TS 227 .L5 Copy 1 ELECTRIC WELDING Electric Arc Weldin THIRD EDITION PUBLISHED BY The Lincoln Electric Co. General Offices and Plan I Cleveland, Ohio 1 Hi' oln Motor o| ■'-i.iinrj under water, New York Citj Buffalo - ;ton Branch Offn . s at Philad) Iphia I hi< ago I Detroit ( harlotte, X. C ( 'olumbus I ■ 11 1 into Pittsburgh Monti eal M inn< apolis Agencies in other principal J No. HU \ Copyright. 1918, by The Lincoln Electric Cr, ate \3 wo .1 () 7 8 A !t : I ■ J : ii ELECTRIC ARC WELDING in in ■>■ mil mil nmr ii i < 1 1 1 rn 1 1 w necessary of work. ELDING in the modern sense of the word, covers a number of dis- tinct operations. In order to thor- oughly understand the subject it is to divide welding into two classes 1st. forge or pressure welding, 2nd, autogenous welding'. Forge or Pressure Welding This term, for want of a better one, is ap- plied to welding processes where two pieces of metal are heated to the plastic state, then forced together by pressure or hammering to thoroughly unite them, and complete the weld. The familiar example of this is the weld which the blacksmith makes by heating two piece- of steel or iron in the forge fire, then hammering the ends together on his anvil. A weld similar to this has been made for some time by the use of electricity, where two pieces of metal are heated by an electric current, then forced together to complete the weld. This process is known as butt or spot welding and is not the process under discussion in this book. Autogenous Welding I hi> term is applied to welds winch are made by heating metals to such temperature that they will fuse together on contact, without any pres- sure being applied. The difference between autogenous welds and those formerly described is mainly the difference in temperature of the metal. In the autogenous weld, the metal is heated to a state of fluidity and the two pieces flow t< igether. The use of the autogenous process, however, i- not confined to the uniting of two pieces of metal. It is used to even a greater extent for adding molten metal to other metal pieces or parts, thus building them up or filling defects. Electric Arc Welding Electric Arc Welding is an autogenous process. It is used both for joining metal parts and also for adding or building metal on such parts. In fact, when two pieces ire welded together by this process, it is done by filling in molten metal, between the two pieces, rather than by melting the two so that they will join. The Electric Arc The Electric Arc is formed when electric cur- rent is made to jump or arc from one electric conductor to another, through the air or some other substance, which is not a good conductor of electricity. \ familiar example of this is the sparking which occurs when you touch together two wires connected with an ordinary electric door bell battery. Another familiar example is the spark which passes between two wire terminals on the spark plug in the automobile engine and serves ti i ignite the gas. The arc or spark is produced because the elec- tric current is forced through a medium which offers great resistance to its passage and hence produces heat. The object, or the conductor, from which the current come 1 - is called the positive electrode, the object to which it passes is called the nega- tive electrode. In arc welding, one wire of an electric circuit is attached to or laid upon the steel which is to be welded, the other wire is attached to a piece of carbon or metal which the welder holds and which is called the negative electrode. The cur- rent passes or arcs from the piece which is to be welded to the electrode which the operator holds. In doing so it creates such great heat on the i NEGATIVE 1 ig 1 In aic welding, one wire (the positive) from the weldii g apparatus is attached or laid upon the steel which is to be welded, the other wire (the negative) is attached to the electrodi of carbon or metal which the operator hold? 1 Ill i! ■: '..ii. ii.'.. ■ ;u ::::. ...:.: ELECTRIC ARC WELDING i 11 minium ill ii ' ii piece, thai the portion of the piece around the are actually melts and turns into vapor and the arc is continuously passing through this vapor. The only purpose of the electric arc in weld- ing is t" produce the heat fur melting tiie metal. Advantages of the Arc The electric arc has no mysterious qualities which make it especially adapted for welding purposes. It is simply the most efficient means known for producing welding heat. Heat for welding purposes may he supplied by the blacksmith's forge lire, by chemical com- bination of materials such as thermit or by the burning of a gas such as acetylene in the pres- ence of oxygen. The heat produced by any of these agencies is the same in every particular as that produced by the electric arc; the only advan- tages of the arc are : 1st — Production of a Higher Temperature. 2nd — Convenience in Application. 3rd — 1 j i\\ ( '.i ist. Arc Produces Great Heat It is a well known fact that the highest obtain- able temperature can lie produced in the electric arc. In fact, a temperature can he reached which is so high that it cannot lie measured with any instruments developed up to the present time. The reason an electric arc produces such a high temperature is that a large amount of heat is produced in a very small area. This in itself suggests why the arc is the most efficient means of heating metals for welding. Fig. J. Photograph of Electric Arc in operation. A large amount of heat is produced in a very small area, which makes the arc a most efficient means of heating metal-. .<.,." v.v THE WELDING ENGINEER.) Adaptability of Different Processes \s stated above, any of the other methods of producing heat will serve for welding work, but the difficulty comes in applying them in just the way desired. The forge lire, for instance. K'lves very well where two pieces of metal can lie placed in it, heated and then put together as they are on (he anvil. This application is. of course, very limited In fact, most welding is now done by the addi tion of new- metal between the welder) pie Thermit Welding It was the necessity of adding new metal in certain welds which led to the development oi the Thermit process of welding. This process depends upon the chemical combination of cer tain substances which produce a great heat antl release molten iron from the combination. Ibis process has been wonderfully successful. lis advantages can be readily seen in case oi two pieces such as a broken locomotive frame, which could not be convenienth welded by the forge process. By building up a mold around the two ends and by pouring in the molten steel gener- ated by the Thermit process, new metal could be added between the ends and they could be thor- oughly united. Thermit welding is in fact a casting proce and always requires the mold built up around the parts to be joined and usually requires pre heating of those parts in a charcoal fire or bv gas torches. While applicable to quite a range -'t repair work, it is not usable in the great field of welding, recently developed. Oxy Acetylene Weld l II O" Oxy-Acetylene Welding has the- advantage over both forge welding and thermil welding in that this process can be applied to any surface. The lie.it is produced by burning acetylene gas in oxvgen gas 1 i •. \ -acetylene has gradually widened the use of welding and has made it a common manufac- turing process. Even the small garage, the blacksmith, anil the jeweler can now use oxy- acetylene welding and make great savings over fi inner methods. llimillilllllilillllliiitiiiiiiiiimiiiii m d niiiimin id :uiiiiii diiiiii "nun id n niinii! 