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The welding handbook
The Welding Handbook for maritime welders The Welding Handbook Barwil Unitor Ships Service Mail: P.O. Box 33 NO-1324 Lysaker, Offi ce: Strandveien 20, 1326 Lysaker, Norway Tel: +47 67 58 45 50, Fax: +47 67 58 45 70, Internet: www.barwilunitor.com Price: USD 25.00 Id no. 811002 Rev: 03, Printer: Pozkal/ Brdr. Fossum, 10 k. 08.07. Country of origin NO. All reasonable care has been taken in compiling the information in this document. All recommendations and sugges- tions on the use of Unitor products are made without guarantee since the conditions of use are beyond the control of the Company. It is the customer’s responsibility to ensure that each product is fit for its intended purpose and that the actual conditions of use are suitable. This book and any advice is provided by Barwil Unitor accordingly on terms that no liability (including liability for negligence) will attach to the Company or its servants or agents arising out of or in connection with or in relation to this brochure or any such advice. Any goods supplied by the Company will be supplied solely upon its standard conditions of sale, copies of which are available on request. The Company’s policy of continuous product development renders specifica- tions liable to modification. Information provided in this book is therefore subject to change without prior notification. Rev01_Welding Handbook Cover.ind1 1Rev01_Welding Handbook Cover.ind1 1 03-07-07 08:46:1003-07-07 08:46:10 Maritime Welding Handbook Welding and Related Processes for Repair and Maintenance Onboard 10th edition Notice: All welding is carried out on the welder’s own risk and account. Welding should be executed by a qualified and experienced welder and adequate safety measures should always be adhered to. The information and guidelines in this Welding Handbook are based on general information and knowledge at hand and are believed to be accurate and reliable, but the information and guidelines are not to be taken as a guarantee or warranty for a special purpose. The information and guidelines are provided to the welder solely for his own consideration, and Wilhelmsen Maritime Services AS assumes no legal responsibility or liability for eventual damages and/or losses should the information and/or guidelines turn out to be incorrect or un-suitable. Wilhelmsen Maritime Services AS is not liable for any loss or damages whatsoever and howsoever arising which is due to force majeure, other events beyond the reasonable control of Wilhelmsen Maritime Services AS or events that could not reasonably be foreseen by Wilhelmsen Maritime Services AS when this Welding Handbook was made. Wilhelmsen Maritime Services AS is in no event liable for indirect, incidental or consequential damages or losses, including damages for loss of profits, resulting from lack of conformity, including but not limited to loss resulting from goods or software not working when connected to other goods/software or for any related cause thereto. Wilhelmsen Maritime Services AS’s liability shall in any event not exceed the total purchase price of the Wilhelmsen Maritime Services AS goods used during the welding operations. Theses conditions are automatically accepted by anybody using the information and guidelines in this Welding Handbook. 