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    14 views15 pages

    Pertemuan Ke 1. Introduction

    Uploaded by

    Rifqie kurniawanMesin

    Copyright:

    © All Rights Reserved
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    of 15
    INTRODUCTION Welding isa practical skill that is challenging, rewarding, and alzo great fun, We encounter welded items throughout our daly lives and activities—they are practically infinite. The appliances in our homes the reiling on our porches or stars, our automobile: the bridges and infrastructure we drive on, the structure of the buildings we workin, and even our computers. Welding makes everyday tasks more ‘manageable, Welding can also bring joy toa craftsman ‘making items for use in the shop, hame décer, and ‘outdoor living and décor In this book, we will thereughly discuss the basics of welding and fabrication: safety, equipment, macerial selection, tools, and the various welding and cutting pracasss. With afirm understanding of the baci, applying safety and commor and apply your newfound knowledge to spectfc projects inthe book, complete with how-to instructions, too ists, material lits, blueprints and ilustrateé pictorsl plans, and photos. Developing your new welding and fabrication skill will provide hours of satisfaction as you create items and furnishings for your home, shop, and outdoor living space ze, we wil then move on The shop section includes plans and instructions for making practical and useful item epacifc for your working space that will provide years of useful service. These tools include a roling welding curtain, welding and cutting table, welding cart with cylinder rack, and an expandable welding table The home décor section includes plans and instructions: tables, and ,a5 well as decorative items, lable candelabrum, hy a8 coat hoa forcommenly used items, shel and decorative wall fixtures. The outdoor section includes plans and instructions for projects suitable for all hardworking Divers, including a yard trailer and truck rack. Aloincluded are plans and instructions for outdoor living space tems, such as railings, 2 gardenlyara gate, arbor, and firept Iie important es 2 welder to understand and use the correct terminology when discussing welaing ane the related pracesses. This will be useful in ordering ‘equipment, anc in selecting the proper filler metal and materials. The weldment the perts to ke joined is referred to as the base metal. Addtional metal, called the filler metal, is then added to the molten base metal to forma moiten puddle t row known asthe heat affected zone (HAZ). This is will eolidiy into a new me the area of focus for the welder. To maintain the proper fusion and strength af the newly formed weld, it ie very important for the base metal and filler metal te have the same composition. The processes for joining mets without fusion are saldering, brazing. and braze welding These proce: issimilar metals can be 1d to join either similar or ‘The strength and quality of any weld is dependent on many factors. To achieve the proper amount of penetration, or weld fusion, iis critical that the heat input ic controlled through an understanding af howto set, ‘edjust, end maintain the following variables + Baze metal selection + Filer metal selection + Proper heat input fora selected material thickness + Work angle +Travel angle + Acclength +Travel speed +Aim + Electrode manipulation + Joint design Welding is about managing heat input—whether itis from ‘fuel scurce such at exyacetylene welding (OAWI, er from electricity inan are welding system, suchas shieldes metal arc welding [SMAW), gas metal arc welding [GMAW flux core arc welding IFCAWI, or gas tungsten arc welding (GTAW]. Each process has its own, SAFETY Shielded metal are welding MAW Gas metal ar welding oma, advantages and dhcadvantages Once a welding pracess ic celected the goalie o jen the eelacted parts te form a ussiul tol or ite in 4 permanent manner. Leeming to manage the heat input elows the welder to conirol the molten metal pudote ar the HAZ. thus allowing the base metal, original part, and filler metal to flow and fuse into a new coalesced area, ening the parts into a neldment. (OAW