Welding Operations, I
Task 1. Electrodes Classification and Intended uses, Authomotive Welding Processes, Matarials
Identification and Uses of Electrodes
Classification of Electrodes.
The electrode identification system for stainless steel arc-welding is set up as follows:
Types of Electrodes
Shielded-arc or Heavy-coated Electrodes.
Figure 2. Arc Action and Electric Welding Polarity
Functions of Electrode Coatings
Polarity of Welding Current (figure 2, View B).
Direct Current Arc-Welding Electrodes.
Electrodes Defects and Their effects.
Automotive Welding Processes, Materials, and Identification
Determining the Welding Method
Figure 3. Preparing Engine Block For Welding.
Procedure - od165180020
Heat Treated Parts.
Figure 4. Reinforcing Frame Members
Rear Axle Housings.
Welding Joint Design
Corner Joint
Figure 6. Corner, Edge, Lap , and Tee Joints.
Edge Joint
Figure 7. Tee joint Edge Preparation
Figure 8. Groove Welds
Figure 9. Surfacing, Plug , and Slot Welds
Figure 10. Seam. Spot, flash. and Upset Welds.
Welding tecniques
Figure 11. Welding Positions
Table 1. Current Settings for bare And Lightly Coated Electrodes.
Table 2. Current Settings for Mineral and Cellulose Coated Electrodes.
Figure 12. Starting the Arc
Two Procedures, Describes in the following Subparagraphs, Are Use to .Break the Arc
Table 3. Effets of Maladjustments of Welding Current voltage And Speed on ther Bead Characteristics.
Figure 13. Arc Characteristic and Deffects
Bead Welding (fig14 on the Following Page.).
Figure 14. orrect EletrorodePositiopn for Welds and Proper Bead And Welds
Flat Position Welding (Figure !5 on the following 5)
figure 15. Flat Position Welding
Figure 16.Multipass Bead Wels , Weldinjg Motions, abnd undercutting and Welds with BacksStrips
Butt Joints in Flat Oisition with Backup Strips (Figure 16, View D. )
Figure 17. Plug and Slot Joints and tack welding Tee Joints
Horizontal Position Welding.
Figure 18: Fifllet Welding
Figure 19: IntermittentWelds,ack Welding, And electrode Position
Vertical Position Welding
Figure 20. Lap Joints and Welding Vertically.
Butt Joints
Figure 21 . Vertical Welding And Butt Joints.
Figure 22. Vertical Fillet Welds
Bead Welds
Figure 23. Overhead Position Welding
Butt Joints.
Fillet Welds (figure 24).
Electric Arc Welding of Ferrous Metals
Tool Steels.
High Yield Strenght, Low Alloy Structural Steels.
Cast Iron
Electric Arc Welding of Nonferrous Metals
Welding Techniques.
Conclusion - od165180065
Describe the theory, principles, and procedures of welding armor plate
General - od165180067
Welding Armor Plate
File Test.
Cutting Armor Plate
Figure 25. Cutting Stainless Steel Welds
Figure 26. Removing Surface Defects From Stainless Steel Welds
Cutting with the Electric Arc
Welding Homogenous Armor Plate
Figure 27. Welding Cracks in Homogenous Armor
Figure 28. Root Bead Weld
Procedure - od165180077
Figure 29. Weld Beads On Homogenous Armor Plate
Figure 30. Homogenous Armor Common Defects And Remedial Procedures
Figure 31. Welding Single V Joints On Homogenous Armor Plate.
Figure 32. Welding Double V Joints On Homogenous Armor Plate.
Emergency Repairs
Repairing Bulges.
Repairs Made from One Side
Figure 35. Double V Plug Welding.
Figure 36. Correct and Incorrect Plug Weld Preparation
Repairs with Nonwelded Butt Strap.
Welding Face Hardened Armor Plate
Figure 38. Prepairing Gouges in Homogenous Armor Plate
Figure 39. Butt Strap Welds for Face Hardened Armor Plate.
Figure 40. Sealing Crack in Face Hardened Armor
Figure 41. Butt Strap.
Armor Plate Repair Methods.
Figure 43. V Joint Welding Face Hardened Armor Plate.
Figure 44. Depressed Joint On face Hardened Armor Plate And Seal Bead Weld.
Armor Plate Welding Electrodes.
Testing of Welds
Physical Tests.
Destructive Tests.
Figure 45. Guided Bend Test Jig.
Free Bend Test.
Figure 46. Free Bend Test.
Figure 47. Nick Break Test.
Nondestructive Tests.
Troubleshooting Welds.
Poor Weld Appearance.
Warping of Thin Plates.
Practical Exercise - od165180108
Practical Exercise Cont. - od165180109
Lesson 1. Practical Exercise- Answers - od165180110
Lesson 1. Practical Exercise- Answers cont. - od165180111
References - od165180112
References - od165180113
Task 1. Electrodes Classification and Intended uses, Authomotive Welding Processes, Matarials
Identification and Uses of Electrodes
Classification of Electrodes.