11. i i iiiimiiiiiiiiiiiiiiiiiuiiiiiiiiiii mill nun .urn \ i inn ' '' i:iiiimiiiiiimiu COMPARED WITH OTHER PROCESSES III!!!!!!!!,: Illlttllllllll:!!!! A rail wl hi proces s and is as solid as a new rail The cutting of metals by oxy-acetylene is an- other field which has been very widely developed. It is used for cutting up scrap, for wrecking steel structures, bridges, vessels, etc.. and is without any rival as far as speed is concerned in this field of work. There are many places, however, where even acetylene welding cannot be conveniently or suc- cessfully applied. In the first place, the heat of the acetylene torch is spread over a relatively wide area. The greatest heat in the acetylene lurch is produced at a point in the inside of the flame proper, and in order to get this point down to the metal, it is necessary to hold the flame very close so that it spreads out over the surface of the metal to a considerable degree. In welding steel sheets or plates, for instance, this causes a great deal of difficulty, owing to the buckling and bulging of the sheets, produced h\ the wide heating. At a recent convention of the Railway Master Blacksmiths Association, Joseph Grine, of the New York Central Railroad, in discussing this point says, "In welding boiler sheets the electric process is superior to oxy-acetylene because the latter generates too much heat and causes the sheets to buckle." In another discussion of this same subject at a General Foreman's Convention, J. M. Kerwin of the Chicago, Rock Island Railroad, says, "We use the electric and oxy-acetylene processes, and have found that the electric is the best for weld- ing patches and cracks, and oxy-acetylene is best for cutting." *tV?V ~ I ig t A rail which has been welded together by the oxy- acetylene process but owing to the severe contraction of the metal on cooling the rail has broken, Still another expression of opinion is given b\ the Committee < )n Design, of The American Railway .Master Mechanics Association, who state, in their report, "From the reports received from different roads, they indicate that consider- able difficulty is experienced from welding flues with oxy-acetylene process, while roads using the electric process report very satisfactory results," These opinions from railway men. are given at length, because of their very wide experi- ence with welding processes. Safety Another factor which enters into considera- tion of the acetylene process is the matter of safety. It is not to be denied that there is a great element of danger in the oxy-acetylene welding process, particularly where a generat- ing plant is used. At the meeting of the West Coast Safety En- gineers Association, in San Francisco, January. 1917, R. L. Hemingway, of the Industrial Acci- dent Commission of California, called particular attention to the possible small amounts of hydro- gen existing in the oxygen gas and this commis- sion has issued a warning to the public not to use oxygen gas, for acetylene welding, unless absolutely assured that ii does not contain more than 2' i of hydrogen gas. These matters are not brought up in any effort to discredit acetylene welding, but because they are necessary to any intelligent practical con- sideration of the subject. '; I ' t. mi: . II! ELECTRIC ARC WELDING Arc Welding is Convenient and Safe \"o\v let us compare arc welding with the other processes, as in convenience and safety. Arc welding can be applied anywhere that electric current is available or can be generated, and where an electric cable can be carried. It i all forms ol wi can be used inside boilers and fire boxes, in ship lipids, perhaps the most inaccessible location that can be imagined, Owing to the action of the arc. seams, etc., can be welded over tic head oi the operator with no great difficulty. Electric arc welding can be used for joining parts, for building in molten metal or fur build ing up. With apparatus of the proper design, arc well- ing is the simplest welding process m exist It requires a minimum of preparation. Preheat- ing' "i the part- to he welded is necessar) only in the case of high carbon steel or cast iron. The heat is applied on a \cr\ small area, so that there is no buckling or undue expansion of sheets or plates. The steel for filling in or building on is pro- duced bv the melting of the electrode which the operator holds in his right hand, thus the left hand is always free for placing of parts and adjustments, making the process practically con- tinuous'. There is absolutely no danger in the operation of properlv constructed electric arc welding apparatus. The voltage employed is very low, in fact lower than that of a residence lighting system, and cannot by any possibility injure the operator. Comparative Cost of Arc Welding .Did Acetylene Welding It is not necessarx to discuss the forge weld- ing process or thermit welding, as to cost. In each of these processes the o >st of preparing the parts for welding is vcr\ high and neither "i the processes are usable except in certain limited applications. '|'],e 1 1 nest i, ,n of cost res. ih es itself int" a com- parison of electric arc welding with oxy-acety- lene. The simple fact that the electric arc pro- duces a higher temperature than the acetylene gives the arc a decided advantage. Perhaps the best comparison can he obtained b\ giving actual figures on such operations. One large manufacturer of tanks and similar prod- nets, employs both oxy-acetylene and are proi esses and has made careful comparisons oi o I The report from one particular test made on identically the same work is summarized below and shows conclusively that the arc will weld this tank at less than one-half the cosl of the acety lene pn icess. Objects Welded —Six 215 gallon tanks. •■." shell, ;," heads with one 3" and _'" and l 1 :" standard o mplings. -FEET WELPEP LOHG SEAM 6.69" EOUOL TO 31.SFT CI(?CUL(!R SEAM XZ + VW • " 9S>. COUPLING S 6 « 2" 0" » •• 12. t-ii-iPE coupling. TOTAL FOR SIX TANKS 110 .5 FT J-3 PlPf COUPLING, £-2 PIPE COUPL'MG 215 dflLLOrl TflMK ■1' SHELL\ j£ HEAPS I ig ' Gallon Tank comparative cost test was made. iMiiiiJinmniifi mi in i'i> Mlililll.lllllm mi COMPARATIVE COSTS ii Acetylene If elding Welding Outfit: — Stationary Generator, No. 2, Welding torch number 7 and 8 tip. Time of welding, 18' 4 hrs. Ca 30c per hr $ 578 < Ixygen consumed. 