|
IIIIIIIIIITl iN T Ii
BULLETIN 72 F-9
AUGUST, 1968
ELECTRIC WELDING
JOB OPERATION SHEETS
DIVISION OF VOCATIONAL,
TECHNICAL, AND ADULT EDUCATION
CARL W. PROEHL, Assistant Superintendent
AGRICULTURAL
EDUCATION SECTION
C. M. Lawrence, Director
ELECTRIC WELDING
JOB O PERAT ION SHEETS
Prepared by
Carl E. Beeman
Assistant Professor of Pgricultural Education
University of Florida
Published by*
Agricultural Education Department
Instructional Materials Service'
University of Florida
Gainesville. Florida
and
Florida State Department of Education
Division of Vocational, Technical, and Adult Education
Agricultral Education Section
Tallahassee, Florida
1968
*Renroduced from materials developed Pnd published
by the Agricultural Erlucati-in Department
Suhject Matter Service, Mlississir~i State University
F
"~;a
IX
JOB OPERATION SHEET ELECTRIC WELDING
JOB: #1
MATERIALS NEEDED:
TOOLS NEEDED:
Identifying Kind of Metal to be Welded (Spark Test)
Samples of several unknown metals, samples of known metals
for comparison, gloves, and clear goggles
Electric grinder, medium grain grinding wheel, emery rock
dresser, and a flat file
PROCEDURE (step-by-step)
STEP
APPROVED PROCEDURE
1. Using the
grinding
wheel or
spark test
for identify-
ing metals
a. Testing
wrought
iron
b. Testing
low-carbon
steel
c. Testing
high-carbon
steel
d. Testing
cast iron
e. Testing
unknown
samples
of metal
NOTE: METALS HAVE TWO GENERAL CLASSIFICATIONS, FERROUS AND
NON-FERROUS METALS. FERROUS METALS CONTAIN LARGE
AMOUNTS OF IRON AND WILL GIVE OFF SPARKS WHEN GROUND.
NON-FERROUS METALS CONTAIN LITTLE OR NO IRON AND WILL
NOT PRODUCE SPARKS WHEN GROUND.
NOTE: MAKE THE TEST BY HOLDING THE METAL FIRMLY AGAINST
GRINDING WHEEL AT NORMAL SPEED. COMPARE SPARKS WITH
SPARKS FROM KNOWN METAL WITH SPARKS FROM UNKNOWN METAL.
a. Sparks produced will be long orange tracer sparks
with practically no sprigs at the ends.
b. Low-carbon steel is pure iron with 5 to 30 points of
carbon added, plus 30 to 50 points of manganese. The
spark stream will consist of long shafts, and the
sprigs will increase as the carbon content increases.
c. High-carbon steel ranges from 65 to 170 points carbon;
it can be heat treated and tempered. It produces a
white spark stream with many sprigs.
d. Cast iron gives off a small volume spark stream of
numerous small sparks. The color will be dull red
as they leave the grinder wheel, but, will then turn
yellow.
e. Compare spark stream of each unknown metal with known
samples until positive identification is made.
CAUTION: USE EMERY ROCK DRESSER ON GRINDING WHEEL TO CLEAN OFF ANY OTHER METAL
BEFORE MAKING TEST.
NOTE: IT IS HELPFUL TO PLACE A BLACK BACKGROUND BEHIND GRINDER WHEEL. SPARKS
CAN BE SEEN MUCH BETTER AGAINST A DARK BACKGROUND.
CAUTION: ALWAYS WEAR SAFETY GOGGLES WHEN USING AN ELECTRIC GRINDER.
Questions:
1. What are the two general classifications of metals?
2. What are the characteristics of sparks given off from cast iron?
References:
Shopwork on the Farm, by Jones, p. 360.
Arc Welding, by James F. Lincoln Foundation, p. 25.
Spark Test Characteristics
Very fine silvery white
crystalline formation.,
Surface appearance
Evidences of sand mold.
Color, dark gray.
Fracture Fracture Fracture
Bright gray Light gray Medium gray
Surface Appearance
Dark gray-rolling' or
forging marks are
present. Evidence of
sand mold on cast
steel.
Surface Appearance
Dark gray-rolling or
forging lines may be
noticeable.
Surface Appearance
Dark gray-smooth.
Dark gray color
rubs off black.
Surface Appearance
Evidences of sand mold.
Color, dark gray.
Characteristics of spark test on different metal
Courtesy of James F. Lincoln Arc Welding Foundation
'Spark Test
Fracture
JOB: #6, 7, 8
MATERIALS NEEDED:
TOOLS NEEDED:
JOB OPERATION SHEET ELECTRIC WELDING
Striking Arc and Welding in Flat Position
Electrodes, E6011 or E6013, base metal to weld, proper current for
welding
Electric arc welder, ground clamps, electrode holder, welder's
helmets, welder's gloves, chipping hammer, wire brush, welding
table, clear goggles
PROCEDURE ( step by step )
STEP
APPROVED PROCEDURE
1. Preparing for
welding
2. Adjusting
amperage
3. Striking arc
and running
bead
4. Examining
bead
1. Assemble tools and materials in convenient location.
2. Clean area of metal to be welded.
3. Secure metal to welding table.
4. Secure ground clamp to welding table or metal.
5. Place bare end of electrode in electrode holder.
6. Adjust helmet for comfortable fit.
NOTE: BE SURE EVERYONE HAS HELMET ON BEFORE STRIKING ARC. DO
NOT WELD NEAR COMBUSTIBLE MATERIALS. WELD IN WELL-VENTI-
LATED AREA.