and Oxyacetylene cutting {OAC} use acetylene forthe fuel ourceta produce flames togensrats heat to melt the base and filler metal for welding or for cutting of ferrous metals, Acetylene ie the fue of chaice for welding, because itis the only fuel source that, wil generate a truly neutral flame When alternative fuel sources ch a propane er natural gs are used, the procezzie then referred to es Oxy-iuel welding (OFW/ and Oxy-fuel cutting (OFC. These fuels ae alten selected far cutting purposes because of theit lower cost and eace of access White performing OAW, the formation ofthe puddle is easier to see, asitis a slower process. The welder is watching for acolor change ofthe base matal ait approachas the melting temperature. As the temperature increases, the colar reaches e reddish color and appears glossy asi siarts to mel wer cut, This wetting action allows the melting baze metal to lower join withthe filer metal that iz added othe joint to form the new metal nthe HAZ. This forms a seamless molten area that wil slit into new meta The are melding (AWM procesces—SMAW, GNAW, FCAW, GTAW, and PAC-all use electrical current t produce an arc te generate the heat necessary to melt the base and fer metal to frm the wel With the AW process, the are forms the puddle quickly and may be dificult to see without the proper lene shade, du to the intense light created by the arc. This is why wearing the proper shad of iter lensis important Penetration o the weldiealze a ercal heat dependent factor A strong weld penetrates all the way through the base metal. To ensures successiu, completely fused weld, te filler metal size. heat input velding current, ang base metal thickness must be ‘matched to travel speed, travel ancl, and arc Length. Itis easy to achieve an appropriately shaped weld profile that has not penetrated the bace metal at all and merslysite on the curface. The teknown 52 “cold” weld and s associated with insufficient current. An oppesite problem is “burn through’—ahere the current is set too high r the arc length is toc ing and overheats the hase metal, making the pudele dificult te maintain and eventually burning ‘through the base metal, leaving ahole thet can be dificult to correct or cepa. Distortion caused by heat appliod during all walding and cuting operations, whether by feme or electrical ac, isan unwanted by-product the welder must tearm ta identity Pre-nelding setup, welcing eaquence, and post-weld hast management are key to accurate dimensions. The welding or cuting racezs selected con produce flame or are with a temperature of up to 10,090 degrees Fahrenet. As we apply the arc (heat or current] to malt the base metal are filer metals form the new materialin the HAZ the metal expands; a¢ the metal cools, it contracts, causing potential strezces to form inthe metal and the weld joint If the expansion and contraction ofthe metelare nat considered during the f-up, the welding process can cause parts to move out of alignment or ultimately fail though the welder can clamp and/or tack weld parts together, he or she stil needs to consider the stress inthe HAZ andler eurrounding area. Clamping or improperly located tack= cen elter where the stress concentrates, potentially cousing premature fare ofthe weldment tis also imperative thatthe welcing process is property metchec for each fype and thickness ofbace metal. Far atample, SMAW i typealy beet euited for welding on material Yainch or thicker, due to the heat input of the arc and dificlty in meintsning the arc on thinner material. GMAW, onthe ether hand, is well suite for thinner materia or sheet meta. {G32 tungsten are welding (GTAW). ‘Ac the arcic developing the HAZ or welding puddle, tic eriteal that Oreaaime/aanySoat>n stenespherie air—msiniy onygen and ntrogen-—ielcept away from the puddle while it is molten and aa it cools or soligies. Oxygen ard nitrogen thet contaminate the puddle as it cools will procuce a very weak ane britie material. The welding process selected provides @ protective ares arcund the puddle to chielc& art coals or slides Jn OFW, the properly adjusted neviral lame burns off ambient cxygen in a small zone around the weld puddle. GMAW and GTAN processes ullizean