 4.2.3 Electroslag Surfacing with Electrodes of Large Cross-Section 4.2.4 Electroslag Surfacing with Discrete Filler Metal 4.2.5 Electroslag Surfacing with Liquid Filler Metal 4.2.6 Electroslag Surfacing with Strips with Free Formation 4.3 Features of Physic-Chemical Processes During Electroslag Surfacing 4.4 Materials for Electroslag Surfacing 4.4.1 Fluxes 4.4.2 Electrode Wires and Strips 4.4.3 Electrodes with Large Cross-Section 4.4.4 Discrete Filler Materials 4.4.5 Liquid Filler Materials Reference 5 Gas Surfacing 5.1 Physical Phenomena of Gas Surfacing 5.2 Materials for Gas Surfacing 5.3 Gas Surfacing Procedures References 6 Induction Surfacing 6.1 Physical Phenomena of Induction Surfacing 6.2 Methods of Induction Surfacing 6.3 Materials for Induction Surfacing Reference 7 Laser Surfacing 7.1 Physical Phenomena of Laser Surfacing 7.2 Methods of Laser Surfacing 7.3 Materials for Laser Surfacing 7.3.1 Filler Powders 7.3.2 Filler Wires 7.4 Procedures of Laser Surfacing References 8 Other Methods of Coating Production 8.1 Rolling and Extrusion Cladding 8.2 Explosion Cladding 8.3 Electric Resistance Weld Cladding 8.4 Furnace Surfacing 8.5 Electron-Beam Surfacing 8.6 Friction Stir Surface Cladding 9 Additive Technologies 9.1 Terminology and Classification 9.2 Laser and Electron Beam Melting 9.3 Wire Arc Additive Manufacturing 9.4 Calculation of Stress–Strain State References 10 Structure and Properties of Surfaced Metal of Different Alloying Systems 10.1 General Classification of Surfacing Metals of Different Alloying Systems and Typical Applications According to EN 14700:2014 10.2 Unalloyed and Low-Alloyed Steels with Carbon Content up to 0.4% (Fe1 Group) 10.3 Surfaced Unalloyed and Low-Alloyed Steels with Carbon Content Above 0.4% (Fe2 Group) 10.4 Surfaced Chrome-Tungsten, Chrome-Molybdenum, and Other Heat-Resistant Tool Steels (Fe3 Group) 10.5 Surfaced High-Speed Steels (Fe4 Group) 10.6 Surfaced Low-Carbon Chromium Steels (Fe7 Group) 10.7 Surfaced Chromium Steels with Increased Carbon Content (Fe8 Group) 10.8 Surfaced High-Manganese Austenitic Steels (Fe9 Group) 10.9 Surfaced Chromium-Nickel, Chromium-Nickel-Manganese Stainless Austenitic Steels (Fe10, Fe11, Fe12 Groups) 10.10 Surfaced High-Chromium High-Alloyed Cast Irons (Fe14, Fe15, Fe16 Groups) 10.11 Surfaced Nickel-Based Alloys Alloyed with Chromium, Boron, and Silicon (Ni1, Ni3 Groups) 10.12 Surfaced Nickel-Based Alloys Alloyed with Molybdenum and Chromium (Ni2 Group) 10.13 Surfaced Carbide-Based Alloys (Fe20, Ni20 Groups) 10.14 Surfaced Cobalt Alloys Alloyed with Chromium and Tungsten (Co1, Co2, Co3 Groups) 10.15 Surfaced Copper-Based Alloys (Cu1 Group) References 11 Surfacing and Additive Manufacturing Imperfections 11.1 General Information 11.2 Cracks 11.3 Gas Pores 11.4 Lack of Fusion 11.5 Imperfect Bead Shape 11.6 Less Common Surfacing and Additive Manufacturing Imperfections References 12 Procedures’ Qualification for Surfacing and Additive Manufacturing 12.1 Definitions of Procedure Qualification 12.2 Control Samples 12.3 Program of Control Samples’ Testing 12.4 Welding Procedure Qualification Record (WPQR) References