1. Select amperage range of 90 to 1i5, using trial setting of
90 for E6011, 100 for E6013 electrodes.
NOTE: ADJUST AMPERAGE FOR THICKNESS OF STEEL BEING WELDED.
SWITCH WELDER OFF WHEN CHANGING AMPERAGE SETTING.
1. Adjust helmet and gloves.
2. Turn on welder.
3. Using scratching motion, strike arc.
NOTE: THERE ARE TWO METHODS OF STRIKING AN ARC, TAPPING AND
SCRATCHING.
4. Hold electrode 1/16"to 1/8" from metal.
5. Hold electrode at a 90-degree angle to metal, tipped 15 to
25 degrees in direction of travel.
6. Move electrode along metal slow enough to form a bead 1-1/2
times the diameter of electrode.
NOTE: PRACTICE RUNNING STRAIGHT BEAD UNTIL PROFICIENCY IS
ACHIEVED IN MOVING ELECTRODE AT PROPER SPEED AND MAIN-
TAINING PROPER ARC LENGTH.
Using chipping hammer and wire brush, remove slag.
Examine bead for penetration and smoothness,
Questions: I
1. Why should base metal be cleaned?
2. Why is the type of electrode important?
3. Why is arc length important?
4. Why should electrode be tilted in direction of travel while welding a bead on
a flat surface?
5. Why is it best to run bead in one continuous operation?
References:
Farm Mechanics Text and Handbook., by Phipps, McColly, Scranton, and Cook.
pp. 241-259.
Shopwork on the Farm, by Jones. pp. 478-500.
Teacher's Guide for the Lincoln Short Course in Farm Arc Welding, pp. 7-13.
1
1. Tapping method of striking an arc
2. Scratching method of striking an arc
Method of striking arc on partly
bead
5. Position of electrode when welding in flat
position
4. View of arc length, crater, and electrode
on parent metal
6. Types of bead irregularities
Courtesy of James F. Lincoln Arc Welding Foundation
*
JOB OPERATION SHEET ELECTRIC WELDING
Welding in Vertical Position
MATERIALS NEEDED: 1/8" to 1/4" mild-steel plate, 1/8" mild-steel electrodes such as E6011 or E6013,
electric current for welding.
TOOLS NEEDED:
Electric arc welder, welder's helmet, welder's gloves, welding table, chipping
hammer, wire brush, metal clamp, grinder.
PROCEDURE (step-by-step)
STEP
APPROVED PROCEDURE
I. Vertical Upward
1. Preparing for
vertical welding
2. Adjusting
amperage
3. Striking arc
and running
bead
4. Checking the
bead
II. Vertical Down-
ward
1. Striking arc
and running
bead
2. Checking the
bead
1. Assemble tools and materials in convenient location.
2. Clean area of metal to be welded.
3. Secure practice metal in vertical position.
NOTE: METAL SHOULD NOT BE TIPPED MORE THAN 30 DEGREES TOWARD OR AWAY FROM
OPERATOR.
4. Secure ground clamp to welding table or practice metal.
5. Place electrode in electrode holder so that it points directly away
from operator.
1. Set amperage at 85 to 110, starting with trial setting of 90 amperes.
NOTE: LOWER AMPERAGE IS USUALLY REQUIRED FOR VERTICAL WELDING THAN FOR
FLAT WELDING.
1. Strike arc near point where bead is to begin.
NOTE: USE SCRATCHING METHOD TO ESTABLISH ARC.
2. Holding moderately long arc, move to point where weld is to begin.
3. Point electrode directly at spot where weld is to begin, using 90-
degree angle, until puddle forms in crater.
4. Move electrode tip upward and away from toe of crater a distance equal
to the diameter of electrode.
NOTE: THIS MOVEMENT ALLOWS TIME FOR THE MOLTEN METAL TO SOLIDIFY.
5. Quickly return electrode tip to toe of crater (when metal has sol.id-
ified).
NOTE: HOLD CLOSE ARC WHEN ELECTRODE TIP IS IN TOE OF CRATER.
6. Repeat steps 4 and 5 until upper edge of weld is reached.
7. When upper edge of metal is reached point electrode downward and over
heel of crater.
NOTE: VERTICAL WELDING REQUIRES FASTER MOVEMENTS THAN FLAT WELDING.
1. Using chipping hammer and wire brush, remove slag.
NOTE: IF ICICLE APPEARS, IT MAY BE DUE TO HIGH AMPERAGE SETTING, HOLDING
ARC IN CRATER TOO LONG, OR RETURNING ELECTRODE BELOW TOE OF CRATER.
