Welding Operations I

SUBCOURSE EDITION
OD1651 8
WELDING OPERATIONS, I
WELDING OPERATIONS, I
SUBCOURSE NO. OD1651
United States Arm C!m"ined Arms s#$$!rt C!mmand
%!rt Lee, &ir'inia ()*+1,1*+-
6 Credit .!#rs
GENERAL
T/e $#r$!se !0 t/is 1!#rse is t! intr!d#1e t/e "asi1 re2#irements
in3!43ed in meta4,ar1 5e4din' !$erati!ns.
T/e s1!$e !0 t/is s#"1!#rse 1!nsists !0 des1ri"in' t/e 14assi0i1ati!n
!0 e4e1tr!des and t/eir intended #ses6 des1ri"in' a#t!m!ti3e 5e4din'
$r!1esses, materia4s and identi0i1ati!n $r!1esses6 des1ri"in' t/e
met/!ds !0 destr#1ti3e and n!ndestr#1ti3e testin' !0 5e4ds and
tr!#"4es/!!tin' $r!1ed#res6 des1ri"in' t/e t$e and te1/ni2#es !0 7!int
desi'n6 and des1ri"in' t/e t/e!r, $rin1i$4es, and $r!1ed#res !0
5e4din' arm!r $4ate.
Si8 1redit /!#rs are a5arded 0!r s#11ess0#4 1!m$4eti!n !0 t/is
s#"1!#rse.
Less!n 1 ELECTRODES CLASSI%ICATION AND INTENDED USES6 AUTO9OTI&E
WELDING PROCESSES, 9ATERIALS, AND IDENTI%ICATION
PROCESSES6 9ET.ODS O% DESTRUCTI&E AND NONDESTRUCTI&E
TESTING O% WELDS AND TROUBLES.OOTING PROCEDURES6 T:PES
AND TEC.NI;UES O% <OINT DESIGN6 AND T.E T.EOR:,
PRINCIPLES, AND PROCEDURES O% WELDING AR9OR PLATE
i
WELDING OPERATIONS I - OD1651
TAS= 1> Des1ri"e t/e $r!1esses 0!r identi0in'
e4e1tr!des " 14assi0i1ati!n, and intended #ses6 and
t/e a#t!m!ti3e 5e4din' $r!1esses, materia4s, and
identi0i1ati!n $r!1esses6 and t/e t$es and
te1/ni2#es !0 7!int desi'n.
TAS= (> Des1ri"e t/e t/e!r, $rin1i$4es, and
$r!1ed#res !0 5e4din' arm!r $4ate6 and met/!ds !0
destr#1ti3e and n!ndestr#1ti3e testin' !0 5e4ds, and
tr!#"4es/!!tin' $r!1ed#res.
ii
WELDING OPERATIONS I - OD1651
TABLE O% CONTENTS
Se1ti!n Pa'e
TITLE.......................................................... i
TABLE O% CONTENTS.............................................. iii
Less!n 1> ELECTRODES CLASSI%ICATION AND
INTENDED USES, AUTO9OTI&E WELDING
PROCESSES, 9ATERIALS, AND
IDENTI%ICATION PROCESSES6 9ET.ODS
O% DESTRUCTI&E AND NONDESTRUCTI&E
TESTING O% WELDS AND
TROUBLES.OOTING PROCEDURES6 T:PES
AND TEC.NI;UES O% <OINT DESIGN6 AND
T.E T.EOR:, PRINCIPLES, AND
PROCEDURES O% WELDING AR9OR
PLATE.............................................. 1
Tas? 1> Des1ri"e t/e $r!1esses 0!r
identi0in' e4e1tr!des " 14assi0i1ati!n,
and intended #ses6 and t/e a#t!m!ti3e
5e4din' $r!1esses, materia4s, and
identi0i1ati!n $r!1esses6 and t/e t$es
and te1/ni2#es !0 7!int desi'n............................ 1
Tas? (> Des1ri"e t/e t/e!r, $rin1i$4es,
and $r!1ed#res !0 5e4din' arm!r $4ate6 and
met/!ds !0 destr#1ti3e and n!ndestr#1ti3e
testin' !0 5e4ds, and tr!#"4es/!!tin'
$r!1ed#res................................................ 61
Pra1ti1e E8er1ise 1............................................ 1+)
Ans5ers t! Pra1ti1e E8er1ise 1................................. 1+5
RE%ERENCES..................................................... 1+@
iii
WELDING OPERATIONS I - OD1651 - LESSON 1/TASK 1
LESSON 1
ELECTRODES CLASSI%ICATION AND
INTENDED USES6 AUTO9OTI&E WELDING PROCESSES,
9ATERIALS, AND IDENTI%ICATION PROCESSES6
9ET.ODS O% DESTRUCTI&E AND NONDESTRUCTI&E
TESTING O% WELDS AND TROUBLES.OOTING PROCEDURES6
T:PES AND TEC.NI;UES O% <OINT DESIGN6 AND
T.E T.EOR:, PRINCIPLES, AND PROCEDURES O%
WELDING AR9OR PLATE
TAS= 1. Des1ri"e t/e $r!1esses 0!r identi0in'
e4e1tr!des " 14assi0i1ati!n, and intended
#ses6 and t/e a#t!m!ti3e 5e4din'
$r!1esses, materia4s, and identi0i1ati!n
$r!1esses6 and t/e t$es and te1/ni2#es !0
7!int desi'n.
CONDITIONS
Wit/in a se40,st#d en3ir!nment and 'i3en t/e s#"1!#rse te8t, 5it/!#t
assistan1e.
STANDARDS
Wit/in t/ree /!#rs
RE%ERENCES
N! s#$$4ementar re0eren1es are needed 0!r t/is tas?.
1. Intr!d#1ti!n
We4din' is !ne !0 t/e m!st im$!rtant 0#n1ti!ns $er0!rmed in "!t/ an
intermediate dire1t s#$$!rt AIDSB and intermediate 'enera4 s#$$!rt
AIGSB maintenan1e 1!m$an. E8$erien1e 'ained d#rin' t/e se1!nd 5!r4d
5ar re3ea4ed t/at man "r!?en $arts 1an "e 5e4ded and $#t "a1? int!
ser3i1e, t/#s !0ten sa3in' t/e e8$ense !0 0a"ri1atin' !r $#r1/asin' a
ne5 $ie1e !0 e2#i$ment. As a res#4t !0 t/is e8$erien1e, a ser3i1e
se1ti!n 1!ntainin' a meta45!r?in' s/!$ 5it/ 5e4din' 1a$a"i4ities is n!5
esta"4is/ed 5it/in t/ese maintenan1e !r'aniCati!ns.
1
T/e 0irst tas? !0 t/is 4ess!n is desi'ned t! assist !# in
4earnin' t/e $r!1esses 0!r identi0in' e4e1tr!des "
14assi0i1ati!n, and intended #ses6 t/e a#t!m!ti3e 5e4din'
$r!1esses, materia4s, and identi0i1ati!n $r!1esses, and t/e
te1/ni2#es !0 7!int desi'n as t/e $ertain t! e4e1tri1 ar1
5e4din'.
(. Identi0i1ati!n and Uses !0 E4e1tr!des
a. General. D#rin' e4e1tri1 ar1 5e4din' !$erati!ns, 5/en m!4ten
meta4 is e8$!sed t! t/e atm!s$/ere, it 5i44 a"s!r" !8'en and
nitr!'en 0r!m t/e air and 5i44 "e1!me "ritt4e. T! $r!te1t it
0r!m t/is dama'in' rea1ti!n, a s4a' 1!3er !3er t/e m!4ten !r
s!4idi0in' meta4 m#st "e $r!3ided. T/is 1!3er is made "
1!atin' t/e e4e1tr!de 5it/ a s#"stan1e t/at 5i44 3a$!riCe and
de0#se in t/e ar1 stream t! 0!rm a $r!te1ti3e 1!3er t/at 5i44
sta"i4iCe t/e ar1 and $r!te1t t/e meta4. Be1a#se t/ere are
se3era4 di00erent t$es !0 meta4s #sed in Arm e2#i$ment, it is
ne1essar t! #se t/e 1!rre1t e4e1tr!de 5/ene3er 5e4din' t/is
e2#i$ment. T/e 0!44!5in' s#"$ara'ra$/s des1ri"e t/e
14assi0i1ati!n !0 e4e1tr!des, t/eir intended #ses, and t/e
0a1t!rs t! "e 1!nsidered 5/en se4e1tin' e4e1tr!des.
". Factors in Selecting an Electrode. T/e $#r$!se !0 se4e1tin'
t/e 1!rre1t t$e e4e1tr!de is t! $r!3ide ar1 sta"i4it,
sm!!t/ness !0 t/e 5e4d "ead, eas s4a' rem!3a4, and minim#m
s$atter t/at are essentia4 t! t!$ 2#a4it 5e4din'. %a1t!rs t! "e
1!nsidered 5/en se4e1tin' e4e1tr!des are>
A1B S$e1i0i1 meta4 $r!$erties re2#ired in t/e 5e4d s#1/ as
1!rr!si!n resistan1e, d#1ti4it, !r /i'/ tensi4e stren't/.
A(B T$e !0 "ase meta4 t! "e 5e4ded.
A)B P!siti!n !0 t/e 5e4d, s#1/ as 04at !r 3erti1a4.
ADB T/e t$e !0 e4e1tri1a4 1#rrent t/at is a3ai4a"4e.
A5B E4e1tri1 1#rrent $!4arit Astrai'/t !r re3erseB 5/i1/ is
a3ai4a"4e.
A6B Dimensi!ns !0 t/e se1ti!n t! "e 5e4ded.
A@B T/e t$e !0 0it t/at t/e 5!r? $ermits.
2
1. Classification of Electrodes.
A1B 9eta4,ar1 e4e1tr!des ma "e 'r!#$ed and 14assi0ied as "are
e4e1tr!des, t/in4 1!ated e4e1tr!des, and s/ie4ded,ar1 !r /ea3
1!ated e4e1tr!des. A 14assi0i1ati!n n#m"er series, A0!rm#4ated
" t/e Ameri1an We4din' S!1ietB, /as "een ad!$ted " t/e 5e4din'
ind#str 0!r t/e identi0i1ati!n !0 e4e1tr!des. B means !0 t/is
n#m"erin' sstem, t/e 0!44!5in' 1/ara1teristi1s !0 a 'i3en
e4e1tr!de 1an "e identi0ied>
AaB W/et/er t/e e4e1tr!de /as a 4i'/t !r /ea3 1!atin'.
A"B T/e 1!m$!siti!n !0 t/e 1!atin'.
A1B T/e re1!mmended 5e4din' $!siti!n.
AdB T/e t$e !0 e4e1tri1 1#rrent Adire1t !r a4ternatin'
1#rrentB and t/e $!4arit 0!r 5/i1/ t/e e4e1tr!de is intended.
AeB T/e "ase meta4 0!r 5/i1/ t/e e4e1tr!de is re1!mmended.
A(B T/e identi0i1ati!n sstem 0!r stee4 ar1 5e4din' e4e1tr!des
is a 0!#r di'it n#m"er series $re1eded " a 4etter as des1ri"ed
"e4!5>
AaB T/e sm"!4 E indi1ates t/at t/e e4e1tr!de is intended 0!r
#se in e4e1tri1a4 5e4din'.
A"B T/e 0irst t5! A!r t/reeB di'its !0 t/e n#m"er indi1ate t/e
tensi4e stren't/ At/e resistan1e !0 t/e materia4 t! 0!r1es trin'
t! $#44 it a$artB, in t/!#sands !0 $!#nds $er s2#are in1/, !0 t/e
de$!sited meta4.
A1B T/e t/ird A!r 0!#rt/B di'it indi1ates t/e $!siti!n !0 t/e
5e4d. T/e n#m"er + in eit/er !ne !0 t/ese $!siti!ns indi1ates
t/e 14assi0i1ati!n is n!t #sed. T/e n#m"er 1 indi1ates t/e
e4e1tr!de ma "e #sed 0!r a44 5e4din' $!siti!ns. T/e n#m"er (
indi1ates t/at t/e e4e1tr!de ma "e #sed !n4 in t/e 04at and
/!riC!nta4 $!siti!ns. T/e n#m"er ) indi1ates t/e e4e1tr!de is t!
"e #sed !n4 in t/e 04at 5e4din' $!siti!n.
AdB T/e 0!#rt/ A!r 4astB di'it indi1ates t/e t$e !0 1!atin' !n
t/e e4e1tr!de, and t/e $!5er s#$$4 Aeit/er a4ternatin' 1#rrent
Aa1B !r dire1t
3
1#rrent Ad1B, strai'/t $!4arit As$B, !r re3erse $!4arit Ar$BB
t! "e #sed 5it/ t/e $ertinent e4e1tr!de.
AeB A 4istin' !0 t/e t$es !0 1!atin's, 5e4din' 1#rrents, and
$!4arit re2#irements !0 t/e 0!#rt/ A!r 4astB identi0in' di'it
!0 t/e e4e1tr!de is 4isted "e4!5.
A0B T/e n#m"er E6+1+ identi0ies an e4e1tri1 5e4din' e4e1tr!de
5it/ a minim#m stress re4ie3ed tensi4e stren't/ !0 6+,+++ $si
A$!#nds $er s2#are in1/B. It 1an "e #sed t! 5e4d in a44
$!siti!ns, $re0era"4 #sin' dire1t 1#rrent re3erse $!4arit
e4e1tri1it. .!5e3er, a4ternatin' 1#rrent and dire1t 1#rrent
strai'/t $!4arit 1an a4s! "e #sed.
A)B T/e e4e1tr!de identi0i1ati!n sstem 0!r stain4ess stee4
ar1,5e4din' is set #$ as 0!44!5s>
AaB T/e sm"!4 E indi1ates e4e1tri1 5e4din'.
A"B T/e 0irst t/ree di'its indi1ate t/e Ameri1an Ir!n and Stee4
Instit#te t$e !0 stain4ess stee4.
A1B T/e 4ast t5! di'its indi1ate t/e 1#rrent and t/e 5e4din'
$!siti!n in 5/i1/ it is #sed.
AdB A11!rdin' t! t/is sstem, t/e n#m"er E,)+*,16 identi0ies a
stain4ess stee4 e4e1tr!de t$e )+*, 0!r #se 5it/ a4ternatin' !r
re3erse $!4arit dire1t 1#rrent in a44 5e4din' $!siti!ns.
4
d. Types of Electrodes. T/ere are t/ree di00erent t$es !0
e4e1tr!des. T/e are> "are, t/in4 1!ated, and s/ie4ded,ar1 !r
/ea3,1!ated e4e1tr!des.
A1B Bare Electrodes. Bare e4e1tr!des are made !0 5ire
1!m$!siti!ns re2#ired 0!r s$e1i0i1 a$$4i1ati!ns and /a3e n!
1!atin's !t/er t/an t/!se re2#ired in 5ire dra5in'. T/ese 5ire
dra5in' 1!atin's /a3e s!me s4i'/t sta"i4iCin' e00e1t !n t/e ar1,
"#t are !t/er5ise !0 n! 1!nse2#en1e. Bare e4e1tr!des are #sed
0!r 5e4din' man'anese a44! stee4, and !t/er $#r$!ses 5/ere a
1!ated e4e1tr!de is n!t re2#ired !r is #ndesira"4e. A
dia'rammati1 s?et1/ !0 t/e trans0er !0 meta4 a1r!ss t/e ar1 !0 a
"are e4e1tr!de is s/!5n in 0i'#re 1, 3ie5 A, !n t/e 0!44!5in'
$a'e.
A(B Thinly Coated Electrodes.
AaB T/in4 1!ated e4e1tr!des are made !0 a 5ire !0 a de0inite
1!m$!siti!n. A t/in 1!atin' is a$$4ied !n t/e s#r0a1e !0 t/e
e4e1tr!de " 5as/in', di$$in', "r#s/in', s$rain', t#m"4in', !r
5i$in' t! im$r!3e t/e sta"i4it and 1/ara1teristi1s !0 t/e ar1
stream. T/e are 4isted #nder t/e ED5 series in t/e e4e1tr!de
identi0i1ati!n sstem des1ri"ed in $ara'ra$/ (1, "e'innin' !n
$a'e ).
A"B T/e 1!atin' !n t/ese t$es !0 e4e1tr!des 'enera44 ser3es
t/e 0#n1ti!ns des1ri"ed "e4!5>
1 It diss!43es !r red#1es im$#rities, s#1/ as !8ides, s#40#r,
and $/!s$/!r!#s, and t/#s ?ee$s im$#rities !#t !0 t/e 5e4d
de$!sit.
( It red#1es t/e ad/esi3e 0!r1e "et5een t/e m!4ten meta4 and
t/e end !0 t/e e4e1tr!de, !r 1/an'es t/e s#r0a1e tensi!n !0 t/e
m!4ten meta4 s! t/at t/e '4!"#4es !0 meta4 4ea3in' t/e end !0 t/e
e4e1tr!de are sma44er and m!re 0re2#ent, t/#s ma?in' t/e 04!5 !0
m!4ten meta4 m!re #ni0!rm and 1!ntin#!#s.
) It in1reases t/e sta"i4it !0 t/e ar1 " intr!d#1in'
materia4s readi4 i!niCed int! t/e ar1 stream. T/at is, t/e
1!atin' 0#e4s t/e ar1 " $r!3idin' sma44er $arti14es 5/en t/e
e4e1tri1 1/ar'e !11#rs.
5
%IGURE 1. BARE ELECTRODE 9OLTEN 9ETAL
TRANS%ER AND LIG.T COATED
ELECTRODE ARC ACTION.
A1B S!me !0 t/e 4i'/t 1!atin's ma $r!d#1e a s4a', "#t it is
2#ite t/in and d!es n!t a1t in t/e same manner as t/e s/ie4ded,
ar1, s4a',t$e e4e1tr!de. T/e a1ti!n !0 an ar1 !"tained 5it/ a
4i'/t,1!ated e4e1tr!de is s/!5n in 0i'#re 1, 3ie5 B.
A)B Shielded-arc or Heavy-coated Electrodes. S/ie4ded,ar1 !r
/ea3,1!ated e4e1tr!des are #sed 0!r 5e4din' stee4s and 1ast
ir!n. T/e ar1 a1ti!n !"tained 5it/ a s/ie4d,ar1 !r /ea3,1!ated
e4e1tr!de is s/!5n in 0i'#re (, 3ie5 A, !n t/e 0!44!5in' $a'e.
T/is t$e !0 e4e1tr!de is made !0 5ire 5it/ a t/i1? 1!atin' 5/i1/
/as "een a$$4ied "
6
%IGURE (. ARC ACTION AND ELECTRIC
WELDING POLARIT:.
di$$in', e8tr#si!n, !r !t/er s#ita"4e $r!1ess. T/e e4e1tr!des
are man#0a1t#red 5it/ t/ree 'enera4 t$es !0 1!atin's> 1e44#4!se,
minera4, and 1!m"inati!ns !0 minera4 and 1e44#4!se 1!atin'.
7
AaB T/e 1e44#4!se,1!ated t$es are 1!m$!sed !0 s!4#"4e 1!tt!n
!r !t/er 0!rms !0 1e44#4!se 5it/ a sma44 am!#nt !0 $!tassi#m,
s!di#m, !r titani#m and, in s!me 1ases, !t/er minera4s. T/is
1!atin' $r!3ides $r!te1ti!n t! t/e m!4ten !r s!4idi0in' meta4 "
de3e4!$in' a 'ase!#s C!ne ar!#nd t/e ar1 and a s4a' de$!sit !3er
t/e 5e4d.
A"B T/e minera4 1!atin's 1!nsist !0 s!di#m si4i1ate, meta44i1
!8ides, 14a, and !t/er in!r'ani1 s#"stan1es !r 1!m"inati!ns
t/ere!0. Wit/ t/e minera4,1!ated e4e1tr!de, $r!te1ti!n t! t/e
m!4ten !r s!4idi0in' meta4 is $r!3ided !n4 " a s4a' de$!sit.
A1B T/e 1!m"inati!n !0 a minera4 and 1e44#4!se 1!atin' is
1!m$!sed !0 3ari!#s 2#antities !0 t/e s#"stan1es $re3i!#s4
des1ri"ed 0!r ea1/ !0 t/ese 1!atin's. T/ese 1!atin's $r!3ide
3ari!#s $r!te1ti!n e00e1ts t! t/e ar1, and t! t/e m!4ten !r
s!4idi0in' meta4, de$endin' !n t/e t$e !0 "ase meta4 "ein'
5e4ded.
e. Functions of Electrode Coatings. S!me !0 t/e m!re im$!rtant
0#n1ti!ns !0 t/e 1!atin's !n t/e s/ie4ded,ar1 !r /ea3,1!ated ar1
e4e1tr!des are des1ri"ed in t/e 0!44!5in' s#"$ara'ra$/s.
A1B T/e 1!atin's $r!d#1e a red#1in' !r n!n!8idiCin' atm!s$/ere
ar!#nd t/e ar16 t/#s, $re3entin' t/e 1!ntaminati!n !0 t/e meta4
in t/e ar1 " !8'en and nitr!'en 0r!m t/e air. Wit/!#t t/is
1!atin', t/e !8'en 5!#4d readi4 1!m"ine 5it/ t/e m!4ten meta4,
rem!3e a44!in' e4ements 0r!m t/e meta4, and 1a#se $!r!sit and
!8idati!n !0 t/e 5e4d. T/e nitr!'en 5!#4d 1a#se "ritt4eness, 4!5
d#1ti4it and, in s!me 1ases, 4!5 stren't/ and $!!r resistan1e t!
1!rr!si!n.
A(B T/e 1!atin's red#1e im$#rities s#1/ as !8ides, s#40#r, and
$/!s$/!r!#s s! t/at t/ese im$#rities 5i44 n!t im$air t/e 5e4d
de$!sit.
A)B T/e $r!3ide s#"stan1e t! t/e ar1, 5/i1/ tend t! in1rease
its sta"i4it, s! t/at t/e ar1 1an "e maintained 5it/!#t
e81essi3e s$atterin'.
ADB C!atin's red#1e t/e attra1ti3e 0!r1e "et5een t/e m!4ten
meta4 and t/e end !0 t/e e4e1tr!de, and red#1e t/e s#r0a1e
tensi!n !0 t/e m!4ten meta4. &a$!riCed and me4ted 1!atin's 1a#se
t/e m!4ten
8
meta4 Aat t/e end !0 t/e e4e1tr!deB t! "rea? #$ int! 0ine sma44
$arti14es.
A5B T/e 1!atin's 1!ntain in'redients s#1/ as si4i1ates t/at,
5/en me4ted, 0!rm a s4a' !3er t/e me4ted 5e4d and "ase meta4.
Sin1e t/e s4a' s!4idi0ies at a re4ati3e4 s4!5 rate, it /!4ds t/e
/eat and a44!5s t/e #nder4in' meta4 t! 1!!4 and s!4idi0 s4!54.
T/is s4!5 s!4idi0i1ati!n !0 t/e meta4 $re14#des t/e tra$$in' !0
'ases 5it/in t/e 5e4d and $ermits s!4id im$#rities t! 04!at t!
t/e s#r0a1e. S4!5 1!!4in' a4s! /as an annea4in' e00e1t !n t/e
5e4d de$!sit.
A6B T/e $/si1a4 1/ara1teristi1s !0 t/e 5e4d de$!sit are
m!di0ied " in1!r$!ratin' a44!in' materia4s in t/e e4e1tr!de
1!atin'. A4s!, t/e 04#8in' a1ti!n !0 t/e s4a' 5i44 $r!d#1e a
5e4d !0 a "etter 2#a4it and $ermit 5e4din' at /i'/er s$eeds.
A@B T/e 1!atin' ins#4ates t/e sides !0 t/e e4e1tr!de s! t/at
t/e ar1, at t/e end !0 t/e e4e1tr!de, is 1!n1entrated int! a
1!n0ined area. T/is 0a1i4itates 5e4din' in a dee$ EUE !r E&E
'r!!3e.
A*B T/e 1!atin' $r!d#1es a 1#$, 1!ne, !r s/eat/, as s/!5n in
0i'#re (, 3ie5 A, !n $a'e @, at t/e ti$ !0 t/e e4e1tr!de, 5/i1/
a1ts as a s/ie4d, 1!n1entrates and dire1ts t/e ar1, red#1es /eat
4!sses, and in1reases t/e tem$erat#re at t/e end !0 t/e e4e1tr!de.
0. Polarity of Welding Current A0i'#re (, 3ie5 BB.
A1B T/e e4e1tr!de $!4arit re1!mmendati!ns esta"4is/ed " t/e
man#0a1t#rer s/!#4d "e 0!44!5ed 5/en a s$e1i0i1 t$e !0 e4e1tr!de
is "ein' #sed. T/e $!4arit re1!mmended ma "e eit/er Estrai'/tE
!r Ere3erse.E In strai'/t $!4arit, t/e e4e1tr!de is in t/e
ne'ati3e side !0 t/e 1ir1#it. Wit/ re3erse $!4arit, t/e
e4e1tr!de is in t/e $!siti3e side !0 t/e 1ir1#it.
A(B In 'enera4, strai'/t $!4arit is #sed 0!r a44 mi4d,stee4,
"are, !r 4i'/t4 1!ated e4e1tr!des. Wit/ e4e1tr!des !0 t/is
t$e, t/e 'reater /eat is de3e4!$ed at t/e 5!r?$ie1e "ein' 5e4ded
5/i1/ is t/e $!siti3e side !0 t/e 1#rrent. .!5e3er, 5/en /ea3,
1!ated e4e1tr!des are #sed, t/e 'ases 'i3en !00 in t/e ar1 ma
a4ter t/e /eat 1!nditi!ns s!
9
t/at t/e !$$!site is tr#e and t/e 'reater /eat is $r!d#1ed !n t/e
ne'ati3e side. E4e1tr!de 1!atin's a00e1t t/e /eat 1!nditi!ns
di00erent4, de$endin' !n t/eir 1!m$!siti!n. One t$e !0 /ea3
1!atin' ma $r!3ide t/e m!st desira"4e /eat "a4an1e 5it/ strai'/t
$!4arit, 5/i4e an!t/er t$e !0 1!atin' !n t/e same e4e1tr!de ma
$r!3ide a m!re desira"4e /eat "a4an1e 5it/ re3erse $!4arit.
A)B Re3erse $!4arit is #sed in t/e 5e4din' !0 n!n0err!#s
meta4s s#1/ as a4#min#m, "r!nCe, m!ne4, and ni1?e4. Re3erse
$!4arit is a4s! #sed 5it/ s!me t$es !0 e4e1tr!des 0!r ma?in'
3erti1a4 and !3er/ead 5e4ds.
ADB T/e $r!$er $!4arit 0!r a 'i3en e4e1tr!de 1an "e re1!'niCed
5/en attem$tin' a 5e4d " t/e s/ar$, 1ra1?in' s!#nd !0 t/e ar1.
T/e 5r!n' $!4arit 5i44 1a#se t/e ar1 t! emit a /issin' s!#nd and
t/e 5e4din' "ead 5i44 "e di00i1#4t t! 1!ntr!4.
'. Direct Current rc-!elding Electrodes.