371 cu. ft. at .0135c 5.0085 Acetylene consumed, 325 cu. ft. at .008c cu. ft - 2.60 Filling material. 15^ lbs. at 12c per 11. 1.89 Total cost for 6 tanks $15.2785 Cost of welding I tank 2.S-4 Arc Welding Welding Outfit — Transportable type for one operator, manufactured by The Lincoln Electric Co., Cleveland. Ohio. Time of welding. 14 hrs. (8 30c per hr $4.20 Kilowatts consumed. 60 kilowatts (S 2c per 1.20 Filling rod used. 27 lbs. (S 7 3-10c 1.97 Total cost for 6 tanks §7.37 Cost of welding I tank / .23 The Railway Electrical Engineers Association have made a very careful investigation of this subject, since the railroads use welding to an enormous extent. Their committee on this sub- ject reporting at their 1916 Convention, states, "Three kilowatt hours of electric energy (cosl 6 cents) will produce the same amount of heat as mav be produced by approximately 6-6,. 10 cubic feet of acetylene (cost 1 1 y _■ cents) and 7-5 10 cubic feet of oxygen (cost 15 cents)." The parentheses in the above quotation are our own and they indicate the normal prices of electric current, acetylene and oxygen. It will he seen that 6 cents expended in electric energy will do the same amount of welding work as 26 J / 2 cents spent for oxy-acetylene gas, on the assumption that the two processes make equally effective use of the heat produced. This assumption, however, is not in accord- ance with the facts, since it can be shown that nil any welding operation, the heat produced by the electric arc will be at least three times as effective; that is, three times as much welding can be accomplished with it as can be done by the same amount of heat produced by the oxy- acetvlene torch. I'ig. 7 tias tank mail.' by the Boom Boiler & Welder Co., Cleveland This tank has been made both by arc welding and bj acetylene welding. The an welding cost '4 to '. .0 mm I. as gas welding. The tank is tested at 150 lbs water pressure Fig, 8. A radiator welded by the Standard 1 Ml Co., of Indiana Comparative costs by Acetylene and Arc Welding were as follows: Cost af Acetylene Weld on Radiators 40 cu. ft. acetylene at $ Jit $ .4n 48 cu. ft. oxygen at .016 .768 2 hrs. time at .45 .90 Cost Of Sil'liC 16.6 K. W. H. at 2 hrs. time at $2,068 with Electric Weld .006 per K. W. II. $ .10 45 per hr. .90 $1.00 ELECTRIC ARC WELDING Minn nun mi .11,1 n i: The same committee submitted to the Conven- tion, a chart which i- reproduced on page 7, showing the oust comparison between gas and electric welding", based on the amount of beat produced. The table on page 6 shows a complete com- parison of cost~ compiled by an engineer, who has made a special subject of welding, in a mini bet" of different fields Gordon Fox, writing in the Railway Mechani- cal Engineer, November. 1916, sums the whole matter up as f< >lli i\vs : "For work "ii brass, bronze or aluminum the oxy-acetylene flame has no competition. 1 he main point of superiority of the arc method is its economy, as tin- electric arc produces the necessary heat at a much lower cost than does the oxy-acetylene flame. In its field, the arc also produces results as good, if ii"t better, than can be obtained with gas, i. e., flue welding, < i To avoid excessive cost, predicating is almost ahvavs necessary in gas welding, but may often be dispensed with in arc welding. The cost oi electric power for a welding job will only be from 15 to 25 per cent of the cost of oxygen and acetylene for the same job." It will be seen from a careful stud) "t the above authorities that arc welding is beyond question far more economical than acetylene welding, where a large amount of work is to he done. In a -mall shop, such as a garage or black- mail, or in any place where welding i- onl\ done at long intervals, such as repair work in ma- chine shops, the acetylene process lias the advan- tage because of the low firs! cost of equipment. Wherever there is work enough in a com- mercial welding shop to keep two or three opera- tors continually busy, arc welding will show a saving great enough to pa\ for the additional cost of equipment in a ver\ short time. In ,! niaiin fai 1 in ing plain w here tile w i irk can be done with the arc, it will sometimes pa\ to install an arc welder when there is only enough work to keep an operator bus) with the gas torch five In airs per day. While some -aving may be made in acetylene welding, by generating the acetylene at the plant. a g 1 generator for this purpose will cost quite as much as arc welding apparatus, and acetylene welding will still cost twice as much as the arc process. TABLE OF COMPARATIVE WELDING COSTS— METAL SHEETS AND PLATES BASED ON FIGURES IN YEAR 1916 Acetylene Welding Arc Welding •111' No Thickness of Metal Cu it p, hour i . i T P il.il COSl l "ost per Welded ft K W e Welded Total it welded 1 3.21 3.65 all .15 .58 .01') _> 4.84 : 5li 2? .19 64 1 .06 25 T : 1124 3 1 8.14 9 28 .'n 33 78 , - 5 iis or, 20 : i .025 4 12.511 14 27 15 5li 'i : , 063 Sll in 1 ; .51 . 1 134 5 1 .. 17.81 21.32 ') 1 1. is .151 90 .07 111 .52 052 6 ' . 24.97 28.46 ii 1 INI 1 45 llll 4 15 1 l,V . 55 067 7 53.24 57.90 s 1 55 1 7s 110 4.15 55 067 8 ; s 41.'' 1 ' 47.87 4 1 (k'S 2 15 . 555 12ii 4 ',4 .11'' : 54 His 9 '-■ 57.85 5 2.51 2 76 o 15n .12 . 57 19 in s s 82.50 "4 H5 ) iO 1 .870 15ii 5 . 75 .12 5 57 Above data based en following Call irific \ alue i if COSl Acetylene 2c per cu. ft. Cb Power 2i pi i K. \V. Hr Lab , r Hr. :etylene is 1555 B. T. U. per cu. ft. One K. \\\ Hr, i? equivalent to 5415 B. T. U. Iilimuiliiliiiiiii I iililiillltlilllllli CARBON AxND METAL ELECTRODES iii'uu minimum , i i mini! M n i;ii'"i mm ■■ mn mi minimum m mil i i [minimum m n iiminmnmiii in urn inn, urn ■ ■ 1 1 1 1 1 II 1 1 1 1 / ! Acetylene Gas. If per cu. ft. Oxygen Qas 24 - » « Power, liper KWH from 75 Voll Line / / / 3 BO J / 1 ' / 1 / / / zao / / / / / &SO Co si en 7 s I / Z40 Pi r He ul i I r 1 1 / Si l u VI 7/6 •m l /> re 500 1 f* /It r>r >er PC IBO I / 4 SO 1 1 7 / / 1 1 1 ' /,' f 1 B50 / 1 Cl .r 7 oi • / 4- ■fc\ ■ o 'S /e , \ir IC ) y a X Pe rjjot a~ / / y / S. U & to ZO 30 40 SO 60 70 &0 90 fOO Heaf units Per Hour- B.T.U. +/0OO. Fig. 9 Curves showing the comparison between cost of gas and electric welding based on the number of heat units per hour. Taken from Association of Railwaj Electrical Engineers Report. - Carbon and Metal Electrode In electric arc welding there are two distinct processes. In one, the electrode manipulated by the operator is a carbon pencil, from '4 inch to l'j inch in diameter, and 6 to 12 inches in length, pointed to bring the arc into as small a space as possible. The carbon arc is simply used to supply the heat and the operator feeds in the filling metal from a melt bar held in his left hand. In the other process, known as the metal elec- trode process, the electrode is a metal wire of comparatively small diameter and this wire grad- ually melts itself away, furnishing the metal for tilling. The carbon electrode process is only used where it is desired to do fast melting and to heat over a