externally applied inert sivelding gas to protect the puddle from atmospheric air asit solidifies: his is accomplished by attaching an extarnal high-preseure cylinder. The most common shielding gae utlized ie argon, chosen because itis cevzer than a and settles around the weld pudéle, and because itis inert and does not react with the atmospheric air or the weld puddle. SMAW and FCAW processes use flutes chemical compounds) added in or en the filer metal When these flies urn or elt, they procice shielding gaces and form a protective coating [clag, both of wi protect the weld area uni thas solidified Plasma arc cutting [PAC Welding can be dificult end takes years to master, but with basic ‘knowledge and lots of practice its possible to make many useful fang decorative tems. H you wien to meve heyans the projects butlined in thie Book, talk with 8 more experenced welder and have him or her evaluate somo of your practice welds. Remember the sefetyof others is volved when you choose tomake e lity trailer or spiral siaitcase. Take the ime and make the efort i ensure thot any project you makes safe Thizbook ic intended ae a reference for people who have had come ‘exposure to welding and who con follow the steps and safety precautions oulGined in each project. tis not intended i teach welding ta someone wha has never nandled welcing equigment. It You wish to further yourweicing experience and improve your ski set, many community colleges, technical celegas, ad art centers are an idea vay t learn the basics of welding the proper techniques associaied with each process, and specticwelcing sefety, Oxyacetylene cutting OAC BASICS ‘The cozt inuelved in setting up a well-equipped home welding shop are comparable ta seting una well ‘equipped woodworking chop. A knowledgeable welder withthe proper equpmact haz agrest savant, because the projects ane repars he or she can sccompich are tos numerous te count. The avaabilty of ssinanpensive mater ‘create, From base repairs 0 but 3 work stations to creating tems you can ities with welding ae only imted by your imagination and experience. Always striving to learn and improve your craft lets you experience the wow fcler when ethers see and admire your work eas Salety 10 Metal Basies w Meta Shapes & Sizes n Purchasing Metis 5 Meta Cleaning & Preparation % Setting Up the Welding Shop wv Shop Toots 8 Metal Repsie » Safety very importent when welding. The potential dangers inherent te welding and cutting processes are ‘numerous. Failure to follow or overlook manufacturer's rial Date Safety Sheets [MSDS], recommended practices, and guidelines can result in injury or death. Welders may encounter such hazards as electrical shock, exposure to fumes and gases, ire, explosion, arc radiation burns, and cuts and abrasions. Prager preparation fara welding end cutting operations is critical for yaur personal safety ad the safety of thase around you. Always fomilirize yourself with ALL safety information pertaining to a piece of welding or cutting ‘equipment, and apply the inlormation outlined in ‘American National Standards Institute (ANSI) publication 1191, Safety in Welding, Cutting, and Allieg Procesce. A tree copy ofthis standard can be downloaded from the American Welding Society website, wwru.aws.org Important: when in doubt or when you have @ question, consult the operetor’s manual or manufacturer's website, ‘and remember safety is your first responsbiity. Fellow all safety rules and never take shortcuts. FUMES. Welding procuces potentially hazardous fumes. ‘ond gases. Always keep your face out ofthe weld plume, and avoid breathing concentrations of those fumes. Welding indoors requires apecial precautions. When ond what type of ventilation to selectis the first and most. impertant question to ack when welding indoors. Typically any areawith a ceiling lower than 16 feet or awitha total araaofless than 10 D0D SS Welcing safety equipment includes: (A) safety glasses, (B] particle mas (C1) tow-profi.erespiratar, 0} Leather slip-on boots, (E) fire-retardant jacket, F fire-retardant jacket with leather sleeves, 6] welding cap, [leather cape wath apron, leather gloves wrth gauntlets, ) heavy-duty welding aloves, [KI welding