NOTE: FOLLOW STEPS 1 AND 2 ABOVE.
1. Strike arc near point where bead is to begin,
2. Tip electrode ahead--in direction of travel--so that a 60-degree angle
will be formed between work and electrode.
NOTE: SHORTER ARC IS REQUIRED THAN FOR FLAT WELDING.
3. Use straight downward motion, no weaving.
NOTE: TRAVEL FAST ENOUGH TO PREVENT MOLTEN METAL FROM DROPPING BETWEEN TIP
END OF ELECTRODE AND BASE OF CRATER. ALLOW TIME FOR GOOD PENETRA-
TION.
1. Using chipping hammer and wire brush, remove slag from weld.
2. Examine for smoothness and penetration.
Questions:
1. Why is it necessary to use a short arc in vertical welding?
2. Why should lower amperage be used in vertical welding than in flat position?
3. What size and kind of electrode is best for vertical welding?
4. What advantage is gained in welding from bottom upward?
References:
Shopwork on the Farm, by Mack M. Jones, pp. 510-512.
Arc Welding Lessons, by Harold L. Kugler, pp. 162-175.
Farm Mechanics Text and Handbook, by Phipps, McColly, Scranton, and Cook, pp. 261-265.
JOB: #9
0
1. Position of electrode when welding up in vertical position
a ---- 'T' J
SCRATER N HEEL
2. Movement of electrode to avoid metal
running down over hdel of weld
3. Patterns of motion used when welding
vertical upward
4. Position of electrode when welding
vertical downward
5. Patterns of motion used when welding
vertical downward
Courtesy of James F. Lincoln Arc Welding Foundation
JOB OPERATION SHEET ELECTRIC WELDING
JOB: 410
Welding in Overhead Position
MATERIALS NEEDED: Metal for practice, 1/8" electrodes (E6011 and E6013)
TOOLS NEEDED:
Electric welder, helmet, welder's gloves, wire brush, chipping
hammer, welding jig
PROCEDURE ( step-by-step )
STEP
1. Preparing for
welding
2. Adjusting
amperage
3. Positioning
body for welding
4. Striking arc
and establish-
ing bead
5. Running the
bead
6. Examining the
bead
APPROVED PROCEDURE
1. Assemble materials in convenient location at welding station.
2. Clean metal.
3. Fasten metal in overhead position 8" to 10" above head level.
1. Use trial setting of 100 amperes for E6013 electrodes, for
E6011 use trial setting of 90 amperes.
NOTE: ADJUST AMPERAGE FOR MATERIAL BEING WELDED.
1. Position yourself so as not to be directly under the arc.
2. Maintain a comfortable position.
3. Use position that will permit free wrist movement.
4. Keep palms of hands turned down.
5. Drop cable over shoulder to relieve weight from electrode
holder.
1. Place electrode in electrode holder.
2. Turn on welder.
3. Place helmet on head and adjust.
4. Use scratching motion to establish arc.
5. Maintain moderately long arc until metal in crater begins
to melt.
6. When crater forms, move electrode close and deposit metal.
1. Keep electrode holder tipped ahead 5 to 10 degrees.
2. Hold short arc, placing tip of electrode at toe of crater.
3. Oscillate electrode ahead in direction of travel a distance
equal to the diameter of electrode.
NOTE: HOLD THIS POSITION UNTIL DEPOSITED METAL REACHES THE HEEL
OF CRATER AND BEAD FORMS.
4. Return electrode tip to toe of crater when metal in crater
begins to solidify.
NOTE: OBSERVE ACTION WITHIN THE CRATER AT ALL TIME.
5. Continue process until bead is completed.
1. With chip hammer and wire brush, remove slag.
2. Check bead for uniformity and penetration.
NOTE: THE SPEED OF ELECTRODE MOVEMENT IS VERY IMPORTANT IN
OVERHEAD WELDING. TOO SLOW WILL CAUSE METAL TO PILE
UP, TOO FAST WILL CAUSE IRREGULAR, POORLY FUSED WELDS.
Questions:
1. Why is it essential to have backs of hands toward the arc?
2. Why is it necessary to use a short arc in overhead welding?
3. What is the reason for using a small electrode when welding overhead?
4. What type electrode is generally used to weld overhead?
References:
Shopwork on the Farm, by Mack M. Jones, pp. 509-512
Arc Welding Lessons, by Harold L. Kugler, pp. 176-181
Farm Mechanics Text and Handbook, by Phipps, McColly, Scranton, and Cook, pp.
261-262.
1. Position of electrode when stringer bead is run in overhead position
2, Irregularities occur when electrode is not returned to the crater correctly.
C is normal bead
3. Overhead fillet weld
4. Overhead fillet weld. First pass
with stringer bead; circular motion
used to lay second pass
Court6ey of James F. Lincoln Arc Welding Foundation
0
JOB OPERATION SHEET ELECTRIC WELDING
JOB: #11
Welding in Horizontal Position
MATERIALS NEEDED:
TOOLS NEEDED:
STEP
Two pieces 1/8"or 1/4" mild-steel plate 1" to 4" wide, mild-steel
electrodes such as E6011 or E6013, electric current for welding.