A1B In 'enera4, dire1t 1#rrent Ad1B, s/ie4ded,ar1 e4e1tr!des
are desi'ned eit/er 0!r re3erse $!4arit Ae4e1tr!de $!siti3eB !r
0!r strai'/t $!4arit Ae4e1tr!de ne'ati3eB and are n!t
inter1/an'ea"4e. 9an, "#t n!t a44, !0 t/e dire1t 1#rrent
e4e1tr!des, "!t/ re3erse and strai'/t $!4arit, a4s! 1an "e #sed
5it/ a4ternatin' 1#rrent. Dire1t 1#rrent is $re0erred 0!r man
t$es !0 "are and 1!3ered n!n0err!#s and a44! stee4 e4e1tr!des.
T/ese e4e1tr!des are #sed 5/en 0err!#s 5e4ds are t! "e made in
/!riC!nta4, 3erti1a4, !r !3er/ead $!siti!ns. Re1!mmendati!ns
0r!m e4e1tr!de man#0a1t#rers in14#de t/e t$e !0 "ase meta4 0!r
5/i1/ 'i3en e4e1tr!des are s#ita"4e.
A(B In m!st 1ases, strai'/t $!4arit e4e1tr!des Ae4e1tr!de
ne'ati3eB 5i44 $r!3ide 4ess $enetrati!n t/an t/e re3erse $!4arit
e4e1tr!des Ae4e1tr!de $!siti3eB and, 0!r t/is reas!n, 5i44 $ermit
'reater 5e4din' s$eed. G!!d $enetrati!n 1an "e !"tained 5it/
eit/er t$e #nder $r!$er 5e4din' 1!nditi!ns and ar1 mani$#4ati!n.
/. lternating Current rc-!elding Electrodes.
A1B C!ated e4e1tr!des t/at 1an "e #sed 5it/ eit/er dire1t !r
a4ternatin' 1#rrent are a3ai4a"4e. A4ternatin' 1#rrent is m!re
desira"4e #nder 1ertain !$eratin' 1!nditi!ns. A4ternatin'
1#rrent red#1es
10
ar1 "4!5 Aan #nsta"4e ar1 1!nditi!nB t/at is $arti1#4ar4 /arm0#4
5/en 5e4din' in 1!rners !r restri1ted $4a1es and 5/en /i'/
1#rrents, as re2#ired in t/i1? se1ti!ns, are #sed. Ar1 "4!5, in
t/ese 1ases, 1a#ses "4!5/!4es and s4a' in14#si!ns in t/e 5e4d as
5e44 as a 4a1? !0 0#si!n.
A(B A4ternatin' 1#rrent is #sed in at!mi1 /dr!'en 5e4din', and
in t/!se 1ar"!n,ar1 $r!1esses t/at re2#ire t/e #se !0 t5! 1ar"!n
e4e1tr!des, in !rder t/at a #ni0!rm rate !0 5e4din' and e4e1tr!de
1!ns#m$ti!n ma "e a11!m$4is/ed. In 1ar"!n,ar1 $r!1esses, 5/ere
!ne 1ar"!n e4e1tr!de is #sed, strai'/t $!4arit 5it/ dire1t
1#rrent is re1!mmended "e1a#se t/e e4e1tr!de is t/#s 1!ns#med at
a s4!5er rate.
i. Electrode Defects and their Effects.
A1B I0 1ertain e4ements, !r t/eir !8ides, are $resent in
e4e1tr!de 1!atin's, t/e 5i44 materia44 e00e1t t/e sta"i4it !0
t/e ar1. I0 t/ese im$#rities are $resent in 1!nsidera"4e
2#antities !0 4i'/t !r /ea3 1!atin's, t/e e4e1tr!des 5i44 n!t "e
a"4e t! 1!m$ensate 0!r de0e1ts in t/e 5ire. In "are e4e1tr!des,
"e1a#se t/ere is a4m!st n! 1!atin' !n t/e 5ire, t/e 1!m$!siti!n
and #ni0!rmit !0 t/e 5ire is an im$!rtant 0a1t!r in t/e 1!ntr!4
!0 ar1 sta"i4it. Im$#rities in t/e 5ire 1an 1a#se t/e ar1 t!
"e1!me #nsta"4e.
A(B A4#min#m !r a4#min#m !8ide, e3en 5/en $resent in 2#antities
n!t e81eedin' +.+1 $er1ent, 5i44 1a#se t/e ar1 t! "e1!me
#nsta"4e. Si4i1!n, si4i1!n di!8ide, and ir!n s#40ate a4s! tend
t! ma?e t/e ar1 #nsta"4e. B#t, ir!n !8ide, man'anese !8ide,
1a41i#m !8ide, and ir!n s#40ide tend t! sta"i4iCe t/e ar1.
A)B W/en $/!s$/!r!#s !r s#40#r are $resent in e81ess !0 +.+D
$er1ent, t/e 5i44 im$air t/e 5e4d meta4 "e1a#se t/e are
trans0erred 0r!m t/e e4e1tr!de t! t/e m!4ten meta4. P/!s$/!r!#s
1a#ses 'rain 'r!5t/, "ritt4eness, and E1!4d s/!rtnessE A"ritt4e
5/en "e4!5 red /eatB in t/e 5e4d, and t/ese de0e1ts in1rease in
ma'nit#de as t/e 1ar"!n 1!ntent !0 t/e stee4 in1reases. S#40#r
a1ts as a s4a', "rea?s #$ t/e s!#ndness !0 t/e 5e4d meta4, and
1a#ses E/!t s/!rtnessE A"ritt4e 5/en a"!3e red /eatB. S#40#r is
$arti1#4ar4 /arm0#4 t! "are, 4!5,1ar"!n stee4 e4e1tr!des 5it/ a
4!5 man'anese
11
1!ntent. 9an'anese $r!m!tes t/e 0!rmati!n !0 s!#nd 5e4ds.
ADB I0 t/e /eat treatment 'i3en t/e 5ire 1!re !0 an e4e1tr!de
is n!t #ni0!rm, t/e e4e1tr!de 5i44 $r!d#1e 5e4ds in0eri!r t!
t/!se $r!d#1ed 5it/ an e4e1tr!de !0 t/e same 1!m$!siti!n 5/i1/
/as "een $r!$er4 /eat treated.
A5B T/is 1!m$4etes t/e dis1#ssi!n !0 14assi0in' t$es and #ses
!0 e4e1tr!des. T/e s#11eedin' $ara'ra$/s des1ri"e t/e 5e4din'
$r!1esses, materia4s, and identi0i1ati!n $r!1esses !0 a#t!m!ti3e
5e4din'.
). A#t!m!ti3e We4din' Pr!1esses, 9ateria4s, and Identi0i1ati!n
a. Deter"ining Welda#ility of E$uip"ent. Be0!re re$airin' an
dama'ed materie4, it is ne1essar t! 0irst determine 5/et/er !r
n!t t/e materia4 1an "e satis0a1t!ri4 5e4ded. T/is
determinati!n 1an "e made " 1!nsiderin' t/e 0!44!5in' 0a1t!rs>
A1B T/e nat#re and e8tent !0 t/e dama'e and t/e am!#nt !0
strai'/tenin' and 0ittin' !0 t/e meta4 t/at 5i44 "e re2#ired.
A(B T/e $!ssi"i4it !0 rest!rin' t/e str#1t#re t! an !$era"4e
1!nditi!n 5it/!#t 5e4din' it.
A)B T/e t$e !0 meta4 #sed in t/e dama'ed $art, 5/et/er it 5as
/eat treated, and i0 s!, 5/at /eat treatment 5as #sed.
ADB I0 t/e 5e4din' /eat 5i44 dist!rt t/e s/a$e !r in an manner
im$air t/e $/si1a4 $r!$erties !0 t/e $art t! "e re$aired.
A5B Determine i0 /eat treatin' !r !t/er e2#i$ment !r materia4s
5i44 "e re2#ired in !rder t! ma?e t/e re$air " 5e4din'.
". Deter"ining Welda#le Parts. We4din' !$erati!ns !n Arm
materie4 are restri1ted 4ar'e4 t! t/!se $arts 5/!se essentia4
$/si1a4 $r!$erties are n!t im$aired " t/e 5e4din' /eat.
S#11ess0#4 5e4ded re$airs 1ann!t "e made !n ma1/ined $arts t/at
1arr a dnami1 4!ad. T/is a$$4ies $arti1#4ar4 t! /i'/ a44!
stee4s t/at are /eat treated 0!r /ardness !r t!#'/ness, !r "!t/.
9a1/ined $arts s#1/ as 'ears, s/a0ts, anti,0ri1ti!n "earin's,
s$rin's, 1!nne1tin'
12
r!ds, $ist!ns, 3a43es, and 1ams are 1!nsidered #ns#ita"4e 0!r
0ie4d 5e4din'. T/e $rin1i$a4 reas!n 0!r t/is is t/at t/ese $arts
/a3e "een $re3i!#s4 /eat treated t! 1reate desira"4e $er0!rman1e
1/ara1teristi1s A/ardness !r t!#'/nessB6 5e4din' /eat a4ters !r
destr!s t/ese 1/ara1teristi1s.
1. Deter"ining the Welding %ethod. A#t!m!ti3e e2#i$ment s#1/ as
tr#1?s, tan?s, tr#1?,tra1t!rs, and !t/er 3e/i14es, are
1!nstr#1ted 0r!m a 4ar'e 3ariet !0 meta4s t/at are /eat treated
#nder 3ari!#s $r!1esses. T/e meta4s #sed in14#de 1!$$er a44!s
!0 3ari!#s t$es, 1ar"!n and a44! stee4s, titani#m, a4#min#m,
ma'nesi#m, 4ead, am!n' !t/ers. T/e $rin1i$a4 7!inin' $r!1esses
t/at ma "e #sed are !8a1et4ene, ar1 5e4din', "raCin', and
s!4derin'. O8a1et4ene 5e4din' is #sed 0!r 5e4din' !0 t/in
meta4s and "raCin' !0 1ast ir!n $arts !n a#t!m!ti3e e2#i$ment,
5/i4e s!4derin' is #sed 0!r re$airin' s#1/ $arts as 0#e4 tan?s,
radiat!rs, and e4e1tri1a4 1!nne1ti!ns. T/is 4ess!n, /!5e3er,
1!n1entrates !n t/e ar1 5e4din' $r!1esses 0!r re$air !0
a#t!m!ti3e e2#i$ment. %!r 0#rt/er in0!rmati!n $ertainin' t!
!8a1et4ene 'as 5e4din' and s!4derin', re0er t! T9 -,()@. T/e
0!44!5in' s#"$ara'ra$/s des1ri"e 5e4da"4e a#t!m!ti3e $arts and
t/e met/!ds !0 re$air. T/is 4istin' is an e8tra1t. A m!re
1!m$4ete 4ist !0 re$aira"4e $arts 1an "e 0!#nd in Ta"4es B,( and
B,) !0 T9 -,()@.
A1B Cast &ron' Cast Steel' Car#on Steel' and Forgings.
Genera44, $arts 1!m$!sed !0 t/ese meta4s 1an "e re$aired " t/e
same $r!1ed#re as t/at #sed 0!r t/eir assem"4 !r " "raCin' !r
s!4derin' i0 t/e 7!inin' e2#i$ment !ri'ina44 #sed is n!t
a3ai4a"4e !r s#ita"4e 0!r t/e $#r$!se. %!r e8am$4e, 1ast ir!n
and 1ast stee4 ma "e re$aired " 'as 5e4din', ar1 5e4din', !r "
"raCin'. Parts !r se1ti!ns made !0 1ar"!n stee4 !ri'ina44
assem"4ed " s$!t, $r!7e1ti!n, !r 04as/ 5e4din' ma "e re$aired
" 'as !r ar1 5e4din'. T/is same $r!1ed#re is tr#e !0 0!r'in's.
A(B Cast &ron Engine Bloc(s A0i'#re ), !n t/e 0!44!5in' $a'eB.
AaB General. En'ine "4!1?s ma "e re$aired " 5e4din' !r
"raCin' in t/e 0ie4d !n4 #nder e8treme emer'en1 1!nditi!ns and
i0 a re$4a1ement "4!1? is n!t a3ai4a"4e. We4din' !r "raCin' !0
en'ine "4!1?s is 4imited t! t/!se areas des1ri"ed "e4!5>
13
%IGURE ). PREPARING ENGINE BLOC=
%OR WELDING.
1 A11ess!r m!#nts s#1/ as 'enerat!r, starter, !r en'ine
m!#nts. Be1a#se !0 $!ssi"4e 5ar$a'e, m!#nt a4i'nment m#st "e
1/e1?ed a0ter 5e4din'.
( Sma44 sand $its A1astin' de0e1tsB dete1ted at time !0 !34
#s#a44 "e t!! $!r!#s and m#st "e rem!3ed and t/e 5e4d re$eated
#nti4 a s!#nd 0irst $ass is !"tained.
14
A"B Procedure. B!t/ t/e s/ie4ded meta4,ar1 met/!d and "raCin'
5it/ !8a1et4ene ma "e #sed 0!r re$air !0 1ra1?s in 1ast ir!n
en'ine "4!1?s. W/en #sin' t/e s/ie4ded meta4,ar1 met/!d !0
re$air, a 5e4din' r!d 5it/ a /i'/ ni1?e4 1!ntent !0 at 4east 5+
t! 6+ $er1ent m#st "e #sed. Cra1?s in a 1ast ir!n en'ine "4!1?
m#st "e $r!$er4 $re$ared $ri!r t! 5e4din', !t/er5ise Aa0ter
1!!4in'B, t/e 5e4d de$!sit s/rin?s, 5/i1/ $#44s t/e 1ra1?
t!'et/er and res#4ts in t/e 0!rmati!n !0 interna4 stress. T/is
stress 0ina44 re4ie3es itse40 " 1ra1?in' d#e t! 1!ntin#ed
3i"rati!n d#rin' en'ine !$erati!n. S#"se2#ent $ara'ra$/s $r!3ide
t/e ste$s t/at s/!#4d "e 0!44!5ed t! e4iminate t/is stress and
e00e1ti3e4 re$air t/e 1ra1?.
1 Dri44 a 1F* in1/ diameter /!4e 1FD in1/ "e!nd ea1/ end !0
t/e 1ra1? as s/!5n in 0i'#re ), 3ie5 A, !n t/e $re3i!#s $a'e.
( C4ean and 'r!!3e t/e 1ra1? and rem!3e t/e Eas 1astE s#r0a1e
!r s?in " 'rindin' !r ma1/inin'.
) Pre/eat t/e 1astin' " "a?in' !r 4!1a44 /eatin' t/e
1astin' at 1+++G %a/ren/eit 0!r a 0e5 min#tes t! rem!3e a44
m!ist#re. AIt is im$erati3e t/at a44 m!ist#re "e rem!3ed,
!t/er5ise t/e 5e4d 5i44 n!t ad/ere t! t/e "ase meta4.B
D Dri44 and ta$ a /!4e t! re1ei3e a 1FD in1/ "!4t in t/e
1enter !0 t/e 1ra1? as s/!5n in 0i'#re ), 3ie5 B. S1re5 and
ti'/ten a "!4t s4i'/t4 dee$er t/an t/e t/i1?ness !0 t/e "ase
meta4. Sta?e t/e sides !0 t/e "!4t 5it/ a 1enter $#n1/ s! t/at
it 5i44 n!t "a1? !#t, and 1#t !00 t/e "!4t as s/!5n in 0i'#re ),
3ie5 C.
5 We4d t/e 1ra1? #sin' t/e "a1?ste$ met/!d s/!5n in 0i'#re ),
3ie5 D, and $een ea1/ "ead 5it/ a r!#nd n!se t!!4.
6 T/e minim#m $re/eat and inter$ass tem$erat#re s/!#4d n!t "e
"e4!5 D++G t! 5++G % 5/en #sin' a ni1?e4 r!d, and t/e 5e4d s/!#4d
n!t "e a44!5ed t! 1!!4 5/en a$$4in' m!re t/an !ne $ass. I0 a44
t/e im$re'nated !i4 !r 'as is n!t e4iminated d#rin' $re/eatin',
t/e 0irst $ass 5i44 #s#a44 "e t!! $!r!#s and m#st "e rem!3ed and
t/e 5e4d re$eated #nti4 a s!#nd 0irst $ass is !"tained.
@ A44!5 t/e 1!m$4eted 5e4d t! 1!!4 s4!54 " $4a1in' an
as"est!s "4an?et !3er t/e 5e4ded area.
15
N!n#ni0!rm !r ra$id 1!!4in' 5i44 1reate interna4 stresses.
We4ded en'ine "4!1?s m#st "e 4ea? tested "e0!re $4a1in' t/em "a1?
in !$erati!n. Lea? testin' $r!1ed#res are s$e1i0ied in T9 -,()@.
A)B Heat Treated Parts.
AaB T/e 0#n1ti!ns $er0!rmed " 1ertain $arts in a#t!m!ti3e
e2#i$ment re2#ire /eat treatment d#rin' t/eir man#0a1t#re.
We4din' !0 t/ese $arts s/!#4d n!t "e attem$ted #n4ess t/e re$air
s/!$ is e2#i$$ed 5it/ s#ita"4e /eat treatin' e2#i$ment 0!r
/and4in' t/ese $arts a0ter 5e4din'.
A"B In s!me 1ases, a44! stee4s, !r s$e1ia44 treated $arts,
ma "e re$aired " #sin' a /eat a00e1ted C!ne t/at is 5ea?er t/an
t/e !ri'ina4 /eat treated $art. In 'enera4, 5/ere it is $!ssi"4e
t! /eat treat t/e $arts a0ter 5e4din', t/e s/!#4d "e annea4ed
$ri!r t! 5e4din' t/em. %i44er meta4 !0 t/e same 1!m$!siti!n !r
$r!$erties as t/e "ase meta4 s/!#4d "e #sed, and t/e $arts /eat
treated a0ter 5e4din'.
A1B In 1ases 5/ere t/e $art t! "e 5e4ded is in a /eat treated
1!nditi!n, a stain4ess stee4 0i44er r!d and t/e transiti!n "ead
5e4din' met/!d ma "e #sed as des1ri"ed "e4!5>
1 De$!sit a 4aer !0 stain4ess stee4 A(5 $er1ent 1/r!mi#m, (+
$er1ent ni1?e4, !r m!di0ied 1* $er1ent 1/r!mi#m, * $er1ent ni1?e4
stain4ess stee4 r!dB !n t/e s#r0a1es !0 t/e "r!?en ed'es.
( We4d t/e $re$ared ed'es 5it/ mi4d stee4 !r /i'/ stren't/
0i44er meta4. Use 11 t! 1D $er1ent man'anese !r /i'/ stren't/
0i44er meta4 !n t/e stain4ess stee4 4aer instead !0 mi4d stee4
5/ere /ardness and t!#'/ness are re2#ired. T/e 5e4d t/en ma "e
1!3ered 5it/ a 4aer !0 /ard s#r0a1in' meta4.
AdB T/ese met/!ds are #se0#4 in t/e 0ie4d, "#t s/!#4d "e #sed
#nder emer'en1 1!nditi!ns !n4.
ADB Wheel )ehicle Co"ponents.
AaB Fra"es. T/e re$air !0 0rames " 5e4din' is n!t a#t/!riCed.
Cr!ssmem"ers and /!rns 0!r t/e 0rame ma "e strai'/tened,
re$aired, and rein0!r1ed. A 1!mm!n4 #sed met/!d !0 re$airin'
and stren't/enin' a "r!?en !r 5ea?ened 1r!ssmem"er !r /!rn is
$er0!rmed " #sin' rein0!r1in' $4ates as
16
s/!5n in 0i'#re D. T/is met/!d !0 re$air s/!#4d "e 0!44!5ed 5/en
rein0!r1ement $4ates are 5e4ded t! an'4es, tees, "!8 se1ti!ns, !r
I,"eams. T/e t$e !0 rein0!r1ement se4e1ted de$ends !n t/e
4!1ati!n !0 t/e re$air and $!ssi"4e inter0eren1e 5it/ t/e
%IGURE D. REIN%ORCING %RA9E 9E9BERS.
17
!$erati!n !0 1!m$!nents. A44 $r!tr#si!ns s/!#4d "e 'r!#nd d!5n
04#s/ "e0!re rein0!r1in' $4ates are a$$4ied. Rein0!r1ement
$4ates s/!#4d "e a$$r!8imate4 t/e same t/i1?ness as t/e 0rame
se1ti!n and t/e 5idt/ s#00i1ient t! "rin' t/e 5e4d 04#s/ 5it/ t/e
t!$ and "!tt!m se1ti!ns !0 t/e 1/anne4. It s/!#4d "e n!ted t/at
t/e 5e4ded ends !0 t/e $4ates $r!d#1e /eat a00e1ted areas !0
de1reased stren't/ a1r!ss t/e "a1? and 4e's !0 t/e 1/anne4.
A"B Front *les. %r!nt a84es are made !0 /eat treated a44!
dr!$ 0!r'in's. Re$airs " 5e4din' s/!#4d n!t "e made !n t/ese
a84es e81e$t as a tem$!rar meas#re #nder e8treme emer'en1
1!nditi!ns.
A1B +ear *le Housings. T/ese 1!m$!nents are made !0 5e4ded
$ressed stee4 !r ma44ea"4e 1ast ir!n !r 1ast stee4. T/e $ressed
stee4 and 1ast stee4 /!#sin's 1an "e ar1 5e4ded. T/e ma44ea"4e
ir!n /!#sin's s/!#4d "e re$aired " "raCin'6 a4t/!#'/, t/e 1an
"e 5e4ded i0 e8treme $re1a#ti!ns are maintained. Castin's s/!#4d
"e ?e$t 14ean in t/e 3i1init !0 t/e 5e4d.
AdB Drive Shafts. Dri3e s/a0ts are #s#a44 made !0 medi#m
1ar"!n stee4 seam4ess t#"in' and are readi4 5e4da"4e " eit/er
ar1 !r 'as 5e4din'.
AeB %achined lloy Steel Parts. T/ese t$e $arts s#1/ as
1ran?s/a0ts, 1!nne1tin' r!ds, 'ears, and a84e dri3e s/a0ts are
n!t 'enera44 re$aired " 5e4din' "e1a#se t/e /eat !0 5e4din'
5i44 im$air t/e meta4 2#a4ities $r!d#1ed " $re3i!#s /eat
treatment.
A0B +adiators. Radiat!rs 1an "e re$aired 5it/ an !8a1et4ene
5e4din' t!r1/ 1!ntainin' a $r!$er ti$, 1!mm!n 5+,5+ s!4der, and
04#8. T/e !8a1et4ene 04ame s/!#4d "e ad7#sted t! 'i3e a s4i'/t
1ar"#riCin' mi8t#re. T/e areas ar!#nd t/e 4ea?s in t/e 1!$$er
t#"es s/!#4d "e t/!r!#'/4 14eaned, $re0era"4 5it/ a 5 $er1ent
s!4#ti!n !0 /dr!1/4!ri1 a1id, and tinned "e0!re t/e 7!int is
made in !rder t! ens#re a ti'/t 7!int. %!r 4ea?s "et5een 1!$$er
and 1ast ir!n, t/e s#r0a1e !0 t/e ir!n s/!#4d "e $i1?4ed "e0!re
t/e re$air is made. Pi1?4in' t/e s#r0a1e !0 t/e ir!n is d!ne "
a$$4in' a 5 $er1ent /dr!1/4!ri1 a1id s!4#ti!n t! it at t/e
7!int and /eatin' it #nti4 t/!r!#'/4 14eaned.
18
A5B Co"#at )ehicles. Tan? /#44s are 1!nstr#1ted !0 arm!r $4ate
0!r $r!te1ti!n !0 t/e 1re5 and t! 5/i1/ t/e interna4 and e8terna4
me1/anisms !0 t/e tan? are 0astened t! t/e /#44. T/e s#s$ensi!n
sstem 1!nsists 4ar'e4 !0 1astin's and 0!r'in's. &ari!#s
1astin's are #sed t/r!#'/!#t t/e $!5ertrain. C!m$!nent $arts
t/at d! n!t 1arr t/e dri3in' $!5er 4!ad 1an "e re$aired "
5e4din'. In 'enera4, t/e re$air !0 t/ese $arts re2#ires s$e1ia4
$re1a#ti!ns s#1/ as $re/eatin', $!st5e4d /eat treatments, and t/e
$r!$er 5e4din' $r!1ed#re. One !0 t/e $rin1i$a4 re$airs $er0!rmed
!n 1!m"at 3e/i14es is 5e4din' dama'e se1ti!ns !0 arm!r $4ate.
T/e te1/ni2#e 0!r 5e4din' arm!r $4ate 5i44 "e dis1#ssed in Tas?
(. T/e 0!44!5in' $ara'ra$/s des1ri"e t/e t$e and te1/ni2#es !0
7!int desi'n.
D. We4din' <!int Desi'n
a. General. T/e $r!$erties !0 a 5e4ded 7!int de$end $art4 !n
t/e 1!rre1t $re$arati!n !0 t/e ed'es "ein' 5e4ded. T/e 7!int
ed'es s/!#4d "e 14eaned !0 a44 r#st, !8ides and !t/er im$#rities,
and $re$ared t! $ermit 0#si!n 5it/!#t e81essi3e me4tin'. T/is
$re$arati!n is '!3erned " t/e 0!rm, t/i1?ness, ?ind !0 meta4,
t/e 4!ad t! "e s#$$!rted, and t/e a3ai4a"4e means 0!r $re$arin'
t/e 7!int.
". Types of ,oints. T/ere are "asi1a44 0i3e t$es !0 7!ints
#sed t! 5e4d 3ari!#s 0!rms !0 meta4. T/ese t$es !0 7!ints are
des1ri"ed in t/e 0!44!5in' s#"$ara'ra$/s.
A1B Butt ,oint A0i'#re 5 !n t/e 0!44!5in' $a'eB. T/is t$e
7!int is #sed 0!r 7!inin' t/e ed'es !0 t5! $4ates !r s#r0a1es
4!1ated a$$r!8imate4 in t/e same $4ane. P4ain s2#are "#tt
7!ints 0!r t/in meta4 se1ti!ns are s/!5n in 0i'#re 5, 3ie5 A.
T/ese 7!ints are #sed 0!r "#tt 5e4din' 4i'/t s/eet meta4. B#tt
7!ints 0!r /ea3 se1ti!ns 5it/ se3era4 t$es !0 ed'e $re$arati!n
are s/!5n in 0i'#re 5, 3ie5s B t/r!#'/ E. T/ese ed'es 1an "e
$re$ared " 04ame 1#ttin', s/earin', 04ame 'r!!3in', ma1/inin',
1/i$$in', !r 'rindin'. P4ate t/i1?nesses !0 )F* t! 1F( in1/ 1an
"e 5e4ded #sin' t/e sin'4e & !r sin'4e U 7!ints as s/!5n in
0i'#re 5, 3ie5s B and C. T/e ed'es !0 /ea3ier se1ti!ns s/!#4d "e
$re$ared as s/!5n in 0i'#re 5, 3ie5s D and E. In 'enera4, "#tt
7!ints $re$ared 0r!m "!t/ sides $ermit easier 5e4din', $r!d#1e
4ess dist!rti!n, and ens#re "etter 5e4d meta4 2#a4ities in /ea3
se1ti!ns t/an 7!ints $re$ared 0r!m !ne side !n4.