holmet with auto-darkening tens, (L) ‘Welding helmet with flip-up lens, (MI full-face WS filter, INI full-face clear protective shield. MINIMUM LENS SHAD! NU essseeelan ING) APPLICATION. SUSOESTED ‘SHADE ‘re netang Sv te Yo" eats a i corny ‘Ae Wel (CVA acl iu ‘as Tungsten ‘Arc Woking (STAN) stot oes Cuting * Oncevone Weng 5 esi oe ‘Waing teres areola aatabe wh er leesin 5 sar are se rable Clara protective erase for grinding or shpping en ho HS fer Terocacetvonecoertins METAL BASICS The suitability ofa metal for welding is dependent upon what elemenisare used to create the metal. tis important to identify the type of metal ang what alloying elements have been added to increase iissirength, toughness, impact resistance, corrasion resistance, or ductility. We typically divide metal into two categories ferrous and nonferrous. Ferrous matale contain ron a2 their major element and include cast iron, forged steel, mild steel, and saintess steels. These metals are typically magnetic. Nonferrauz metale include the “pure elements, such as aluminum, Because they do nat contain iron, they are nonmagnetic and have a lower melting temperature. Iti exsential that base metal ard filler metal are matched to ensure that like metale are Welded. Because this process does involve the melting ard fusion ofthe bose ane filer into one new metal, smelting temperatures and matal characteristics must be similar. We can join dissimilar metals by brazing, braze welcing, or soldering, because these processes do rot actually melt the base metal, Ferrous metals contain iron with varying ameunts of carton and other elloying elements, such as chromium, molybdenum, manganese, and nickel. Each alleyimparts a unique characteristic tothe law carbon steel. Mild steel (low carbon stee!) isthe msi commonly used type and the casieat with which te work. Mild steel can be cut and welded with all of the processes covered inthis book. It makes up mostof the metal items you commonly use, rake, or repair, including autemebie kodiee, bicycles, railings. furniture, cabinets, and shelving. Adding rmore ‘carbon tothe steel makes it harder but alsa more bitte ‘and more dificult to cut or weld. These high-carbon steals are ured te make cutting tools, such ae drill bite, machining bts, and knife blades. Adcing other alloying elements, such as chromium and nickel, tothe low ‘carbon ateel produces stainless atecl. Secauce the Stainless steel does not axiize [rust easily, itis cut hest witha plasma cutter. As always when welding Low carbon teal or alloyed steel, the filler metal must be matched to the elements to ensure = high-quality weld ie produced ‘Aluminum is the most widely used nonferrous metal, because it is ightwsight and corrosion resistant. Like ‘steal, it is avadable in many allaye and is olten heat treated to increase strength. Aluminum is used for engine parts, boats bicycles, furiture, kitchenware, and non ‘sutomabile frames. Variaus characterities make aluminum difficult toweld successtully—it doesnot cchenge color whenit melts it conducts heat rapidly, and itimmecistely develope an oxide layer that melts at 2 higher temperature than the base metal tse, causing ‘overheating and extreme distortion and metal destruc TING POINT METAL, WELDING PROCESS CUTTING PROCESS METAL MELTING POINT (FD Mile ste Allwelding processes Oxyfuel, plasma Aluminum aire ‘Aluminum {Gas tungsten are Plasma Brose 1652 17240 ttt Bronze 1565 1832 Stoess steel Gas ingen arc Plasma chara oa shielded metal arc Copper 9812 Chrame maly steel Gas tungsten are, Plasma Bold 19442 tt iron 2784 Titanium Gastungstenarc Plasma em = Castiran Shielded meal are Plasma ieee Figs ae Brass Braze welding Plasma Titanium 323° Tungsten 5430" Zine METAL SHAPES & SIZES Vil stel and mos! other metals come ina variety of shapes, szes, and thichnesses. Metal thickness may be given 35 faction of an inch, decimal, or gauge. Sheot ‘metalic typiealy inch of less thickness and called fut as a gauge rumber, and plate metal is “inch or thick- er Structural meta typical sientiied by is length width and by its nell, leg, or web thickness. Seme ofthe ‘mest commen structure types and sige callout ae: [A Rectangular tubing ls ured fer structural