Electric arc welder, welder's helmet, welder's gloves, welding
table, chipping hammer, wire brush, clamp, grinder.
PROCEDURE (step-by-step)
APPROVED PROCEDURE
1. Preparing for
horizontal
welding
2. Adjusting
amperage
3. Striking arc
and running
bead
4. Checking
the bead
1. Assemble tools and materials in convenient location.
2. Clean area of metal to be welded.
3. Tack-weld 2 pieces of metal together (ends and middle).
4. Chip slag from tack welds.
5. Secure metal in horizontal position.
6. Secure ground clamp to table or practice metal.
7. Place electrode in electrode holder.
1. Select amperage range of 90 to 110, using trial setting of
90 for E6011, 100 for E6013 electrodes.
1. Strike arc within 1" of corner where weld is to begin.
2. Bring electrode into position in corner of weld, holding
arc until bead is established.
3. Point electrode upward, 45-degree angle to metal, and for-
ward 15 to 25 degrees.
4. Hold electrode so that coating is 1/16" to 1/8" from metal
being welded.
NOTE: USE SLOW, STEADY MOVEMENT OF ELECTRODE. POSITION ELEC-
TRODE TO COMPENSATE FOR UNDERCUTTING OR PILING UP OF
METAL.
1. Using chip hammer and wire brush, remove slag.
NOTE: DETERMINE IF BEADS ARE EVEN AND PENETRATION INTO THROAT
AND LEGS OF THE WELD ARE OF EQUAL LENGTH.
Questions:
1. Why is it necessary to clean metal to be welded?
2. What are the recommended angles for an electrode to be held--upward and
forward?
3. How can undercutting be prevented?
4. What is the meaning of "leg", "toe", 'throat" of weld puddle?
References:
Shopwork on the Farm, by Jones, p. 511.
The Lincoln Short Course in Arc Welding, p. 14.
Arc Welding Lessons for School and Farm Shop, by Harold L. Kugler, pp. 150-161.
Farm Mechanics Text and Handbook, by Phipps, McColly, Scranton, and Cook, pp. 261-
2,62.
HORIZONTAL BEAD
MARGIN -
CONVEX BEAD SURFACE
I
,THROAT
I-WELD LEG /z
ROOT OF WELD
1. Types of horizontal and fillet weld
joints
SIDE V E' : ...
3. Position of electrode when welding
fillet in horizontal position
FLAT BEAD MARGIN J kc WELD LEG Y"3
2. Parts of horizontal position fillet
weld
4. Angle of electrode to control deposit
of metal
5. Position of electrode when welding
metals of different thicknesses
6. Sequence followed when making multiple
pass welds
Courtesy of James F. Lincoln Arc Welding Foundation
JOB OPERATION SHEET ELECTRIC WELDING
JOB: #12
MATERIALS NEEDED:
TOOLS NEEDED:
STEP
Welding Cast Iron
1/8" cast welding electrodes (such as Lincoln "Ferroweld"), pieces
of broken castings (gray cast perferred), electric current for
welding.
Electric arc welder, welder's helmet, welder's gloves, welding
table, chipping hammer, wire brush, clamp, grinder.
PROCEDURE (step-by-step)
APPROVED PROCEDURE
1. Preparing cast
iron for weld-
ing
2. Adjusting
amperage
3. Striking arc
and running
bead
4. Checking the
weld
1. Clean area to be welded.
2. Using grinder, make a 60-degree vee joint.
NOTE: METAL 3/8" THICKNESS OR LESS, VEE ON ONE SIDE OF JOINT.
OVER 3/8" THICKNESS, VEE BOTH SIDES. LEAVE 1/16" TO
3/32" THICKNESS OF ORIGINAL EDGE TO PROVIDE PROPER
ALIGNMENT OF ORIGINAL PIECE OF METAL.
3. Grind surface along edge of vee to remove casting skin.
1. Select amperage range of 90 to 120, using trial setting
of 90 amperes.
2. Secure ground clamp to table or to weld metal.
NOTE: WHEN AMPERAGE IS CORRECT, METAL FLOWS FROM ELECTRODE
TIP AND MAKES SMOOTH DEPOSIT. IF WELD HAS ROUGH
APPEARANCE, INCREASE AMPERAGE. IF BURN-THROUGH OR
BUBBLES APPEAR, REDUCE AMPERAGE.
NOTE: RUN SHORT BEADS, 3/8" TO 1/2" AT THE TIME. USE BACK
STEP TECHNIQUE.
1. Using scratching motion, strike arc.
2. Hold long arc during the entire welding pass.
NOTE: IF METAL DROPS OFF IN GLOBULES, RAISE OR LOWER ELECTRODE
AS REQUIRED.
3. Lay stringer bead in botton of vee joint.
4. Tip electrode ahead 5 to 10 degrees in direction of travel.
5. Position electrode so both sides of joint are fused.
NOTE: ALLOW METAL TO COOL BETWEEN PASSES.