19
%IGURE 5. BUTT <OINTS.
A(B Corner ,oint A0i'#re 6, 3ie5s A t/r!#'/ D, !n t/e 0!44!5in'
$a'eB. T/is t$e 7!int is #sed t! 7!in t5! mem"ers 4!1ated
a$$r!8imate4 at ri'/t an'4es t! ea1/ !t/er in t/e 0!rm !0 an L.
T/e 0i44et 5e4d 1!rner 7!int, s/!5n in 0i'#re 6, 3ie5 A, is #sed
in t/e 1!nstr#1ti!n !0 "!8es, "!8 0rames, tan? 1!ntainers and
simi4ar 0a"ri1ati!ns. T/e 14!sed 1!rner 7!int, s/!5n in 0i'#re
6, 3ie5 B, is #sed !n 4i'/ter s/eets 5/en /i'/ stren't/ is n!t
re2#ired at t/e 7!int. W/en #sin' !8a1et4ene 5e4din', t/e
!3er4a$$in' ed'e is me4ted d!5n and
20
%IGURE 6. CORNER, EDGE, LAP, AND
TEE <OINTS.
4itt4e !r n! 0i44er meta4 is added. In ar1 5e4din', !n4 a 3er
4i'/t "ead is re2#ired t! ma?e t/e 7!int. T/e !$en 1!rner 7!int,
s/!5n in 0i'#re 6, 3ie5 C, is #sed !n /ea3ier s/eets and $4ates6
t/e t5! ed'es are me4ted d!5n and 0i44er meta4 is added t! 0i44
#$ t/e 1!rner. C!rner 7!ints !n /ea3 $4ates are 5e4ded 0r!m
"!t/ sides as s/!5n in 0i'#re 6, 3ie5 D. T/e 7!int is 0irst
5e4ded 0r!m t/e !#tside, t/en rein0!r1ed 0r!m t/e "a1? side 5it/
a sea4 "ead.
21
A)B Edge ,oint A0i'#re 6, 3ie5s E, %, and G !n t/e $re3i!#s
$a'eB. T/is t$e 7!int is #sed t! 7!in t5! !r m!re $ara44e4
mem"ers s#1/ as ed'es !0 s/eet meta4, an'4es, m#004ers, 4i2#id
tan? 1!ntainers, assem"4 /!#sin's, and rein0!r1in' $4ates in
04an'es !0 I "eams. T5! $ara44e4 $4ates are 7!ined t!'et/er as
s/!5n in 0i'#re 6, 3ie5 E. On /ea3 $4ates, s#00i1ient 0i44er
meta4 is added t! 0#se !r me4t ea1/ $4ate ed'e 1!m$4ete4 and t!
rein0!r1e t/e 7!int. Li'/t s/eets are 5e4ded as s/!5n in 0i'#re
6, 3ie5 %. N! $re$arati!n is ne1essar !t/er t/an t! 14ean t/e
ed'es and ta1? 5e4d t/em in $!siti!n. T/e ed'es 1an t/en "e
0#sed t!'et/er 5it/!#t 0i44er meta4 re2#ired. T/e /ea3 $4ate
7!int s/!5n in 0i'#re 6, 3ie5 G, re2#ires t/at t/e ed'es "e
"e3e4ed 0!r '!!d $enetrati!n and 0#si!n !0 t/e side 5a44s.
%i44er meta4 is #sed in t/is 7!int.
ADB -ap ,oint A0i'#re 6, 3ie5s ., I, and <B. T/is t$e !0
7!int is #sed t! 7!in t5! !3er4a$$in' mem"ers. A sin'4e 4a$
7!int, 5/ere 5e4din' m#st "e d!ne 0r!m !ne side, is s/!5n in
0i'#re 6, 3ie5 .. T/e d!#"4e 4a$ 7!int s/!5n in 0i'#re 6, 3ie5
I, is 5e4ded !n "!t/ sides and de3e4!$s t/e 0#44 stren't/ !0 t/e
5e4ded mem"ers. T/e !00set 4a$ 7!int s/!5n in 0i'#re 6, 3ie5 <,
is #sed 5/ere t5! !3er4a$$in' $4ates m#st "e 7!ined and 5e4ded in
t/e same $4ane. T/e !00set 4a$ 7!int is str!n'er t/an t/e sin'4e
4a$ t$e, "#t is m!re di00i1#4t t! $re$are.
A5B Tee ,oint. Tee 7!ints are #sed t! 5e4d t5! $4ates !r
se1ti!ns 5/!se s#r0a1es are 4!1ated a$$r!8imate4 -+ de'rees t!
ea1/ !t/er at t/e 7!int. A $4ain tee 7!int 5e4ded 0r!m "!t/
sides is s/!5n in 0i'#re 6, 3ie5 L. A $4ain tee 7!int, re2#irin'
!n4 14eanin' t/e end !0 t/e 3erti1a4 $4ate and t/e s#r0a1e !0
t/e /!riC!nta4 $4ate, is s/!5n in 0i'#re @, 3ie5 A, !n t/e
0!44!5in' $a'e. T/e sin'4e "e3e4 7!int s/!5n in 0i'#re @, 3ie5
B, is #sed in $4ates and se1ti!ns #$ t! 1F( in1/ t/i1?. T/e
d!#"4e "e3e4 7!int s/!5n in 0i'#re @, 3ie5 C, is #sed !n /ea3
$4ates t/at 1an "e 5e4ded 0r!m "!t/ sides. T/e sin'4e < 7!int
s/!5n in 0i'#re @, 3ie5 D, is #sed 0!r 5e4din' $4ates 1 in1/
t/i1? !r /ea3ier 5/ere 5e4din' is d!ne 0r!m !ne side. T/e d!#"4e
< 7!int s/!5n in 0i'#re @, 3ie5 E, is #sed 0!r 5e4din' 3er /ea3
$4ates 0r!m "!t/ sides.
22
WELDING OPERATIONS I OD1651 - LESSON 1/TASK 1
%IGURE @. TEE <OINT EDGE PREPARATION.
1. Types of Welds. T/e t$e !0 5e4d #sed 5i44 determine t/e
manner !0 seam, 7!int, !r s#r0a1e $re$arati!n. A 4istin' !0 t/e
di00erent 5e4ds #sed is $r!3ided in t/e 0!44!5in' s#"$ara'ra$/s.
A1B Groove Weld A0i'#re * !n t/e 0!44!5in' $a'eB. T/ese are
5e4ds t/at are made in a 'r!!3e "et5een t5! mem"ers t! "e 7!ined.
In t/is $!siti!n, t/e a8is !0 t/e 5e4d 4ies a$$r!8imate4 in a
/!riC!nta4 $4ane and t/e 0a1e !0 t/e 5e4d 4ies a$$r!8imate4 in a
3erti1a4 $4ane.
A(B Surfacing Weld A0i'#re - !n $a'e (5B. T/is t$e 5e4d is
1!m$!sed !0 !ne !r m!re strin' !r 5ea3e "eads de$!sited !n an
#n"r!?en s#r0a1e t! !"tain desired $r!$erties !r dimensi!ns.
23
%IGURE *. GROO&E WELDS.
24
WELDING OPERATIONS I 0D1651 - LESSON 1/TASK 1
%IGURE -. SUR%ACING, PLUG AND SLOT WELDS.
A)B Plug Weld A0i'#re -B. T/is is a 1ir1#4ar 5e4d made t/r!#'/
!ne mem"er !0 a 4a$ !r tee 7!int 7!inin' t/at !ne mem"er 5it/ t/e
!t/er. T/is t$e 5e4d ma !r ma n!t "e made t/r!#'/ a /!4e in
t/e 0irst mem"er.
ADB Slot Weld A0i'#re -B. T/is 5e4d is made in an e4!n'ated
/!4e in !ne mem"er !0 a 4a$ 7!int !r tee 7!int 7!inin' t/at
mem"er t! t/e s#r0a1e !0 t/e !t/er mem"er t/at is e8$!sed t/r!#'/
t/e /!4e.
A5B Fillet Weld. T/is t$e 5e4d is s/!5n in 0i'#re 6, 3ie5 L,
!n $a'e (1. It is a trian'#4ar 1r!ss se1ti!n 5e4d 7!inin' t5!
s#r0a1es at ri'/t an'4es t! ea1/ !t/er.
A6B Flash Weld A0i'#re 1+ !n t/e 0!44!5in' $a'eB. T/is 5e4d is
made " t/e a$$4i1ati!n !0 $ress#re !3er t/e entire area !0
a"#ttin' s#r0a1es a0ter /eatin' t/em is 1!m$4eted.
25
%IGURE 1+. SEA9, SPOT, %LAS., AND UPSET WELDS.
A@B Sea" Weld A0i'#re 1+B. T/is 5e4d is made eit/er " ar1
seam 5e4din' in 5/i1/ a 1!ntin#!#s 5e4d is made a4!n' 0rain'
s#r0a1es " dra5in' t/e ar1 "et5een t/e e4e1tr!de and t/e
5!r?$ie1e, !r " resistan1e seam 5e4din' 5/ere t/e 5e4d is a
series !0 !3er4a$$in' s$!t 5e4ds made $r!'ressi3e4 a4!n' a 7!int
" r!tatin' t/e 1ir1#4ar e4e1tr!des.
26
A*B Spot Weld A0i'#re 1+ !n t/e $re3i!#s $a'eB. T/is is a 5e4d
made " eit/er ar1 s$!t 5e4din' 5/ere a 5e4d is made in !ne s$!t
" dra5in' t/e ar1 "et5een t/e e4e1tr!de and t/e 5!r?$ie1e, !r
resistan1e s$!t 5e4din' 5/ere t/e siCe and s/a$e !0 t/e
indi3id#a44 0!rmed 5e4ds are 4imited " t/e siCe and 1!nt!#r !0
t/e e4e1tr!des.
A-B .pset Weld A0i'#re 1+B. T/is is a 5e4d made sim#4tane!#s4
!3er t/e entire area !0 a"#ttin' s#r0a1es !r $r!'ressi3e4 a4!n'
a 7!int 5/i4e $ress#re is a$$4ied "e0!re /eatin' is started and
is maintained t/r!#'/!#t t/e /eatin' $eri!d.
d. Welding Positions A0i'#re 11 !n t/e 0!44!5in' $a'eB. A44
5e4din' 1an "e 14assi0ied a11!rdin' t! t/e $!siti!n !0 t/e
5!r?$ie1e !r t/e $!siti!n !0 t/e 7!int !n t/e $4ates !r se1ti!ns
"ein' 5e4ded. T/ere are 0!#r 'enera4 $!siti!ns in 5/i1/ 5e4ds
are re2#ired t! "e made. T/ese $!siti!ns are desi'nated as 04at,
/!riC!nta4, 3erti1a4, and !3er/ead.
5. We4din' Te1/ni2#es
a. General. In meta4,ar1 5e4din' a n#m"er !0 se$arate 0a1t!rs
are res$!nsi"4e 0!r t/e trans0er !0 m!4ten 0i44er meta4 and
m!4ten s4a' t! t/e "ase meta4. Am!n' t/ese are t/e te1/ni2#es
em$4!ed in t/e a1t#a4 $r!1ess !0 5e4din'. T/e 0!44!5in'
s#"$ara'ra$/s ser3e t! des1ri"e t/ese te1/ni2#es.
". Welding Current' )oltage' and d/ust"ents.
A1B T/e se4e1ti!ns !0 t/e $r!$er 5e4din' 1#rrents and 3!4ta'es
de$end !n t/e siCe !0 t/e e4e1tr!de, t/e t/i1?ness !0 t/e $4ate
"ein' 5e4ded, t/e 5e4din' $!siti!n, and t/e 5e4derHs s?i44.
E4e1tr!des !0 t/e same siCe 1an 5it/stand /i'/er 1#rrent and
3!4ta'e 3a4#es 5/en 5e4din' in t/e 04at 5e4din' $!siti!n t/an in
3erti1a4 !r t/e !3er/ead 5e4din' $!siti!n. In 'enera4, t/e
$r!$er 1#rrent and 3!4ta'e settin's are !"tained 0r!m e8$erien1e
and s/!#4d 0i44 t/e re2#irements !0 t/e $arti1#4ar 5e4din'
!$erati!n. Sin1e se3era4 0a1t!rs a00e1t 1#rrent and 3!4ta'e
re2#irements, data $r!3ided " 5e4din' a$$arat#s and e4e1tr!de
man#0a1t#rers s/!#4d "e #sed. %!r initia4
27
%IGURE 11. WELDING POSITIONS.
28
settin's, ta"4e 1, indi1ates t/e 1#rrent t! "e #sed 5/en 5e4din'
5it/ "are !r 4i'/t4 1!ated e4e1tr!des. T/e ar1 3!4ta'e 5i44
3ar 0r!m a$$r!8imate4 15 3!4ts 0!r 1F16 in1/ e4e1tr!des t! )+
3!4ts 0!r )F* in1/ e4e1tr!des !0 eit/er t/e "are !r 4i'/t4
1!ated t$es. Us#a44, a )F16 in1/ diameter e4e1tr!de is t/e
ma8im#m siCe 0!r 3erti1a4 and !3er/ead 5e4din' $!siti!ns.
TABLE 1. CURRENT SETTINGS %OR BARE AND
LIG.TL: COATED ELECTRODES.
A(B T/e minera4,1!ated t$e !0 s/ie4ded,ar1 e4e1tr!de, 5/i1/
$r!d#1es a s4a' as a s/ie4d, re2#ires a /i'/er 5e4din' 1#rrent
t/an t/e 1e44#4!se,1!ated t$e, 5/i1/ $r!d#1es a 4ar'e 3!4#me !0
'as t! s/ie4d t/e ar1 stream. Ta"4e ( !n t/e 0!44!5in' $a'e
s/!5s t/e 1#rrent re2#irements 0!r t/e minera4,1!ated and t/e
1e44#4!se,1!ated t$es !0 e4e1tr!des. T/e 5e4din' 3!4ta'e 5i44
ran'e 0r!m (+ 3!4ts 0!r t/e )F)( in1/ e4e1tr!de t! )+ 3!4ts 0!r
t/e )F* in1/ /ea3,1!ated e4e1tr!des !0 eit/er t$e.
A)B S/ie4ded,ar1 !r /ea3,1!ated e4e1tr!des are #sed 0!r m!st
5e4din' !$erati!ns !n stee4 rat/er t/an t/e "are !r 4i'/t4
1!ated t$es. T/e /ea3,1!ated e4e1tr!des a44!5 /i'/er 5e4din'
s$eeds, $r!3ide a44!in' e4ements int! t/e 5e4d meta4 " means !0
t/e 1!atin' !n t/e e4e1tr!de, as is d!ne 5it/ 1ertain stain4ess
stee4 e4e1tr!des. T/e s/ie4ded,ar1 t$e !0 e4e1tr!de is #sed 0!r
5e4din' n!n0err!#s meta4s and 1ertain a44! stee4s, $arti1#4ar4,
stain4ess stee4 a44!s.
29
TABLE (. CURRENT SETTINGS %OR 9INERAL AND
CELLULOSE COATED ELECTRODES.
ADB In $re$arati!n 0!r 5e4din', t/e 5e4din' ma1/ine m#st "e
ad7#sted t! $r!3ide $r!$er 5e4din' 1!nditi!ns 0!r t/e $arti1#4ar
siCe and t$e !0 e4e1tr!de "ein' #sed. T/ese ad7#stments in14#de
$r!$er $!4arit, as 5e44 as 1#rrent and 3!4ta'e settin's. T/e
d#a4,1!ntr!4 ma1/ines ma?e $!ssi"4e t/e se$arate 1!ntr!4 !0
3!4ta'e and 1#rrent t/at is de4i3ered t! t/e ar1. In sin'4e,
1!ntr!4 #nits, t/e 5e4din' 1#rrent is 1!ntr!44ed man#a44 5/i4e
t/e 3!4ta'e is ad7#sted a#t!mati1a44.
A5B W/en $r!$er ad7#stment !0 t/e 5e4din' ma1/ine is !"tained,
t/e e8$!sed end !0 t/e e4e1tr!de s/!#4d "e 'ri$$ed in t/e
e4e1tr!de /!4der s! t/at t/e entire #sa"4e 4en't/ 1an "e
de$!sited, 5it/!#t "rea?in' t/e ar1. In s!me 1ases, 5/en 5e4din'
5it/ 4!n' e4e1tr!des, t/e 1enter !0 t/e e4e1tr!de is "ared and
'ri$$ed in t/e 1enter. Car"!n and 'ra$/ite e4e1tr!des s/!#4d "e
'ri$$ed s/!rt !0 t/e 0#44 4en't/ t! a3!id !3er/eatin' t/e entire
e4e1tr!de.
1. Starting the rc A0i'#re 1( !n t/e 0!44!5in' $a'eB.
A1B T/e 0!44!5in' are t5! met/!ds #sed 0!r startin' t/e ar1>
A1B t/e stri?in' !r "r#s/in' met/!d s/!5n in 0i'#re 1(, 3ie5 A,
and A(B t/e ta$$in' met/!d s/!5n in 0i'#re 1(, 3ie5 B. In "!t/
met/!ds, t/e ar1 is 0!rmed " s/!rt 1ir1#itin' t/e 5e4din'
1#rrent "et5een t/e e4e1tr!de and t/e 5!r? s#r0a1e. T/e s#r'e !0
/i'/ 1#rrent 1a#ses "!t/ t/e end !0 t/e e4e1tr!de and a sma44
s$!t !n t/e "ase meta4 "eneat/ t/e e4e1tr!de t! me4t instant4.
30
%IGURE 1(. STARTING T.E ARC.
A(B In t/e stri?in' and "r#s/in' met/!d, t/e e4e1tr!de is
"r!#'/t d!5n t! t/e 5!r? 5it/ a 4atera4 m!ti!n simi4ar t! t/at !0
stri?in' a mat1/. As s!!n as t/e e4e1tr!de t!#1/es t/e 5!r?
s#r0a1e, t/e e4e1tr!de is raised t! esta"4is/ t/e ar1. T/e ar1
4en't/ !r 'a$ "et5een t/e end !0 t/e e4e1tr!de and t/e 5!r?
s/!#4d "e a$$r!8imate4 e2#a4 t! t/e diameter !0 t/e e4e1tr!de.
W/en t/e $r!$er 4en't/ !0 t/e ar1 is !"tained, a s/ar$ 1ra1?4in'
s!#nd 1an "e /eard.
A)B In t/e ta$$in' met/!d, t/e e4e1tr!de is /e4d in a $!siti!n
3erti1a4 t! t/e s#r0a1e !0 t/e 5!r?.
31
T/e ar1 is esta"4is/ed " 4!5erin' t/e e4e1tr!de, ta$$in' !r
"!#n1in' it !n t/e 5!r? s#r0a1e, t/en s4!54 raisin' it a s/!rt
distan1e, a$$r!8imate4 t/e diameter !0 t/e e4e1tr!de. W/en t/e
$r!$er 4en't/ !0 ar1 is !"tained, a s/ar$ 1ra1?4in' s!#nd 1an "e
/eard.
ADB I0 t/e e4e1tr!de is 5it/dra5n t!! s4!54, 5it/ eit/er ar1
startin' met/!d des1ri"ed a"!3e, it 5i44 sti1? !r 0reeCe t! t/e
$4ate !r "ase meta4. I0 t/is !11#rs, t/e e4e1tr!de 1an #s#a44
"e 0reed " a 2#i1? side5as 5rist m!ti!n t! sna$ t/e end !0 t/e
e4e1tr!de 0r!m t/e $4ate. W/en t/is met/!d 0ai4s, rem!3e t/e
e4e1tr!de /!4der 0r!m t/e e4e1tr!de !r st!$ t/e 5e4din' ma1/ine
and 0ree t/e e4e1tr!de 5it/ a 4i'/t 1/ise4 "4!5.
WARNING
I0 t/e e4e1tr!de "e1!mes 0r!Cen t! t/e "ase meta4
d#rin' t/e $r!1ess !0 startin' t/e ar1, a44 5!r? t!
0ree t/e e4e1tr!de 5/en t/e 1#rrent is !n s/!#4d "e
d!ne 5it/ t/e 0a1e s/ie4d $#44ed d!5n !3er t/e ees.
A5B S!me e4e1tr!des, ?n!5n as 1!nta1t e4e1tr!des, are n!rma44
str#1? " /!4din' t/em in 1!nta1t 5it/ t/e 5!r?. T/ese
e4e1tr!des are #sed m!st4 " $ri3ate ind#str rat/er " t/e Arm
in t/e 0ie4d.
A6B T5! $r!1ed#res, des1ri"ed in t/e 0!44!5in' s#"$ara'ra$/s,
are #sed t! "rea? t/e ar1.
AaB In man#a4 5e4din', 5/en t/e e4e1tr!de is 1/an'ed and t/e
5e4d is t! "e 1!ntin#ed 0r!m t/e 1rater, t/e ar1 is s/!rtened and
t/e e4e1tr!de m!3ed 2#i1?4 side5as !#t !0 t/e 1rater. W/en t/e
ar1 is re,esta"4is/ed it is started at t/e 0!r5ard !r 1!4d end !0
t/e 1rater, m!3ed "a1?5ard !3er t/e 1rater, t/en 0!r5ard a'ain t!
1!ntin#e t/e 5e4d. T/e 1rater is a4s! 0i44ed " t/is $r!1ed#re.
A"B In semia#t!mati1 5e4din', 5/ere 0i44in' !r $artia4 0i44in'
!0 t/e 1rater is re2#ired, t/e e4e1tr!de is /e4d stati!nar 0!r a
time s#00i1ient t! 0i44 t/e 1rater and t/en is 'rad#a44
5it/dra5n #nti4 t/e ar1 "rea?s.
32
d. Proper and &"proper rc Control.
A1B %alad/ust"ents. Ta"4e ) $r!3ides a 4istin' !0 t/e e00e1ts !n
5e4din' as a res#4t !0 im$r!$er 1#rrent, 3!4ta'e, and 5e4din' s$eed
1!ntr!4.
TABLE ). E%%ECTS O% 9ALAD<UST9ENTS O%
WELDING CURRENT &OLTAGE AND
SPEED ON T.E BEAD
C.ARACTERISTICS.
33
A(B -ong rc A0i'#re 1)B. W/en 5e4din' 5it/ a 4!n' ar1, as
s/!5n in 0i'#re 1), 3ie5 A, t/e $r!te1tin' ar1 04ame, as 5e44 as
t/e m!4ten '4!"#4e at t/e end !0 t/e e4e1tr!de, 5i44 5/ir4 and
!s1i44ate 0r!m side t! side. T/e 04#1t#atin' 04ame 5i44 $ermit
t/e m!4ten "ase meta4 t! "e1!me
%IGURE 1). ARC C.ARACTERISTICS,
AND DE%ECTS.
34
!8idiCed !r "#rned "e0!re rea1/in' t/e m!4ten meta4. T/e
dire1ti!n !0 t/e m!4ten 0i44er meta4, as it $asses t/r!#'/ t/e
ar1, 5i44 "e di00i1#4t t! 1!ntr!4 and a 1!nsidera"4e $!rti!n !0
t/is meta4 5i44 "e 4!st as s$atter. T/e 4!n' ar1 5i44 me4t t/e
e4e1tr!de 2#i1?4, and t/e meta4 is n!t a45as de$!sited at t/e
$!int desired. In 'enera4, t/e 4!n' ar1 res#4ts in $!!r 5e4d
$enetrati!n, e81essi3e !3er4a$, and "#rned and $!r!#s meta4 in
t/e 5e4d as s/!5n in 0i'#re 1), 3ie5s B t/r!#'/ D, !n t/e
$re3i!#s $a'e.
A)B Short rc.
AaB T/e s/!rt ar1 A0i'#re 1), 3ie5 EB is t/e 1!rre1t and
desired $r!1ed#re 0!r 5e4din'. Wit/ t/e s/!rt ar1, t/e m!4ten
meta4 4ea3in' t/e end !0 t/e e4e1tr!de $asses 0r!m t/e atm!s$/ere
" 5a !0 an en3e4!$in' ar1 04ame. T/e s/!rt ar1 $ermits "etter
1!ntr!4 !0 t/e 5e4d meta4 de$!sited res#4tin' in a 5e4ded "ead !0
"etter 2#a4it. Genera44, a s/!rt ar1 $r!3ides ma8im#m
$enetrati!n and "etter $/si1a4 $r!$erties in t/e 5e4d and
de$!sits t/e ma8im#m am!#nt !0 meta4 at t/e $!int !0 5e4din'.
P!r!sit, !3er4a$, and 5e4d meta4 s$atter are ?e$t t! a minim#m.
A"B A 3er s/!rt ar1, /!5e3er, is #ndesira"4e. It 5i44 $r!d#1e
m#1/ s$atter, 5i44 '! !#t 0re2#ent4, and ma?e 1!ntin#!#s 5e4din'
di00i1#4t6 t/e res#4ts "ein' simi4ar t! t/!se s/!5n in 0i'#re 1),
3ie5 B.
e. Bead Welding A0i'#re 1D !n t/e 0!44!5in' $a'eB.
A1B W/en t/e ar1 is str#1?, meta4 $arti14es me4t !00 t/e end !0
t/e e4e1tr!de and are de$!sited in t/e m!4ten $#dd4e !n t/e
s#r0a1e !0 t/e 5!r?. As t/e e4e1tr!de me4ts it "e1!mes s/!rter
and 1a#ses t/e ar1 t! in1rease in 4en't/ #n4ess t/e e4e1tr!de is
0ed d!5n t! t/e 5!r? as 0ast as t/e end is me4ted !00 and
de$!sited. Be0!re m!3in' t/e e4e1tr!de 0!r5ard, t/e ar1 s/!#4d
"e /e4d at t/e startin' $!int 0!r a s/!rt time t! ens#re '!!d
0#si!n and t! a44!5 t/e "ead t! "#i4d #$ s4i'/t4. W/en t/e
5e4din' ma1/ine is ad7#sted 0!r $r!$er 1#rrent and $!4arit, '!!d
"ead 5e4ds 1an "e made " maintainin' a s/!rt ar1 and 5e4din' in
a strai'/t 4ine at a 1!nstant s$eed.
35
%IGURE 1D. CORRECT ELECTRODE POSITION %OR
WELDS AND PROPER BEAD WELDS.
A(B %!r "ead 5e4din', t/e e4e1tr!de s/!#4d "e /e4d at !r near a -+
de'ree an'4e t! t/e "ase meta4 as s/!5n in 0i'#re 1D, 3ie5 A. .!5e3er,
in !rder t! !"tain a 14earer 3ie5 !0 t/e m!4ten $#dd4e, 1rater, and
ar1, t/e e4e1tr!de s/!#4d "e ti4ted "et5een 5 and 15 de'rees t!5ard t/e
dire1ti!n !0 tra3e4 as s/!5n in 0i'#re 1D, 3ie5 B.