framing ‘ealers, and furniture. Dimensions fr rectangular tubing are specified by wisth x height x wall thickness length. B, Square tubing is used for structural raring, tellers, and furniture Dimension for square tubing ae 2p22 fied by wicth height « wal thickness x length. Rail cap is used for making handrails. Rall cap dimen sions are the overall width and the wits ofthe chen= nelson the underside 1. Channa soften used for making handrails. Very large channel can be used in trac frames ane structural ‘tems, such ac bridges or ingustrat equipment. The lege, fr flanges, make i stronger than flat bars. Dimensions {or channel ae specified by flange thickness x lange height x channel width outside) x erath Round tubing cnet the same a pipe. Roun tubing is ‘used for siructural tems, wile pipe i use to traneport liquids or gases Dimensions for eune tusing ae speci= fied by outside diameter (0D) x wall thickness xlength 1. T-bar dimensions are given as with » height» thick ness af flanges height. 1, finale ar angle ren nae many structural and decorative ‘uses Limancions fer angle are speciied by fangs thick nese fange width (leg) lange heigh le) x Length Angle con be equal eg length ar unequal eg length WLL.J. Square, round, or hexegenal bar thex ber) dimen ions are specified by withVoutside diameter ltt lat for horagoral bar length Fiat bar/stap (not pictured is avelable in many sizes ands typically not wider than 12" for flat ber are spec= ‘ied by thickness xwiath x lenath ‘Shoot metal (ct pictured i 7" or ese in thickness, and Is oitanreerree toby ite gauge number. Plata ie or ‘greater in thickness, and x specified by its hickness in Iroctons ofan inch, Diamond plate is used as 2 heavy-duty siding for toalhares and carts because of ite durability and strength. It is also used far decorative applications. Itis sold as length x width x thickness. Perforated sheet metal is used for industrial shelving fence jr treads, grates for flnar drains, and = hostof decorative sidings ard top treatments. There are numerous shapes and styles available. They are sometimes referred to as perforated metal screens. Periorated sheets are sold as length x width x thickness. Lighter-weight sheets are sold by the yard in arall Test | Appearance | Fracture ‘chip Spark | Volume of stream Manganese |Dullcastfinish| Rough graned Ferns bright [Hardto chip Bright white |Noderstely steel red, mets Jbursts, heavy flarge uicly atterh Stainless steel Bright, smooth] Bright Dependson [Turns bright [Smooth chip, |Very ew shart [Moderate surface ines. [appearance exact red, mets [smooth bright [fll red sparkes Jcompesition | quickly color with few forks Tow carbon |Gray.fine [Gray bright [Highly Gives off [Chips easly, |Longwhite [Moderately steel (rtd crystalline |magnetic | sparks when |smaoth and {sparks, some large steel <30% Imetted,poot long chip [forks near end carbon sciifies of stream rail Medium __|Grayfinsh [Light gray _|Fighly Melts quickly, |Ohips easly, |Longwhite _ |Noderately carbon steel magnetic aires off some |smoath and sparks with large [30 to 45% sparks long chip secondary carbon) Joursts atorg stream High carbon [Dark gray, _ [Light gray. |Fighly Melts quick, |Dificoltto — |Large volume [Moderate steel [>45% |smooth fnish fwhite, ner |magnetic molten metal |chip, brittle of briliant carbon) grained than isbrighter lwhite sparks Jiow carbon than fow steel cerbon steel NWrougitiron (Gray, fine [Fibrous __ | Righty Melts quickly, |Ohps easly, |Siraw-colored [Large surface Lnes structure, spit|magnetic sight continuous sparks near in seme tendency to |chip lwheet, few direction of spark lwhite forks bers Jncar stream lend foastiren | Roagh,very [Brie gray _ [Highly Terns dullrea|Verysrallend)Dullred __|Small dull gray magnetic first puddle is brite chios sparks formed| very fluid, no Jeloce to wheel sparks High aulfor —[Darkgray | Gray vecyline [Aighly Melts quickly, [Chips easly, Bright carrer [Large steel grain magnetic turns bright |smoath and lines with edbefere long chips eigar-shaped melting swells PURCHASING METALS Finding metal supplier can be a challenging task The ‘materials that are readily availableat home certers and hardware stores may not be the