2 INTRODUCTION A ship at sea depends upon the knowledge, skills and self-reliance of the crew to carry out necessary maintenance and repair work. One of the important skills required is a good command of modern welding techniques. The purpose of the Unitor Welding Handbook for maritime welders is to provide guidance in modern welding and related processes and to provide the welder with a source of practical information on the right solution to specific onboard welding problems. Unitor’s business activity traces back to 1905 and the company NAG with Acetylene production as a basic activity. The first maritime deliveries from this period were supply of Acetylene as fuel gas for the guiding light beams from numerous lighthouses along the long and weather-beaten coast of Norway. The focus changed towards gas and arc welding techniques when these were developed to useful production and repair methods through the 1930es. A main objective became to develop and maintain a range of welding equipment that is suitable for onboard welding, backed by a worldwide service network, training and documentation. In 1943 the company name was changed to UNITOR. Mergers and increasing activity in the department for sales to ships led to the establishment of this department as a separate company; Unitor Ships Service AS in 1968. In 2005 the company was bought by Wilh.Wilhelmsen ASA and the brand Unitor is now incorporated in Barwil Unitor Ships Service, a part of Wilhelmsen Maritime Services AS, a company in the Wilh. Wilhelmsen Group Experience gained from user contact and welding training of crewmembers showed that documentation aimed specifically at on board welding solutions was needed. This led to the development of the first Unitor welding handbook for on board repair and maintenance welding already the 1950es. This edition of the Unitor Welding Handbook builds upon all the earlier editions and on product development and experience gained since the previous edition. Barwil Unitor Ships Service enjoys close co-operation with its customers and would like to thank the many who have taken the effort to contribute with examples of successful solutions to real life maintenance situations. 1.00 3 UNITOR WELDING HANDBOOK 9 2.01 Introduction & quick guides to processes 35 2.02 Filler material consumption 47 2.03 Metal identification 50 2.04 Unalloyed / low alloyed steel 55 2.05 Problem steels 62 2.06 Stainless steels 65 2.07 Cast iron 78 2.08 Copper and copper alloys 104 2.09 Aluminium 112 2.10 Evaluation of welds 114 3.01 Coated Electrodes 125 3.02 Tig Welding Rods & Fluxes 199 3.03 Wires for Wire Welding 217 3.04 Gas Welding Rods & Fluxes 241 3.05 Brazing Rods & Fluces 251 3.06 Cold Repair Compounds 277 4.01 Electrode welding & gouging 333 4.02 Tig Welding 381 4.03 Wire Welding 403 4.04 Plasma Cutting 441 4.05 Current Distribution System 455 5.01 AC/OX cutting, welding, brazing 459 5.02 Gas Supplies and gas distribution system 511 529 1 SAFETY IN WELDING 2 SOLUTIONS 3 CONSUMABLES 4 ARC WELDING AND CUTTING PROCESS & EQUIPMENT 5 GAS WELDING AND CUTTING PROCESS & EQUIPMENT 2.01 2.02 2.03 2.04 2.05 2.06 2.07 2.08 2.09 2.10 3.01 3.02 3.03 3.04 3.05 3.06 4.01 4.02 4.03 4.04 4.05 5.01 5.02 6 MISCELLANEOUS INFORMATION 6.00 UNITOR WELDING HANDBOOK 4 1 SAFETY IN WELDING . . . . . . . . . . . . . . . . . . . . 9 1.01 Introduction . . . . . . . . . . . . . . . . . . . . . . . . 10 1.02 How to use the handbook . . . . . . . . . . . . 11 1.03 Welding instructions and training . . . . 12 1.04 Personal protection . . . . . . . . . . . . . . . . . 13 1.04.01 Arc welding face shields . . . . . 14 1.04.02 Protective goggles . . . . . . . . . . . 18 1.04.03 Welder's protective clothing . . 20 1.05 Work site protection . . . . . . . . . . . . . . . . 22 1.05.01 Welding curtain . . . . . . . . . . . . . . 22 1.05.02 Welding blanket . . . . . . . . . . . . . 22 1.05.03 Fire extinguisher . . . . . . . . . . . . . 23 1.06 Welding fumes . . . . . . . . . . . . . . . . . . . . . 24 1.06.01 Welding fumes . . . . . . . . . . . . . . 26 1.06.02 Fume extraction . . . . . . . . . . . . . 28 1.07 Safety check list . . . . . . . . . . . . . . . . . . . 30 1.07.01 Equipment . . . . . . . . . . . . . . . . . . 30 1.07.02 Work place . . . . . . . . . . . . . . . . . . 31 1.07.03 Hot work procedure . . . . . . . . . . 32 1.07.04 Operator protection . . . . . . . . . . 