Professional Documents
Culture Documents
- Fire - Fumes
Prevention of Shock
Use a wooden grating on concrete floors
Rubber soled shoes are best
Danger of shock is increased with higher temperature and humidity - perspiration Disconnect power before repairing
Qualified electrician should complete maintenance and repairs
Prevention of Shock
Use special welding cables with high quality insulation
Repair solid dont use tape Keep in good condition free of grease, oil, out of water, ditches, etc.
Electrode holders and cables should be fully insulated Turn main switch to welder off when leaving the work area Follow usual precautions in handling electric power
Skin
Completely cover body
UV Light will cause sunburn type burn
Mark hot metal to prevent others from coming in contact with welded pieces Pick up hot metal with pliers or tongues, not gloves or hands Dont hand hot metal to instructor or TAs
Prevention of Fire
Clothing
Stand while Arc welding Dont roll cuffs Keep free of oil, grease, etc. Sweatshirts turned inside out
Do not weld near flammable materials Proper fire extinguishing equipment should be stationed near welding operations
General Safety
Good housekeeping
Keep area clean
Electrode stubs Slag on concrete floor Cables hung up Tools put away
Good workmanship in making sound welds is essential to that others may not be injured due to failure of welded parts
Correct amperage
Depends upon electrode type, size, position, and metal thickness Influence burn off rate and affect arc length and speed of travel
Angle of electrode
Determines the bead shape and controls slag and gas inclusions
AC/DC
Alternating Current electrons change direction every 1/120 of a second (60 cycles per second)
Rapid reversal causes the welding heat to be evenly distributed on both the work and the electrode
Electrode Selection
Early arc welding done with bare, low carbon steel wire electrodes on DC welders Early 1930s flux coated electrodes
Exhaustive research into chemical and physical properties and chemical combinations
American Welding Society (AWS) has classified electrodes to allow for wide choices for many applications
Classification of Electrodes
Classified according to filler metal specifications by AWS and ASTM (American Society for Testing Materials)
Lincoln, AIRCO, Hobart, etc. will all be the same
Classification cont.
The fourth or fifth and last digit indicates the type of welding current and the type of flux covering
E-xx10 - DC reverse polarity (electrode positive) only (cellulose sodium). E-xx11 - AC or DC reverse polarity (cellulose potassium ) Fast freeze, cutting E-xx13 - AC or DC straight polarity (titania potassium) Pg. 161
Electrode storage
Store electrodes in protected place
Avoid cracking or chipping flux by bending or striking
Function of Flux
Improves the performance in handling, storage and operation of the electrode Floats out impurities Directs arc stream (stabilizer) Insulator Prevents oxidation (slag or gas) Holds in heat Iron-powder improves striking ability and increases metal deposition rate (E7024)
Amperage Setting
Influences the rate of metal deposition Influences the speed of welding
Bead should be 2x the diameter of the electrode wire
Type of electrode influences amp. setting Unusual to select the proper setting on the first try
For steel, start at 90 amps and adjust from there
Scratch Method
AC or DC welders Contact by sweeping motion
Angle of Electrode
Arc has a definite directional force Flat welding
Perpendicular from side to side Tilted in direction of travel about 15
Vertical up
90 side; 0-5 slant 6011
Horizontal
5-10 side; 15-20 lead 6013, 6011
Vertical down
90 side; 10-15 lead 6013
Overhead
90 side; 10-15 lead 6011
Arc length should be equal to the diameter of the wire in the electrode (1/8) Tighter arc will give even penetration, metal deposition, a strong bead, and less spatter
Speed of Travel
Movement of electrode forward and downward Travel speed influences:
Bead width Penetration General shape of the bead
Controlling distortion
(Volume changes of expansion followed by contraction during cooling)