A)B T/e $r!$er ar1 4en't/ 1ann!t "e a11#rate4 7#d'ed " t/e ee, "#t
1an "e re1!'niCed " t/e s!#nd !0 t/e ar1. W/en "ead 5e4din' 5it/ a
s/!rt ar1, t/e t$i1a4 s/ar$, 1ra1?4in' s!#nd s/!#4d "e /eard a44 t/e
time t/e e4e1tr!de is in 1!nta1t and "ein' m!3ed a4!n' t/e s#r0a1e !0
t/e 5!r?.
36
ADB A $r!$er4 made "ead 5e4d s/!#4d 4ea3e 4itt4e s$atter !n
t/e s#r0a1e !0 t/e 5!r? A0i'#re 1D, 3ie5 C, !n t/e $re3i!#s
$a'eB. W/en t/e ar1 is "r!?en, t/e 1rater !r de$ressi!n in t/e
"ead, s/!5n in 0i'#re 1D, 3ie5 C, s/!#4d "e "#i4t #$ s4i'/t4.
T/is meta4 "#i4d,#$ s/!#4d n!t !3er4a$ t/e t!$ s#r0a1e !0 t/e
5e4d. An !3er4a$ 5!#4d indi1ate $!!r 0#si!n at t/is $!int !0 t/e
5e4d. T/e de$t/ !0 t/e 1rater at t/e end !0 t/e "ead 1an a4s! "e
#sed as an indi1ati!n !0 $enetrati!n int! t/e "ase meta4.
0. Flat Position Welding A0i'#re 15 !n t/e 0!44!5in' $a'eB.
A1B Butt ,oints in the Flat Position. A "#tt 7!int is #sed t!
7!in t5! $4ates /a3in' s#r0a1es in a$$r!8imate4 t/e same $4ane.
Se3era4 0!rms !0 7!ints are #sed t! ma?e "#tt 5e4ds in t/e 04at
$!siti!n. T/e m!st im$!rtant !0 t/ese 0!rms are des1ri"ed in t/e
0!44!5in' s#"$ara'ra$/s.
AaB P4ates 1F* in1/ t/i1? 1an "e 5e4ded in !ne $ass 5it/!#t an
s$e1ia4 ed'e $re$arati!n "ein' ne1essar. P4ates 0r!m 1F* t!
)F16 in1/ t/i1?ness 1an "e 5e4ded 5it/ n! s$e1ia4 ed'e
$re$arati!n " ma?in' a "ead 5e4d !n "!t/ sides !0 t/e 7!int.
Ta1? 5e4ds s/!#4d "e #sed t! ?ee$ t/e $4ates a4i'ned 0!r 5e4din'.
T/e e4e1tr!de m!ti!n is t/e same as t/at #sed in ma?in' a "ead
5e4d.
A"B W/en 5e4din' 1FD in1/ !r /ea3ier $4ates, t/e ed'es !0 t/e
$4ates s/!#4d "e $re$ared " "e3e4in' !r " E<,E EU,E !r E&E
'r!!3in', 5/i1/e3er is t/e m!st a$$4i1a"4e. Sin'4e !r d!#"4e
"e3e4s !r 'r!!3es ma "e #sed de$endin' !n t/e t/i1?ness !0 t/e
$4ate "ein' 5e4ded. T/e 0irst "ead s/!#4d "e de$!sited t! sea4
t/e s$a1e "et5een t/e t5! $4ates and t! 5e4d t/e r!!t !0 t/e
7!int. T/is "ead Aa4s! re0erred t! as a 4aer !r 5e4d meta4B
m#st "e t/!r!#'/4 14eaned t! rem!3e a44 s4a' "e0!re t/e se1!nd
4aer !0 meta4 is de$!sited. W/en ma?in' m#4ti$ass 5e4ds A0i'#re
16, 3ie5 A, !n $a'e )-B, t/e se1!nd, t/ird, and 0!#rt/ 4aers !0
5e4d meta4 are de$!sited #sin' an !0 t/e 5ea3in' m!ti!ns !0 t/e
e4e1tr!de, as s/!5n in 0i'#re 16, 3ie5 B. Ea1/ 4aer !0 meta4
m#st "e 14eaned "e0!re de$!sitin' t/e s#11eedin' 4aers.
37
%IGURE 15. %LAT POSITION WELDING.
38
%IGURE 16. 9ULTIPASS BEAD WELDS, WELDING
9OTIONS, UNDERCUTTING, AND
WELDS WIT. BAC=STRIPS.
39
A1B W/en #sin' an !0 t/e 5ea3in' m!ti!ns, t/e e4e1tr!de s/!#4d
"e !s1i44ated !r m!3ed #ni0!rm4 0r!m side t! side 5it/ s4i'/t
/esitati!n at t/e end !0 ea1/ !s1i44ati!n and, as in "ead
5e4din', t/e e4e1tr!de s/!#4d "e in14ined 5 t! 15 de'rees in t/e
dire1ti!n !0 5e4din'. I0 t/e 5ea3in' m!ti!n is n!t $r!$er4
$er0!rmed, #nder1#ttin' 5i44 !11#r at t/e 7!int as s/!5n in
0i'#re 16, 3ie5 C, !n t/e $re3i!#s $a'e. E81essi3e 5e4din' s$eed
5i44 a4s! 1a#se #nder1#ttin' and $!!r 0#si!n at t/e ed'es !0 t/e
5ea3e "ead.
A(B Butt ,oints in Flat Position !ith Bac(up Strips A0i'#re 16,
3ie5 DB.
AaB Ba1?#$ !r "a1?in' stri$s are #sed 5/en 5e4din' )F16 in1/
$4ate !r /ea3ier t! !"tain 1!m$4ete 0#si!n at t/e r!!t !0 t/e
5e4d and t! $r!3ide "etter 1!ntr!4 !0 t/e ar1 and t/e 5e4d meta4.
T/e ed'e !0 t/e $4ates t! "e 5e4ded are $re$ared in t/e same
manner as re2#ired 0!r 5e4din' 5it/!#t "a1?in' stri$s. T/e
"a1?in' stri$s, 1 in1/ 5ide and )F16 in1/ t/i1? 0!r $4ates #$ t!
)F* in1/ t/i1?, 1 1F( in1/ side, and 1FD in1/ t/i1? 0!r $4ates
!3er 1F* in1/ t/i1?, are ta1? 5e4ded t! t/e "ase !0 t/e 7!int.
T/e "a1?in' stri$ 5i44 a1t as a 1#s/i!n 0!r t/e 0irst "ead !r
4aer de$!sited in t/e 7!int.
A"B T/e 7!int s/!#4d "e 1!m$4eted " addin' additi!na4 4aers
!0 meta4 #sin' t/e $r!1ed#res $res1ri"ed in $ara'ra$/s 5e, !n
$a'es )5 and )6.
A1B A0ter t/e 7!int is 1!m$4eted, t/e "a1?#$ stri$ ma "e
5as/ed !00 !r 1#t a5a 5it/ a 1#ttin' t!r1/ and, i0 ne1essar, a
sea4in' "ead ma t/en "e a$$4ied a4!n' t/e r!!t !0 t/e 7!int.
A)B Plug and Slot ,oints A0i'#re 1@ !n t/e 0!44!5in' $a'eB.
AaB P4#' and s4!t 5e4ds, s/!5n in 0i'#re 1@, 3ie5s A and B, are
#sed t! 7!in t5! !3er4a$$in' $4ates, " de$!sitin' and 0i44in' a
/!4e !r s4!t in t/e #$$er $4ate. S4!t 5e4ds are #sed in "#tt
stra$s t! 7!in 0a1e /ardened arm!r $4ate ed'es 0r!m t/e "a1? !r
s!0t side. T/e are a4s! #sed t! 0i44 #$ /!4es in $4ates and t!
7!in t5! !3er4a$$in' $4ates 5/ere it is im$!ssi"4e t! 7!in t/em
" an !t/er met/!d.
40
%IGURE 1@. PLUG AND SLOT <OINTS, AND
TAC= WELDING TEE <OINTS.
A"B A 1!ntin#!#s 0i44et 5e4d as s/!5n in 3ie5 B is made t!
!"tain a '!!d 0#si!n "et5een t/e side5a44s !0 t/e /!4e !r s4!t
and t/e s#r0a1e !0 t/e 4!5er $4ate. T/e $r!1ed#re 0!r t/is
0i44et 5e4d is t/e same as 0!r 4a$ 7!ints, 5/i1/ 5i44 "e
des1ri"ed in $ara'ra$/ 5'A(B !n $a'e D5. T/e /!4e !r s4!t is
t/en 0i44ed in t! $r!3ide additi!na4 stren't/ in t/e 5e4d.
A1B T/e $4#' 5e4d $r!1ed#re ma "e #sed t! rem!3e "!4ts !r
st#ds t/at /a3e "een "r!?en !r t5isted !00 04#s/ 5it/ t/e s#r0a1e
!0 t/e $art. A
41
n#t, s!me5/at sma44er t/an t/e "!4t siCe, s/!#4d "e 1entered !n
t/e "!4t !r st#d t! "e rem!3ed. A /ea3,1!ated e4e1tr!de is
4!5ered int! t/e n#t and an ar1 str#1? !n t/e e8$!sed end !0 t/e
"r!?en "!4t !r st#d. T/e n#t is t/en 5e4ded !nt! t/e "r!?en "!4t
!r st#d and s#00i1ient meta4 is added t! 0i44 t/e /!4e.. T/e
"r!?en "!4t !r st#d 1an t/en "e rem!3ed 5it/ a 5ren1/.
'. Hori0ontal Position Welding.
A1B Tee ,oints A0i'#re 1@, 3ie5 C, !n t/e $re3i!#s $a'eB. In
ma?in' tee 7!ints in t/e /!riC!nta4 $!siti!n t/e t5! $4ates are
4!1ated a$$r!8imate4 at ri'/t an'4es t! ea1/ !t/er in t/e 0!rm
!0 an in3erted T. T/e ed'e !0 t/e 3erti1a4 $4ate ma "e ta1?
5e4ded t! t/e s#r0a1e !0 t/e /!riC!nta4 $4ate.
AaB A 0i44et 5e4d A0i'#re 1*, 3ie5s A and B, !n t/e 0!44!5in'
$a'eB is #sed in ma?in' t/e 7!int " #sin' a s/!rt ar1 t! $r!3ide
'!!d 0#si!n at t/e r!!t and a4!n' t/e 4e's !0 t/e 5e4d. T/e
e4e1tr!de s/!#4d "e /e4d at an an'4e !0 D5 de'rees t! t/e t5!
$4ate s#r0a1es and in14ined a$$r!8imate4 15 de'rees in t/e
dire1ti!n !0 5e4din'.
A"B Li'/t $4ates 1an "e 0i44et 5e4ded in !ne $ass 5it/ 4itt4e
!r n! 5ea3in' !0 t/e e4e1tr!de. We4din' !0 /ea3ier $4ates ma
re2#ire t5! !r m!re $asses 5it/ t/e se1!nd $ass !r 4aer made
#sin' a semi1ir1#4ar 5ea3in' m!ti!n as s/!5n in 0i'#re 1*, 3ie5
C. A s4i'/t $a#se is made at t/e end !0 ea1/ 5ea3e t! !"tain
'!!d 0#si!n "et5een t/e 5e4d and "ase meta4 5it/!#t an
#nder1#ttin'.
A1B A 0i44et,5e4ded tee 7!int !n 1F( in1/ !r t/i1?er $4ate 1an
"e made " de$!sitin' strin' "eads in t/e se2#en1e s/!5n in
0i'#re 1*, 3ie5 D.
AdB C/ain !r sta''ered intermittent 0i44et 5e4din's as s/!5n in
0i'#re 1-, 3ie5 A, !n $a'e DD are #sed 0!r 4!n' tee 7!ints.
%i44et 5e4ds !0 t/ese t$es are #sed 5/ere /i'/ 5e4d stren't/ is
n!t re2#ired6 /!5e3er, t/e s/!rt 5e4ds are s! arran'ed t/at t/e
0inis/ed 7!int is e2#a4 in stren't/ t! a 0i44et 5e4d a4!n' t/e
entire 4en't/ !0 a 7!int 0r!m !ne side !n4. A4s!, t/e 5ar$a'e
and dist!rti!n !0 t/e 5e4ded $arts are /e4d t! a minim#m 5it/
intermittent 5e4ds.
42
%IGURE 1*. %ILLET WELDING.
43
%IGURE 1-. INTER9ITTENT %ILLET WELDS,
TAC= WELDING, AND
ELECTRODE POSITION.
44
A(B -ap ,oint A0i'#re 1-, 3ie5s B and C, !n t/e $re3i!#s $a'eB.
AaB In ma?in' 4a$ 7!ints, t5! !3er4a$$in' $4ates are ta1?
5e4ded in $4a1e and a 0i44et 5e4d in t/e /!riC!nta4 $!siti!n is
de$!sited a4!n' t/e 7!int.
A"B T/e $r!1ed#re 0!r ma?in' t/is 5e4d is simi4ar t! t/at #sed
0!r ma?in' 0i44et 5e4ds in tee 7!ints. T/e e4e1tr!de s/!#4d "e
/e4d s! as t! 0!rm an an'4e a$$r!8imate4 )+ de'rees 0r!m t/e
3erti1a4 and ti4ted 15 de'rees in t/e dire1ti!n !0 5e4din'. T/e
$!siti!n !0 t/e e4e1tr!de in re4ati!n t! t/e $4ates is s/!5n in
0i'#re 1-, 3ie5 C. T/e 5ea3in' n!ti!n is t/e same as t/at #sed
0!r tee 7!ints, e81e$t t/at t/e $a#se at t/e ed'e !0 t/e t!$
$4ate is s#00i1ient4 4!n' t! ens#re '!!d 0#si!n and n! #nder
1#t. La$ t/e 7!int " de$!sitin' a series !0 !3er4a$$in' "eads
!n t!$ !0 ea1/ !t/er.
A1B In ma?in' 4a$ 7!ints !n $4ates !0 di00erent t/i1?nesses as
s/!5n in 0i'#re (+, 3ie5 A, !n t/e 0!44!5in' $a'e, t/e e4e1tr!de
is /e4d s! as t! 0!rm an an'4e !0 (+ t! )+ de'rees 0r!m t/e
3erti1a4. Care m#st "e ta?en n!t t! !3er/eat !r #nder1#t t/e
t/inner $4ate ed'e. A4s!, t/e ar1 m#st "e 1!ntr!44ed t! 5as/ #$
t/e m!4ten meta4 t! t/e ed'e !0 t/is $4ate.
/. )ertical Position Welding.
A1B Bead Welds A0i'#re (+, 3ie5s B t/r!#'/ EB.
AaB We4din' !n a 3erti1a4 s#r0a1e is m!re di00i1#4t t/an
5e4din' in t/e 04at $!siti!n. Be1a#se !0 t/e 0!r1e !0 'ra3it,
t/e m!4ten meta4 tends t! 04!5 d!5n5ard.
A"B W/en meta4,ar1 5e4din' in t/e 3erti1a4 $!siti!n, 1#rrent
settin's s/!#4d "e 4ess t/an t/!se #sed 0!r t/e same e4e1tr!de in
t/e 04at $!siti!n. T/e 1#rrents #sed 0!r 5e4din' #$5ard !n a
3erti1a4 s#r0a1e are s4i'/t4 /i'/er t/an t/!se #sed 0!r 5e4din'
d!5n5ard !n t/e same s#r0a1e.
A1B T/e $r!$er an'4e "et5een t/e e4e1tr!de and t/e "ase meta4
is a4s! ne1essar in !rder t! de$!sit a '!!d "ead 5e4d 5/en
5e4din' 3erti1a44.
45
%IGURE (+. LAP <OINTS AND WELDING
&ERTICALL:.
46
AdB W/en 5e4din' #$5ard, t/e e4e1tr!de s/!#4d "e /e4d at -+
de'rees t! t/e 3erti1a4 as s/!5n in 0i'#re (+, 3ie5 B, !n t/e
$re3i!#s $a'e. W/en 5e4din' #$5ard and 5ea3in' is ne1essar, t/e
e4e1tr!de s/!#4d "e !s1i44ated as s/!5n in 0i'#re (+, 3ie5 C.
AeB W/en 5e4din' d!5n5ard, t/e !#ter end !0 t/e e4e1tr!de
s/!#4d "e in14ined d!5n5ard a"!#t 15 de'rees 0r!m t/e /!riC!nta4
5it/ t/e ar1 $!intin' #$5ard t!5ard t/e de$!sited m!4ten meta4 as
s/!5n in 0i'#re (+, 3ie5 D. W/en 5e4din' d!5n5ard, in t/e
3erti1a4 $!siti!n, and a 5ea3e "ead is re2#ired, t/e e4e1tr!de
s/!#4d "e !s1i44ated as s/!5n in 0i'#re (+, 3ie5 E.
A0B W/en de$!sitin' a "ead 5e4d in t/e /!riC!nta4 dire1ti!n !n
a 3erti1a4 $4ate, t/e e4e1tr!de s/!#4d "e /e4d at ri'/t an'4es t!
t/e 3erti1a4 as s/!5n in 0i'#re (1, 3ie5 A, !n t/e 0!44!5in' $a'e
and ti4ted 15 de'rees t!5ard t/e dire1ti!n !0 5e4din' s! as t!
$r!3ide a "etter 3ie5 !0 t/e ar1 and 1rater.
A(B Butt ,oints.
AaB B#tt 7!ints !n $4ates in t/e 3erti1a4 $!siti!n are $re$ared
0!r 5e4din' in t/e same 5a as t/!se re2#ired 0!r "#tt 7!ints in
t/e 04at $!siti!n.
A"B In !rder t! !"tain '!!d 0#si!n and $enetrati!n 5it/ n!
#nder1#ttin', a s/!rt ar1 s/!#4d "e /e4d and t/e m!ti!n !0 t/e
ar1 s/!#4d "e 1are0#44 1!ntr!44ed.
A1B B#tt 7!ints !n "e3e4ed $4ates 1FD in1/ t/i1? 1an "e made "
#sin' a trian'#4ar 5ea3e m!ti!n as s/!5n in 0i'#re (1, 3ie5 B.
We4ds !n 1F( in1/ $4ate !r /ea3ier s/!#4d "e made in se3era4
$asses as s/!5n in 0i'#re (1, 3ie5 C. T/e 4ast $ass s/!#4d "e
de$!sited 5it/ a semi1ir1#4ar 5ea3in' m!ti!n 5it/ a s4i'/t 5/i$,
#$ and $a#se t! t/e e4e1tr!de at t/e ed'e !0 t/e "ead.
AdB W/en 5e4din' "#tt 7!ints in t/e /!riC!nta4 dire1ti!n !n
3erti1a4 $4ates, a s/!rt ar1 is ne1essar at a44 times and t/e
meta4 is de$!sited in m#4ti$ass "eads as s/!5n in 0i'#re (1, 3ie5
D. T/e 0irst $ass is made 5it/ t/e e4e1tr!de /e4d at -+ de'rees
t! t/e 3erti1a4 $4ates. T/e se1!nd, t/ird, and s#"se2#ent $asses
are made 5it/ t/e
47
e4e1tr!de /e4d $ara44e4 t! t/e "e3e4ed ed'e !$$!site t/e ed'e !n
5/i1/ t/e "ead is "ein' de$!sited.
%IGURE (1. &ERTICAL WELDING AND
BUTT <OINTS.
48
A)B Fillet Welds A0i'#re ((B.
AaB W/en ma?in' 0i44et 5e4ds in eit/er tee !r 4a$ 7!ints in t/e
3erti1a4 $!siti!n, t/e e4e1tr!de s/!#4d "e /e4d at -+ de'rees t! t/e
$4ates !r n!t
%IGURE ((. &ERTICAL %ILLET WELDS.
49
m!re t/an 15 de'rees a"!3e t/e /!riC!nta4 0!r $r!$er m!4ten meta4
1!ntr!4. T/e ar1 s/!#4d "e /e4d s/!rt t! !"tain '!!d 0#si!n and
$enetrati!n.
A"B W/en 5e4din' tee 7!ints in t/e 3erti1a4 $!siti!n, t/e 7!int
s/!#4d "e started at t/e "!tt!m and 5e4ded #$5ard and t/e
e4e1tr!de s/!#4d "e m!3ed in a trian'#4ar 5ea3in' m!ti!n as s/!5n
in 0i'#re ((, 3ie5 A, !n t/e $re3i!#s $a'e. A s4i'/t $a#se in
t/e 5ea3e, at t/e $!ints indi1ated, 5i44 im$r!3e t/e side5a44
$enetrati!n and $r!3ide '!!d 0#si!n at t/e r!!t !0 t/e 7!int.
1 I0 t/e 5e4d meta4 s/!#4d !3er/eat, t/e e4e1tr!de s/!#4d "e
2#i1?4 s/i0ted a5a 0r!m t/e 1rater 5it/!#t "rea?in' t/e ar1 as
s/!5n in 0i'#re ((, 3ie5 B. T/is 5i44 $ermit t/e m!4ten meta4 t!
s!4idi0 5it/!#t r#nnin' d!5n5ard. T/e e4e1tr!de s/!#4d "e
ret#rned immediate4 t! t/e 1rater !0 t/e 5e4d in !rder t!
maintain t/e desired siCe !0 t/e 5e4d.
( W/en m!re t/an !ne $ass is ne1essar t! ma?e a tee 5e4d,
eit/er !0 t/e 5ea3in' m!ti!ns s/!5n in 0i'#re ((, 3ie5s C and D,
ma "e #sed. A s4i'/t $a#se at t/e end !0 t/e 5ea3e 5i44 de3e4!$
'!!d 0#si!n 5it/!#t #nder1#ttin' at t/e ed'es !0 t/e $4ates.
A1B T! ma?e 5e4ds !n 4a$ 7!ints in t/e 3erti1a4 $!siti!n, t/e
e4e1tr!de s/!#4d "e m!3ed in a trian'#4ar 5ea3in' m!ti!n as s/!5n
in 0i'#re ((, 3ie5 E. T/e same $r!1ed#re 0!r ma?in' t/e tee
7!int is #sed e81e$t t/e e4e1tr!de is dire1ted t!5ard t/e
3erti1a4 $4ate mar?ed EGE in 0i'#re ((, 3ie5 E. T/e ar1 s/!#4d
"e /e4d s/!rt, and t/e $a#se at t/e s#r0a1e !0 $4ate EGE s/!#4d
"e s4i'/t4 4!n'er. Care s/!#4d "e ta?en n!t t! #nder1#t eit/er
!0 t/e $4ates !r t! a44!5 t/e m!4ten meta4 t! !3er4a$ at t/e
ed'es !0 t/e 5ea3e.
AdB La$ 7!ints in t/e 3erti1a4 $!siti!n !n /ea3 $4ate re2#ire
m!re t/an !ne 4aer !0 meta4. T/e de$!sited "ead s/!#4d "e
t/!r!#'/4 14eaned and s#"se2#ent "eads de$!sited as s/!5n in
0i'#re ((, 3ie5 %.
i. 1verhead Position Welding A0i'#re () !n t/e 0!44!5in' $a'eB.
A1B Bead Welds. T/e !3er/ead $!siti!n is t/e m!st di00i1#4t
$!siti!n t! 5e4d in "e1a#se it
50
re2#ires a 3er s/!rt ar1 5/i1/ m#st "e maintained in !rder t!
retain 1!m$4ete 1!ntr!4 !0 t/e m!4ten meta4. As in 3erti1a4
$!siti!n 5e4din', t/e 0!r1e !0 'ra3it tends t! 1a#se t/e m!4ten
meta4 t! dr!$
%IGURE (). O&ER.EAD POSITION WELDING.
51
d!5n !r sa' !n t/e $4ate. I0 t/e ar1 is t!! 4!n', t/e di00i1#4t
in trans0errin' meta4 0r!m t/e e4e1tr!de t! t/e "ase meta4 is
in1reased and 4ar'e '4!"#4es !0 m!4ten meta4 5i44 dr!$ 0r!m t/e
e4e1tr!de and t/e "ase meta4. T/is a1ti!n 1an "e $re3ented "
0irst s/!rtenin' and t/en 4en't/enin' t/e ar1 at inter3a4s. Care
m#st "e ta?en n!t t! 1arr t!! 4ar'e a $!!4 !0 m!4ten meta4 in
t/e 5e4d.
AaB W/en "ead 5e4din', t/e e4e1tr!de s/!#4d "e /e4d at an an'4e
!0 -+ de'rees t! t/e "ase meta4 as s/!5n in 0i'#re (), 3ie5 A, !n
t/e $re3i!#s $a'e. T/e e4e1tr!de ma "e ti4ted a$$r!8imate4 15
de'rees in t/e dire1ti!n !0 5e4din' as s/!5n in 0i'#re (), 3ie5 B
t! $r!3ide a "etter 3ie5 !0 t/e ar1 and 1rater !0 t/e 5e4d.
A"B Wea3e "eads 1an "e made in t/e !3er/ead $!siti!n " #sin'
t/e m!ti!n i44#strated in 0i'#re (), 3ie5 C. A ra$id m!ti!n is
ne1essar at t/e end !0 ea1/ semi1ir1#4ar 5ea3e in !rder t!
1!ntr!4 t/e m!4ten meta4 de$!sit. E81essi3e 5ea3in' s/!#4d "e
a3!ided "e1a#se t/is 5i44 1a#se !3er/eatin' !0 t/e 5e4d de$!sit
and t/e 0!rmati!n !0 a 4ar'e $!!4 !0 meta4 5/i1/ 5i44 "e /ard t!
1!ntr!4.
A(B Butt ,oints.
AaB T/e $4ates s/!#4d "e $re$ared 0!r "#tt 5e4din' in t/e
!3er/ead $!siti!n in t/e same manner as t/at re2#ired in t/e 04at
$!siti!n, and t/e m!st satis0a1t!r res#4ts are !"tained i0
"a1?#$ stri$s are #sed. I0 t/e $4ates are "e3e4ed 5it/ a 0eat/er
ed'e and n! "a1?#$ stri$ is #sed, t/e 5e4d 5i44 tend t! "#rn
t/r!#'/ re$eated4 #n4ess e8treme 1are is ta?en " t/e !$erat!r.
A"B %!r !3er/ead "#tt 5e4din', "ead rat/er t/an 5ea3e 5e4ds are
$re0erred. Ea1/ "ead s/!#4d "e 14eaned and t/e r!#'/ areas
1/i$$ed !#t "e0!re t/e 0!44!5in' $ass is de$!sited. T/e 0irst
$ass s/!#4d "e made 5it/ t/e e4e1tr!de /e4d at -+ de'rees t! t/e
$4ate as s/!5n in 0i'#re (), 3ie5 D.
A1B T/e $!siti!n !0 t/e e4e1tr!de and t/e !rder t! "e 0!44!5ed
in de$!sitin' "eads !n 1FD and 1F( in1/ $4ates are i44#strated in
0i'#re (), 3ie5s E and %.
AdB %air4 sma44 diameter e4e1tr!des s/!#4d "e #sed t! assist
in /!4din' a s/!rt ar1 and de3e4!$in' a '!!d $enetrati!n at t/e
r!!t !0 t/e
52
7!int. E81essi3e 1#rrent 5i44 1reate a 3er 04#id $#dd4e, 5/i1/
5i44 "e di00i1#4t t! 1!ntr!4.
