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PREFACE:
A strong case can be made that joining methods—whether through mechanical fastening, design interlocking, adhesive bonding, or welding (including brazing and soldering)—are among the most critical processes in both manufacturing and construction. This is because joining typically takes place after significant value has already been invested in producing near-net-shaped components for assembly.
Among these methods, welding stands out as the most technically complex, requiring highly skilled professionals, and represents about half of all joining operations. In terms of value, its share is even greater. Consequently, any unresolved issue in welding becomes a serious concern.
As of 2017, key industrial sectors relying on welding, in descending order, included:
- Energy (~23%)
- Construction (~20.5%)
- Transportation (~19.5%)
- Process industries and others (~15%)
- Heavy machinery (~11%)
- Shipbuilding (~8%)
- Aerospace and defense (~3%)
Welding applications span a wide range, covering industries such as agriculture, aviation, automotive, construction, chemical processing, food and beverage, mining, shipbuilding, power generation, oil and gas, pharmaceuticals, and rail transportation. Simply put, while digital technology has reshaped our lifestyles, it is welding that makes the modern world physically possible.
Although books and courses explain welding processes and metallurgy in depth, far less attention is given to why welding sometimes fails and, more importantly, how to prevent or fix those problems. This is exactly where A Practical Guide to Welding Solutions: Overcoming Technical and Material-Specific Issues comes in.
What every welder and welding engineer wants most is guidance on avoiding issues when possible, and solving them when they arise. This book addresses problems from three practical perspectives:
1️⃣ By manifestation (e.g., defects or distortions).
2️⃣ By location (e.g., in the weld metal or heat-affected zone).
3️⃣ By material (e.g., brittle martensite in hardenable steels, sensitization in stainless steels).
The global welding consumables market alone (such as electrodes and wires) exceeded $15 billion in 2017, projected to grow 1.7× over the following decade. Since consumables usually make up only about 5% of welding costs, with labor being far more expensive, the total economic impact of welding is immense.
After 25 years and eight technical books, I have come to realize one thing: engineers solve problems. That is why this book cuts straight to the point—helping professionals tackle welding challenges head-on.
Special thanks go to my assistant editor, Lesley Jebaraj, for patience and dedication; my production editor, Vishnu Priya, for exceptional skill; and my editor, Martin Preuss, for his encouragement and belief in this project. It may be late, but as the saying goes: Better late than never!