6. Use weaving pass to complete the weld.
1. Using chipping hammer and wire brush, clean weld.
2. Observe deposited metal (it should be fused into base
metal).
3. Cool slowly to room temperature by covering with dry lime,
ashes, or asbestos paper.
CAUTION: ALWAYS PREHEAT CASTINGS AND COMPLETE WELD WHILE HOT.
COOL SLOWLY.
Questions:
1. What type electrodes are best for welding cast iron?
2. How should cast be prepared for welding9
3. What precautions are necessary in welding cast?
4. Why is it important to avoid overheating cast?
5. Why must a cast weld be cooled slowly?
References:
Arc Welding Lessons for School and Farm Shop, by Harold L. Kugler, pp. 192-209.
The Lincoln Short Course in Arc Welding, pp. 20-21.
Farm Mechanics Text and Handbook, by Phipps, McColly, Scranton, and Cook, pp. 513-
514.
Shopwork on the Farm, by Jones, pp. 513-514.
1. Using carbon-arc torch to preheat cast
gear
3. Casting veed for welding
ST 3/ A I ,60
A ^T ^" *OR 5 B \/ L6" To 3/"
(GRIND SURFACE TO '* a
REMOVE CASTING SKIN LEAVE UNGROUND 6 TO 52
60,
C ,6"TO 0' oVER 3/V"
2. Procedures used in preparing cast
iron joints for welding
4. Casting welded and ground to
smooth finish
Courtesy of James F. Lincoln Arc Welding Foundation
JOB OPERATION SHEET ELECTRIC WELDING
JOB: #14
MATERIALS NEEDED:
TOOLS NEEDED:
STEP
Welding Pipe
1/8" mild-steel electrodes (E6011 or E6013), piece of pipe for
welding, electric current for welding.
Electric arc welder, welder's helmet, welder's gloves, chipping
hammer, wire brush, grinder, clamps.
PROCEDURE (step-by-step)
APPROVED PROCEDURE
1. Preparing for
welding pipe
2. Adjusting
amperage
setting
3. Striking arc
and running
bead
4. Checking
the bead
1. Assemble tools and materials in convenient location.
2. Cut pipe to be welded.
3. Using wire brush, clean weld area until surface is bright.
4. Using grinder, shape joints to fit, beveling edges if pipe
is more than 1/8" thick.
NOTE: WHEN WELDING PIPE END TO END, LEAVE SMALL SPACE BETWEEN
JOINTS. TACK WELD TO HOLD IN POSITION.
5. Place pipe in position for welding.
6. Secure pipe with clamps.
7. Secure ground clamp to table or pipe.
8. Place electrode in electrode holder.
1. Adjust amperage so that there is
fuse the electrode with the base
NOTE: TRY SAME AMPERAGE AS FOR MILD
F6011; 100 AMPERES FOR E6013.
(WATCH FOR "BURN-THROUGH").
only enough heat to properly
metal.
STEEL: 90 AMPERES FOR
IF TOO HOT, LOWER AMPERAGE
1. Turn on welder.
2. Strike arc within 1" of spot where weld is to begin.
3. Move arc to point of weld, holding in position until crater
is formed.
4. Move electrode in direction of travel fast enough to form
bead.
NOTE: HOLD ELECTRODE IN SAME POSITION AS WELDING MILD STEEL
IN VARIOUS POSITIONS, AS REQUIRED.
CAUTION: WHEN PIPES ARE OF UNEQUAL THICKNESS, DIRECT ARC TO-
WARD THICKEST PIPE. MANIPULATE ELECTRODE TO GET
PROPER PENETRATION ON BOTH PIECES.
5. Continue welding until bead is complete, turning pipe as
required.
1. Using chipping hammer and wire brush, remove slag.
2. Examine bead for penetration and smoothness.
NOTE: BLACK PIPE IS EASIER TO WELD THAN GALVANIZED PIPE.
CAUTION: WELD GALVANIZED PIPE ONLY IN WELL-VENTILATED LOCATION,
AS IT GIVES OFF POISONOUS ZINC FUMES.
Questions:
1. How should pipe be prepared for welding?
2. What precaution should be used in welding galvanized pipe?
3. Why is it necessary to pre-fit pipe before welding?
References:
Arc Welding Lessons for School and Farm Shop, by Harold L. Kugler, pp. 279-292.
MULTIPLE
PASS
SEQUENCE 5
I DIRECTION f TRAVEL
ST ACK WELD
A TEE JOINT WELD
DIRECTION /WELD
TACK WELD
SCARF PIPE WHEN.
THICKNESS EXCEEDS j
B ELL JOINT WELD
1. Position electrode so arc is concentrated
on heavy section of metal
2. Observations to be made when welding
tee and angle pipe joints
A
3. Flatten end of pipe when making a T-joint
weld
B
4. Steps in closing end of pipe with
orange-peel plug
Courtesy of James F. Lincoln Arc Welding Foundation
0
JOB OPERATION SHEET ELECTRIC WELDING
Hard-Surfacing with Electrode
MATERIALS NEEDED:
TOOLS AND EQUIP-
MENT NEEDED:
STEP
Pieces of steel plate, discarded plowshares, 1/8" hard-facing
electrodes
Electric welder, chipping hammer, wire brush, file, helmet, welder's
gloves, clamp or brick, and welding table.