large area. Such work would be found in the filling in of large holes in castings, The carbon arc demands from 300 to 600 am- peres of current and the beat produced is 50 intense and the glare so blinding that the opera- tor must wear gauntlet gloves and a shield com- pletely covering the head and shoulders. The metal electrode process is used for 90 per cent of all welding work. The heat is only spread over a very small area, enabling the operator to deposit the metal very accurately on edges of sheets, plates, etc. This process re- quires only 50 to 175 amperes current and since the heat is not so intense the head and shoulder Fig. 10, Cart. mi Electrode Welding. The operator holds the carl electrode with the right hand and feeds the filling metal into the weld from a rod held in his left hand. Fig. 11. Metal Electrode Welding, The electrode in tins i lsi a metal wire of small diameter and this wire gradually itself away, furnishing metal for the weld li iiiiiiiimiiiiiiHiiiiiiiiinui 1111111111(11 Ill ■ I in iiiiiiiiiimiiiiiiiiiiiiiiiiiiiiiimmiii ELECTRIC ARC WELDING Illllllllllllllllllll: shield is not necessary but a fact- shield with colored glasses can be worn instead. The question of which process to use is de- termined entirely by the work to be done and a good idea can be obtained by studying the various applications of welding presented later in this b< » ik. Operation of Electric Arc Generally speaking, no greater skill is required in the operation of the electric arc than would be necessary in any other modern manufacturing process. An intelligent man can learn to do simple welding work in from two days to . week's time, depending on the nature of the work. Great skill is of course acquired by prac- tice. Electrical knowledge is not necessary. The apparatus now available for this use prac- tically never needs attention and can be operated with less care than almost any machine tool used in the modern sin >p. Fig I This woman h.is learned to use the electric arc weldci ■ 55 than .1 week and lias replaced the man who formerly did this work, allowing him to enter military service. Characteristics of the If eld h should never be overlooked in considering welding that the new metal in a weld is simply metal which has been melted and cm. led again, and il partakes of the properties of a cast metal rather than of rolled or wrought metal For instance, in welding two pieces oi boiler plate the weld will have just as great tensile strength as the original plate, but being cast steel it cannot have the ductility which rolled steel stock possesses. The cast steel in the weld may have tin- properties oi ingol steel so tar as duc- tility is concerned. ii used i" be common opinion thai a weld could not be made which could be readily ma- chined, but this mistaken impression lias long since been corrected. The weld, when properly made, can be machined as readily as any steel casting i >r flange steel. Welding has been used to such an extent for ring breakage and defects that unless thor- oughly po-ted, the e man is apt to look upon it as a "patching" or "doctoring" process, whereas it is accepted in the most advanced engi- neering practice and is used to a wonderful ex- tent in automobile, locomotive and other con sti action of the highest charai ter. '''s' 13. An Arc V . as , ... , i This ' ,! " u ~ ■"' armatun been worn in service, then l,ullt «P b J welding on new teel I - i g turned CHARACTERISTICS OF WELDING llll ' I Applications of Arc Welding It is beyond the power of any one man and certainly beyond the limits of this book to give an adequate idea of the applications of electric arc welding. Within the last few years the apparatus for this purpose has been highly perfected. Such enormous strides have been made in its applica- tion and use, that it is difficult to see any limits to its adaptability. The following pages are intended as an outline of work which has actually been done. To any one interested in applying the process to his product, the best advice is to consult an expert in this line of work as to the feasibility of the particular job he has in mind. What Metals Can be Welded Electric arc welding is most successful on Steel, iron and the various alloys of these metals. It has been applied with great success to the welding" of cast iron in various forms but cannot, because of the great heat produced, be used on cast iron where the sections are thinner than : inch. Ilie arc is not practicable for welding alumi- num. Acetylene is the best process thus far dis- covered for this work. General Rule Wherever steel or iron parts are to be joined or breakage and wear of such parts repaired, there should at least be a careful investigation of the possibilities of arc welding. It can be stated with certainty that any job of this char- acter which can be done with acetylene can be done at lower cost and at greater speed with the electric arc. While the following pages do not represent one per cent of the total possible applications of this process, they will serve as suggestions t<> manufacturers and others interested in the high development of iron and steel fabrication. Fig. 14. Electric Arc Welder used by tin- Standard Oil Co., to caulk leaks in vapur lines an, I Mil stills, Tin- vapors are very inflammable and every joint must be absolutely tight, hence welding is used in addition to riveting. (See Fig. 73.) k in: ■ .-...: ,! ,.■ ' ,. UNI I ■ ELECTRIC ARC WELDING ■n in, Steel Foundries I jg 15 [-"illing blow holi in ;i casl st< el tnotoi 11 ui U ■■■ heel. These ' strain, wen approved foi use in militar) m '"i trucks when ciefeel wen repaired with the electi I i- if. r.lmv holes in steel casting whii epaired in . f< \\ minutes h\ i li welding. Fig, 17. Tin- lol -i castings showed defects which would have delayed delivi i customer one oi two days. Willi i Wcldei thej perfect an. I delivered on scheduh tinu I he first large cunimercial 1 1 - • oi an weld- ing was in the repairing of defects in steel cast nigs Tin- manufacture of these castings i- a must difficult process owing t<> the high melting point and ilif difficulties of pouring molten steel Even in pouring the straight steel ingot, it i- difficult enough in secure a sound ingot, owing in the gases which air given off, causing blow holes in the castings. In tin- more complicated shapes in which steel '-a-tmu- arc made, it is almost impossible to produce a large run of iiiL's without sand spots, caused 1>\ the washing awa\ nf parts of the mold, or blow holes caused by tin- formation nf ^.'ims. Even where the cast- ing is otherwise sound, the excessive shrinkage i a' tin- steel frequently causes shrinkage cracks to appear or causes undue -tram- to be set up in the inside of tin- casting itself. A few years ago, automobile construction and refinement in agricultural implements and other lines greatly increased the demand fur steel casting? I . numbers of these castings had small defects which did not serioush affect their strength, but