A)B Fillet Welds A0i'#re (DB.
AaB In ma?in' 0i44et 5e4ds in eit/er tee !r 4a$ 7!ints in t/e
!3er/ead $!siti!n, a s/!rt ar1 s/!#4d "e /e4d and t/ere s/!#4d "e
n! 5ea3in' !0 t/e e4e1tr!de. T/e !rder in 5/i1/ t/e "eads are
de$!sited is s/!5n in 0i'#re (D, 3ie5 A. T/e e4e1tr!de s/!#4d "e
/e4d a$$r!8imate4 )+ de'rees t! t/e 3erti1a4 $4ate and m!3ed
#ni0!rm4 in t/e dire1ti!n !0 t/e 5e4din' as s/!5n in 0i'#re (D,
3ie5 B. T/e ar1 m!ti!n s/!#4d "e 1!ntr!44ed t! se1#re '!!d
$enetrati!n t! t/e r!!t !0 t/e 5e4d and '!!d 0#si!n 5it/ t/e
side5a44s !0 t/e 3erti1a4 and /!riC!nta4 $4ates. I0 t/e m!4ten
meta4 "e1!mes t!! 04#id and tends t! sa', t/e e4e1tr!de s/!#4d "e
5/i$$ed a5a 2#i1?4 0r!m t/e 1rater and a/ead !0 t/e 5e4d s! as
t! 4en't/en t/e ar1 and a44!5 t/e meta4 t! s!4idi0. T/e
e4e1tr!de s/!#4d t/en "e ret#rned immediate4 t! t/e 1rater and
t/e 5e4din' 1!ntin#ed.
%IGURE (D. O&ER.EAD POSITION
%ILLET WELDING.
53
A"B %i44et 5e4ds 0!r eit/er tee !r 4a$ 7!ints, !n /ea3 $4ate
in t/e !3er/ead $!siti!n, re2#ire se3era4 $asses t! ma?e t/e
7!int. T/e 0irst $ass is a strin' "ead 5it/ n! 5ea3in' m!ti!n !0
t/e e4e1tr!de. T/e se1!nd, t/ird, and 0!#rt/ $asses are made
5it/ a s4i'/t 1ir1#4ar m!ti!n !0 t/e e4e1tr!de 5it/ its t!$
ti4ted a"!#t 15 de'rees in t/e dire1ti!n !0 5e4din' as s/!5n in
0i'#re (D, 3ie5 C, !n t/e $re3i!#s $a'e. T/is m!ti!n !0 t/e
e4e1tr!de $ermits 'reater 1!ntr!4 and "etter distri"#ti!n !0 t/e
5e4d meta4 "ein' de$!sited. A44 s4a' and !8ides m#st "e rem!3ed
0r!m t/e s#r0a1e !0 ea1/ $ass " 1/i$$in' !r 5ire,"r#s/in' "e0!re
a$$4in' additi!na4 "eads.
6. E4e1tri1 Ar1 We4din' !0 %err!#s 9eta4s
a. General. A44 !0 t/e 0err!#s meta4s #sed !n Arm 'r!#nd
e2#i$ment 1an "e s#11ess0#44 e4e1tri1 ar1 5e4ded, $r!3ided
n!rma4 1are is #sed and t/e 1!rre1t $r!1ed#re 0!44!5ed. T/e
0!44!5in' s#"$ara'ra$/s $r!3ide t/e 5e4din' te1/ni2#es 0!r 0!#r
!0 t/e m!st 1!mm!n t$es !0 0err!#s meta4s 0!#nd !n t/is
e2#i$ment. T/e des1ri$ti!n !0 5e4din' te1/ni2#es 0!r !t/er
0err!#s meta4s ma "e 0!#nd in T9 -,()@.
". High-Car#on Steels.
A1B General. .i'/,1ar"!n stee4s in14#de t/!se t/at /a3e a
1ar"!n 1!ntent e81eedin' +.D5 $er1ent. Be1a#se !0 t/e /i'/
1ar"!n 1!ntent and t/e /eat treatment #s#a44 'i3en t! t/ese
stee4s, t/eir "asi1 $r!$erties are t! s!me de'ree im$aired " ar1
5e4din'. Pre/eatin' t/e meta4 "et5een 5++ t! *++ %a/ren/eit
"e0!re 5e4din' and stress re4ie3in' it " /eatin' 0r!m 1(++ t!
1D5+ 5it/ s4!5 1!!4in' s/!#4d "e #sed t! a3!id /ardness and
"ritt4eness in t/e 0#si!n C!ne. Eit/er mi4d,stee4 !r stain4ess
stee4 e4e1tr!des 1an "e #sed t! 5e4d t/ese stee4s.
A(B Welding Techni$ue.
AaB T/e 5e4din' /eat s/!#4d "e ad7#sted t! $r!3ide '!!d 0#si!n
at t/e side5a44s and r!!t !0 t/e 7!int 5it/!#t e81essi3e
$enetrati!n. .i'/ 5e4din' /eat 5i44 1a#se e81essi3e $enetrati!n
and $#dd4in' 5/i1/ in t#rn 1an 1a#se 4ar'e areas in t/e 0#si!n
C!ne t! "e1!me /ard and "ritt4e. C!ntr!4 !0 t/e 5e4din' /eat and
e81essi3e $enetrati!n 1an "e a11!m$4is/ed " de$!sitin' t/e 5e4d
meta4 in sma44 strin' "eads. T/e area !0 t/ese /ard C!nes in t/e
54
"ase meta4 1an "e red#1ed " ma?in' t/e 5e4d 5it/ a series !0
sma44 strin' !r 5ea3e "eads. %#si!n "et5een t/e 0i44er meta4 and
t/e side5a44s s/!#4d "e 1!n0ined t! a narr!5 C!ne. T/is 1an "e
a11!m$4is/ed " dire1tin' t/e e4e1tr!de t!5ard t/e $re3i!#s4
de$!sited 0i44er meta4 ad7a1ent t! t/e side 5a44s t/an t!5ard t/e
side 5a44s dire1t4. T/is $r!1ed#re 1a#ses t/e 5e4d meta4 t!
5as/ #$ a'ainst t/e side !0 t/e 7!int and 0#se 5it/ it 5it/!#t
dee$ !r e81essi3e $enetrati!n.
A"B W/en 5e4din' s/eet meta4 #$ t! 1F* in1/ in t/i1?ness, t/e
$4ain s2#are "#tt 7!int t$e !0 ed'e $re$arati!n ma "e #sed.
.ea3 $4ates s/!#4d "e "e3e4ed #$ t! 6+ de'rees, de$endin' !n t/e
t/i1?ness. T/e $arts s/!#4d "e ta1? 5e4ded and t/e r!!t 5e4d
made 5it/ a 1F* t! 5F)( in1/ e4e1tr!de. Additi!na4 $asses !0
0i44er meta4 s/!#4d "e made 5it/ a 5F)( !r )F16 e4e1tr!de. .ea3
se1ti!ns t/at /a3e "een "e3e4ed 0r!m "!t/ sides s/!#4d "e 5e4ded
" de$!sitin' 5ea3e "eads a4ternate4 !n !ne side and t/en t/e
!t/er t! red#1e t/e am!#nt !0 dist!rti!n in t/e 5e4d str#1t#re.
A1B Sma44 /i'/,1ar"!n stee4 $arts are s!metimes re$aired "
"#i4din' #$ 5!rn s#r0a1es. W/en t/is is d!ne, t/e $ie1e s/!#4d
"e annea4ed !r s!0tened " /eatin' t! a red /eat and 1!!4in'
s4!54. T/en t/e $ie1e s/!#4d "e 5e4ded !r "#i4t #$ 5it/ medi#m,
1ar"!n !r /i'/,stren't/ e4e1tr!des and /eat treated, a0ter
5e4din', t! rest!re its !ri'ina4 $r!$erties.
1. Tool Steels.
A1B General. Stee4s in t/is 'r!#$ /a3e a 1ar"!n 1!ntent
ran'in' 0r!m +.*+ t! 1.5 $er1ent. T/e are rare4 5e4ded " ar1
5e4din' "e1a#se !0 t/e e81essi3e /ardness $r!d#1ed in t/e 0#si!n
C!ne !0 t/e "ase meta4. I0 ar1 5e4din' m#st "e d!ne, eit/er
mi4d,stee4 !r stain4ess,stee4 e4e1tr!des 1an "e #sed.
A(B Welding Techni$ue.
AaB I0 t/e $arts t! "e 5e4ded are sma44, t/e s/!#4d "e
annea4ed !r s!0tened "e0!re 5e4din'. T/e ed'es s/!#4d t/en "e
$re/eated #$ t! 1,+++, de$endin' !n t/e 1ar"!n 1!ntent and
t/i1?ness !0 t/e $4ate, and t/e 5e4din' d!ne 5it/ eit/er a mi4d,
stee4 !r /i'/,stren't/ e4e1tr!de.
55
A"B .i'/,1ar"!n e4e1tr!des s/!#4d n!t "e #sed 0!r 5e4din' t!!4
stee4s. T/e 1ar"!n $i1?ed #$ 0r!m t/e "ase meta4 " t/is 0i44er
meta4 5i44 1a#se t/e 5e4d t! "e1!me '4ass /ard6 5/ereas, t/e
mi4d,stee4 5e4d meta4 1an a"s!r" additi!na4 1ar"!n 5it/!#t
"e1!min' e81essi3e4 /ard. T/e 5e4ded $art s/!#4d t/en "e /eat,
treated t! rest!re its !ri'ina4 $r!$erties.
A1B W/en 5e4din' 5it/ stain4ess stee4 e4e1tr!des, t/e ed'es !0
t/e $4ates s/!#4d "e $re/eated t! $re3ent t/e 0!rmati!n !0 /ard
C!nes in t/e "ase meta4. T/e 5e4d meta4 s/!#4d "e de$!sited in
sma44 strin' "eads t! ?ee$ t/e /eat in$#t d!5n t! a minim#m. In
'enera4, t/e a$$4i1ati!n $r!1ed#re is t/e same as t/at re2#ired
0!r /i'/,1ar"!n stee4s des1ri"ed in $ara'ra$/ 6"A(B "e'innin' !n
$a'e 5D.
d. High 2ield Strength' -o! lloy Structural Steels.
A1B General. .i'/ ie4d stren't/, 4!5 a44! str#1t#ra4 stee4s
are s$e1ia4 stee4s t/at are tem$ered t! !"tain e8treme t!#'/ness
and d#ra"i4it. T/e s$e1ia4 a44!s and 'enera4 ma?e,#$ !0 t/ese
stee4s re2#ire s$e1ia4 treatment t! !"tain satis0a1t!r 5e4dments.
A(B Welding Techni$ues.
AaB Re4ia"4e 5e4din' !0 /i'/ ie4d stren't/, 4!5 a44!
str#1t#ra4 stee4s 1an "e $er0!rmed " #sin' t/e 1!rre1t
e4e1tr!des. .dr!'en is t/e n#m"er !ne enem !0 s!#nd 5e4ds in
a44! stee4s. T/ere0!re, #se !n4 4!5 /dr!'en A9IL,E,1*+)* !r
9IL,E(((++F1B e4e1tr!des t! $re3ent 1ra1?in'. Under"ead 1ra1?in'
is 1a#sed " /dr!'en $i1?ed #$ in t/e e4e1tr!de 1!atin',
re4eased int! t/e ar1, and a"s!r"ed " t/e m!4ten meta4.
A"B E4e1tr!des m#st "e ?e$t dr t! e4iminate a"s!r$ti!n !0
/dr!'en. I0 t/e e4e1tr!des are in an airti'/t 1!ntainer,
immediate4 #$!n !$enin' t/e 1!ntainer, $4a1e t/e e4e1tr!des in a
3enti4ated /!4din' !3en set at (5+G t! )++G %. In t/e e3ent t/at
t/e e4e1tr!des are n!t in an airti'/t 1!ntainer, $#t t/em in a
3enti4ated "a?in' !3en and "a?e 0!r 1 t! 1 1FD /!#rs at *++G %.
Ba?ed e4e1tr!des s/!#4d, 5/i4e sti44 5arm, "e $4a1ed in a /!4din'
!3en #nti4 #sed. E4e1tr!des m#st "e ?e$t dr t! e4iminate
a"s!r$ti!n !0 /dr!'en.
56
A1B E4e1tr!des are identi0ied " 14assi0i1ati!n n#m"ers 5/i1/
are a45as mar?ed !n t/e e4e1tr!de 1!ntainers. %!r 4!5 /dr!'en
1!atin's, t/e 4ast t5! n#m"ers !0 t/e e4e1tr!de 14assi0i1ati!n
s/!#4d "e 15, 16, !r 1*. E4e1tr!des !0 5F)( and 1F* in1/ in
diameter are t/e m!st 1!mm!n4 #sed sin1e t/e are m!re ada$ta"4e
t! a44 t$es !0 5e4din' !0 t/is t$e stee4.
A)B It is im$!rtant t! a3!id e81essi3e /eat 1!n1entrati!n 5/en
5e4din' in !rder t! a44!5 t/e 5e4d area t! 1!!4 rat/er 2#i1?4.
%!r satis0a1t!r 5e4ds, a4!n' 5it/ '!!d 5e4din' $ra1ti1es, #se a
strai'/t strin'er "ead 5/ene3er $!ssi"4e. Restri1t t/e 5ea3e t!
a $artia4 5ea3e $attern. Best res#4ts are !"tained " a s4i'/t
1ir1#4ar m!ti!n !0 t/e e4e1tr!de 5it/ t/e 5ea3e area ne3er
e81eedin' t5! e4e1tr!de diameters. Ne3er #se a 0#44 5ea3e
$attern. S?i$ 5e4d as $ra1ti1a4, and $een t/e 5e4d t! re4ie3e
stresses 5/i4e 1!!4in' 4ar'er $ie1es. A3!id t!e 1ra1?s and
#nder1#ttin'. A s!0t stee4 5ire $edesta4 1an /e4$ t! a"s!r"
s/rin?a'e 0!r1es. B#tter 5e4din' A4ain' a "ead, t/en 'rindin'
it !00B in t/e t!e area "e0!re 0i44et 5e4din' stren't/ens t/e
area 5/ere a t!e 1ra1? ma start.
e. Cast &ron.
A1B General. Gra 1ast ir!n /as 4!5 d#1ti4it6 t/ere0!re, it
5i44 neit/er e8$and, n!r stret1/, t! an 1!nsidera"4e e8tent
"e0!re "rea?in' !r 1ra1?in'. Be1a#se !0 t/is 1/ara1teristi1,
$re/eatin' is ne1essar 5/en 1ast ir!n is 5e4ded " t/e
!8a1et4ene 5e4din' $r!1ess. .!5e3er, it 1an "e 5e4ded 5it/ t/e
meta4 ar1 5it/!#t $re/eatin' i0 t/e 5e4din' /eat is 1are0#44
1!ntr!44ed. T/is 1an "e a11!m$4is/ed " 5e4din' !n4 s/!rt
4en't/s !0 t/e 7!int and a44!5in' t/ese se1ti!ns t! 1!!4. B
t/is $r!1ed#re, t/e /eat !0 5e4din' is 1!n0ined t! a sma44 area
and t/e dan'er !0 1ra1?in' t/e 1astin' is e4iminated. Lar'e
1astin's 5it/ 1!m$4i1ated se1ti!ns, s#1/ as m!t!r "4!1?s, 1an "e
5e4ded 5it/!#t dismant4in' !r $re/eatin'. S$e1ia4 e4e1tr!des
desi'ned 0!r t/is $#r$!se are #s#a44 desira"4e.
A(B Welding Techni$ues.
AaB Cast ir!n 1an "e satis0a1t!ri4 5e4ded 5it/ a 1!ated stee4
e4e1tr!de, "#t t/is met/!d s/!#4d "e #sed as an emer'en1 meas#re
!n4. W/en #sin' a stee4 e4e1tr!de t/e 1!ntra1ti!n !0 t/e
57
stee4 5e4d meta4, t/e 1ar"!n $i1?ed #$ 0r!m t/e 1ast ir!n " t/e
5e4d meta4, and t/e /ardness !0 t/e 5e4d meta4 1a#sed " ra$id
1!!4in' m#st "e 1!nsidered. Stee4 s/rin?s m!re t/an 1ast ir!n
5/en 1!!4ed 0r!m a m!4ten t! a s!4id state and, 5/en a stee4
e4e1tr!de is #sed, t/is #ne3en s/rin?a'e 5i44 1a#se strains at
t/e 7!int a0ter 5e4din'. W/en a 4ar'e 2#antit !0 0i44er meta4
is a$$4ied t! t/e 7!int, t/e 1ast ir!n ma 1ra1? 7#st "a1? !0 t/e
4ine !0 0#si!n #n4ess $re3enti3e ste$s are ta?en. T! !3er1!me
t/ese di00i1#4ties, t/e $re$ared 7!int s/!#4d "e 5e4ded "
de$!sitin' t/e 5e4d in s/!rt strin' "eads, )FD t! 1FD in1/ 4!n',
made intermittent4 and, in s!me 1ases, " t/e ste$,"a1? !r s?i$,
5e4din' $r!1ed#re. T! a3!id /ard s$!ts, t/e ar1 s/!#4d "e str#1?
in t/e & and n!t !n t/e s#r0a1e !0 t/e "ase meta4. Ea1/ s/!rt
4en't/ !0 5e4d meta4 a$$4ied t! t/e 7!int s/!#4d "e 4i'/t4
$eened, 5/i4e /!t, 5it/ a sma44 "a44$een /ammer and a44!5ed t!
1!!4 "e0!re additi!na4 5e4d meta4 is a$$4ied. T/e $eenin' a1ti!n
0!r'es t/e meta4 and re4ie3es meta4 strain d#rin' 1!!4in'.
A"B T/e e4e1tr!des #sed s/!#4d "e 1F* in1/ in diameter s! as t!
$re3ent 'eneratin' e81essi3e 5e4din' /eat. T/e 5e4din' s/!#4d "e
d!ne 5it/ re3erse $!4arit. Wea3in' !0 t/e e4e1tr!de s/!#4d "e
/e4d t! a minim#m. Ea1/ meta4 de$!sit s/!#4d "e t/!r!#'/4
14eaned "e0!re additi!na4 meta4 is de$!sited.
A1B Cast ir!n e4e1tr!des are #sed 5/ere s#"se2#ent ma1/inin' !0
t/e 5e4ded 7!int is re2#ired. Stain4ess stee4 e4e1tr!des are
#sed 5/en ma1/inin' !0 t/e 5e4d is n!t re2#ired. T/e $r!1ed#re
0!r ma?in' 5e4ds 5it/ t/ese e4e1tr!des is t/e same as t/at
!#t4ined 0!r 5e4din' 5it/ mi4d,stee4 e4e1tr!des. Stain4ess stee4
e4e1tr!des $r!3ide e81e44ent 0#si!n "et5een t/e 0i44er and "ase
meta4s6 /!5e3er, 'reat 1are m#st "e ta?en n!t t! !3er/eat t/e
"ase meta4. O3er/eatin' t/e "ase meta4 5i44 1a#se 1ra1?in' !0
t/e "ase meta4 a4!n'side t/e 5e4d meta4. T/e reas!n 0!r t/is
1ra1?in' !0 t/e "ase meta4 is t/at stain4ess stee4 e8$ands and
1!ntra1ts a$$r!8imate4 5+ $er1ent m!re t/an mi4d stee4 in e2#a4
1/an'es !0 tem$erat#re.
@. E4e1tri1 Ar1 We4din' !0 N!n0err!#s 9eta4s
a. General. 9!st !0 t/e n!n0err!#s meta4s #sed in Arm 'r!#nd
e2#i$ment 1an "e s#11ess0#44 e4e1tri1 ar1 5e4ded $r!3ided t/e
$r!$er $r!1ed#res are
58
ad/ered t!. T/e 0!44!5in' s#"$ara'ra$/s des1ri"e t/e 5e4din'
te1/ni2#es #sed !n4 0!r a4#min#m. A4#min#m and a4#min#m a44!s
1an "e satis0a1t!ri4 5e4ded " meta4,ar1, 1ar"!n,ar1, and !t/er
ar1,5e4din' $r!1esses. T/e $rin1i$a4 ad3anta'e !0 #sin' t/e ar1,
5e4din' $r!1esses is t/at a /i'/4 1!n1entrated /eatin' C!ne is
!"tained 5it/ t/e ar1 and, 0!r t/is reas!n, e81essi3e e8$ansi!n
and dist!rti!n !0 t/e meta4 is $re3ented. Wit/ t/e e81e$ti!n !0
t/e 5e4din' r!d #sed, t/e 5e4din' te1/ni2#es #sed 0!r !t/er
n!n0err!#s meta4s, name4 titani#m, ni1?e4, "r!nCe, "rass,
ma'nesi#m, and m!ne4, are t/e same as t/!se #sed 0!r a4#min#m.
". Welding Techni$ues.
A1B Be1a#se !0 t/e di00i1#4t !0 1!ntr!44in' t/e ar1, "#tt and
0i44et 5e4ds are di00i1#4t t! $r!d#1e in $4ates 4ess t/an 1F*
in1/ t/i1?. In 5e4din' $4ate /ea3ier t/an 1F* in1/, a $4ate 5it/
a )+ "e3e4 5i44 /a3e stren't/ e2#a4 t! a 5e4d made " t/e
!8a1et4ene $r!1ess, "#t t/is 5e4d ma "e $!r!#s and #ns#ited
0!r 4i2#id, !r 'as,ti'/t 7!ints. 9eta4 ar1 5e4din' is, /!5e3er,
$arti1#4ar4 s#ita"4e 0!r /ea3 materia4 and is #sed !n $4ates #$
t! ( 1F( in1/es t/i1?.
A(B T/e 1#rrent and $!4arit settin's 5i44 3ar 5it/ ea1/
man#0a1t#rerHs t$e !0 e4e1tr!des, and t/e $!4arit t! "e #sed
s/!#4d "e determined " tria4 !n t/e 7!ints t! "e made.
A)B Be0!re "ein' 5e4ded, a "r!?en a4#min#m 1astin' s/!#4d "e
1are0#44 14eaned " 5ire "r#s/in' 5it/ minera4 s$irits, $aint
t/inner, !r dr 14eanin' s!43ent #sed t! rem!3e a44 !i4, 'rease,
and !t/er 0!rei'n matter. I0 t/e 1astin' /as a /ea3 1r!ss
se1ti!n, t/e 1ra1? s/!#4d "e t!!4ed !#t t! 0!rm a E&.E
ADB Eit/er meta4 ar1 !r 1ar"!n ar1 5e4din' 1an "e #sed 0!r
a4#min#m 1astin's, "#t t/e 1ar"!n ar1 is $re0erred "e1a#se it
$r!d#1es 5e4ds 0ree !0 !8ides and $!r!sit. %4#8,1!ated r!ds are
essentia4 0!r '!!d ar1 5e4ds. A44 s4a' and 04#8 m#st "e rem!3ed
0r!m t/e 0inis/ed 5e4d t! $re3ent 1!rr!si!n !0 t/e 7!int and t/e
entire $ie1e s/!#4d "e 1!3ered 5it/ sand !r as"est!s t! a00!rd
s4!5 1!!4in'.
59
*. C!n14#si!n
T/is tas? ser3ed t! des1ri"e met/!ds 0!r identi0in' e4e1tr!des
" t$e and intended #se6 t/e a#t!m!ti3e 5e4din' $r!1esses,
materia4s, and identi0i1ati!n $r!1esses6 and t/e t$es and
te1/ni2#es !0 7!int desi'n. T/is in0!rmati!n $r!3ides a "asis
0!r t/e 0!44!5in' tas?. T/e ne8t tas? 5i44 des1ri"e t/e t/e!r,
$rin1i$4es, and $r!1ed#res !0 5e4din' arm!r $4ate6 and t/e
met/!ds !0 destr#1ti3e and n!ndestr#1ti3e testin' 5e4ds, and
tr!#"4es/!!tin' $r!1ed#res.
60
LESSON 1
ELECTRODES CLASSI%ICATION AND
INTENDED USES6 AUTO9OTI&E WELDING PROCESSES,
9ATERIALS, AND IDENTI%ICATION PROCESSES6
9ET.ODS O% DESTRUCTI&E AND NONDESTRUCTI&E
TESTING O% WELDS AND TROUBLES.OOTING PROCEDURES6
T:PES AND TEC.NI;UES O% <OINT DESIGN6 AND
T.E T.EOR:, PRINCIPLES, AND PROCEDURES O%
WELDING AR9OR PLATE
TAS= (. Des1ri"e t/e t/e!r, $rin1i$4es, and
$r!1ed#res !0 5e4din' arm!r $4ate6 and
met/!ds !0 destr#1ti3e and n!ndestr#1ti3e
testin' !0 5e4ds, and tr!#"4es/!!tin'
$r!1ed#res.
CONDITIONS
Wit/in a se40,st#d en3ir!nment and 'i3en t/e s#"1!#rse te8t, 5it/!#t
assistan1e.
STANDARDS
Wit/in t5! /!#rs
RE%ERENCES
N! s#$$4ementar re0eren1es are needed 0!r t/is tas?.
1. Intr!d#1ti!n
T/e $re3i!#s tas? des1ri"ed t/e met/!ds 0!r 14assi0in' e4e1tr!des "
t$e and intended #ses6 t/e a#t!m!ti3e 5e4din' $r!1esses, materia4s,
and identi0i1ati!n $r!1esses6 and t/e t$es and te1/ni2#es !0 7!int
desi'n. T/e $re3i!#s in0!rmati!n $r!3ided t/e "asis 0!r t/is tas?,
5/i1/ des1ri"es t/e t/e!r, $rin1i$4es, and $r!1ed#res 0!r 5e4din'
arm!r $4ate, t/e met/!ds !0 destr#1ti3e and n!ndestr#1ti3e testin', and
tr!#"4es/!!tin' !0 5e4ds.
61
(. Genera4
a. r"or Plate .ses. Arm!r $4ate is #sed !n tan?s, se40,
$r!$e44ed '#ns, and !t/er 1!m"at 3e/i14es 0!r t/e $r!te1ti!n !0
$ers!nne4 and e2#i$ment 0r!m t/e destr#1ti3e 0!r1e !0 enem
$r!7e1ti4es. It is 0a"ri1ated "!t/ in t/e 0!rm !0 1astin's and
r!44ed $4ates, 5/i1/ are /eat treated t! de3e4!$ t/e desired
str#1t#ra4 and $r!te1ti3e $r!$erties. T/e man#0a1t#re !0 '#n
t#rrets and 1!m"at tan? /#44s in14#des !ne,$ie1e 1astin's and
5e4ded assem"4ies !0 r!44ed $4ates and se1ti!ns t/at /a3e "een
1ast.
". +epair of r"or Plate. We4din' /as re$4a1ed ri3etin' 0!r t/e
re$air !0 arm!r $4ate a4t/!#'/, in s!me 1ases, ri3etin' is sti44
#sed !n s!me 3e/i14es $r!te1ted " 0a1e /ardened arm!r.