PROCEDURE ( step by step )
APPROVED PROCEDURE
1. Preparing metal
for hard-surfaci
2. Selecting
electrodes
3. Adjusting
amperage
4. Positioning
the work for
welding
5. Striking arc and
running bead
6. Examing bead
Questions:
Why should
Why should
Why should
Why should
ng
1. Grind metal to remove rust, scale, and brighten surface.
NOTE: SHARPEN PLOW SHARES BEFORE HARD-FACING.
1. Use high carbon or work-hardening type electrode. (Such
as Lincoln's Abrasoweld.)
2. Use 1/8 inch diameter electrode.
1. Use amperage range 80-100. Make trial setting of 85
amperes.
NOTE: USE AMPERAGE RANGE LOWER THAN IS USED WITH MILD STEEL
ELECTRODE.
2. Avoid excessive penetration.
1. Position work for comfort of operator.
2. Tilt piece slightly, so weld will be made in downhill
position.
1. Maintain moderately long arc (about 1/8 inch).
2. Use weaving pass.
3. Makes passes close enough for each pass to bond together.
4. Lay bead 1/2" wide on plow-shares.
NOTE: USE HAMMER TO PFEN SURFACE TO INCREASE HARDNESS IF
WORK-HARDENING TYPE ELECTRODE IS USED.
1. When bead has cooled, with chip-hammer and brush remove
slag.
2. Bead should be smooth and evenly deposited.
3. Rub across bead with file to demonstrate hardness.
you never hard-surface both sides of a plow share?
entire process be fast?
a moderately long arc be maintained?
beads go no closer than 1/8" of the edge of a plow share?
References:
Teacher's Guide for the Lincoln Short Course in Farm Arc Welding, pp. 26-31.
Shopwork on the Farm, by Jones, pp. 514-515.
Arc Welding Lessons for School and Farm Shop, by Harold L. Kugler, pp. 275-276.
Farm Mechanics Text and Handbook, by Phipps, McColly, Scranton, and Cook, pp.
275-276.
JOB: #15
1. Plowshare positioned for hard-facing
2. Position of electrode in hard-facing
plowshare
T. - i
3. Parts subjected to abrasion may be 4. Applying hard-facing application to
protected by hard-facing harrow runner
Courtesy of James F. Lincoln Arc Welding Foundation
Cra~n~n~
JOB OPERATION SHEET ELECTRIC WELDING
Cutting and Piercing With Electrode
MATERIALS NEEDED:
TOOLS NEEDED:
STEP
1/8" to 5/32" mild-steel electrodes (E6011 or E6013) broken
cast iron parts, soapstone, water, electric current for welding.
Electric arc welder, welder's helmet, welder's gloves, chipping
hammer, wire brush, bucket, clamp, grinder.
PROCEDURE (step-by-step)
APPROVED PROCEDURE
1. Preparing
for cutting
and piercing
2. Adjusting
amperage
3. Cutting or
piercing
the metal
(steel and
cast)
4. Checking
the cut
1. Assemble tools and materials in convenient location.
2. Place on floor beside table a bucket half filled with water.
3. Using soapstone, mark line to be cut.
4. Position metal so molten metal will fall into bucket.
NOTE: METAL OVER 1/8" THICK SHOULD BE PLACED IN VERTICAL POSITION.
5. Secure ground clamp to table or metal to be cut.
NOTE: IF MUCH CUTTING OR PIERCING IS TO BE DONE, DIP ELECTRODES
IN WATER BEFORE USE. THIS MAKES THEM LAST LONGER.
6. Place electrode in electrode holder, using 1/8" for thin
metal, 5/32" for thick metal.
CAUTION: ALWAYS USE HELMET GLOVES AND PROTECTIVE CLOTHING. CUT
AND PIERCE IN WELL-VENTILATED PLACE.
1. Select maximum amperage for electrode used--1/8" electrode,
125 to 140 amperes; 5/32" electrode, 140 to 180 amperes.
NOTE: IF ELECTRODE BECOMES RED HOT AND COATING BURNS, REDUCE
SETTING 10 AMPERES.
1. Put on gloves and helmet.
2.. Make proper adjustments.
3. Strike arc at top edge of metal directly above cutting line.
4. When heat of arc melts metal in crater, move electrode tip
back and forth across surface.
NOTE: TO CUT LARGE HOLES, START CUT IN CENTER AND MOVE ELECTRODE
IN CIRCULAR PATH. MAKE SURE SLAG CAN FALL CLEAR OF CUT--
NOT ON SHOES OR CLOTHING.
1. Using chipping hammer and wire brush, remove excess slag.
2. Check edges of cut for accuracy.
3. Smooth cut or pierced area by using grinder, if needed.
Questions:
1. What type electrodes are best for cutting?
2. What safety precautions should be observed when cutting?
3. How is amperage for cutting determined?
References:
Arc Welding Lessons for School and Farm Shop, by Harold L. Kugler, pp. 215-223.