size and shapes needed for a project and can be very expensive; and if ordered online or through a catalog, product weight can create significant shipping charges. With some searching, though, most preducts can be found at reascnable prices. ‘Once a metal supplier nas been found, materials can typically be purchased by weight or per tinear foot. The price for small pieces af mita steelat a hame center or hardware store might be as much as $3 to $5 per pound, but the price ata larger steel supplier may be as litle as 1 per pound, depending on the type of material ordered. Many steel suppliers have an odds and erds bin or rack. ‘where material is discounted even more than Fetal oF wholesale prices. Staintes: higher cost relative to mild steel. When purchasing at 2 hhome canter or hardware store, material can be purchasedin three-, four-, or even six fost lengths that fare much easierto handle, When purchasing fram a cleat ‘supplier, the commen lengths are 10, 12, and even 20 fee, 0 plan accordingly -ae always convenience will cest more. Steel cuppliars have most cemman types and steel and aluminum are INCH EQUIVALENT Pale Nls Auge INCHES 2 0020 2 0026 20 0032 6 0.043 ie 056 ik 0.049 2 0098 w 013. 10 0128 Metal less than 1" thick is offen referred to by gauge. Far reference, the decimal equivalent af 4" is 0.125, lengths in stock end cen order other sizes, Some steel suppliers are distributors for decorative metal products, but many specialty tems, such as wrought-ron reilirg materials, decorative accescories, and weldable hardware, are only aveilable by eataleg. A number of catalog supply companies sell to the public and have \aried selections and reasonable prices love Rezources! Wall plates, hooks, rings, balls, bushings, candle cups, arp plates, and stomped or cas! items are available in a wide variety of shapes, sizes, and sheets, METAL CLEANING & PREPARATION Asuccessful weld becins with a well-prepared welding joint. More attention paid while clearing and preparing the welding jaint ensures e higher quality weld with an ‘acceptable appearance. When working with hot rolled steel [HRS), the mill scale—a thin layer of oxide formed hen the material is processed while itis het-—needs to be removed. Cleanall project parts to remove any cit, dirt, rust, and mill scale, This can be time consuming but will ensure a long-lasting project that will need little maintenance or repair For any project that willbe painted co powder coated, bis important to clean the entire project. I parts will be lowed to rust ar become aged, thoroughly cleanall areas to be welced. The first step in cleaning isto remove all grease, ol, or dirt by wiping the part down with denatured alcoho, ‘acetone, or 3 commercial degreaser. Alcohol works the best, 2c it haz minimal odor and does not diceclve or damage plastics like acetone does. Both ecetone and degreasers tend to leave a residue that may diminish the duality ofthe final weld or finish, Once the grease, ol, and drt have been removed fram the surface, the mil scale must be removed. Youcan do this by wire brushing, grinding, sanding, er cand blasting the part. A benich-mounted grinder with a wire bush works well for cleaning small parts ar the ends of smaller parts, but it cannot be used on larger surfaces. For larger surfaces, youvill need an angle grinder outfitted with a grinding wheel, wire Brush, or flap wheel. Ahanc-hels, tatiery-powered eril. with awire brush or wire brush cup will alsowork, Remember, when working with any power tools, you must wear the appropriate DE, including cafety glasses, face shield, andlong sleeves fo protect your eyes ané body from wire fragments that can be thrown from the brush. Also, never force or apply too much pressure to an angle grinder or drill as the tool can Jick back and couse savers injuries, Once all parts have been cleaned and you have removed all of the mill zcale, it ic important to complete the preject ina timely manner before the metal rusts. ‘Apply denatured alcohol with aclean rag to clean dirt ‘and oil from project parts, Wear ruber gloves te protect your hands. Cleaning the mill cale off mild tee ie an important

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