De3e4!$in' a s#ita"4e te1/ni2#e 0!r 5e4din' arm!r $4ate de$ends
#$!n 1!nsiderati!n !0 t/e 0!44!5in' 0a1t!rs a00e1tin' t/e
5e4da"i4it !0 arm!r $4ate>
A1B ?n!54ed'e !0 t/e e8a1t t$es !0 arm!r "ein' 5e4ded6
A(B ?n!54ed'e !0 t/e $r!$er re$air met/!ds6
A)B t/e 0#n1ti!n !0 t/e dama'ed str#1t#re6
ADB $r!$er se4e1ti!n !0 5e4din' materia4s and re$air
$r!1ed#res6
A5B #r'en1 !0 t/e re$air re2#ired t! a11!m$4is/ t/e 1!m"at
missi!n6
A6B 1are0#4 ana4sis !0 t/e de0e1t in terms !0 t/e $r!$er
7!int, e4e1tr!de, 1#rrent, 3!4ta'e, $!4arit, and minim#m 5e4din'
stresses and 5ar$a'e d#rin' re$air6 and
A@B ?n!54ed'e !0 sa0et /aCards 0ire and sa0et /aCard
$r!1ed#res.
T/e t/e!r, $rin1i$4es, and $r!1ed#res 0!r 5e4din' arm!r $4ate
are "asi1a44 t/e same as t/!se #sed 0!r ind#stria4 0a"ri1ati!n,
"#t m#st "e m!di0ied at times "e1a#se !0 t/e 3arin' t$es !0
dama'e t/at 1an !11#r in t/e "att4e0ie4d.
62
). We4din' Arm!r P4ate
a. Properties of r"or Plate. Arm!r $4ate is /ardened "
n!rma4iCin' !r /eatin' it t! its #$$er 1riti1a4 $!int and 4ettin'
it 1!!4 in sti44 air. T/e "ase meta4 2#en1/in' e00e1t $r!d#1ed
ne8t t! a 5e4d in /ea3 arm!r $4ate #nder n!rma4 5e4din'
1!nditi!ns is a"!#t /a405a "et5een t/e e00e1ts !0 air 1!!4in'
and !i4 2#en1/in' it. D#rin' t/e 5e4din' !0 arm!r $4ate t/e
tem$erat#re !0 t/e 5e4d meta4 ran'es #$5ards !0 )+++G % 0r!m t/e
!ri'ina4 tem$erat#re !0 t/e "ase meta4. T/ere0!re, a narr!5 C!ne
!n ea1/ side !0 t/e de$!sited 5e4d meta4 is /eated a"!3e its
1riti1a4 tem$erat#re. T/is narr!5 C!ne is t/en 2#en1/ed " t/e
re4ati3e4 1!4d "ase meta4 and "e1!mes a /ard "ritt4e C!ne ?n!5n
as martensite. It is in t/is C!ne t/at 1ra1?s are m!st 4i?e4 t!
!11#r #$!n t/e a$$4i1ati!n !0 a 4!ad. %!r t/is reas!n, s$e1ia4
$re1a#ti!ns m#st "e ta?en in a44 5e4din' !$erati!ns t! minimiCe
t/e 0!rmati!n !0 /ard C!nes. In additi!n, 1are m#st "e ta?en t!
$re3ent ra$id 1!!4in' !0 t/e arm!r $4ate a0ter 5e4din' in !rder
t! a3!id t/e 0!rmati!n !0 1ra1?s in /ard C!nes.
". Types of r"or Plate.
A1B General. T/ere are t5! t$es !0 arm!r t/at are #sed !n
1!m"at 3e/i14es> /!m!'ene!#s, 5/i1/ 1an "e 1ast !r r!44ed, and
0a1e /ardened, 5/i1/ is r!44ed. It is essentia4 t/at t/e arm!r
$4ate "e s$e1i0i1a44 identi0ied "e0!re an 5e4din' !r 1#ttin'
!$erati!ns are $er0!rmed. T/is is im$!rtant "e1a#se t/e 5e4din'
$r!1ed#res 0!r ea1/ t$e !0 arm!r are distin1t4 di00erent and
are n!t inter1/an'ea"4e.
A(B Ho"ogeneous r"or Plate. .!m!'ene!#s arm!r is /eat treated
t/r!#'/ its entire t/i1?ness t! de3e4!$ '!!d s/!1? !r im$a1t
resistin' $r!$erties. T/is t$e !0 arm!r is #ni0!rm in /ardness,
1!m$!siti!n, and str#1t#re t/r!#'/!#t and 1an "e 5e4ded !n eit/er
side. A4#min#m arm!r $4ate is in t/e /!m!'ene!#s 14ass. We4din'
$r!1ed#res 0!r a4#min#m arm!r $4ate are t/e same as 0!r 'as
meta4,ar1 5e4din', 5/i1/ are dis1#ssed in t/e inert 'as 5e4din'
!$erati!n s#"1!#rse.
A)B Face Hardened r"or Plate. %a1e /ardened arm!r $4ate /as
an e8treme4 /ard s#r0a1e 4aer 5/i1/ is !"tained " 1ar"#riCin'.
ACar"#riCin' is t/e $r!1ess !0 1!m"inin' 1ar"!n 5it/ an!t/er
a44!
63
!r im$re'natin' a meta4 5it/ 1ar"!n t! stren't/en itB. T/is /ard
s#r0a1e e8tends t! a de$t/ !0 1F5 t! 1FD !0 t/e !#t5ard 0a1in'
t/i1?ness !0 t/e arm!r !n t/e tan? !r arm!red 3e/i14e. T/e
$rimar $#r$!se !0 0a1e /ardened arm!r is t! $r!3ide '!!d
resistan1e a'ainst $enetrati!n 0r!m enem $r!7e1ti4es. T/e inner
side is 1!m$arati3e4 s!0t and /as $r!$erties simi4ar t! t/!se !0
/!m!'ene!#s arm!r. As a matter !0 0a1t, t/e inside and !#tside
!0 0a1e /ardened arm!r $4ate /as t5! di00erent ?inds !0 stee4.
%a1e /ardened stee4 #$ t! 1F( in1/ in t/i1?ness s/!#4d "e 5e4ded
0r!m t/e s!0t side !n4.
1. &dentification of r"or Plate. A 3er im$!rtant $art !0
5e4din' 4ies in t/e 5e4der /a3in' t/e a"i4it t! identi0 meta4
$r!d#1ts t! "e 5e4ded. T/e 0!44!5in' $ara'ra$/s des1ri"e t5!
sim$4e "#t a11#rate tests t/at ma "e made in a 0ie4d s/!$ 0!r
identi0in' arm!r $4ate.
A1B File Test. T/is t$e test is $er0!rmed 5it/ t/e #se !0 an
!rdinar 0i4e 0!#nd in t/e me1/ani1s and 5e4ders t!!4 sets.
AaB Ho"ogeneous r"or. A 0i4e 5i44 "ite int! /!m!'ene!#s arm!r
!n "!t/ t/e !#tside and inside !0 t/e $4ate. As t/e 0i4e is
dra5n a1r!ss eit/er s#r0a1e !0 t/e arm!r $4ate, t/e teet/ !n t/e
0i4e 5i44 "ite int! t/e meta4, ma?in' it ne1essar t! a$$4 0!r1e
t! dra5 t/e 0i4e a1r!ss t/e meta4. T/is t$e test is $er0!rmed
" a$$4in' t/e 0i4e !n4 !n1e !r t5i1e a1r!ss t/e s#r0a1e. T/e
arm!r $r!te1ti!n 2#a4ities !0 t/e arm!r $4ate 1an "e im$aired "
re$eated a$$4i1ati!ns !0 t/e 0i4e6 t/ere0!re, t/e n#m"er !0
a$$4i1ati!ns s/!#4d "e 4imited.
A"B Face Hardened r"or. In t/is t$e arm!r t/e 0i4e 5i44 "ite
!n4 int! t/e s!0t side !0 0a1e /ardened arm!r $4ate. W/en
a$$4ied a1r!ss t/e 0a1e side A!#tsideB !0 t/e arm!r $4ate, t/e
0i4e 5i44 s4i$ instead !0 "itin' int! t/e meta4. B#t 5/en t/e
0i4e is a$$4ied t! t/e re3erse side AinsideB, t/e 0i4e 5i44 "ite
as in /!m!'ene!#s meta4.
A(B Fracture Test. S!me meta4s 1an "e 2#i1?4 identi0ied "
4!!?in' at t/e s#r0a1e !0 t/e "r!?en $art !r " st#din' t/e
1/i$s $r!d#1ed 5it/ a /ammer and 1/ise4.
64
AaB Ho"ogeneous r"or. T/e meta4 ed'es !0 /!4es !r 1ra1?s made
" an anti,tan? $r!7e1ti4e in /!m!'ene!#s arm!r $4ate are ra''ed
and "ent, 5it/ t/e meta4 dri0ted in t/e dire1ti!n !0 $enetrati!n.
Cra1?s in /!m!'ene!#s arm!r are #s#a44 1a#sed " stresses in t/e
meta4. T/ese 1ra1?s are $resent at se3ere "#4'es !r "ends in t/e
dama'ed arm!r $4ate.
A"B Face Hardened r"or. T/e meta4 ed'es !0 /!4es and 1ra1?s
in 0a1e /ardened arm!r are re4ati3e4 14ean 1#t and s/ar$. T/e
$4ates d! n!t "#4'e t! an 'reat e8tent "e0!re 1ra1?in'. B
e8aminin' t/e ed'es !0 0res/4 "r!?en 0a1e /ardened arm!r, it 1an
"e n!ted t/at t/e meta4 at t/e 0a1e side is "ri'/ter and !0 a
0iner str#1t#re t/an t/e meta4 at t/e s!0t side. T/e "ri'/ter
meta4 e8tends t! a de$t/ !0 a$$r!8imate4 1F5 t! 1FD in1/ in
t/i1?ness 0r!m t/e !#tside s#r0a1e.
D. C#ttin' Arm!r P4ate
a. Ho"ogeneous r"or Plate. Eit/er t/e !8'en 1#ttin' t!r1/ !r
t/e e4e1tri1 ar1 1an "e #sed t! 1#t /!m!'ene!#s arm!r $4ate. T/e
!8'en 1#ttin' t!r1/, /!5e3er, is $re0era"4e. T/e 1ar"!n ar1 1an
"e #sed t! 1#t !#t 5e4ds and t! 1#t 1astin's and $4ates, "#t t/e
s/ie4ded meta4,ar1 is $re0erred 5/en !8'en and a1et4ene are n!t
a3ai4a"4e.
". Face Hardened r"or Plate.
A1B General. T/e $r!1ed#re 0!r 1#ttin' t/is t$e !0 arm!r is
essentia44 t/e same as t/at re2#ired 0!r /!m!'ene!#s arm!r.
.!5e3er, e3er $re1a#ti!n s/!#4d "e ta?en t! ?ee$ as m#1/ /eat as
$!ssi"4e a5a 0r!m t/e /ard 0a1e side !0 t/e $4ate. T/is is d!ne
" 1#ttin' 0r!m t/e s!0t side !0 t/e arm!r $4ate. C#ttin' 0r!m
t/e s!0t side 4imits t/e e8tent !0 /eatin' and 1!nse2#ent
s!0tenin' !0 t/e /ard 0a1e side.
A(B Cutting !ith the 1*ygen Torch.
AaB T/e 'enera4 $ra1ti1e #sed 0!r !8'en t!r1/ 1#ttin' 1an "e
a$$4ied 0!r 1#ttin' arm!r $4ate, "#t t/e ti$ siCe, 1#ttin'
!8'en, and $re/eatin' 'as tem$erat#res s/!#4d "e ?e$t at t/e
minim#m, 1!nsistent 5it/ '!!d 2#a4it 1#ts, t! $re3ent
!3er/eatin'.
A"B Stain4ess stee4 is a n!n!8idiCin' meta4. T/ere0!re, 5/en
1#ttin' stain4ess stee4 t$e 5e4ds
65
5it/ an !8'en 1#ttin' t!r1/, it is ne1essar t! #se an
!8idiCa"4e stee4 r!d. T/e !8'en 1!m"ines 5it/ meta4 0r!m t/e
stee4 r!d 1reatin' /i'/ tem$erat#re dr!$s !0 m!4ten stee4. T/ese
dr!$s !0 m!4ten stee4 5as/ !00 !nt! t/e 5e4d and /e4$ me4t t/e
stain4ess stee4 5e4d. T/is 5as/in' a1ti!n is a11!m$4is/ed " an
!s1i44atin' m!ti!n !0 t/e t!r1/ ti$ 5/i1/ 1a#ses t/e m!4ten 5e4d
meta4 t! 5as/ a5a in t/in 4aers. W/en t/i1? stain4ess stee4
5e4ds are 1#t, t/e stee4 r!d s/!#4d "e /e4d a'ainst t/e side !0
t/e 5e4d and 0ed d!5n5ard s4!54 t! 'enerate t/e /i'/ tem$erat#re
re2#ired t! 1reate t/e m!4ten stee4 int! dr!$s. T/e 1#ttin'
$r!1ess #sin' a stee4 r!d is i44#strated in 0i'#re (5.
%IGURE (5. CUTTING STAINLESS STEEL WELDS.
66
A1B Cra1?s !r !t/er de0e1ts !n t/e 0a1e !0 stain4ess stee4
5e4ds 1an "e rem!3ed " /!4din' t/e 1#ttin' ti$ at a s4i'/t an'4e
a5a 0r!m t/e 0a1e !0 t/e 5e4d as s/!5n in 0i'#re (6. T/e
rea1ti!n "et5een t/e 1#ttin' !8'en and t/e stee4 r!d de3e4!$s
s#00i1ient /eat t! me4t t/e 5e4d meta4 and is t/en 5as/ed a5a.
A0ter5ards, t/e 7!int s#r0a1e 1an "e re5e4ded.
%IGURE (6. RE9O&ING SUR%ACE DE%ECTS %RO9
STAINLESS STEEL WELDS.
67
A)B Cutting !ith the Electric rc.
AaB E4e1tri1 ar1 1#ttin' is a $r!1ed#re 5/ere" meta4 is 1#t
#sin' t/e /eat !0 an ar1 maintained "et5een t/e e4e1tr!de and t/e
"ase meta4. T/ree $r!1ed#res des1ri"ed in t/e 0!44!5in'
s#"$ara'ra$/s are #sed in 1#ttin' 5it/ t/e e4e1tri1 ar1.
A"B Car"!n,ar1 1#ttin' is a $r!1ess 5/ere" t/e 1#ttin' !0
meta4s is a11!m$4is/ed " $r!'ressi3e me4tin' 5it/ t/e /eat !0 an
e4e1tri1 ar1 "et5een a meta4 e4e1tr!de and t/e "ase meta4.
Dire1t 1#rrent strai'/t $!4arit Ae4e1tr!de ne'ati3eB is
$re0erred. T/e 1ar"!n ar1 is #sed #nder s!me 1!nditi!ns in
1!n7#n1ti!n 5it/ a 7et !0 1!m$ressed air 0!r t/e rem!3a4 !0
de0e1ti3e a#steniti1 A1!rr!si!n resistantB 5e4d meta4. C#ttin'
5it/ t/e 1ar"!n ar1 is #sed 0!r 1#ttin' "!t/ 0err!#s and
n!n0err!#s meta4, "#t d!es n!t $r!d#1e a 1#t !0 $arti1#4ar4 '!!d
a$$earan1e. T/e e4e1tr!des are eit/er 1ar"!n !r 'ra$/ite,
$re0era"4 5it/ a $!inted end t! red#1e ar1 5anderin', and t/#s
$r!d#1e 4ess errati1 1#ts.
A1B 9eta4,ar1 1#ttin' is a $r!1ess 5/ere" t/e 1#t is $r!d#1ed
" $r!'ressi3e4 me4tin' t/e meta4. Dire1t 1#rrent strai'/t
$!4arit is $re0erred 0!r t/is $r!1ess. C!ated e4e1tr!des
ran'in' in diameter 0r!m 1F* t! 1FD in1/ are #sed6 4ar'er
diameters are n!t satis0a1t!r "e1a#se !0 e81essi3e s$atter. T/e
t/i1?ness !0 t/e meta4 t/at 1an "e 1#t " t/e meta4,ar1 $r!1ess
is 4imited !n4 " t/e 4en't/ !0 t/e e4e1tr!de. T/e 1!atin' !n
t/e e4e1tr!de ser3es as an ins#4at!r "et5een t/e 1!re !0 t/e
e4e1tr!de and t/e side 5a44 !0 t/e 1#t, res#4tin' in 4ess s/!rt,
1ir1#itin' a'ainst t/e ?er0. C#ts made " t/e meta4,ar1 $r!1ess
are 4ess ra''ed t/an t/!se $r!d#1ed 5it/ 1ar"!n,ar1, "#t t/e
m#st sti44 "e $re$ared " 'rindin' !r 1/ise4in' "e0!re re5e4din'
is a11!m$4is/ed.
AdB O8,ar1 1#ttin' is a11!m$4is/ed " dire1tin' a stream !0
!8'en int! t/e m!4ten $!!4 !0 meta4. T/e $!!4 is ?e$t m!4ten "
t/e ar1 str#1? "et5een t/e "ase meta4 and t/e 1!ated t#"#4ar
1#ttin' r!d. T/e r!d is 1!ns#med d#rin' t/e 1#ttin' !$erati!n.
T/e t#"#4ar r!d a4s! $r!3ides an !8idiCin' 04#8 and a means !0
1!n3er'in' !8'en !nt! t/e s#r0a1e "ein' 1#t. T/e
68
t#"#4ar 1#ttin' e4e1tr!de is made !0 mi4d stee4. C!ntaminati!n
!0 t/e meta4 is e4iminated " t/e e8treme4 /i'/ /eat and !8'en
emitted " t/is $r!1ess. T/is /i'/ /eat and !8'en a4s! !8idiCe
t/e r!d and 1!atin' t/ere" $re3entin' t/e r!d meta4 0r!m 0#sin'
5it/ t/e "ase meta4.
AeB A0ter 1!m$4etin' t/e 1#t 5it/ an ar1 1#ttin' $r!1ess, t/e
r!#'/ ed'es and s4a' s/!#4d "e rem!3ed " /ammerin', 1/i$$in', !r
'rindin' $ri!r t! 5e4din'.
5. We4din' .!m!'ene!#s Arm!r P4ate
a. General. Be0!re 5e4din' dama'ed arm!r $4ate, t/e t$e !0
arm!r m#st 0irst "e identi0ied. T/is identi0i1ati!n 1an "e
a11!m$4is/ed in t/e 0ie4d " !ne !0 t/e met/!ds des1ri"ed in
$ara'ra$/ (1 !n $a'e 6). .!m!'ene!#s arm!r $4ate 1an "e
satis0a1t!ri4 5e4ded #sin' t/e e4e1tri1 ar1 5e4din' $r!1ess and
1*,* stain4ess stee4 /ea3 1!ated e4e1tr!des 5it/ re3erse
$!4arit. Arm!red 3e/i14es t/at /a3e "een e8$!sed t! 1!nditi!ns
!0 e8treme 1!4d s/!#4d n!t "e 5e4ded #nti4 t/e "ase meta4 /as
"een $re/eated s#00i1ient4 t! "rin' t/e tem$erat#re !0 t/e "ase
meta4 in t/e C!ne !0 5e4din' #$ t! n! 4ess t/an 1++ %. At t/is
tem$erat#re, t/e meta4 5i44 "e n!ti1ea"4 5arm t! t/e t!#1/. I0
t/is $re/eat is n!t a$$4ied, 1ra1?in' 5i44 !11#r in t/e de$!sited
5e4d meta4.
". Procedure.
A1B Sim$4e 1ra1?s as s/!5n in 0i'#re (@, 3ie5 A, !n t/e
0!44!5in' $a'e, s/!#4d "e 04ame 1#t int! a "e3e4ed & 7!int as
s/!5n in 0i'#re (@, 3ie5 B, "e0!re 5e4din'. Care s/!#4d "e ta?en
t! r!#nd !00 t/e 1!rners at t/e t!e and r!!t !0 t/e 7!int. T/is
is ne1essar in !rder t! e4iminate e81essi3e 5e4d meta4 di4#ti!n.
T/e in14#ded an'4e !0 "e3e4, as s/!5n in 0i'#re (@, 3ie5 C,
s/!#4d "e a$$r!8imate4 D5 de'rees t! $r!3ide e4e1tr!de 14earan1e
0!r ma?in' t/e r!!t 5e4din' "eads. T/e r!!t !$enin', as s/!5n in
0i'#re (@, 3ie5 D, s/!#4d "e 0r!m )F16 t! 5F16 in1/, de$endin' !n
$4ate t/i1?ness.
A(B T/e 5e4d "eads de$!sited at t/e r!!t !0 t/e 5e4d m#st "e
'!!d 2#a4it. It is essentia4 t/at 1are "e ta?en t! $re3ent
1ra1?s, !8ide and s4a' in14#si!ns, in1!m$4ete $enetrati!n, !r
e81essi3e 5e4d meta4 di4#ti!n in t/is area. S!me !0 t/e met/!ds
re1!mmended as $re$arat!r ste$s 0!r r!!t
69
%IGURE (@. WELDING CRAC=S IN
.O9OGENEOUS AR9OR.
70
"ead 5e4din' are s/!5n !n 0i'#re (*. %!r narr!5 r!!t !$enin's, a
)F16 in1/ stain4ess stee4 e4e1tr!de 5it/!#t 1!atin' 1an "e ta1?
5e4ded in $4a1e as s/!5n in 0i'#re (*, 3ie5 A. We4din' "ead
n#m"ers 1 t/r!#'/ D are t/en de$!sited se2#entia44. T! ens#re a
s!#nd 5e4d, rem!3e a44 s4a' and !8ides 0r!m t/e 7!int "e0!re
de$!sitin' "eads ) and D. I0 a mi4d stee4 r!d !r stri$, as s/!5n
in 0i'#re (*, 3ie5 B, t/e "a1? side !0 t/e "a1?in' r!d !r stri$
s/!#4d "e 1/i$$ed !#t a0ter "eads 1 and ( are de$!sited t!
minimiCe di4#ti!n in "eads ) and D. T/e #se !0 a stain4ess stee4
stri$ as a "a1?in' 0!r r!!t "eads in a 5ide r!!t !$enin' is s/!5n
as 3ie5 C !0 0i'#re (*. An a4ternate
%IGURE (*. ROOT BEAD WELD.
71
met/!d, s/!5n in 0i'#re (*, 3ie5 D, !n t/e $re3i!#s $a'e, #ses a
mi4d stee4 stri$. W/en t/is met/!d is #sed, t/e "a1?in' r!d !r
stri$ s/!#4d "e 1/i$$ed !#t "e0!re de$!sitin' "eads ) and D.
An!t/er $r!1ed#re, as s/!5n in 0i'#re (*, 3ie5 E, #ses a 1!$$er
"a1?in' "ar. T/e 1!$$er "ar is rem!3ed a0ter "eads 1 and ( are
de$!sited. AT/e "eads 5i44 n!t 5e4d t! t/e 1!$$er "ar.B Beads )
and D are de$!sited a0ter rem!3a4 !0 t/e 1!$$er "ar. In 1ertain
1ases, 5/ere $4ates !0 /!m!'ene!#s arm!r are 1ra1?ed a4!n' t/eir
entire 1r!ss se1ti!n !0 t/e $4ate, an!t/er met/!d !0 7!int
$re$arati!n, as s/!5n at 0i'#re (*, 3ie5 %, 1an "e #sed. In t/is
!t/er met/!d, r!!t "eads A and B are de$!sited !$$!site 0r!m ea1/
!t/er at t/e "ase !0 t/e "e3e4. T/ese r!!t "eads a1t as "a1?in'
0!r "eads 1 t/r!#'/ 6, 5/i1/ are de$!sited a0ter5ards.
A)B We4d 1rater and 0#si!n C!ne 1ra1?in', es$e1ia44 in t/e
r!!t "eads, is a ma7!r 0a1t!r in3!43ed in 5e4din' 1ra1?s in arm!r
t/at terminate 5it/in t/e $4ates. T! $re3ent t/is 1ra1?in', an
intermittent "a1?ste$ and !3er4a$ $r!1ed#re, as s/!5n in 0i'#re
(-, 3ie5 A, !n t/e 0!44!5in' $a'e, is re1!mmended. It s/!#4d "e
n!ted t/at a44 !0 t/e 5e4din' ste$s ne1essar 0!r "ead n#m"er 1
m#st "e 1!m$4eted "e0!re de$!sitin' "ead n#m"er (. B "a1?
ste$$in', t/e 1raters at t/e end !0 ea1/ $re3i!#s $ass are
4!1ated and 0i44ed. A44 1raters !n s#"se2#ent $asses, t/at d!
n!t terminate !n $re3i!#s de$!sited meta4, s/!#4d "e 0i44ed " a
/esitati!n and dra5"a1? te1/ni2#e. T/e 0i44in' #$ !0 5e4d
1raters a3!ids t/e 0!rmati!n !0 star 1ra1?s 5/i1/ are 1a#sed "
t/e s!4idi0i1ati!n !0 s/a44!5 de$!sits !0 m!4ten 5e4d meta4.
ADB Ea1/ $ass in "eads 1 t/r!#'/ D, s/!5n in 0i'#re (-, 3ie5s B
and C, is 4imited 0r!m 1 t! ( in1/es in 4en't/ and s/!#4d "e
$eened 5/i4e t/e 5e4d meta4 is sti44 /!t t! /e4$ !3er1!me t/e
1!!4in' stresses. N! e4e1tr!de 5ea3in' m!ti!n s/!#4d "e #sed
5/en t/e r!!t "eads are de$!sited. T/e 5e4din' s/!#4d "e
$er0!rmed $re0era"4 5it/ a 5F)( in1/ e4e1tr!de. Peenin' a4s!
tends t! e4iminate !r minimiCe 5ar$a'e in t/e se1ti!n "ein'
5e4ded. Ar1 "4!5 s/!#4d "e 1!ntr!44ed " $r!$er4 ad7#stin' t/e
met/!d !0 5e4din'. S!me !0 t/e m!re 1!mm!n de0e1ts en1!#ntered
5/en 5e4din' r!!t "eads !n /!m!'ene!#s arm!r $4ate and t/e $r!$er
remedia4 $r!1ed#res are s/!5n in 0i'#re )+, !n $a'e @D.
72
%IGURE (-. WELD BEADS ON .O9OGENEOUS
AR9OR PLATE.
73
%IGURE )+. .O9OGENEOUS AR9OR CO99ON DE%ECTS
AND RE9EDIAL PROCEDURES.
A5B T/e se2#en1e !0 5e4din' "eads and t/e $r!1ed#re re1!mmended
t! 1!m$4ete4 5e4d t/e sin'4e & 7!int are s/!5n in 0i'#re )1, !n
t/e 0!44!5in' $a'e. We4din' s/!#4d "e $er0!rmed 5it/ a 5F)( !r
)F16 in1/ e4e1tr!de. T/e e4e1tr!de is dire1ted a'ainst t/e side
5a44 !0 t/e 7!int, s! as t! 0!rm an an'4e !0 a$$r!8imate4 (+ t!