32 2 SOLUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 2.01 Introduction . . . . . . . . . . . . . . . . . . . . . . . . 36 2.01.01 Quick reference for cutting . . . 39 2.01.02 Quick reference for joining . . . . 40 2.01.03 Quick reference for rebuilding, hardfacing and coating . . . . . . . 43 2.01.04 Quick reference to cold repairs . . . . . . . . . . . . . . . . . 45 2.02 Filler material consumption . . . . . . . . . . 47 2.03 Metal identification . . . . . . . . . . . . . . . . . 50 2.04 Unalloyed / low alloyed steel . . . . . . . . 55 2.04.01 Introduction . . . . . . . . . . . . . . . . . 55 2.04.02 Unalloyed steel . . . . . . . . . . . . . . 55 2.04.03 Low alloyed steel . . . . . . . . . . . . 55 2.04.04 Heat resistant steel . . . . . . . . . . 55 2.04.05 Low temperature steel . . . . . . . . 56 2.04.06 Weathering steel . . . . . . . . . . . . 56 2.05 Problem steels . . . . . . . . . . . . . . . . . . . . . 62 2.06 Stainless steels . . . . . . . . . . . . . . . . . . . . 65 2.06.01 Introduction . . . . . . . . . . . . . . . . . 65 2.06.02 Austenitic Stainless Steel . . . . . 66 2.06.03 Ferritic Stainless Steel . . . . . . . . 68 2.06.04 Martensitic Stainless Steel . . . . 69 2.06.05 Duplex Stainless Steel . . . . . . . . 70 2.06.06 Clad Steel . . . . . . . . . . . . . . . . . . . 71 2.06.07 Stainless Steel corrosion types 72 2.06.08 Storing and handling of Stainless Steel onboard . . . . . . 74 2.06.09 Grinding/cutting consumables for Stainless Steel . . . . . . . . . . . 75 2.07 Cast iron . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 2.07.01 Introduction . . . . . . . . . . . . . . . . . 78 2.07.02 Grey cast iron . . . . . . . . . . . . . . . 79 2.07.03 White cast iron . . . . . . . . . . . . . . 80 2.07.04 Malleable cast iron . . . . . . . . . . 80 2.07.05 Ductile cast iron . . . . . . . . . . . . . 81 2.07.06 High alloy cast iron . . . . . . . . . . 82 2.07.07 Identification of cast iron . . . . . 83 2.07.08 Preparation of the work piece . . . . . . . . . . . . . . . . . . 84 2.07.09 Arc welding of cast iron . . . . . . 87 2.07.10 Braze welding of cast iron . . . . 95 2.07.11 Cold repair on cast iron . . . . . . . 97 2.08 Copper and copper alloys . . . . . . . . . . . 104 2.08.01 Introduction . . . . . . . . . . . . . . . . . 104 2.08.02 Brass . . . . . . . . . . . . . . . . . . . . . . . 104 2.08.03 Aluminium brass (Yorcalbro) . . 105 2.08.04 Bronze . . . . . . . . . . . . . . . . . . . . . . 106 2.08.05 Nickel bronses (Cunifer) . . . . . . 107 2.09 Aluminium . . . . . . . . . . . . . . . . . . . . . . . . 112 2.10 Evaluation of welds . . . . . . . . . . . . . . . . . 114 2.10.01 Typical welding faults . . . . . . . . 114 2.10.02 Inspection of welded joints . . . 118 2.10.03 Crack detection . . . . . . . . . . . . . . 123 3 CONSUMABLES . . . . . . . . . . . . . . . . . . . . . . . . . 125 3.01 Coated Electrodes . . . . . . . . . . . . . . . . . . 126 3.01.01 Introduction . . . . . . . . . . . . . . . . . 127 3.01.02 Types of electrodes . . . . . . . . . . 128 3.01.03 Storing and re-drying . . . . . . . . . 134 3.01.04 Classification and approvals . . 140 3.01.05 Welding positions . . . . . . . . . . . . 148 UNITOR WELDING HANDBOOK 5 3.01.23 NIFE-334 N Nickel Iron Electrode for Cast Iron . . . . . . . . . . . . . . . . . . . . 184 3.01.24 NICKEL-333 N Nickel Electrode for Cast Iron 186 3.01.25 TINBRO-341 Electrode for Copper Alloys . . . 188 3.01.26 ALBRONZE-344 Electrode for Copper Alloys . . . 190 3.01.27 ALUMIN-351 N Electrode for Aluminum . . . . . . . 192 3.01.28 CH-2-382 Electrode for Chamfering . . . . . 194 3.01.29 ACA-384 Electrode for Air Carbon Arc Gouging . . . . . . . . . . . . . . . . . . . . 196 3.02 Tig welding rods and fluxes . . . . . . . . . 199 3.02.01 Introduction . . . . . . . . . . . . . . . . . 200 3.02.02 Classification . . . . . . . . . . . . . . . . 201 3.02.03 IMS-210 . . . . . . . . . . . . . . . . . . . . 