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Home > Ordnance Documents and other related manuals > > Troubleshooting Welds.
Nondestructive Tests.
Poor Weld Appearance.

Welding Operations, I
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WELDING OPERATIONS I - OD1651 - LESSON 1/TASK 2
9.
Troubleshooting Welds.
a.  Thus  far,  this  lesson  has  described  the  processes  for
identifying  electrodes,  the  automotive  welding  processes,  the
types and techniques of joint design, the procedures for welding
armor plate, and the methods of destructive and nondestructive
testing of welds.
This material provided the basis for  the
troubleshooting  of  welds  to  be  discussed  in  the  succeeding
paragraphs.  Each of the troubleshooting procedures discussed are
based on specific malfunctions detected as a result of visually
examining welds.  The troubleshooting procedures discussed below,
therefore, are based on a total of five specific malfunctions
most likely to be encountered in a maintenance unit in the field.
For further information on other troubleshooting procedures refer
to TM 9-237.
b.  Procedure.
Listed below are the procedures that the welder
would  follow  in  troubleshooting  a  weld  upon  detecting  the
malfunction indicated.
(1) Poor Fusion.
Step 1.  Check the diameter and the length of the electrode.  The
electrode selected should be  of a  size  that will permit its
reaching the bottom of the joint to obtain adequate penetration
and good fusion.
Step 2.  Check  the  welding  current  setting.
Use  sufficient
welding current to permit adequate deposit and penetration of the
weld.
Heavier  plates  require  higher  current  for  a  given
electrode than light plates.
Step 3.  Check the welding technique used.
Be sure that the
weave is wide enough to thoroughly melt the sidewalls of the
joint.
Step 4.  Check the preparation of the joint.  The deposited metal
should fuse with the base metal and not curl away from it or
merely stick to it.
(2) Poor Penetration.
Step 1.  Check  to  see  if  the  electrode  is  designed  for  the
welding  position  being  used.
Electrodes  should  be  used  for
welding in the position for which they were designed.  Be sure to
allow the proper root openings at the bottom of a weld.  Use
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