did impair their appearance. The high cosl tin- steel castings and the percentage nf waste in Illll mum niii.; miillillliliijiiiimini' ■ I n imi >. mil STEEL FOUNDRIES led sonic one to hit upon the electric arc as a method of repairing these minor defects. They reproduced on a small scale the conditions of the electric furnace. It was a perfectly logical run- elusion that if steel was melted and poured into these defects, the defect would he filled with cast steel which would be in every way as good as the rest of the casting. It was not long before the steel foundry-man and all users of steel castings became convinced of the merits of this process and castings with defects repaired in this manner were accepted and used without question, as being in every way equal to castings which came perfect from the mold. Better Deliveries This use of the electric arc has not only saved great sums of money for the steel foundryman, but it has greatly improved deliveries of eastings. Formerly, the foundryman could not absolutely assure his customer that all of any given days' production could be counted upon, but with the introduction of the electric are, defects are quick- ly repaired and delivery schedules can thus be accurate!)' maintained. Manufacturers who use steel castings fre- quently find it advisable to install their own weld- ing outfits thus saving the return of the castings to the foundry when small defects are discovered in machining or in testing. In face of the traffic conditions recently exist- ing one firm found it very profitable to install the arc welder rather than to ship the castings hack to the foundry thirty miles away. The use of the arc welder saved and time. both money Less Skilled Liib or Electric arc welding has also relieved the labor situation in the foundry. It has become harder and harder to secure skilled labor, especially molders, for this work. The supply of such men di es not keep 'pace with the increase in demand. Under former conditions it was useless to put an apprentice on such work, as the material he would spoil and the floor space he would occupy would lose for the foundryman far more than it would gain for him. B( fo \Il.r Fig. is. Steel Pulley 1. ' . t ■- 1 1 1 l ljl on which .1 defective boss has been repaired by building up with the are welder. A shrinkage crack in the rim has also been repaired h\ arc welding. Before \it er Fig 19. Large Steel Geai showing shrinkagt would have made it necessary to scrap the casting In 1 11 f'H .in welding. ck ulne iad it m Defi Mi. Wl llll ] ig 20 Ali't-H Bracket Steel Casting from which a riser has been cut with the arc welder This cut was through about 3 inches of steel and took approximately six minutes. 11 iiiimiiiliiiniiilliiiiiiiniiimiiiiiiimiiiimiiiiiii i i h i i him nm mi i in minim miiiiiiiiiiiiiiiiimiiiiiiiiiiiiiiiiiiiimi ELECTRIC ARC WELDING IIIIIMI M I n An Wi M I I'oundi ; Co., i !hii ago, 111 With the electric arc, however, the mistake? which the heginners make cm in nine cases out of ten he remedied and one or two welders can take care of the work for a fairly large foundry, even where the proportion of cheap help is quite high. \s has been stated, arc welding is not in am sense a "patching" or "doctoring" process. 1 he defective parts of the casting are melted and i i in solid steel. These welded parts are just as strong a- any other portion of the casting ami when the work is carefulh done the) ma chine and finish perfectly. Mam steel foundries where welders are in use arrange to take hack castings which have shown defects in the machine -In i]i ami alter welding them return them to the custi uner. Operation <>f Arc M i- eas\ t<> prevent the usual troubli to tin- so called "chilled" or hard weld. I>\ apply- ing the arc for some minutes to the pari m 1"' welded, thus thoroughly preheating the surround ing metal. When the weld i^ made the whole mass then cools off slowly and the sudden chill ing of the new metal is avoided. The ,nc can he used i"i' pre heating the cast ings m exacth the same manner as the acetylene flame is used. Sometimes a slag covering i- provided to ex- clude the air from the molten metal and thus prevent the presence of oxide in the finished weld. This i^ only necessan in special ca i With these simple precautions anj steel foun- dry can use the arc welder successfull} and many castings that would otherwise be a dead loss William W'l Co . Easton, I'.i 23A. Defective pulley casting Re] I. iiu ciln Arc Welder saved 5 I" 2 1 inute? STEEL FOUNDRIES iiiiniiiiiiiiiniiim muni ' i ' i ni: « m " iiitiiiiiiiiiini! II IIIIIIIIIIIIIIIMIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIlllllllllll iiiiiiii n Welds Easily Machined The weld in the casting is as soft and is as readily machined as any other portion of the work. The blow holes or shrinkage cracks, sand holes, etc., are first pre-heated by playing the arc over the surface, holding the casting in such a position that sand and foreign matter will he Hushed out. This work is done with the carbon electrode. The filling material can be obtained from steel wire, especially made for the purpose or even from steel scraps or bars <>| suitable analysis. Burning out sand spots with the oxy- acetylene flame is impractical, because the re- flected heat burns off the end of the tip. \\ here the oxy-acetylene flame is used, it is necessary to chip out sand spots with a pneumatic tool, which makes the cost of the operation very high. Electric Steel Foundry The electric steel foundry can use electric arc welding to particular advantage. In these castings, the metal electrode process will ordi- narily be best suited. The defects can be chipped out with a pneumatic hammer and since they are nut large, can lie readily repaired with the metal electrode. I ig, 24. Lincoln Arc Weldei 400 ampere capacity installed in Hi,, plant of 'I'lu Standard Steel Castings Co., Cleveland. O. I ti tin background i^ space i ■ i ■ ■ ^ ni- 'I foi tl stall •' of another welder Sizes of Welders The size of welder adapted for certain work is a matter which should he passed on by the manu- facturer of the apparatus. However, certain general sizes can be suggested. For steel foundries using the metal electrode or very light carbon electrodes on small work, a welder supplying 20(1 amperes will usually be sufficient. This is an ideal size for the electric steel foundries. For the foundry making castings up to Unto pounds, a welder should be used which has a 300 ampere capacity. For the very large foundry, where large work is produced a 400 ampere welder is the ideal size, and is arranged so that two or more machines can he connected together in parallel, thus giving the current for heavy carbon electrode cutting. Equipment See pages 50-54 for illustration suitable for steel foundries. of apparatus Fig. Filling in a lil Electrodt n ,i -till casting bj tin i process 13 . IIIIIIIIIKII Ill ELECTRIC ARC WELDING ■ ... . . in ■ I = : 1 1 1 - - - . 