The Lincoln Short Course in Arc Welding, p. 16.
Farm Mechanics Text and Handbook, by Phipps, McColly, Scranton, and Cook, pp.
267-269.
JOB: #16
0
1. Various uses for arc welding equipment 2. Method of placing material for
in cutting metal cutting
4. Movement of electrode when piercing
holes
5. Position for thick metal
6. Movement of electrode for cutting
large holes
Courtesy of James F. Lincoln Arc Welding Foundation
3. Cutting round stock
JOB OPERATION SHEET ELECTRIC WELDING
Heating with Carbon-Arc Torch
MATERIALS NEEDED:
TOOLS NEEDED:
STEP
Two each 1/4", 5/16", 3/8", and 1/2" carbons, metal to be heated, electric
current for welding.
Carbon-arc torch, electric welder, welder's helmet, welder's gloves, weldingtable.
PROCEDURE (step-by-step)
APPROVED PROCEDURE
1. Preparing to heat
with carbon-arc
torch
2. Installing and
adjusting carbons
3. Adjusting amperage
setting
4. Adjusting
flame
5. Heating
1. Assemble tools and materials in convenient location.
2. Clean metal to be heated.
3. Attach two cables from carbon-arc torch to welder, one to ground, other
in electrode holder.
4. Select carbon size in accordance with thickness of metal.
1. Insert carbons in clamps of carbon-arc torch.
2. Adjust each carbon, from point of carbon to clamp of torch.
3. Using device on torch, pull carbon tips together, then make final
adjustment.
NOTE: CARBON TIPS MUST BE PERFECTLY ALIGNED IN CLOSED POSITION, FORMING A
"VEE".
4. Using device provided on torch, pull carbons apart before turning on
welder.
1. Adjust amperage for carbon size and metal thickness.
NOTE: 1/4" CARBON, 20 TO 50 AMPERES: 3/8" CARBON, 40 TO 90 AMPERES; 1/2"
CARBON, 75 TO 140 AMPERES. FOR THIN METAL, USE SMALL CARBON AND
LOW AMPERAGE. FOR THICK METAL, USE LARGER CARBON AND HIGHER AMPER-
AGE.
NOTE: ALWAYS USE GLOVES, HELMET, AND PROTECTIVE CLOTHING WHEN USING CARBON
TORCH.
1. Turn on welder.
2. Position helmet.
3.- Using adjustment device, pull carbon tips together until arc is
established.
4. After arc is established, widen gap between carbons from 1/16" to 3/16'.
5. Make final adjustment so a wide, soft, quiet flame is produced.
1. Play flame back and forth on area to be heated.
2. Raise or lower flame to get proper distance for heating the metal.
3. When heating is completed, separate carbons to extinguish flame.
NOTE: WHEN CARBON TIPS BECOME BURNED, THEY MAY BE REPOINTED BY GRINDING.
CAUTION: THE ULTRA-VIOLET RAYS PRODUCED BY CARBON-ARC TORCH ARE MORE
INTENSE AND CAUSE BURNS WORSE THAN RAYS FROM METALLIC ARC. ALL
PARTS OF THE BODY SHOULD BE PROTECTED FROM THESE RAYS. BE SURE
THAT HELMET (COLORED) LENS IS NOT CRACKED OR CHIPPED AT CORNERS.
Questions:
1. What are the most common size carbons used in the carbon-arc torch?
2. How should carbons be adjusted?
3. What is the amperage range for 1/4" and 3/8" carbons?
4. How can burned carbons be repointed?
References:
Arc Welding Lessons for School and Farm Shop, by Harold L. Kugler, pp. 57-63.
The Lincoln Short Course in Arc Welding, p. 19.
Farm Mechanics Text and Handbook, by Phipps, McColly, Scranton, and Cook, pp. 273-275.
Shopwork on the Farm, by Jones, pp. 520-522.
JOB: #17
1. Carbon arc torch
INNER' 2. Adjust carbons according to measurements
ME given
OUTER HEAT ZONE
ON FLAME
N, 'EAT
INTO CORNERS
3. Outline of flame when carbons are properly
adjusted
,..' .. I 4. Heating metal with carbon arc torch
5. Using carbon arc torch to heat rusted nut
x
6. Using carbon arc torch to heat tool steel
for tempering
Courtesy of James F. Lincoln Arc Welding Foundation
JOB OPERATION SHEET ELECTRIC WELDING
Brazing with Carbon-arc Torch
MATERIALS NEEDED:
TOOLS NEEDED:
Brazing flux, welding (filler) rod, carbon rods, scrap metal
to be brazed
Carbon-arc torch, electric welder, helmet, gloves, clamp or
brick
PROCEDURE ( step-by-step )
STEP
APPROVED PROCEDURE
1. Preparing tools,
equipment, and
materials to be
used in brazing
2. Starting and
adjusting arc
3. Applying bronze
1. Attach the two cables from the carbon-arc torch to welder.
2. Clean metal to be brazed.
3. Have nearby all tools and materials needed.
4. Turn on welder and set amperage.
1. Adjust carbons to make tips touch. After the arc is
established, move carbons until the tips are approximately
3/16 inch apart.
