Ⅰ. 용접야금
?서울산업대학교 강계명 교수
Ⅰ. 재료 구성 원리 ···············································3
Ⅱ. 원소 (Elements) ·············································4
1. 주기율표의 원소들에 의한 분류 ·····································4
2. THE PERIODIC TABLE ··········································5
Ⅲ. 상 평형 (Phase Equilibria) ····································9
1. 1원계 물질의 기본 상 ·············································9
2. 다성분계 (Muti-Component System) ·······························9
3. 상률 (Phase Rule) ···············································10
Ⅳ. 결정 구조 (Crystalline Structure) ····························11
Ⅴ. 합금의 상 (Phase of Alloy) ·································13
Ⅵ. 응고 (Solidification) ·········································15
Ⅶ. 재료의 결함 (Defects) ·······································17
1. 결함의 종류 ······················································17
2. 결함 생성 원인 (3차원 결함에 관하여) ·····························17
Ⅷ. 철과 강 (Iron and Steel) ····································18
1. 철과 강의 분류 ···················································18
2. 강(Steel) ························································21
3. 주 철 (Cast Iron) ················································22
4. 주요 구성 원소 ···················································23
Ⅸ. Fe-Fe₃C 상태도 ············································25
1. Fe-C Equilibrium Phase Diagram ································25
2. Fe-C 평형상태도에 관한 설명 ·····································26
3. Cu-Sn 이원상태도(Cu-Sn binary phase diagram) ··················30
Ⅹ. 금속 조직과 TTT 도 ·······································31
1. 금속조직 ·························································31
2. TTT 도와 IT 도 ·················································39
?. 열처리 (Heat Treatment) ····································42
1. 열처리의 분류 ·················································42
2. 열처리에 따른 재료 열화 현상 ·····································43
3. 주요 열처리 사례 ·················································44
?. 용접열영향부 ················································45
XIII. 용접용 CCT도 (Continuous Cooling Transformation Diagram for
Welding) ···················································50
XIV. 용접부의 기계적 성질 ······································51
1. 용접부의 경도분포 ················································51
2. 용접부의 Notch 인성 ·············································52
XV. 용접열영향부의 취성 ········································52
Ⅱ. 용접실무１
?서울산업대학교 이철구 교수
1. 머리말 ······················································57
2. 용접 일반 ···················································57
2-1. 개요 ·························································57
3. 아크 용접 ··················································61
3-1. 아크의 물리적 성질 ············································61
3-2. 피복금속 아크 용접법 (shielded metal arc welding,SMAW) ······62
3-3. 탄소 아크 용접법(carbon arc welding, CAW) ····················62
3-4. 정극성과 역극성 ···············································62
3-5. 피복금속 아크 용접봉 ··········································63
3-6. 연강용 피복 아크 용접봉 ·······································64
3-7. 특수강용 피복 아크 용접봉 ·····································66
3-8. 용접봉 표시법과 선택 ··········································67
3-9. 아크 용접기기 ·················································68
3-10. 아크 용접기에 필요한 조건 ····································69
3-11. 피복 아크 용접법 ·············································70
4.가스 용접 ···················································72
4-1. 용접용 가스 ···················································72
4-2. 카바이드와 아세틸렌 ···········································73
4-3. 산소 가스 ·····················································74
4-4. 아세틸렌가스 발생기 ···········································75
4-5. 가스 압력 조정기 ··············································76
4-6. 용접 토치와 팁 ················································76
4-7. 가스 용접의 불꽃 ··············································77
4-8. 역화와 역류 ···················································77
4-9. 가스 용접용 용제 ··············································78
4-10. 가스 용접법 ··················································78
5. 특수 용접 ··················································80
5-1. TIG 용접 ·····················································80
5-2. MIG 용접 ·····················································82
5-3. 탄산가스 아크 용접 ············································84
5-4. 서브머지드 아크 용접 ··········································89
5-5. 플라스마 아크 용접 ············································92
5-6. 스터드 용접 ···················································92
6. 절 단 ······················································93
6-1. 가스 절단 ·····················································93
6-2. 아크 절단 ·····················································94
맺음말 ·························································95
참고 문헌 ······················································95
Ⅲ. 용접실무 2
?서울산업대학교 이철구 교수
1. 머리말 ······················································99
2. 용접 설계 ···················································99
2-1. 용접이음 ······················································99
2-2. 용접이음의 강도 ··············································102
2-3. 용접 비용의 계산 ·············································103
2-4. 용접의 결점과 설계상 주의 사항 ·······························104
3. 용접 검사 ··················································105
3-1. 용접부 검사의 의의 ···········································105
3-2. 용접 결함 ····················································106
3-3. 파괴 검사 ····················································107
3-4. 비파괴 검사 ··················································109
4. 용접응력과 변형 ············································110
