This proven guide provides the knowledge and skills you 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 you to the materials, equipment, setup procedures, and critical safety information you 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 you are likely to encounter as you begin your career as a welding professional.
1. Introduction to Welding.
2. Safety in Welding.
3. Shielded Metal Arc Equipment, Setup, and Operation.
4. Shielded Metal Arc Welding of Plate.
5. Shielded Metal Arc Welding of Pipe.
6. Shielded Metal Arc Welding AWS SENSE Certification.
7. Flame Cutting Equipment, Setup, and Operation.
8. Plasma Arc Cutting Equipment, Setup, and Operation.
9. Related Cutting Processes.
10. Gas Metal Arc Welding Equipment, Setup, and Operation.
11. Gas Metal Arc Welding.
12. Flux Cored Arc Welding Equipment, Setup, and Operation.
13. Flux Cored Arc Welding.
14. Gas Metal Arc and Flux Cored Arc Welding of Pipe.
15. Gas Metal Arc and Flux Cored Arc Welding AWS SENSE Certification.
16. Gas Tungsten Arc Welding Equipment, Setup, and Operation.
17. Gas Tungsten Arc Welding of Plate.
18. Gas Tungsten Arc Welding of Pipe.
19. Gas Tungsten Arc Welding Plate and Pipe AWS SENSE Certification.
20. Shop Math and Weld Cost.
21. Reading Technical Drawings.
22. Welding Joint Design and Welding Symbols.
23. Fabricating Techniques and Practices.
24. Welding Codes and Standards.
25. Testing and Inspection.
26. Welding Metallurgy.
27. Weldability of Metals.
28. Filler Metal Selection.
29. Welding Automation and Robotics.
30. Other Welding Processes.
31. Oxyfuel Welding Equipment, Setup, and Operation.
32. Oxyacetylene Welding and Brazing, Braze Welding, and Soldering.
Larry Jeffus is a welder with over 55 years of experience, and he maintains his own well-equipped welding shop. In his career he has passed many welding certification tests in a wide variety of processes, positions, and material types and thicknesses. Jeffus has provided welding and professional consulting services locally, nationally, and internationally to major corporations, small businesses, government agencies, schools, colleges, and individuals. He is a Life Member of the American Welding Society. In addition, he has over 40 years of experience as a dedicated classroom teacher and is the author of several Cengage welding publications. Prior to retiring from teaching, Jeffus taught at Eastfield College, part of the Dallas County Community College District. Today he remains very active in the welding community, especially in the field of education. He serves on several welding program technical advisory committees and has visited high school, college, and technical campuses in more than 40 states and four foreign countries, providing one-on-one help and guidance to welding instructors and students. Jeffus was selected as Outstanding Post-Secondary Technical Educator in the State of Texas by the Texas Technical Society, and he served for 12 years as a board member on the Texas Workforce Investment Council in the Texas Governor's office. He also served as a member of the Apprenticeship Project Leadership Team, helping establish apprenticeship training programs for Texas, and he has made numerous trips to Washington lobbying for vocational and technical education.
The technique of GTAW cup walking is introduced earlier, and the author has developed unique techniques to help students learn the required torch manipulation. Once considered an advanced skill, cup walking has become far more common, and the text is designed to help instructors more easily teach this important skill.
Process-specific chapters include state-of-the-art induction welding machine operations for GTAW, GMAW, FCAW, and SMAW. These advanced machines resemble computers more than traditional welding machines, enabling multi-functionality and sophisticated operations that students will need to understand and apply for long-term success in today's industry.
Innovations in PAC equipment have already improved cut quality, consumable life, and operational cost-efficiency, and new, intelligent PAC systems will enable communication between the torch and the power supply to optimize plasma arc cutting. The Ninth Edition covers these recent and emerging technologies and techniques to equip students for professional success.
Additional CAC-A material and photographs have been included to better prepare students for SENSE CAC-A lab activities, enabling them to gain a broad knowledge of key processes.
Hundreds of new, high-resolution photos provide close-ups of welding details that are critical for a full, detailed understanding of the complex, varied processes involved in skilled professional practice.
Essential information on base metal, welding position, consumables, machine settings, and other fundamental topics has been reformatted to make it easier for students to absorb and retain. Similar to the formatting of many Welding Procedure Specifications (WPS), key material is now presented in a table before each welding practice, providing valuable practice in reading WPS formatted data.
The author has added information on key soft skills to help students develop the non-technical knowledge, interpersonal skills, problem-solving abilities that can be essential for workplace success.
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.
The book contains examples 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, enabling students to prepare for success as they enter the dynamic field of modern welding.
A robust study guide and lab manual to help students to gain hands-on welding practice, as well as PowerPoint® presentations containing all chapter art and additional graphics and photographs to illustrate important concepts.
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