1. Preheat metal at the spot where brazing is to be done.
(until metal sweats)
2. Feed bronze rod into flame. (Let a few drops melt onto
base metal.)
3. Move flame slowly along area to be brazed. The molten
bronze will follow flame and will fuse with base metal.
4. Add more bronze as needed. (a few drops at a time)
NOTE: IF YOU USE RODS THAT ARE NOT COATED WITH FLUX, HEAT
THE TIP OF THE BRONZE ROD SLIGHTLY AND DIP IT INTO
BRAZING FLUX BEFORE YOU FEED THE BRONZE ONTO BASE
METAL.
CAUTION: THE ULTRA-VIOLET RAYS PRODUCED BY CARBON-ARC TORCH ARE MORE INTENSE AND
CAUSE BURNS EASIER THAN RAYS FROM A METALLIC ARC. ALL PARTS OF THE BODY SHOULD BE
PROTECTED FROM THESE TAYS. BE SURE THAT HELMET (COLORED) LENS IS NOT CRACKED OR
CHIPPED AT CORNERS.
Questions:
Why is flux required when brazing with a bare rod?
Why preheat metal until it begins to sweat?
Why does molten bronze follow the flame and heat?
References:
Farm Mechanics Text and Handbook, by Phipps, McColly, Scranton, Cook. p. 274.
Shopwork on the Farm, by Jones. pp. 22 and 521.
Teacher's Guide for the Lincoln Short Course, p. 21.
JOB: #18A
1. Adjusting carbons
as Brazing with carbons arc torch. Note position
of carbons and bronze rod
2. Adjusting flame for brazing
4. Thin metal brazed using carbon arc torch
Courtesy of James F. Lincoln Arc Welding Foundation
JOB OPERATION SHEET ELECTRIC WELDING
JOB: #18B
Brazing with Single Carbon
MATERIALS NEEDED:
TOOLS AND EQUIP-
MENT NEEDED:
STEP
5/32" carbon rod, flux-coated bronze rod, thin metal to be brazed
(14 to 28 guage)
Helmet, welders' gloves, electric welder, wire brush, chipping
hammer, clamps or brick to secure metal to welding table
PROCEDURE (step-by-step)
APPROVED PROCEDURE
1. Preparing metal
for brazing
2. Selecting carbon
and placing in
electrode holder
3. Selecting bronze
rod
4. Attaching ground
cable and adjust-
ing amperage set-
ting
5. Applying the
bronze
1. Clean metal to bright finish.
1. Select a 5/32 inch black or copper covered soft center
carbon.
2. Place carbon in electrode holder so about two inches
extend beyond the holder.
NOTE: IF SMALL CARBON (5/32") IS NOT AVAILABLE, POINT LARGE
CARBON BY GRINDING.
1. Use 3/32" flux-coated bronze rod.
NOTE: PLAIN BRONZE ROD AND POWDERED FLUX CAN BE USED, BUT
IS MORE DIFFICULT DUE TO LOSS OF ARC WHILE FLUXING
THE BRONZE ROD.
1. Attach ground cable to material to be brazed, or to metal
table.
2. Use trial setting of 30 amperes.
NOTE: IF TOO HOT, LOWER THE SETTING. IF TOO COLD, INCREASE
THE SETTING (USUALLY RANGE OF 20 TO 50 AMPERES WILL
DO MOST JOBS).
1. Strike an arc on the metal with the carbon rod.
2. Maintain short arc of 1/16 inch.
3. Place flux-coated bronze rod between carbon tip and base
metal, as the bronze melts, turn the bronze rod so the
flame will always be in contact with the flux.
4. Rotate tip of carbon rod in small circular motion to
concentrate heat toward edges of weld.
NOTE: IF HEAT SETTING IS TOO LOW, THE WELD WILL BE ROUGH
AND IRREGULAR.
IF HEAT SETTING IS TOO HIGH, IT WILL BURN THROUGH
THE METAL.
CAUTION: ALWAYS WEAR HELMET AND GLOVES WHEN USING CARBON-ARC TORCH.
Questions:
1. Why put the arc on the filler rod instead of the base metal?
2. Why wear helmet when brazing with carbon rods?
3. Why is thin metal best for practice in carbon-arc brazing?
References:
Farm Mechanics Text and Handbook, by Phipps, McColly, Scranton, Cook. p. 275.
Arc Welding Lessons, by James F. Lincoln Arc Welding Foundation. pp. 246-7.
Date Due
D', Re turned Due F ;rned
1. Brazing with single carbon, Note position of flux coated bronze rod.
0
Courtesy of James F. Lincoln Arc Welding Foundation
114
.........
Ji:
fA. ?!i -j -,jg,
Zp.
... ... .... ....
WAX
R l -4
ra
Al
"AY
Jv.
51
...... .....
M.:
i.V
'Bi t i
ix
|
RSS
HIDE