)+ de'rees 5it/ t/e 3erti1a4. T/e e4e1tr!de s/!#4d a4s! "e
in14ined 5 t! 15 de'rees in t/e dire1ti!n !0 5e4din'. B t/is
$r!1ed#re, t/e side 5a44 $enetrati!n 1an "e e00e1ti3e4
1!ntr!44ed. T/e e4e1tr!de 5ea3in' m!ti!n s/!#4d n!t e81eed ( 1F(
e4e1tr!de 1!re 5ire diameters. T/is is im$!rtant "e1a#se
stain4ess stee4 /as a 1!e00i1ient !0 e8$ansi!n a$$r!8imate4 1
1F( times t/at !0 mi4d stee46 i0 a 5ea3in' m!ti!n
74
%IGURE )1. WELDING SINGLE & <OINTS ON
.O9OGENEOUS AR9OR PLATE.
'reater t/an t/at re1!mmended is #sed, 4!n'it#dina4 s/rin?a'e
1ra1?s in t/e 5e4d !r 0#si!n C!ne ma de3e4!$.
A6B T/e se2#en1e !0 $asses #sed 0!r 1!m$4ete4 0i44in' a d!#"4e
7!int is s/!5n in 0i'#re )(, 3ie5s A t/r!#'/ C, !n t/e 0!44!5in'
$a'e. T/e de$t/ !0 $enetrati!n !0 5e4d meta4 int! t/e "ase meta4
s/!#4d "e 1!ntr!44ed in !rder t! !"tain '!!d 0#si!n 5it/!#t
e81essi3e di4#ti!n !0 t/e 5e4d.
75
%IGURE )(. WELDING DOUBLE & <OINTS ON
.O9OGENEOUS AR9OR PLATE.
76
E81essi3e di4#ti!n 5i44 1a#se t/e 5e4d t! "e n!n,stain4ess,
"ritt4e, and s#"7e1t t! 1ra1?in'. Pr!$er $enetrati!n 5i44 'i3e a
4!n' s1a44!$ed /eat a00e1ted C!ne !n ea1/ side !0 t/e 5e4d as
s/!5n in 0i'#re )(, 3ie5 D, !n t/e $re3i!#s $a'e. Ins#00i1ient
$enetrati!n As#r0a1e 0#si!nB 5i44 $r!d#1e a 0air4 strai'/t ed'ed
/eat a00e1ted C!ne !n ea1/ side !0 t/e 5e4d. T/is 1!nditi!n is
#ndesira"4e 0r!m t/e stand$!int !0 '!!d "a44isti1 $r!$erties.
A@B Better 1!ntr!4 1an "e maintained !0 t/e /eat in$#t at t/e
7!int and !0 t/e s/a$e !0 t/e 7!int, " a4ternate4 de$!sitin'
t/e 5e4d meta4 !n !ne side !0 t/e 7!int and t/en t/e !t/er. Ea1/
4aer !0 meta4 de$!sited ser3es t! stress re4ie3e t/e 5e4d meta4
immediate4 "eneat/ it, and t! $artia44 tem$er t/e /eat a00e1ted
C!ne $r!d#1ed in t/e "ase meta4 " t/e $re3i!#s 5e4din' "ead.
T/e $asses at t/e t!e !0 t/e 5e4d 7!int, as s/!5n in 0i'#re )(,
3ie5 C, a4s! ser3e t! annea4 t/e "ase meta4 and are de$!sited
"e0!re t/e intermediate $asses are added t! 0i44 t/e 5e4d 7!int.
T/e annea4in' $asses at t/e t!e !0 t/e 5e4d 7!int are an
im$!rtant 0a1t!r in t/e e4iminati!n !0 0#si!n C!ne 1ra1?s 5/i1/
mi'/t start at t/e s#r0a1e !0 t/e 5e4d. T/r!#'/ 1are0#4 1!ntr!4
!0 t/e de$t/ !0 $enetrati!n, a /eat a00e1ted C!ne 5it/ a
s1a44!$ed e00e1t is $r!d#1ed.
1. E"ergency +epairs. T5! met/!ds !0 emer'en1 re$airs !n
1ra1?ed arm!r $4ate t/at 1an "e made " #sin' "#tt stra$s are
s/!5n in 0i'#re )), 3ie5s E and %, !n t/e 0!44!5in' $a'e. T/ese
stra$s are 5e4ded t! t/e "a1? !0 t/e 1ra1?ed arm!r $4ate. T/e
$rimar $#r$!se !0 t/ese "#tt stra$s is t! stren't/en t/e se1ti!n
5ea?ened " t/e 1ra1?.
d. +epairing Penetrations. C!m$4ete $enetrati!ns in /!m!'ene!#s
arm!r $4ate are re$aired " #sin' t/e $r!1ed#res s/!5n in 0i'#res
)D t/r!#'/ )6, !n $a'es @- t/r!#'/ *1. %i'#re )5, 3ie5 A, !n
$a'e *+, s/!5s t/at 1!nsidera"4e str#1t#ra4 dama'e /as "een d!ne
t! t/e meta4 immediate4 ad7a1ent t! t/e s/e44 $enetrati!n.
S/e44 $enetrati!n /!4es sma44er t/an t/e t/i1?ness !0 t/e arm!r
$4ate 1an "e re$aired " t/e "#tt stra$ met/!d. T! e00e1t
re$airs, a44 t!rn and irre'#4ar ed'es !0 t/e dama'ed meta4 s/!#4d
"e rem!3ed t! $ermit '!!d 1!nta1t "et5een t/e "#tt stra$ and t/e
"ase arm!r
77
%IGURE )). BUTT STRAP WELDS ON
CRAC=ED AR9OR PLATE.
$4ate as s/!5n in 0i'#re )D, !n t/e 0!44!5in' $a'e. %!r /!4es
t/at are 4ar'er t/an t/e t/i1?ness !0 t/e arm!r $4ate, a $4#'
$at1/ !0 /!m!'ene!#s meta4 !0 t/e same t/i1?ness as t/e "ase
meta4 s/!#4d "e #sed as s/!5n in 0i'#re )5, 3ie5 B, !n $a'e *+.
T/e 1!rre1t and in1!rre1t met/!d !0 $re$arin' and 5e4din' t/e
$4#' $at1/ is s/!5n in 0i'#re )6, 3ie5s A and B, !n $a'e *1.
Sma44 diameter $enetrati!ns 1an "e re$aired " $4#' 5e4din'
5it/!#t t/e #se !0 a $at1/.
e. +epairing Bulges. B#4'es in arm!r t/at are a4s! 1ra1?ed, "#t
d! n!t inter0ere 5it/ t/e !$erati!n !0 interna4 me1/anisms in t/e
3e/i14e, 1an "e re$aired " 5e4din' t/e 1ra1?ed se1ti!n #sin' t/e
$r!1ed#re des1ri"ed in $ara'ra$/ 1 a"!3e. %!r "est res#4ts, t/e
"#4'e s/!#4d "e 1#t !#t and a $at1/ inserted. B#4'es in t/e
arm!r t/at inter0ere 5it/ t/e !$erati!n !0 interna4 me1/anisms
ma "e rem!3ed " 'rindin' !r 1/i$$in' t/em a5a. In a44
78
1ases, t/e 5e4ds s/!#4d "e made t! t/e 0#44 t/i1?ness !0 t/e
$4ate and a44 1ra1?s !3er 1FD in1/ in 5idt/ s/!#4d "e 1/i$$ed !#t
"e0!re re5e4din'.
0. +epairs %ade fro" 1ne Side. W/ere it is n!t 0easi"4e t! ma?e
t/e 5e4din' re$air 0r!m "!t/ sides !0 t/e arm!r, t/e 7!int m#st
t/en "e made 0r!m !ne side as s/!5n in 0i'#re )1 !n $a'e @5.
N!te t/at eit/er a "#tt stra$ !r stain4ess stee4 stri$ 1an "e
#sed as a "a1?#$ 0!r t/e r!!t "eads !0 t/e 5e4d.
%IGURE )D. E9ERGENC: REPAIRS.
79
%IGURE )5. DOUBLE & PLUG WELDING.
80
%IGURE )6. CORRECT AND INCORRECT PLUG
WELD PREPARATION.
81
'. +epairs !ith 3on!elded Butt Strap. A te1/ni2#e t/at
$ermits rem!3a4 !0 t/e "#tt stra$ a0ter 5e4din' is s/!5n in
0i'#re )@, 3ie5 A. T/is te1/ni2#e is #sed 0!r a$$4i1ati!ns 5/ere
a "#tt stra$ 5!#4d inter0ere 5it/ t/e !$erati!n !0 interna4
me1/anisms. It $ermits 5e4din' a sin'4e & 7!int in /!m!'ene!#s
arm!r $4ate 5it/!#t 5e4din' t/e "#tt stra$ t! t/e 5e4d meta4.
T/is te1/ni2#e
%IGURE )@. WELDING WIT.OUT A BUTT STRAP.
82
re2#ires in1reasin' t/e an'4e !0 t/e e4e1tr!de t! 6+ de'rees, as
s/!5n in 0i'#re )@, 3ie5 B, !n t/e $re3i!#s $a'e, at t/e midd4e
!0 t/e 5ea3e 5/i4e sim#4tane!#s4 in1reasin' t/e 5ea3in' s$eed.
As a res#4t, t/e 5e4d meta4 is de$!sited t! t/e "ase meta4 and t!
$re3i!#s4 de$!sited meta4 instead !0 ad/erin' t! t/e "#tt stra$.
At t/e end !0 ea1/ 5ea3e, t/e an'4e !0 t/e e4e1tr!de is de1reased
t! 15 de'rees, as s/!5n in 0i'#re )@, 3ie5 C, sim#4tane!#s 5it/
t/e 5ea3in' s$eed, and t/e e4e1tr!de is /e4d m!mentari4 ad7a1ent
t! t/e side 5a44 t! ens#re '!!d side 5a44 $enetrati!n. A0ter
de$!sitin' t/e r!!t $ass, t/e "#tt stra$ 1an "e rem!3ed "
"rea?in' t/e ta1? 5e4ds 5/i1/ se1#re it t! t/e arm!r $4ate. A
0ina4 $ass 1an "e a$$4ied t! t/e r!!t !0 t/e 5e4d a0ter rem!3in'
t/e "#tt stra$.
/. +epairing Gouges. O11asi!na44, a $r!7e1ti4e 5i44 im$a1t !n
t/e arm!r $4ate at an an'4e and !n4 '!#'e it 5it/!#t
$enetratin'. T! e00e1t re$airs, t/e '!#'e s/!#4d "e $re$ared
int! a d!#"4e & 7!int, as s/!5n in 0i'#re )*, 3ie5 A, !n t/e
0!44!5in' $a'e, t! a44!5 5e4din' 0r!m "!t/ sides. 9ere4 0i44in'
t/e '!#'e 5it/ 5e4d meta4, as s/!5n in 0i'#re )*, 3ie5 B, is n!t
satis0a1t!r, sin1e it d!es n!t rem!3e an s#"s#r0a1e 1ra1?s t/at
ma /a3e "een 1a#sed " t/e s/e44 im$a1t. A4s!, t/e /eat C!ne
$r!d#1ed at t/e "ase !0 t/e 0i44ed,in '!#'e /as $!!r "a44isti1
stren't/.
6. We4din' %a1e .ardened Arm!r P4ate
a. General.
A1B T/e 0a1e side !0 0a1e /ardened arm!r is e8treme4 /ard and
"ritt4e. Cra1?s !n t/is t$e arm!r $4ate 1an "e 5e4ded
satis0a1t!ri4 0r!m t/e s!0t side. T/ese 1ra1?s 1an "e re$aired
" #sin' 1*,* stain4ess stee4 re3erse $!4arit /ea3 1!ated
e4e1tr!des. S$e1ia4 $re1a#ti!ns, /!5e3er, m#st "e ta?en t! a3!id
dist!rtin' and e81essi3e4 /eatin' t/e arm!r $4ate. Dist!rti!n
and e81essi3e /eat $4a1e stress !n t/e "ase meta4 1a#sin' t/e
$4ate 0a1e t! 1ra1?.
A(B Satis0a1t!r met/!ds 0!r 5e4din' t/is t$e !0 arm!r ma?es
#se !0 t/e "#tt stra$ and "#tt 5e4din' te1/ni2#es, s/!5n in
0i'#res )- and D+ !n $a'es *5 and *6. T/e dimensi!ns !0 t/e "#tt
stra$ de$end !n t/e t/i1?ness !0 t/e arm!r. B#tt stra$
dimensi!ns 0!r arm!r #$ t! !ne in1/ t/i1? are
83
%IGURE )*. REPAIRING GOUGES IN .O9OGENEOUS
AR9OR PLATE.
$r!3ided in T9 -,()@, i0 desired. T/e "#tt stra$ is ta1? 5e4ded
t! t/e s!0t side !0 t/e arm!r t/r!#'/ e4!n'ated s4!ts 1#t int!
t/e stra$. T/e s4!ts are t/en 1!m$4ete4 0i44ed " $4#' 5e4din'
t/em. D! n!t #se e81essi3e 5e4d rein0!r1ement !r #nder1#ttin' at
t/e s#r0a1e !0 t/e $4#'.
84
%IGURE )-. BUTT STRAP WELDS %OR %ACE
.ARDENED AR9OR PLATE.
A)B T! sea4 a 1ra1? in 0a1e /ardened arm!r, as s/!5n in 0i'#re
D+, 3ie5 A, !n t/e 0!44!5in' $a'e, a'ainst s$atter and t! ma?e it
5aterti'/t, 5e4d a sea4 "ead !n t/e s!0t side and 'rind it 04#s/
"e0!re a$$4in' t/e "#tt stra$. A44 5e4din' s/!#4d "e $er0!rmed
!n 14ean, s1a4e 0ree s#r0a1es. Pre3i!#s4 de$!sited 5e4d meta4
s/!#4d "e t/!r!#'/4 14eaned " 1/i$$in' and 5ire "r#s/in' t!
rem!3e s4a' and !8ides t! ens#re s!#nd 5e4ds.
85
%IGURE D+. SEALING CRAC= IN %ACE
.ARDENED AR9OR.
86
ADB Crater 1ra1?s 1an "e e4iminated " t/e "a1?ste$ and !3er4a$
$r!1ed#res !r " #sin' t/e e4e1tr!de /esitati!n and dra5"a1? te1/ni2#e.
Crater 1ra1?s 0!rmed in t/e initia4 5e4d $asses s/!#4d "e 1/i$$ed !#t
"e0!re additi!na4 5e4d meta4 is a$$4ied. T/en t/e 1an "e 5e4ded !#t
s#11ess0#44 " t/e s#"se2#ent $asses. As a $re1a#ti!n, strin' "eads
s/!#4d "e #sed !n t/e initia4 $asses. On s#"se2#ent $asses, d! n!t
5ea3e t/e e4e1tr!de m!re t/an ( 1F( e4e1tr!de 1!re 5ire diameters. T/e
e00i1ien1 !0 t/e 7!int 5e4ded " t/is met/!d de$ends #$!n '!!d 0#si!n
t! t/e "ase meta4 and side 5a44s !0 t/e s4!ts in t/e "#tt stra$.
A5B I0 strai'/tenin' is ne1essar, #se a /ammer !n4 !n t/e s!0t side
!0 0a1e /ardened arm!r, !n t/e "#tt stra$, !r !n t/e $4#' 5e4ds. D!
n!t /ammer !n t/e 0a1e /ardened side. As a r#4e, 0!r1e s/!#4d n!t "e
a$$4ied t! strai'/ten 0a1e /ardened arm!r i0 t/e a$$4ied 0!r1e 5i44
$r!d#1e tensi!n !n t/e 0a1e /ardened side.
A6B W/en t5! !r m!re "#tt stra$s are #sed t! re$air irre'#4ar 1ra1?s
!r t! ma?e $at1/ 5e4ds, t/e "#tt stra$s are 5e4ded t!'et/er 0!r
additi!na4 stren't/ as s/!5n in 0i'#re D1.
%IGURE D1. BUTT STRAP.
87
". r"or Plate +epair %ethods.
A1B C!rner 7!ints 1an "e re$aired " #sin' an'4e ir!n 0!r "#tt
stra$s as s/!5n in 0i'#re D(. T/e $r!1ed#res #sed t! e00e1t t/is
t$e !0 re$air are t/e same as t/!se #sed in ma?in' $4#' 5e4ds
0!r re$airin' 1ra1?s in 0a1e /ardened arm!r and des1ri"ed in
$ara'ra$/ 6aA(B "e'innin' !n $a'e *).
%IGURE D(. CORNER <OINT IN
AR9OR PLATE.
88
A(B Genera44, t/e "#tt stra$ met/!d is satis0a1t!r 0!r
re$airin' #$ t! !ne in1/ !r t/i1?er !0 0a1e /ardened arm!r.
.!5e3er, it is #s#a44 !n4 #sed !n t/i1?nesses #$ t! and
in14#din' 1F( in1/ $4ate.
A)B An!t/er a11e$ted $r!1ed#re 0!r 5e4din' 0a1e /ardened arm!r
a"!3e 1F( in1/ in t/i1?ness is t/e d!#"4e & 7!int met/!d, as
s/!5n in 0i'#re D). T/is met/!d re2#ires t/at t/e s!0t side !0
t/e $4ate "e
%IGURE D). & <OINT WELDING %ACE
.ARDENED AR9OR PLATE.
89
1!m$4ete4 5e4ded "e0!re 5e4din' !n t/e 0a1e side. Usin' strin'
"ead 5e4ds, and t/e "a1?ste$ and !3er4a$ $r!1ed#res 0!r t/e r!!t
$asses, red#1es t/e dan'er !0 1ra1?s de3e4!$in' in t/e 5e4d. T!
?ee$ t/e str#1t#re 0ree !0 5ar$a'e, n! 5ea3in' m!ti!n !0 t/e
5e4din' r!d s/!#4d "e #sed !n t/is t$e 7!int.
ADB A m!di0ied $r!1ed#re, ?n!5n as t/e de$ressed 7!int met/!d,
s/!5n in 0i'#re DD, 3ie5 A, is #sed 0!r 5e4din' #$ t! and
in14#din' 1F( in1/ t/i1? 0a1e /ardened arm!r $4ate. T/is met/!d
#ses a 1F* in1/
%IGURE DD. DEPRESSED <OINT ON %ACE .ARDENED
AR9OR PLATE AND SEAL BEAD WELD.
90
" 1FD in1/ stain4ess stee4 "ar 5/i1/ is $4a1ed in t/e dama'ed
$!rti!n !0 t/e arm!r $4ate. It is t/en "ead 5e4ded in $4a1e.
T/e $rin1i$a4 ad3anta'es !0 t/is 7!int are its sim$4i1it, and
'!!d str#1t#ra4 and "a44isti1 $r!$erties. Care s/!#4d "e ta?en
t/at n! 5e4din' is d!ne !n t/e /ard 0a1e side !0 t/e arm!r $4ate.
1. r"or Plate Welding Electrodes.
A1B T/e m!st satis0a1t!r met/!d 0!r t/e re$air !0 /!m!'ene!#s
and 0a1e /ardened arm!r $4ate is t/e ar1 5e4din' $r!1ess 5it/
stain4ess stee4 e4e1tr!des.
A(B In t/e !8a1et4ene 5e4din' $r!1ess, a 4ar'e se1ti!n !0
"ase meta4 m#st "e /eated t! maintain a 5e4din' $#dd4e t! 5e4d
satis0a1t!ri4. T/is /eatin' destr!s t/e /eat treatment !0 t/e
"ase meta4, 1a#sin' 4ar'e areas t! "e1!me str#1t#ra44 and
"a44isti1a44 5ea?. In additi!n, t/is $r!1ess is s4!5 and
$r!d#1es 1!nsidera"4e 5ar$a'e !0 t/e "ase meta4.
A)B Initia44, de3e4!$ments in arm!r $4ate 5e4din' re2#ired t/e
#se !0 stain4ess stee4 e4e1tr!des 1!ntainin' (5 $er1ent 1/r!mi#m
and (+ $er1ent ni1?e4. %#rt/er de3e4!$ments ser3ed t! $r!d#1e
e4e1tr!des 5it/ a 1!re !0 1* $er1ent 1/r!mi#m and * $er1ent
ni1?e4, and a 1!atin' !0 man'anese !r m!4"den#m, !r "!t/, 5/i1/
$r!d#1e e81e44ent res#4ts. T/ese e4e1tr!des are ?n!5n as
man'anese m!di0ied 1*,*, and m!4"den#m m!di0ied 1*,* stain4ess
stee4 e4e1tr!des. T/e 1an "e #sed 0!r 5e4din' a44 t$es !0
arm!r $4ate " t/e e4e1tri1 ar1 $r!1ess 5it/!#t $re/eatin' !r
$!st/eatin' t/e "ase meta4 str#1t#re.
ADB Current and Polarity. T/e e8a1t 1#rrent re2#ired 0!r ar1
5e4din' 5it/ t/e e4e1tr!des $re3i!#s4 dis1#ssed de$end t! s!me
e8tent !n t/e 7!int t$e, e4e1tr!de desi'n, and $!siti!n !0
5e4din'. Listed "e4!5 are t/e re1!mmended 5e4din' 1#rrent
settin's 4isted 0!r dire1t 1#rrent re3erse $!4arit, a44
$!siti!n, /ea3 1!ated, m!di0ied 1*,* stain4ess stee4 e4e1tr!des.
91
@. Stren't/enin' Ri3eted <!ints in Arm!r P4ate
a. Buttonhead +iveted ,oints. T! stren't/en "#tt!n/ead ri3eted
7!ints in arm!r $4ate, a sea4 "ead 5e4d is re1!mmended as s/!5n
in 0i'#re DD, 3ie5 B, !n $a'e -+. T! a$$4 t/e "ead, t/e ar1 is
str#1? at t/e t!$ !0 t/e ri3et #sin' a stain4ess stee4 e4e1tr!de.
T/e e4e1tr!de is /e4d a"!3e t/e t!$ !0 t/e ri3et 4!n' en!#'/ t!
me4t a$$r!8imate4 1F( in1/ !0 t/e e4e1tr!de. T/e e4e1tr!de is
t/en m!3ed a4!n' t/e 1#r3ed s#r0a1e !0 t/e ri3et d!5n t! t/e
arm!r $4ate and ar!#nd t/e ed'e !0 t/e ri3et #nti4 t/e ri3et is
1!m$4ete4 5e4ded t! t/e arm!r $4ate. Ri3et 7!ints in
/!m!'ene!#s arm!r $4ate 1an "e sea4 5e4ded !n "!t/ sides. Ri3et
7!ints in 0a1e /ardened arm!r, /!5e3er, s/!#4d "e sea4 5e4ded
!n4 !n t/e s!0t side !0 t/e $4ate.
". Countersun( +ivet ,oints. C!#nters#n? ri3et 7!ints are
sea4ed in t/e same manner as "#tt!n/ead ri3et 7!ints.
1. dvantage of Welding +ivet ,oints. Sea4 "ead 5e4din' ri3et
7!ints $re3ents t/e ri3et /ead 0r!m s/earin' !00, and t/e ri3et
s/an? 0r!m $#n1/in' t/r!#'/ t/e $4ate #$!n a $r!7e1ti4e im$a1tin'
!n t/e arm!r $4ate.
*. Testin' !0 We4ds
a. General. T! ens#re t/e satis0a1t!r $er0!rman1e !0 a 5e4ded
str#1t#re, t/e 2#a4it !0 t/e 5e4ds m#st "e determined "
ade2#ate testin' $r!1ed#res. T/e 5e4ded str#1t#re, t/ere0!re,
m#st "e $r!!0 tested #nder 1!nditi!ns t/at are t/e same !r m!re
se3ere t/an t/!se 0!#nd in t/e 0ie4d. Tests a4s! ser3e t!
determine t/e $r!$er 5e4din' desi'n6 and 0!resta44 in7#r,
in1!n3enien1e, and #ntime4 0ai4#re !0 materie4. Genera44,
t/ere are t5! t$es !0 tests t/at 1an "e $er0!rmed t! ens#re t/e
satis0a1t!r $er0!rman1e !0 t/e 5e4ded str#1t#re. T/e are, t/e
$er0!rman1e and t/e $/si1a4 t$es !0 tests.
". Perfor"ance Tests.
9aterie4 re$aired " standard 5e4din' $r!1ed#res ma "e tested "
!$eratin' it t! $er0!rm t/e 0#n1ti!ns 0!r 5/i1/ it 5as desi'ned.
%!r e8am$4e, a 5ea$!n 1an "e tested " 0irin' an e8tra /ea3
1/ar'e t! determine t/e sa0et !0 t/e 5e4d6 a 5/ee4 3e/i14e 1an
"e tested at /i'/ s$eeds !3er r!#'/
92
terrain6 and 5e4ded arm!r $4ate and !t/er /ea3 str#1t#ra4
mem"ers 1an "e tested " '#n0ire. B#t, test 0irin' !0 5ea$!ns
and testin' !0 arm!r $4ate " '#n0ire is n!t 0easi"4e 0!r
maintenan1e #nits in t/e 0ie4d. T/e s#11eedin' $ara'ra$/s,
t/ere0!re, des1ri"e !n4 t/!se $/si1a4 t$e tests t/at 1an "e
1!nd#1ted in intermediate dire1t and 'enera4 s#$$!rt maintenan1e
#nits, in 0ie4d de$!t maintenan1e !$erati!ns, and in CONUS
A1!ntinenta4 United StatesB de$!t maintenan1e !$erati!ns.
1. Physical Tests.
A1B General. T/ese t$es !0 tests are desi'ned t! 1/e1? t/e
s?i44 !0 t/e 5e4der, t/e 2#a4it !0 t/e 5e4d meta4, and t/e
stren't/ !0 t/e 5e4ded 7!int. S!me !0 t/ese tests, s#1/ as t/e
0ree "end and ni1? "rea? tests, are destr#1ti3e. In t/ese tests,
t/e s$e1imen is tested #nti4 it 0ai4s in !rder t/at t/e desired
in0!rmati!n 1an "e 'ained. Ot/er $/si1a4 tests, s#1/ as t/e
/dr!stati1 and ma'neti1 $arti14e tests, are n!t destr#1ti3e.
T/en t/ere are sim$4e $/si1a4 tests, s#1/ as t/e a$$earan1e,
0ra1t#re, and 'rindin' tests, t/at 1an "e $er0!rmed 5it/ t!!4s
0!#nd in a 0ie4d maintenan1e 1!m$an s/!$. T/ese sim$4e $/si1a4
tests are des1ri"ed in t/e 0!44!5in' s#"$ara'ra$/. T/e
destr#1ti3e and n!ndestr#1ti3e t$e tests are des1ri"ed in t/e
s#11eedin' s#"$ara'ra$/s.
A(B Si"ple Physical Tests.
AaB ppearance Test. T/is is a n!ndestr#1ti3e test. In t/is
t$e test, a 3is#a4 e8aminati!n is made !0 t/e 5e4d t! 1/e1? 0!r
s#1/ de0e1ts as "ritt4eness, 1ra1?s, 1raters, #nder1#t, !3er4a$
and s4a' in14#si!ns. A44 t/ese de0e1ts are #na11e$ta"4e and t/e
7!int m#st "e re1!nstr#1ted and re5e4ded.