4-1. 용접 응력 ····················································110
4-2. 용접 응력의 발생 요인 ········································111
4-3. 용접 응력의 영향 ·············································112
4-4. 용접 응력의 측정 ·············································112
4-5. 용접 응력의 완화와 방지법 ····································113
4-6. 용접 변형 ····················································115
4-7. 변형 발생과 그의 영향 ········································115
4-8. 용접 변형의 방지 ·············································116
5. 용접 균열 ··················································117
5-1. 용접 균열의 종류 ·············································117
5-2. 용접 균열의 발생 요인 ········································118
5-3. 용접 균열 감수성 ·············································119
5-4. 고온 균열과 저온 균열 ········································120
5-5. 용접 균열 시험법 ·············································122
5-6. 용접 균열 방지 ···············································123
6. 용접열 영향 ················································123
6-1. 용접 입열 ····················································124
6-2. 용접열 영향부의 열사이클 ·····································124
6-3. 열영향부의 냉각속도 ··········································125
맺음말 ························································131
참고 문헌 ·····················································131
Ⅳ. 용접검사
?서울산업대학교 박은수 교수
Ⅰ. 용접검사 ··················································141
(1) 용접부에 요구되는 품질과 시험?검사 ···························141
(2) 용접부에 발생하는 흠 ··········································142
(3) 시험?검사의 목적 ············································143
(4) 시험?검사의 시기 ·············································144
2. 비파괴시험의 개요 ··········································145
(1) 파괴시험과 비파괴시험 ·········································145
(2) 비파괴시험ㆍ검사ㆍ평가 ·······································145
(3) 비파괴시험 방법의 종류 ········································146
(4) 비파괴시험의 이용 목적 ········································147
3. 표층부 흠의 비파괴시험 ····································148
(1) 육안검사 (Visual-optic testing) ································148
(2) 침투탐상시험 (liquid penetrant testing) ························150
(3) 자분탐상시험 (magnetic particle testing) ························155
(4) 와류탐상시험 (eddy current testing) ····························159
4. 내부흠의 비파괴시험 ········································163
(1) 방사선투과시험(radiographic testing) ····························163
(2) 초음파탐상시험(ultrasonic testing) ·····························170
(3) 누설시험(leak testing) ·········································171
Ⅴ. 용접실습과 검사
?서울산업대학교 박익근 교수
Ⅰ. SMAW, GTAW 실습과 검사 ································177
1. 용접실습지시서(GTAW) ·········································177
2. 용접실습지시서(SMAW) ·········································178
3. 용접부 초음파탐상검사 ···········································179
(1) 수직탐상 ·····················································179
(2) 사각탐상 ·····················································200
(3) 용접부 탐상 ··················································216
(4) C-Scan ·······················································224
(5) 배관에서의 유도초음파 ········································229
Ⅵ. 용접시공
?서울산업대학교 이철구 교수
1. 용접시공 ···················································241
1-1. 용접시공의 흐름 ··············································241
1-2. 용접공정의 결정 ··············································242
1-3. 부재가공과 용접준비 ··········································243
1-4. 용접 작업(본 용접) ···········································246
1-5. 용접 전후의 열처리 ···········································247
1-6. 용접 후처리 ··················································248
2. 용접 시공의 요점 ···········································249
3. 용접 관리의 기본 ···········································250
3-1. 시공 시스템의 확립 ···········································251
3-2. 생산성의 향상 ················································252
3-3. 규격?기준과 시공 관리 ·······································253
3-4. 시공기술 개발 ················································255
4. 용접 관리의 개요 ···········································256
4-1. 제품 개발 단계와 접합 관리 ···································256
4-2. 생산 공정에 있어서 용접?접합 관리 ·····························257
5. 용접 규격의 적용(ASME CODE SECTION Ⅸ을 중심으로) ·····259
5-1. 머 리 말 ·····················································259
5-2. 미국기계학회 규격 ············································260
5-3. ASME 코드의 적용범위 ·······································260
5-4. ASME CODE Section Ⅸ ······································264
5-5. ASME CODE Section Ⅸ의 적용 ·······························272
6. 용접절차서와 용접절차 인정서 기재요령 ······················273
6-2. 용접절차 인정기록서 ··········································274
6-3. WPS의 작성 ·················································274
6-4. WPS 사용법 ·················································274
6-5. WPS 규정내용 ···············································274
7. WPS 와 PQR의 작성예 ······································279
1. SCOPE ·························································279
2. APPLICABLE CODE AND SPECIFICATION ······················279
3. WELDING PROCESS ············································279
4. FILLER METAL ················································280
5. WELDING JOINT PREPARATION AND TOLERANCE OF GROOVE ··280
6. CLEANING ·····················································281
7. PREHEATING ·················································281
8. POST-WELD HEAT TREATMENT (PWHT) ····················281
9. DRYING ·······················································282
10. TACK WELDING ··············································282
11. WELDING REPAIR ············································282