1 1 ! . =" : : ■ ■ iiiiniiiiiiiiiniimiiiiiii Grey Iron and Malleable Foundries I i -• ' .. '■ .. ' ' I part ol Hi. . . I i nut by u rM I ical The use of electric arc welding has recentl) been extended to grey iron and malleable cast- ings to a very large extent. There are man\ minor defects in both grey iron and malleable castings, which mar the appearance of the cast- ing Inn do not seriously affeel its strength. I he-e can be repaired and Idled to good advan- tage with the arc welder, unless the casting? are very thin. The . Imcrican Machinist says: "The arc elec- tric welder is used on malleable iron castings for two purposes: First, for adding material that has been either swept away in the mold or is lack- ing because of a mistake in the design, and sec- ond, in save castings that have blow holes or sand holes. It" metal could not be added to make a sound repair, castings would often have to be scrapped : a i rK patched casting would be con- demned for appearance sake, and one with un sound joints would be weak and tend to frac lure." The difficult} encountered in welding cast iron arises from the expansion and contraction of the local area heated by the arc and the tendency of the wel- Malleable Iron Switch stand showing .i defe* i which i. nt t.i reject it for appearance sake, but which was readilj remedied by \rc Welding. 14 I ■■: : ■■ ii ii 111 Nimimniii III! .iMlllllimliUllllllliiHI ELECTRIC ARC WELDING i :i ■i"'. 'Mi, .in iiiiiiiiii ■ -..i . nun .1 iiiiiiiii ii ■ 'i Railroad Shops Welding ] motive side frame using a portable Lincoln Arc Welder. The same week that this photo was taken $6,000 were saved through arc welding done on tins welder. Xext to the steel foundry, the railroad has probably made the widest use of electric are welding. The use of welding in the railroad shop has become of especial importance since the United States entered the World War. It is impossible to build locomotives fast enough to meet the traffic demands and the only possible solution to the problem is to make re- pairs more quickly and to keep more engines in service. Mr. E. Wanamaker, Electrical Engineer of the Rock Island R. R.. recently in a very inter- esting article in the Railway Electrical Engineer. among other things, says: "Our figures show that the saving effected by the electric arc weld- ing system is being made at the rate of approxi- mated $200,000 a year with our present equip- ment. This figure includes a direct saving as compared with other methods of about $13(3.000. There is also a saving arising from the fact that we keep engines in service a greater portion of the time, which makes up the balance of the $200,000. Our figures show that we are saving about 1400 engine days per year. We have ob- tained, in other words, service of four additional engines without any expenditure beyond that required U> install the welding system. "The net returns secured mi the electric weld- ing investment amounts t>> approximately 500% per vear. These figures show that the installa- tion of the electric welding system on the Rock Island Lines has been a very profitable invest- ment. "There is still a totally unexplored field in the maintenance of freight and passenger cars, which promises to eclipse in importance maintenance of motive power. The present indications are very strong that when we go fully into the electric welding process in the fire box, boiler, locomo- tive, machinery, steel tanks, car work, track work, etc.. we can well use 150 units and effect a net saving of approximately one million dol- lars a year. "We could with this equipment in operation show a saving of around 7000 engine days a year 15 '. iiniiii ii 111 mm... mill! i i mm n iilillllllllllllllillilllllllllimnil ELECTRIC ARC WELDING iiiiiiiiiimiiiiiniiiniiiiiim in mi iii'ii urn I : 1 1. 1- repaii .il by elect mi ■ t these rods w ere badl \ \v ■ : : ,1 was iitult m by the use "t tin .hi nn,- of them I: the othei shows onlj tin rough weld, b itty was the in t hat it is difficult to t- 11 w hich is w I iiln urn i epaii ed 1>\ Klectrii \ti W Tin- lii de hi tin- fulci inn \\ as had j ■ pei band oi ferrule of the right size in the hob and bu up around ii the ferrule could hi knocked out aftei thi ing u a: a pei fectly sni hob . which needed no machining I ii 1 13. An eccentric sheave repaired !>v electrii welding show- ing how it is possible to wild both malleable and grey iron. The l -.i\ in the driving wheel shaft lias also been built up and milled .nit, -.hums tin scrapping of tin- entire shaft which means that we would be able to secuu from our present engines a mileage that will equal that which could otherwise only be secured b} the purchase of 23 additional engines." The figures on the work dune mi the Rod Island R. R. are reproduced on page 24 and are worthy of very careful study. Even day that the locomotive is laid up in the repair shop, means a loss of a large sum of money for tin- road. Tbe use of th< electrii arc has made it possible t<> repair a great num- ber nf cases hi' breakage and wear without dis- mantling the locomotive, thus putting it back into service within a day or two. instead of keeping it in tin- shop a week or ten days. The importance of reclaiming broken and worn parts of rolling stock lias become a sub- ject ol vital importance with the railroads in the past few years. Greater attention than evei before has been given to these smaller economies with a view to building up the earning capacity of the road. In fact, the motive power depart meiit has assumed a very large part in putting the roads on a dividend paying basis. The chief uses of the electric arc in the rad- ii .id shi >p are : 1. Welding flues in back flue-sheet. 2. Building up worn surfaces on die steel castings of the locomotive. 3. Repairing broken frames and other st,-,- : castings. 4. Fire-box welding. .". Repairing of shop tools. (i. Welding in side sheets, tube -beets and rlooi sheets. Metal Electrode I hed In practically all railroad work, the metal elec- le is used. The Railway Mechanical Engi- neer in the issue of November, 1916, savs ■ "The metal process usually gives a more re- liable weld, gives finer texture to the metal, es it less porous, can be more neatly executed and finished, requires less power and may be easier controlled. The carbon process is well suited for filling holes in large castings and similar work, but the metal process is best for building up metal on surfaces since the additioi of metal is largely automatic and the confinement 16 RAILROAD SHOP REPAIRS . iiiiiiniiiiiiiiiiiiii llinill ; Ill of the heat avoids flowing- and run-off tenden- cies ; in other words the added metal stays where it is put. With suitable control provisions it is possible to combine methods, heating' the work- ing zone by the use of the carbon arc, and build- ing up the new metal with the metal electrode, the procedure depending upon the character of the work and the ability to reach the molten condition simultaneously upon object and elec- trode." The carbon