A"B Fracture Test. T/is is a destr#1ti3e test. T! $er0!rm
t/is test, a 1r!ss se1ti!n s$e1imen m#st "e 1#t !00 0r!m t/e
5e4ded meta4. T/e s$e1imen is t/en 0ra1t#red t! e8$!se t/e 5e4d.
T/e 5e4ded C!ne is t/en 3is#a44 e8amined t! 1/e1? 0!r #ne3enness
!0 t/e 5e4d meta4 'rain, 1ra1?s, 1raters, and inade2#ate
$enetrati!n !0 t/e 5e4d int! t/e "ase meta4.
A1B Grinding Test. T/is is a n!ndestr#1ti3e test. It is
$arti1#4ar4 a$$4i1a"4e t! sea4 "ead 5e4ds made 0!r 5ater$r!!0in'
and sea4in' 1ra1?s in
93
0a1e /ardened meta4. T/is t$e 5e4d m#st "e 'r!#nd d!5n 04#s/
5it/ t/e "ase meta4 "e0!re 5e4din' !0 t/e stra$ t! rein0!r1e t/e
dama'ed area. A0ter 'rindin', t/e 5e4d is t/en 3is#a44 e8amined
t! 1/e1? 0!r $r!$er $enetrati!n, 1raters, 1ra1?s, and e3enness in
t/e 5e4d meta4 'rain.
A)B Destructive and 3ondestructive Tests. In t/e 0!44!5in'
s#"$ara'ra$/s, 5e 5i44 des1ri"e a t!ta4 !0 si8 tests, t/ree
destr#1ti3e and t/ree n!ndestr#1ti3e. T/ese si8 test are t/e
!nes m!st 4i?e4 t! "e $er0!rmed in maintenan1e #nits in t/e
0ie4d and de$!t maintenan1e !$erati!ns. I0 m!re in0!rmati!n !n
!t/er tests is desired, it is $r!3ided in T9 -,()@.
AaB Destructive Tests.
1 Guided Bend Test.
a T/is t$e test ser3es t! determine t/e 2#a4it !0 t/e
5e4d meta4 at t/e 0a1e, t/e r!!t !0 t/e 5e4ded 7!int, and t/e
de'ree !0 $enetrati!n and 0#si!n t! t/e "ase meta4. T/ese tests
are made !n a 7i' as s/!5n in 0i'#re D5, 3ie5 A, !n t/e 0!44!5in'
$a'e. T/is 7i' 1an "e 0a"ri1ated t! an siCe desired in a 0ie4d
maintenan1e 1!m$an ma1/ine s/!$.
" T! $er0!rm t/is test, t/e test s$e1imens m#st "e
ma1/ined 0r!m 5e4ded $4ates t! a t/i1?ness 5it/in t/e 1a$a1it !0
t/e "endin' 7i'. T/e s$e1imen is t/en $4a1ed a1r!ss die
s#$$!rts. T/e 5e4d !n t/e s$e1imen m#st "e 1entered !n t/e U
$!rti!n !0 t/e die. T/e $4#n'er is t/en 4!5ered !nt! t/e
s$e1imen 0r!m a"!3e " a /dra#4i1 7a1? !r !t/er de3i1e t! 0!r1e
t/e s$e1imen int! t/e U $!rti!n !0 t/e die. T! 0#40i44 t/e
re2#irements !0 t/is test, t/e s$e1imen m#st "end 1*+ de'rees and
/a3e n! 1ra1?s 'reater t/an 1F* in1/ !n its s#r0a1e.
1 B!t/ a 0a1e "end and a r!!t "end test !0 5e4d, as s/!5n
in 0i'#re D5, 3ie5 B, 1an "e $er0!rmed !n t/is 7i'. T! $er0!rm
t/e 0a1e "end test, $4a1e t/e 0a1e !0 t/e 5e4d 0a1in' d!5n !n t/e
7i'. T/e r!!t "end test is $er0!rmed " $4a1in' t/e s$e1imen !n
t/e die 5it/ t/e 0a1e !0 t/e 5e4d 0a1in' #$.
94
%IGURE D5. GUIDED BEND TEST <IG.
95
( Free Bend Test.
a T/e 0ree "end test /as "een de3ised t! meas#re t/e
d#1ti4it !0 t/e 5e4d meta4 de$!sited in a 5e4d 7!int. A test
s$e1imen is ma1/ined 0r!m t/e 5e4ded $4ate 5it/ t/e 5e4d 4!1ated
in t/e 1enter as s/!5n in 0i'#re D6, 3ie5 A, !n t/e 0!44!5in'
$a'e. Ea1/ 4en't/5ise ed'e !0 t/e s$e1imen s/!#4d "e r!#nded !00
t! a radi#s n!t t! e81eed !ne,tent/ !0 t/e t/i1?ness !0 t/e
s$e1imen. An t!!4 mar?s s/!#4d "e made 4en't/5ise !0 t/e
s$e1imen. And t5! 4ines, !$$!site ea1/ !t/er, are s1ri"ed !n t/e
0a1e !0 t/e 5e4d at a distan1e !0 1F16 in1/ in5ard 0r!m t/e ed'es
!0 t/e 5e4d as s/!5n in 0i'#re D6, 3ie5 B. T/e distan1e "et5een
t/ese t5! 4ines is meas#red in in1/es and re1!rded as t/e initia4
distan1e I. T/e ends !0 t/e s$e1imen are t/en "ent t! 0!rm t5!
)+ de'ree an'4es at a$$r!8imate4 !ne,t/ird !0 t/e 4en't/ in5ard
0r!m t/e ends. T/e 5e4d is t/#s 1entra44 4!1ated t! ens#re t/at
a44 "endin' !11#rs in t/e 5e4d.
" T/e "ent s$e1imen is t/en $4a1ed in a /dra#4i1 !r
me1/ani1a4 ma1/ine as s/!5n in 0i'#re D6, 3ie5 C, and "ent #nti4
a 1ra1? 'reater t/an 1F16 in1/ a$$ears !n t/e 0a1e !0 t/e 5e4d.
I0 n! 1ra1?s a$$ear !n t/in arm!r $4ate, 1!ntin#e "endin' #nti4
t/e s$e1imen 1an "e "ent in a 3ise. .ea3ier $4ate s$e1imens are
#s#a44 tested in a /dra#4i1 $ress !r "endin' 7i'. T! $re3ent
s4i$$in' !0 t/e s$e1imen, a 'r!!3e s/!#4d "e ma1/ined in t/e
#$$er and 4!5er 1!nta1t $4ates !0 t/e "endin' e2#i$ment, as s/!5n
in 0i'#re D6, 3ie5 E.
1 A0ter "ein' "ent t! t/e s$e1i0i1ati!ns $res1ri"ed in t/e
$re1edin' s#"$ara'ra$/, t/e distan1e "et5een t/e s1ri"ed 4ines is
a'ain meas#red and re1!rded as t/e distan1e :. %ind t/e
$er1enta'e !0 e4!n'ati!n " #sin' t/e 0!rm#4a s/!5n in 0i'#re D6.
T/e tested s$e1imen m#st /a3e a minim#m e4!n'ati!n !0 15 $er1ent
5it/ n! 1ra1?s 'reater t/an 1F16 in1/ at t/e 5e4d t! $ass t/is
test.
) 3ic( Brea( Test.
a T/e ni1? "rea? test /as "een de3ised t! determine i0 t/e
5e4d meta4 !0 a 5e4ded "#tt 7!int /as an interna4 de0e1ts, s#1/
as s4a' in14#si!ns, 'as $!1?ets, $!!r 0#si!n, andF!r !8idiCed !r
"#rnt meta4. T/e s$e1imen is !"tained 0r!m a 5e4ded "#tt 7!int
eit/er " ma1/inin' !r " 1#ttin' 5it/ an
96
%IGURE D6. %REE BEND TEST.
97
!8a1et4ene t!r1/. Ea1/ end !0 t/e 5e4d at t/e 7!int is s4!tted
5it/ a /a1?sa5 !r "and sa5 as s/!5n in 0i'#re D@. T/e s$e1imen
is t/en "rid'ed a1r!ss t5! stee4 "4!1?s, and str#1? 5it/ a /ea3
/ammer #nti4 t/e se1ti!n !0 t/e 5e4d "et5een t/e s4!ts 0ra1t#res.
T/e meta4 t/#s e8$!sed s/!#4d "e 1!m$4ete4 0#sed and 0ree 0r!m
s4a' in14#si!ns. T/e siCe !0 an 'as $!1?et m#st n!t "e 'reater
t/an 1F16 in1/ at its 5idest $!int. T/e n#m"er !0 'as $!1?ets !r
$!res s/!#4d n!t e81eed si8 $er s2#are in1/.
" An!t/er "rea? test met/!d is #sed t! determine t/e
s!#ndness !0 0i44et 5e4ds. T/is is ?n!5n as t/e 0i44et 5e4d
"rea? test. T/is test is $er0!rmed " a$$4in' 0!r1e !n t/e a$e8
!0 t/e & s/a$ed s$e1imen 5it/ a /dra#4i1 $ress !r " stri?in' it
5it/ a /ammer #nti4 t/e 0i44et 5e4d r#$t#res. T/e s#r0a1es !0
t/e 0ra1t#re are t/en e8amined 0!r t/e same de0e1ts menti!ned in
t/e $re1edin' $ara'ra$/.
%IGURE D@. NIC= BREA= TEST.
98
A"B 3ondestructive Tests.
1 Hydrostatic Test.
a T/is n!ndestr#1ti3e test is #sed t! 1/e1? t/e 2#a4it !0
5e4ds !n 14!sed 1!ntainers s#1/ as $ress#re 3esse4s and 4i2#id
tan?s.
" One met/!d !0 $er0!rmin' t/is test is t! 0i44 t/e 3esse4
5it/ 5ater and a$$4 a $ress#re 'reater t/an t/e 5!r?in' $ress#re
!0 t/e 3esse4. T/e !#tside s#r0a1e !0 t/e 3esse4 is t/en
!"ser3ed 0!r 4ea?s t/r!#'/ t/e 5e4ds. T! 1/e1? 5e4ds in
n!n$ress#riCed tan?s, t/e ma "e 0i44ed 5it/ 5ater and !"ser3ed
0!r see$a'e !r 4ea?s t/r!#'/ t/e 5e4ds.
( %agnetic Particle Test. T/is met/!d !0 testin' is #sed !n
5e4ds and $arts made !0 ma'neti1 a44! stee4s. It is a$$4i1a"4e
!n4 t! 0err!ma'neti1 materia4s in 5/i1/ t/e de$!sited 5e4d is
a4s! 0err!ma'neti1. A str!n' ma'neti1 0ie4d is set #$ in t/e
0err!ma'neti1 s$e1imen " an e4e1tri1 1#rrent. An dis1!ntin#it
in t/e meta4 5i44 set #$ a 4ea?a'e 0ie4d 5it/ 4!1a4 ma'neti1
$!4es !0 its !5n. T/ese $!4es t/en attra1t t/e ma'neti1
$arti14es s$rin?4ed !n t/e s#r0a1e !0 t/e s$e1imen indi1atin' a
dis1!ntin#it in t/e !3era44 $attern !0 t/e ma'netiCed s$e1imen.
T/is dis1!ntin#it indi1ates t/at a de0e1t, s#1/ as a 1ra1?,
e8ists !n !r 14!se t! t/e s#r0a1e !0 t/e s$e1imen.
) Fluorescent Penetrant Test. %4#!res1ent $enetrant
ins$e1ti!n is a n!ndestr#1ti3e test 5/ere" 1ra1?s, $!res, 4ea?s,
and !t/er dis1!ntin#ities 1an "e 4!1ated in s!4id materia4s. It
is $arti1#4ar4 #se0#4 0!r 4!1atin' s#r0a1e de0e1ts in
n!nma'neti1 materia4s s#1/ as a4#min#m, ma'nesi#m and a#steniti1
stee4 5e4ds and 0!r 4!1atin' 4ea?s in a44 t$es !0 5e4ds. T/is
test ma?es #se !0 a 5ater,5as/a"4e and /i'/4 04#!res1ent
materia4. T/is materia4 is a$$4ied t! t/e 14ean, dr s#r0a1e !0
t/e s$e1imen " "r#s/in', s$rain', !r di$$in'. T/e e81ess
materia4 is rem!3ed " rinsin', 5i$in' 5it/ 14ean 5ater,s!a?ed
14!t/s, !r " sand"4astin'. A 5et !r dr t$e de3e4!$er is t/en
a$$4ied. A0ter5ards, a "4a1? 4i'/t is #sed t! re3ea4
dis1!ntin#ities in t/e 5e4d s$e1imen. T/e dis1!ntin#ities 5i44
s/!5 #$ as "ri44iant 04#!res1ent s$!ts !n t/e s#r0a1e !0 t/e
s$e1imen.
99
-. Tr!#"4es/!!tin' We4ds.
a. T/#s 0ar, t/is 4ess!n /as des1ri"ed t/e $r!1esses 0!r
identi0in' e4e1tr!des, t/e a#t!m!ti3e 5e4din' $r!1esses, t/e
t$es and te1/ni2#es !0 7!int desi'n, t/e $r!1ed#res 0!r 5e4din'
arm!r $4ate, and t/e met/!ds !0 destr#1ti3e and n!ndestr#1ti3e
testin' !0 5e4ds. T/is materia4 $r!3ided t/e "asis 0!r t/e
tr!#"4es/!!tin' !0 5e4ds t! "e dis1#ssed in t/e s#11eedin'
$ara'ra$/s. Ea1/ !0 t/e tr!#"4es/!!tin' $r!1ed#res dis1#ssed are
"ased !n s$e1i0i1 ma40#n1ti!ns dete1ted as a res#4t !0 3is#a44
e8aminin' 5e4ds. T/e tr!#"4es/!!tin' $r!1ed#res dis1#ssed "e4!5,
t/ere0!re, are "ased !n a t!ta4 !0 0i3e s$e1i0i1 ma40#n1ti!ns
m!st 4i?e4 t! "e en1!#ntered in a maintenan1e #nit in t/e 0ie4d.
%!r 0#rt/er in0!rmati!n !n !t/er tr!#"4es/!!tin' $r!1ed#res re0er
t! T9 -,()@.
". Procedure. Listed "e4!5 are t/e $r!1ed#res t/at t/e 5e4der
5!#4d 0!44!5 in tr!#"4es/!!tin' a 5e4d #$!n dete1tin' t/e
ma40#n1ti!n indi1ated.
A1B Poor Fusion.
Ste$ 1. C/e1? t/e diameter and t/e 4en't/ !0 t/e e4e1tr!de. T/e
e4e1tr!de se4e1ted s/!#4d "e !0 a siCe t/at 5i44 $ermit its
rea1/in' t/e "!tt!m !0 t/e 7!int t! !"tain ade2#ate $enetrati!n
and '!!d 0#si!n.
Ste$ (. C/e1? t/e 5e4din' 1#rrent settin'. Use s#00i1ient
5e4din' 1#rrent t! $ermit ade2#ate de$!sit and $enetrati!n !0 t/e
5e4d. .ea3ier $4ates re2#ire /i'/er 1#rrent 0!r a 'i3en
e4e1tr!de t/an 4i'/t $4ates.
Ste$ ). C/e1? t/e 5e4din' te1/ni2#e #sed. Be s#re t/at t/e
5ea3e is 5ide en!#'/ t! t/!r!#'/4 me4t t/e side5a44s !0 t/e
7!int.
Ste$ D. C/e1? t/e $re$arati!n !0 t/e 7!int. T/e de$!sited meta4
s/!#4d 0#se 5it/ t/e "ase meta4 and n!t 1#r4 a5a 0r!m it !r
mere4 sti1? t! it.
A(B Poor Penetration.
Ste$ 1. C/e1? t! see i0 t/e e4e1tr!de is desi'ned 0!r t/e
5e4din' $!siti!n "ein' #sed. E4e1tr!des s/!#4d "e #sed 0!r
5e4din' in t/e $!siti!n 0!r 5/i1/ t/e 5ere desi'ned. Be s#re t!
a44!5 t/e $r!$er r!!t !$enin's at t/e "!tt!m !0 a 5e4d. Use
100
a "a1?#$ "ar i0 $!ssi"4e. C/i$ !r 1#t !#t t/e "a1? !0 t/e 7!int
and de$!sit a "ead !0 5e4d meta4 at t/is $!int.
Ste$ (. C/e1? t/e siCe !0 t/e e4e1tr!de "ein' #sed. D! n!t
e8$e1t e81essi3e $enetrati!n 0r!m an e4e1tr!de. Use sma44
diameter e4e1tr!des in a narr!5 5e4din' 'r!!3e t! $ermit rea1/in'
t/e "!tt!m !0 t/e 'r!!3e.
Ste$ ). C/e1? t/e 5e4din' 1#rrent settin'. Use s#00i1ient
5e4din' 1#rrent t! !"tain $r!$er $enetrati!n.
Ste$ D. C/e1? t/e 5e4din' s$eed. D! n!t 5e4d t!! ra$id4.
C!ntr!4 t/e 5e4din' s$eed t! $ermit $enetrati!n t! t/e "!tt!m !0
t/e 5e4ded 7!int.
A)B .ndercut.
Ste$ 1. C/e1? t/e 5e4din' 1#rrent settin'. Use m!derate 5e4din'
1#rrent and d! n!t tr t! 5e4d at t!! /i'/ a s$eed.
Ste$ (. C/e1? 0!r $r!$er mani$#4ati!n !0 t/e e4e1tr!de. D! n!t
#se t!! 4ar'e an e4e1tr!de. I0 t/e $#dd4e !0 m!4ten meta4
"e1!mes t!! 4ar'e, #nder1#t ma res#4t. E81essi3e 5idt/ !0 5ea3e
5i44 1a#se #nder1#t and s/!#4d n!t "e #sed. A #ni0!rm 5ea3e, n!t
!3er t/ree times t/e e4e1tr!de diameter, 5i44 aid 'reat4 in
$re3entin' #nder1#t in "#tt 5e4ds. I0 an e4e1tr!de is /e4d t!!
near t/e 3erti1a4 $4ate in ma?in' a /!riC!nta4 0i44et 5e4d,
#nder1#t !n t/e 3erti1a4 $4ate 5i44 res#4t.
ADB Poor Weld ppearance.
Ste$ 1. C/e1? 5e4din' te1/ni2#e 0!r $r!$er 1#rrent and e4e1tr!de
mani$#4ati!n te1/ni2#e. Ens#re t/e #se !0 t/e $r!$er 5e4din'
te1/ni2#e 0!r t/e e4e1tr!de #sed. D! n!t #se e81essi3e 5e4din'
1#rrent. Use a #ni0!rm 5ea3e !r rate !0 tra3e4 at a44 times.
Ste$ (. C/e1? t/e 1/ara1teristi1s !0 t$e e4e1tr!de #sed. Use
an e4e1tr!de desi'ned 0!r t/e t$e !0 5e4d, "ase meta4, and t/e
$!siti!n in 5/i1/ t/e 5e4d is t! "e made.
Ste$ ). C/e1? t/e 5e4din' $!siti!n 0!r 5/i1/ t/e e4e1tr!de is
desi'ned. D! n!t ma?e 0i44et 5e4ds
101
5it/ d!5n/and A04at $!siti!nB e4e1tr!des #n4ess t/e $arts are
$!siti!ned $r!$er4.
Ste$ D. C/e1? 0!r t/e $r!$er 7!int $re$arati!n. 9a?e s#re a44
7!ints are $r!$er4 $re$ared.
A5B Warping of Thin Plates.
Ste$ 1. C/e1? 0!r s/rin?a'e !0 t/e de$!sited 5e4d meta4. Se4e1t
an e4e1tr!de 5it/ /i'/ 5e4din' s$eed and m!derate $enetratin'
$r!$erties.
Ste$ (. C/e1? 0!r e81essi3e 4!1a4 /eatin' at t/e 7!int. We4d
ra$id4 t! $re3ent e81essi3e 4!1a4 /eatin' !0 t/e $4ates ad7a1ent
t! t/e 5e4d.
Ste$ ). C/e1? 0!r $r!$er $re$arati!n !0 t/e 5e4d 7!int. A3!id
an e81essi3e r!!t !$enin' in t/e 7!int "et5een t/e $arts t! "e
5e4ded. .ammer t/e 7!int ed'es t/inner t/an t/e rest !0 t/e
$4ates "e0!re 5e4din'. .ammerin' e4!n'ates t/e ed'es and t/e
5e4d s/rin?a'e 1a#ses t/em t! $#44 "a1? t! t/e !ri'ina4 s/a$e.
Ste$ D. C/e1? t/e 5e4din' $r!1ed#re. Use eit/er t/e s$e1ia4
intermittent !r a4ternatin' 5e4din' se2#en1e, !r "a1?ste$ !r s?i$
5e4din' $r!1ed#re.
Ste$ 5. C/e1? t/e 14am$in' !0 $arts. Pr!$er4 14am$ $arts
ad7a1ent t! t/e 7!int. Use "a1?#$ 0i8t#res t! 1!!4 $arts ra$id4.
1+. C!n14#si!n
T/is tas? ser3ed t! des1ri"e t/e t/e!r, $rin1i$4es, and
$r!1ed#res !0 5e4din' arm!r $4ate6 t/e met/!ds !0 destr#1ti3e and
n!ndestr#1ti3e testin' !0 5e4ds, and t/e tr!#"4es/!!tin' !0 5e4ds
$ertainin' t! e4e1tri1 ar1 5e4din'. T/is tas? 1!m$4etes t/e te8t
materia4 !0 t/is 4ess!n. T/e ne8t tas? 1!nsists !0 a $ra1ti1a4
e8er1ise 5/i1/ !# are re2#ired t! 1!m$4ete " $r!3idin' t/e
ans5ers t! t/e 2#esti!ns.
102
WELDING OPERATIONS I - OD1651 - LESSON 1/PE 1
PRACTICAL EIERCISE
Instr#1ti!ns
T/is e8er1ise is $r!3ided t! test !#r $r!'ress in 4earnin' t/e
materia4s in t/e s#"1!#rse. P4ease ans5er t/e 2#esti!ns t/at
0!44!5. :!# ma 1/e1? !#r ans5ers 0r!m t/e $a'e t/at 0!44!5s
t/e 2#esti!ns.
1. List t5! !0 t/e se3en 0a1t!rs t/at m#st "e 1!nsidered in
se4e1tin' e4e1tr!des.
(. W/at are t/e t/ree 'r!#$s int! 5/i1/ meta4,ar1 e4e1tr!des ma
"e 'r!#$ed and 14assi0iedJ
). T/e Ameri1an We4din' S!1iet /as 0!rm#4ated a n#m"er series
0!r t/e identi0i1ati!n !0 e4e1tr!des.
a. W/at d!es t/e 4etter E at t/e "e'innin' !0 t/is n#m"er
si'ni0J
". W/at t5! di'its !0 t/is n#m"er series indi1ate t/e $!siti!n
!0 t/e 5e4d and t/e t$e !0 e4e1tri1a4 1#rrent re2#iredJ
D. W/at is !ne !0 t/e 0#n1ti!ns $er0!rmed " t/e 1!atin' !n
t/in4,1!ated e4e1tr!desJ
5. W/at t5! t$es !0 e4e1tri1 1#rrent are #sed 0!r e4e1tri1 ar1
5e4din'J
6. W/at t5! met/!ds !0 5e4din' ma "e #sed t! re$air 1ra1?s in
1ast ir!n en'ine "4!1?sJ
@. B 5/at 1!mm!n4 #sed met/!d are "r!?en !r 5ea?ened 3e/i14e
0rames 1r!ssmem"ers re$aired !r stren't/enedJ
*. Name t5! !0 t/e 0i3e t$e 5e4din' 7!ints #sed in meta4,ar1
5e4din'.
-. W/at is t/e $re0erred ar1 4en't/s 0!r !"tainin' "etter
1!ntr!4 !0 t/e 0i44er meta4 de$!sited d#rin' 5e4din'J
1+. O0 t/e 0!#r 'enera4 $!siti!ns #sed 0!r 5e4din', 5/i1/ is m!st
di00i1#4t t! 5e4d inJ
103
11. W/at are t/e t5! t$es !0 arm!r $4ate #sed !n Arm 1!m"at
3e/i14esJ
1(. W/at t$e !0 arm!r $4ate ma "e re$aired 0r!m "!t/ sidesJ
1). W/at is !ne !0 t/e t/ree sim$4e tests t/at 1an "e $er0!rmed
in a maintenan1e 1!m$an s/!$ 0!r testin' 5e4dsJ
1D. W/at is !ne !0 t/e t/ree n!ndestr#1ti3e tests t/at is #sed
0!r testin' 5e4dsJ
15. W/at is t/e 0irst ste$ in tr!#"4es/!!tin' a 5e4d 5it/ $!!r
0#si!nJ
104
LESSON 1. PRACTICAL EIERCISE , ANSWERS
1. a. S$e1i0i1 $r!$erties
". T$e !0 "ase meta4
1. P!siti!n !0 t/e 5e4d
d. T$e !0 1#rrent a3ai4a"4e
e. C#rrent $!4arit a3ai4a"4e
0. Dimensi!ns !0 t/e se1ti!n t! "e 5e4ded
'. T/e t$e !0 0it $ermitted " t/e 5!r?
(. a. Bare
". T/in4 1!ated
1. S/ie4ded,ar1 !r /ea3 1!ated
). a. T/e 4etter in t/e n#m"er series indi1ates t/at t/e
5e4din' r!d is intended 0!r #se in meta4,ar1 5e4din'
". T/e t/ird and 0!#rt/ n#m"ers res$e1ti3e4
D. a. It diss!43es !r red#1es im$#rities !n t/e 5e4d meta4
de$!sited
". It red#1es t/e ad/esi3e 0!r1e "et5een t/e m!4ten meta4
and t/e end !0 t/e e4e1tr!de
1. It in1reases t/e sta"i4it !0 t/e ar1
5. A4ternatin' and dire1t 1#rrent.
6. 9eta4,ar1 5e4din' and "raCin' 5it/ !8a1et4ene.
@. B t/e #se !0 rein0!r1in' $4ates.
*. a. B#tt 7!int
". C!rner 7!int
1. Ed'e 7!int
d. La$ 7!int
e. Tee 7!int
-. S/!rt ar1 4en't/.
1+. T/e !3er/ead $!siti!n.
11. .!m!'ene!#s and 0a1e /ardened arm!r $4ate.
1(. .!m!'ene!#s $4ate.
1). a. A$$earan1e test
". %ra1t#re test
1. Grindin' test
105
1D. a. G#ided "end test
". %ree "end test
1. Ni1? "rea? test
15. C/e1? t/e diameter !0 t/e e4e1tr!de.
106
WELDING OPERATIONS I - OD1651 - REFERENCES
REFERENCES
107
WELDING OPERATIONS I - OD1651 - REFERENCES
RE%ERENCES
T/e 0!44!5in' d!1#ments 5ere #sed as res!#r1e materia4s in
de3e4!$in' t/is s#"1!#rse>
T9 -,()@
108

Welding Operations I

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