202 3.02.04 ICROMO-216 . . . . . . . . . . . . . . . . 204 3.02.05 18/8 Mo-221 . . . . . . . . . . . . . . . . . 206 3.02.06 IDUPLEX-222 . . . . . . . . . . . . . . . . 208 3.02.07 ICUNI-30-239 . . . . . . . . . . . . . . . . 210 3.02.08 IALBRO . . . . . . . . . . . . . . . . . . . . . 212 3.02.09 I-FLUX-238 PF . . . . . . . . . . . . . . . 214 3.03 Wires for Wire Welding . . . . . . . . . . . . . 217 3.03.01 Introduction . . . . . . . . . . . . . . . . . 218 3.03.02 Classification . . . . . . . . . . . . . . . . 219 3.03.03 Storage and handling for Flux Cored wires . . . . . . . . . . . . . 221 3.03.04 GPS-W-200 . . . . . . . . . . . . . . . . . . 222 3.03.05 HST-SF-203 . . . . . . . . . . . . . . . . . . 224 3.03.06 HST-SF-232 . . . . . . . . . . . . . . . . . . 226 3.03.07 S 316 M-GF-221 . . . . . . . . . . . . . . 228 3.03.08 S 309 M-GF-222 . . . . . . . . . . . . . . 230 3.03.09 Icuni-W-239 . . . . . . . . . . . . . . . . . 232 3.03.10 Ialbro-W-237 . . . . . . . . . . . . . . . . 234 3.03.11 Alumag-W-235 . . . . . . . . . . . . . . . 236 3.03.12 Abratech-W-230 . . . . . . . . . . . . . 238 3.04 Gas Welding Rods & Fluxes . . . . . . . . . 241 3.04.01 Introduction . . . . . . . . . . . . . . . . . 242 3.01.06 GPO-302 N General Purpose Electrode For Mild Steel . . . . . . . . . . . . . . . 150 3.01.07 GPR-300H High Recovery Electrode for Mild Steel . . . . . . . . . . . . . . . . 152 3.01.08 SPECIAL-303 N Double Coated Electrode for Mild and Ship Quality Steel . . . . 154 3.01.09 LH-314 N Low Hydrogen Electrode for Ship Quality Steel . . . . . . . . . . . . 156 3.01.10 LHH-314 High Recovery Low Hydrogen Electrode for Ship Quality Steel 158 3.01.11 LHV-316 N Vertical Down Welding Low Hydrogen Electrode for Ship Quality Steel . . . . . . . . . . . . 160 3.01.12 LHT-318 N Electrode for High Temperature Steel . . . . . . . . . . . . . . . . . . . . . . . 162 3.01.13 LHL-319 N Electrode for Low Temperature Steel . . . . . . . . . . . . . . . . . . . . . . . 164 3.01.14 LHR-320 N Electrode for Weathering Steel 166 3.01.15 TENSILE-328 N Electrode for Difficult-to- Weld Steel . . . . . . . . . . . . . . . . . . 168 3.01.16 IMPACT-329 S Electrode for Heat Resistant Overlays . . . . . . . . . . . . . . . . . . . . 170 3.01.17 WEARMAX-327 Electrode for Joining & Wear Resistant Overlays . . . . . . . . . . . 172 3.01.18 ABRATECH-330 Electrode for abrasive wear . . . 174 3.01.19 18/8-321 N Electrode for Stainless Steel . . 176 3.01.20 23/14-322 N Electrode for Stainless Steel . . 178 3.01.21 DUPLEX-325 N Electrode for Duplex Steel . . . . 180 3.01.22 PICKLING GEL Pickling Gel for Stainless Steel 182 UNITOR WELDING HANDBOOK 6 3.04.02 MS-200 . . . . . . . . . . . . . . . . . . . . . 244 3.04.03 Alumag-235 . . . . . . . . . . . . . . . . . 246 3.04.04 Aluflux-234 F . . . . . . . . . . . . . . . . 248 3.05 Brazing Rods & Fluxes . . . . . . . . . . . . . . 251 3.05.01 Introduction . . . . . . . . . . . . . . . . . 252 3.05.02 Bronze-264 . . . . . . . . . . . . . . . . . . 256 3.05.03 FC-Bronze-261 . . . . . . . . . . . . . . . 258 3.05.04 FC-Wearbro-262 . . . . . . . . . . . . . 260 3.05.05 FC-Cast Iron-268 . . . . . . . . . . . . . 262 3.05.06 AG-45-253 . . . . . . . . . . . . . . . . . . . 264 3.05.07 AG-60-252 . . . . . . . . . . . . . . . . . . . 266 3.05.08 Tin-240 . . . . . . . . . . . . . . . . . . . . . . 268 3.05.09 Fluxes for Brazing . . . . . . . . . . . . 270 3.05.10 Bronze Flux-261 PF . . . . . . . . . . . 271 3.05.11 Wearbro Flux-262 PF . . . . . . . . . 272 3.05.12 AG-60/45 Flux-252 PF . . . . . . . . . 273 3.05.13 Albro Flux-263 PF . . . . . . . . . . . . 274 3.06 Cold Repair Compounds . . . . . . . . . . . . . 277 3.06.01 Introduction . . . . . . . . . . . . . . . . . 278 3.06.02 Typical application areas . . . . . 278 3.06.03 How do Polymers work? . . . . . . 280 3.06.04 How to prepare the surface . . . 281 3.06.05 How to apply the product . . . . . 