process can only be used effec- tively where the work can be placed upright on a table and where the casting can be subsequently annealed, which practically eliminates its use from the Railroad Shops. Repairing Breakage In repairing broken and worn parts, the prep- aration consists mainly in cleaning the piece of all traces of oil. rust, etc., before welding is begun. Where two pieces are to be joined, the edges of the sections are chipped out with a chip- ping hammer to provide a "v" shaped gn><>\<' at their junction, thereby insuring that the joint is completely filled with metal. Where thick sections are to be joined, it is often advisable to provide a groove in each side, in any event the groove should extend entirely through the junction of the two pieces. In beginning, the arc must reach the bottom of the groove. Liquefy the metal at that point first. For this reason, the groove between the pieces must have an angle sufficiently large to allow the operator to get to the bottom. On boiler plates, the angle is usually 45 degrees, while on large steel castings the angle may be from 45 to 60 degrees. «r MM* L J 3f ™* 34. Weld in Locomotive Side Frame. Fi 6 DEFI iKK Droken Engine Frame with break cut pri pari -I 1< ir welding, Fig. 35. AFTER. The Completed Weld. A piece of boiler plate is placed around the bottom of the gap as shown in the illustration, in order to hold the new metal in place. Fig. 36. gine Frame repaired by the I. it tile Rock Island Shops, 17 i tun i ninmiiiii iiiiuill i n iiiiiuiiiiiiiiiinimuiiiimiiimimii iniiiiimiiii liiiiliiiiimiiniliii mimiii 1 ELECTRIC ARC WELDING Fig BEFI IRE. I chipped out > ith the hamni I ig \ INK. s A Locoi Sidi Fi ante wit It in it. A patch on the mud i i'i \ e separate wi Ids also be (in most work, it is necessary that the two pieces first be aligned, and clamped together or clamped to a third puce. If a one sided heat occurs, some allowance must lie made for unequal contraction. This part of the work calls for experienced men. If it is desired to build up metal of an) height with the carbon arc process a mold of asbestos, lire clay or carbon must be made to retain the molten material. The work of welding should if possible be dime in one con tinuous heat. ' >ne g 1 example is given by The Railwa) Mechanical Engineer, drawings for the job being reproduced on page 18 i big. 39). The\ sav regarding this job, "The frame at crack is first v'd oul on both sides with the ox) acetylene cutting flame, and chipped out with an air hammer and chisel to get a clean surface as shown at \ in Fig. 39. \ inch plate, about 1 inch wider than the frame, is then fastened to the bottom. From tlii-. as a basis the electric welder builds up the full width of the frame first mi one side ami then on the other as shown at I'.. After the v is filled mi both sides, 8 " ll h round bars about 2 inches longer than the full width of the v are welded on the outside as i ement, starting at the bottom and building hi ' i see C, Fig. 39) The very fact that these bars round enables the operator to easily and sui cessfully weld them in by being able to get in around them. The completed weld is shown at D." The cost table i in page 24 compiled in one of the largest locomotive --hops in the country, shows the variety of work and the saving over a period ven months. The cost of electric current is figured at _' cents per kilowatt hour. £' Round Bcr Bcve'ed at Ends Drawing showing mrlln.il of repairing engine i „ v. fi III WA\ VI i HANICAL EXGW1 I 18 WELDING CRACKS AND PATCHES llllllllllllll :'"i:|i|l|r.'l!liMli!'!lill"lilli-Uiil: !!!■: Illlllllllllll Illlllllll illlllllllll Flue Welding Welding the tines and hack flue-sheet, if prop- erly done, will enable a set of tines to go the three-year limit without attention in a "good water" district. The old practice of rolling a few leaky flues after the engine comes in from a run, is entirely eliminated by welding. Weld- ing flues, however, will not entirely cure the flue trouble, which arises from bad water. The Welding Committee of the Railway Electrical Engineers Association makes the fol- lowing recommendations for flue welding with the electric arc: "The ideal preparation of a set of flues for welding is as fellows: 1. Put flues in exactly as if the\ were not to be welded. 2. hire the boiler, or, better still, send the engine out for a run. The object is to burn the oil out from under the beads of the flues and allow the flues to take a permanent set. 3. The flue sheet should then be brushed off with a stiff wire brush or sand blasted. The object is to eliminate, so far as possible, the scale of oxide on the flue sheet and flues. Iron oxide is not a good conductor of electricity and causes difficulties with the arc which in turn may produce a poor weld. The welding of 2-inch flues is done best with ' s-inch electrode. On sand blasted flue sheets 90 to 100 amperes is enough current. Flue sheets that have a thick coat of oxide require from 120 to 130 amperes on this size wire. Five- Fig. 40. A weld on the calking edge of locomotive boiler outside of mud ring. *» • 0- »■■ „ 9 9 „ > » * # " * » # . *' 9 V* *>* '•" 0* 0* r* t' ..»»«►**> t * * <• » * * '.*.*,' a»^» a. m r r r f il! 41. Flues welded in the back flue sheet of Locomotive Boiler by Electric Arc Welding. Flues tr<<|uentlv give three years' service, without attention when welded in tins manm r Fig. 43. Locomotive in the Big Four Shops at Linndale, ' '. Leakage in this locomotive has been repaired by welding around the steam chest pipe and in the smoke box so that the locomo- tive is practically as good as new. 19 iniiiiiiiiiiiiiiiiiimiiiitii ■hi' mimum iiiiiiiuijiiimiimii r,|iiiiuiiii!i ELECTRIC ARC WELDING I. iiiiimuiii Hum mi .inn, ifiimtiiimttm ii , ■ eptioi al I ■- g of this "1 'A illk. Fig 45. Welded in locomotive fire box showing two patches made wil Ord j tins weld would been made but the fire box was t.il- en ■ >u1 I . inch flues should be welded with -/'..-inch elec- trode with 120 to 140 amperes depending upon the condition of the flue sheet." The American Railway Master Mechanics Association is very favorably disposed toward the use of electric welding and as long ago as 1912, had recommended its use. Even at that time, <>ne road had 200 engines running with lines welded in and it was found unnecessary to remove tines when engines came in for repairs It was found that maintenance cost was almost entirely eliminated, engine failures were avoided and engines could be kepi in service a greater length of time. See "Suggestive Applications." Page 49. Welding Cracks and Patches The welding of cracks and patching of seams offer the most difficult problems to the welding operator. The Association of Railway Electrical Engineers, offers the following directions for this class of work: "A crack should be located and at least twi i inches bey< ind each end a ' 2-inch hole drilled. The edges of the crack should then be beveled so that the operator can get at them to make the weld. On horizontal cracks, the lower edge does not need to be beveled but should be chipped to give a square edge. The upper edge should be beveled al least 45 degrees. Vertical cracks should be beveled from 30 de- grees to 45 degrees on each .side. The less ma- terial removed from the crack the better. All welds should he made with the least possible amount of metal between the edges of the orig- inal material. lg for expansion in side sheets by making the weld in the alternate sections Fig. 47 Leaky Rivets in mud ring repaired by building up pad around the head of the rivets as shown. 