The electrode identification system for stainless steel arc-welding is set up as follows:
Types of Electrodes
Shielded-arc or Heavy-coated Electrodes.
Figure 2. Arc Action and Electric Welding Polarity
Functions of Electrode Coatings
Polarity of Welding Current (figure 2, View B).
Direct Current Arc-Welding Electrodes.
Electrodes Defects and Their effects.
Automotive Welding Processes, Materials, and Identification
Determining the Welding Method
Figure 3. Preparing Engine Block For Welding.
Procedure - od165180020
Heat Treated Parts.
Figure 4. Reinforcing Frame Members
Rear Axle Housings.
Welding Joint Design
Corner Joint
Figure 6. Corner, Edge, Lap , and Tee Joints.
Edge Joint
Figure 7. Tee joint Edge Preparation
Figure 8. Groove Welds
Figure 9. Surfacing, Plug , and Slot Welds
Figure 10. Seam. Spot, flash. and Upset Welds.
Welding tecniques
Figure 11. Welding Positions
Table 1. Current Settings for bare And Lightly Coated Electrodes.
Table 2. Current Settings for Mineral and Cellulose Coated Electrodes.
Figure 12. Starting the Arc
Two Procedures, Describes in the following Subparagraphs, Are Use to .Break the Arc
Table 3. Effets of Maladjustments of Welding Current voltage And Speed on ther Bead Characteristics.
Figure 13. Arc Characteristic and Deffects
Bead Welding (fig14 on the Following Page.).
Figure 14. orrect EletrorodePositiopn for Welds and Proper Bead And Welds
Flat Position Welding (Figure !5 on the following 5)
figure 15. Flat Position Welding
Figure 16.Multipass Bead Wels , Weldinjg Motions, abnd undercutting and Welds with BacksStrips
Butt Joints in Flat Oisition with Backup Strips (Figure 16, View D. )
Figure 17. Plug and Slot Joints and tack welding Tee Joints
Horizontal Position Welding.
Figure 18: Fifllet Welding
Figure 19: IntermittentWelds,ack Welding, And electrode Position
Vertical Position Welding
Figure 20. Lap Joints and Welding Vertically.
Butt Joints
Figure 21 . Vertical Welding And Butt Joints.
Figure 22. Vertical Fillet Welds
Bead Welds
Figure 23. Overhead Position Welding
Butt Joints.
Fillet Welds (figure 24).
Electric Arc Welding of Ferrous Metals
Tool Steels.
High Yield Strenght, Low Alloy Structural Steels.
Cast Iron
Electric Arc Welding of Nonferrous Metals
Welding Techniques.
Conclusion - od165180065
Describe the theory, principles, and procedures of welding armor plate
General - od165180067
Welding Armor Plate
File Test.
Cutting Armor Plate
Figure 25. Cutting Stainless Steel Welds
Figure 26. Removing Surface Defects From Stainless Steel Welds
Cutting with the Electric Arc
Welding Homogenous Armor Plate
Figure 27. Welding Cracks in Homogenous Armor
Figure 28. Root Bead Weld
Procedure - od165180077
Figure 29. Weld Beads On Homogenous Armor Plate
Figure 30. Homogenous Armor Common Defects And Remedial Procedures
Figure 31. Welding Single V Joints On Homogenous Armor Plate.
Figure 32. Welding Double V Joints On Homogenous Armor Plate.
Emergency Repairs
Repairing Bulges.
Repairs Made from One Side
Figure 35. Double V Plug Welding.
Figure 36. Correct and Incorrect Plug Weld Preparation
Repairs with Nonwelded Butt Strap.
Welding Face Hardened Armor Plate
Figure 38. Prepairing Gouges in Homogenous Armor Plate
Figure 39. Butt Strap Welds for Face Hardened Armor Plate.
Figure 40. Sealing Crack in Face Hardened Armor
Figure 41. Butt Strap.
Armor Plate Repair Methods.
Figure 43. V Joint Welding Face Hardened Armor Plate.
Figure 44. Depressed Joint On face Hardened Armor Plate And Seal Bead Weld.
Armor Plate Welding Electrodes.
Testing of Welds
Physical Tests.
Destructive Tests.
Figure 45. Guided Bend Test Jig.
Free Bend Test.
Figure 46. Free Bend Test.
Figure 47. Nick Break Test.
Nondestructive Tests.
Troubleshooting Welds.
Poor Weld Appearance.
Warping of Thin Plates.
Practical Exercise - od165180108
Practical Exercise Cont. - od165180109
Lesson 1. Practical Exercise- Answers - od165180110
Lesson 1. Practical Exercise- Answers cont. - od165180111
References - od165180112
References - od165180113