282 3.06.06 Polymer Kit-A . . . . . . . . . . . . . . . 284 3.06.07 Product overview . . . . . . . . . . . . 286 3.06.08 Leak Stop - Pipe repair . . . . . . . 288 3.06.09 Metalgrade Ready-Stick . . . . . . 292 3.06.10 Metalgrade Express . . . . . . . . . . 296 3.06.11 Metalgrade Rebuild . . . . . . . . . . 298 3.06.12 Metalgrade Hi-Temp . . . . . . . . . 304 3.06.13 Aquagrade Rebuild . . . . . . . . . . . 308 3.06.14 Ceramigrade Rebuild . . . . . . . . . 312 3.06.15 Ceramigrade Liner . . . . . . . . . . . 316 3.06.16 Ceramigrade Abrashield . . . . . . 320 3.06.17 Rubbergrade 6 Rebuild . . . . . . . 324 3.06.18 Rubbergrade 6 Remould . . . . . . 328 4 ARC WELDING AND CUTTNG PROCESS & EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333 4.01 Electrode welding & gouging . . . . . . . . 335 4.01.01 Introduction . . . . . . . . . . . . . . . . . 336 4.01.02 Basic principles . . . . . . . . . . . . . 339 4.01.03 Power source characteristics . 340 4.01.04 Selecting power source . . . . . . 342 4.01.05 UWI-150 Autoline . . . . . . . . . . . . 344 4.01.06 UWI-201 . . . . . . . . . . . . . . . . . . . . 348 4.01.07 UWR-303 . . . . . . . . . . . . . . . . . . . . 350 4.01.08 UWI-400 . . . . . . . . . . . . . . . . . . . . 352 4.01.09 UWR-852 . . . . . . . . . . . . . . . . . . . . 358 4.01.10 Primary extension cables . . . . . 359 4.01.11 Secondary cables . . . . . . . . . . . . 360 4.01.12 Electrode holders, cable connectors & ground clamp assembly . . . . . . . . . . . . . 363 4.01.13 Accessories . . . . . . . . . . . . . . . . . 370 4.01.14 Welding techniques . . . . . . . . . . 371 4.01.15 Edge preparation . . . . . . . . . . . . 373 4.01.16 Electrodes for electrode welding & gouging . . . . . . . . . . . 374 4.01.17 Air Carbon arc gouging . . . . . . . 377 4.02 Tig Welding . . . . . . . . . . . . . . . . . . . . . . . . 381 4.02.01 Introduction . . . . . . . . . . . . . . . . . 382 4.02.02 Basic principles . . . . . . . . . . . . . 383 4.02.03 Shielding gas . . . . . . . . . . . . . . . . 384 4.02.04 Tungsten electrodes . . . . . . . . . . 386 4.02.05 TIG torch . . . . . . . . . . . . . . . . . . . 388 4.02.06 Regulator & accessories . . . . . . 391 4.02.07 Preparing the torch . . . . . . . . . . 393 4.02.08 Welding parameters . . . . . . . . . . 394 4.02.09 Welding technique . . . . . . . . . . . 395 4.02.10 Edge preparation . . . . . . . . . . . . 396 4.02.11 Rods and Flux for TIG welding 400 4.03 Wire Welding . . . . . . . . . . . . . . . . . . . . . . 403 4.03.01 Introduction . . . . . . . . . . . . . . . . . 404 4.03.02 Basic principles . . . . . . . . . . . . . 405 4.03.03 Shielding gas . . . . . . . . . . . . . . . . 411 4.03.04 Equipment . . . . . . . . . . . . . . . . . . 412 4.03.05 Speedweld-160 . . . . . . . . . . . . . . 414 4.03.06 SC 12 RC . . . . . . . . . . . . . . . . . . . . 420 4.03.07 Regulator & accessories . . . . . . 426 4.03.08 Application areas . . . . . . . . . . . . 428 4.03.09 Preparation for welding . . . . . . . 429 4.03.10 Welding technique . . . . . . . . . . . 431 4.03.11 Edge preparation . . . . . . . . . . . . 434 4.03.12 Wires for wire welding . . . . . . . 438 UNITOR WELDING HANDBOOK 7 5.01.24 Soldering and brazing techniques . . . . . . . . . . . . . . . . . . 504 5.01.25 Edge preparation . . . . . . . . . . . . 506 5.01.26 Consumables and parameters for brazing . . . . . . . . . . . . . . . . . . 508 5.02 Gas supplies and gas distribution system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511 5.02.01 Introduction . . . . . . . . . . . . . . . . . 512 5.02.02 Argon . . . . . . . . . . . . . . . . . . . . . . 513 5.02.03 Argon-Carbon Dioxide mixture 514 5.02.04 Carbon-Dioxide . . . . . . . . . . . . . . 515 5.02.05 Oxygen . . . . . . . . . . . . . . . . . . . . . 516 5.02.06 Acetylene . . . . . . . . . . . . . . . . . . . 518 5.02.07 Rules & Safety precautions for handling and use of Gas cylinders . . . . . . . . . . . . . . . . 522 5.02.08 Gas Distribution System for Acetylene and Oxygen . . . . . . . . 524 6 MISCELLANEOUS INFORMATION . . . . . . . . . 529 5.04 International system of units . . . . . . . . . 530 5.05 The Greek Alphabet . . . . . . . . . . . . . . . . . 531 5.06 General conversion factors . . . . . . . . . . 532 5.07 Roman numerals . . . . . . . . . . . . . . . . . . . . 533 5.08 Metric and decimal equivalents of fractions of an inch . . . . . . . . . . . . . . . 534 5.09 Wire cross section AWG/mm 2 . . . . . . . . 534 5.10 Common gauge series for sheet thickness and wire . . . . . . . . . . . . . . . . . . 535 5.11 Physical properties of some elements . . . . . . . . . . . . . . . . . . . . . . . . . . . 536 5.12 Hardness comparison table . . . . . . . . . . 537 5.13 Corrosion of galvanic couples in sea water . . . . . . . . . . . . . . . . . . . . . . . . . . 538 5.14 Temperature scales . . . . . . . . . . . . . . . . . 540 5.15 Pressure variations related to temperature . . . . . . . . . . . . . . . . . . . . . 541 5.16 Abbreviations and welding terminology . . . . . . . . . . . . . . . . . . . . . . . . . 542 4.04 Plasma Cutting . . . . . . . . . . . . . . . . . . . . . 441 4.04.01 Introduction . . . . . . . . . . . . . . . . . 443 4.04.02 Basic principles . . . . . . . . . . . . . 445 4.04.03 Plasma cutting equipment . . . . 446 4.04.04 UPC-838 . . . . . . . . . . . . . . . . . . . . 447 4.04.05 Cutting technique . . . . . . . . . . . . 450 4.04.06 Maintenance and trouble shooting . . . . . . . . . . . . . 452 4.05 Current Distribution System . . . . . . . . . . 455 5 GAS WELDING AND CUTTING PROCESS & EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459 5.01 Ac/Ox cutting, welding, brazing . . . . . . 461 5.01.01 Introduction . . . . . . . . . . . . . . . . . 462 5.01.02 The Combination Torch UCT-500 464 5.01.03 UCT-500 Components and spares . . . . . . . . . . . . . . . . . . . . . . 466 5.01.04 The Unitor Workshop Cabinet . 468 5.01.05 Welding and grinding goggles 470 5.01.06 Accessories . . . . . . . . . . . . . . . . . 471 5.01.07 Portable gas equipment . . . . . . 472 5.01.08 Gas hoses . . . . . . . . . . . . . . . . . . 475 5.01.09 Hose connectors . . . . . . . . . . . . 478 5.01.10 Gas regulators for cylinders . . . 480 5.01.11 Flashback . . . . . . . . . . . . . . . . . . . 482 5.01.12 Flashback arrestors . . . . . . . . . . 483 5.01.13 The acetylene/oxygen flame . . 484 5.01.14 Operating instructions for UCT-500 cutting torch . . . . . . . . 486 5.01.15 Cutting procedure . . . . . . . . . . . . 488 5.01.16 Common cutting faults . . . . . . . . 490 5.01.17 Operating instructions for UCT-500 brazing, welding & heating torch . . . . . . . . . . . . . . . . 492 5.01.18 Maintenance of blowpipes . . . . 494 5.01.19 Heating techniques . . . . . . . . . . 496 5.01.20 Flame straightening techniques 497 5.01.21 Welding techniques . . . . . . . . . . 499 5.01.22 Butt joints for gas welding of steel . . . . . . . . . . . . . . . . . . . . . 502 5.01.23 Consumables and parameters for gas welding . . . . . . . . . . . . . . . . . 503 8 WELDING HANDBOOK NOTES 1.00 1.00 SAFETY IN WELDING 9 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 How to use the handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Welding instructions and training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Personal protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Work site protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Welding fumes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Safety check list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 [...]... electric arc welding wear resistant They provide protec B TIG and gas welding gloves tion during welding, especially when Working gloves the welder has to work close to the C Leather jacket, Large for welding workpiece or where movement is C Leather jacket, Extra large for welding restricted It is specially important D Leather trousers with belt that the welding jacket is worn when E Leather cuffs welding. .. SAFETY IN WELDING 1.00 Work site protection Welding Curtain The purpose of the Welding Curtain is to avoid other personnel being harmed by the welding work taking place The curtain blocks out all hazardous ultraviolet and infrared light from the welding arc, but still enables one to see trough the curtain It is made of self-extinguishing material The size of the curtain is 2 m high and 1,3 m wide The top... SAFETY IN WELDING Electric arc welding gloves Gloves must always be worn when arc welding Special welding gloves with long gauntlets are necessary These must be of leather 1.00 Long lined welding gloves are recommended for welding with coated electrodes TIG and Gas welding gloves Thick welding gloves will hamper the control of the torch or rod Special softskin gloves are available for this purpose They... is from the lowest TIG welding settings (5-10A) to extreme processes at + 400A arc current The Flip-Vision Welding face shield The Flip-Vision Welding face shield 14 This is the AutoVision face shield with headband where the AutoVision cassette is replaced with a flip-up front frame A clear safety glass is placed in the fixed frame under the flip-up frame protecting the eyes when chipping slag The flip-up... processes on a self-study basis, start with the chapters at the back of the book and follow the processes from gas to flame, from primary power to arc and then through consumables to solutions If, on the other hand, you have a basic understanding of welding, read the book from the beginning, starting with the chapter on solutions 1.00 When facing a problem Consult the solutions chapter Here you will find... related to the hot work, like fire extinguishers, fume extraction equipment, etc – Proper use of the filler material and fluxes for the job 10 SAFETY IN WELDING How to use the Handbook Read this first Familiarize yourself with the chapter you are now reading, and follow the advice given here whenever you weld If you know little about welding and your objective is to become familiar with the welding processes... and also the instruction manual on the specific power source you have onboard Ensure that the gas supply is in proper order and correctly maintained, that the welding machine is suited for the process at hand, and that the cables are of correct size Cold repair components require no outside energy The energy is built into the products and is released when the base and activator is mixed together In... of the curtain has 7 holes and the curtain comes complete with 7 heavy-duty hooks With the hooks the curtain can be put in a frame, or hooked up on an existing pipe or wire Maximum pipe dia the hooks will fit on is 41 mm In order for the curtain to be drawn freely the pipe should be less than 30 mm It is possible to join two or more curtains together by the use of snap on buttons along the side The. .. sprayed, the ABC powder forms an insulating screen, which protects the user from heat radiation Easy to use 0peration Once the safety pin has been removed, the device is pressurised by pressing on the striking handle The flow rate is controlled by the tap on the final control valve The fact that it is so simple to use means that risks of incorrect use are greatly reduced 23 SAFETY IN WELDING 1.00 Welding. .. correctly positioned, this unit will protect the welder against fume inhalation and also prevent the smoke spreading in the surrounding area and contaminating the area for others Electric arc welding with coated electrodes, may comprise several different components depending on the type of electrode The composition of the smoke will therefore vary depending on the type of electrode Electrodes are divided