20 STANDARD RAILROAD PRACTICE "If the crack or seam is a long one, the metal >hould be put in alternate sections 4-inches to 6-inches long. The operator should put one layer of metal in each of these alternate sections starting near the center of the seam or crack. The open sections can then be filled, starting at the coolest point. Successive layers of metal can then be applied until the seam is completed. Wherever possible, at least 30 percent of rein- forcing should be applied so that the cross -sec- tion through the weld is 30 percent greater than the section of the original plate. After each layer of metal is welded into the seam, it should be thoroughly brushed with a stiff wire brush to remove as much of the oxide as possible. Where the sand blast is available and can be used on the job the results will justify the expenditure of time necessary to clean the metal between layers. The same general care should be taken in the welding of locomotive frames as in the case of the boiler plate of the fire box. "Aside from the use of judgment in the appli- cation of the electric arc welding process, there are three rules which the operator must observe to get the best results in welding: 1. Hold a short arc. 2. I'se a low current. 3. Always work on clean metal." Provision for Expansion ■'Where long seams are to be welded, as fin- example, in welding in a half side sheet, prac tice again differs as to the best method of tak- ing care of expansion. Some operators prefer Fig. 48 A patch built up around a locomotive mud ring. This l-atrb is nearly 8 feet long and made a saving in cost of over $2,1100. besides the saving of a month's delay in m.'ik ing the repair. s •/ I Fig. 49. Worn Engine Cross head repaired by welding on piece of boiler plate at the top and welding crack a* shown. Fig. 50. Arc Welding as used in making smoke box for locomotive boiler Fig. 51. Worn St building ip worn surface by arc welding. 21 ELECTRIC ARC WFI.DIM; i - Arc Weldei R. R n I l i to allow for expansion by widening the gap between the sheet, this being done by setting the new sheet away at a slight angle; the allow- ance usually made by these operators is about ! -.-inch to ' [-inch per foot of length. Then when the weld is begun at one end and the work is carried on, the two edges will gradually draw together, due to the contraction in the weld at cooling. Other operators prefer to place the two edges in final relation to each other, holding them at the proper distance apart by mean- ol 'tacks' at intervals of 12-inches to 18 inches. The weld is then begun at either end and as it approaches a 'tack' the tack itself is cut out by use of a chisel and solid metal welded in. the tack simply serving the purpose of holding the sheets in proper relation until the weld is made. When tacking is used, it has often been found advisable to weld a short space, say six or eight inches from one end to the seam, then go to the other end of the seam .and weld a like distance, thus keeping heating and expansion at a mini- mum." Standard Welding Practice ® , Fig ] i:< prompt repan oi broken shop tools is ofti great ii in tlu railroad repaii shop. *1> A brok< drill socket for 1" diametei drill. A new socket would lo $1 80, i an impoi tanl e same drill - Lincoln Arc Welder Cost pair, including preparation of weld, was pipe wrench for 3" pipe, repaired by the Lincoln Arc Welder. A new wrench would havi ccst about I lir cost 20 cents, including preparation, welding and grinding off super- fluous metal .a weld. Hie Association of Railway Electrical Eng neei i ommended the following with refer to standardization and shop organization based upon the experience of their various mem- bers on different r< >ads. "The importance of the wadding operations in a locomotive shop or engine house is so great that it is necessary for the work to be done under the direction of a competent and responsible member of the radio, id organization. \ very i sful solution to this problem has been made on several systems by the appointment of a Su- pervisor of Electric Welding who is responsible directl) to the general superintendent of motive power, ddie Supervisor of Electric Welding makes the practice of the several shops uniform so that the failure of one shop to get results from a process can he traced to its origin. The Super- visor i if Electric Welding must find a successful way of doing each job and require every dun. to perform the operation according to his instruc- ti' 'tis. "Operators are obtained in most cases from a shop organization. On roads where an ap- prenticeship training is provided most of the STANDARD RAILROAD PRACTICE iiiiiMiini!! 111 i i' minimi ■ i i ii ■ ' i iiiiiiiiiiiiiiiiiimiiiiii i mi ' iimiiiiiiiiiiiiiiiiiimiiiiimiiii m ■ ■ mi ■ mm ' Fig. 54. Lincoln Arc Welder (Portable Type) with canvas hous- ing as used m engine house on Eastern Railroad. The canvas keeps out the dust and dirt prevalent around the engine li aise Fig. Lincoln Arc Welder (Stationary Type) installed engine house on large railroad. operators are men who have just completed the apprentice work. It is desirable to have opera- tors who have had general experience in a rail- road shop. In shops which have a local elec- trician the care of the electric arc welding equip- ment is handled by the chief electrician. In engine houses the operator of the equipment is usually trained to give the equipment whatever care is necessary. " Standardization of Operati (HIS The tendency at the present time is to stand- ardize the welding operations in the same manner that the machine shop and other operations have been standardized. Where welding operations are thoroughly standardized the work can be paid for on a piece work basis. The standardization of welding operations is comparatively simple on systems which employ a Supervisor of Electric Welding. On other roads it is more difficult to standardize the operations, but the necessity for having them standardized is greater. Ninety- five per cent of the electric arc welding done in railroad shops is on operations which can be standardized. The following factors should be determined for. each job of this nature: 1 — Size of electrode, 2 — Kind of electrode. 3 — Current in the arc, and -I — Time required for the opera- tion. Equipment A thorough discussion of the equipment avail- able for electric welding in railroad shops will be found on pages 50-56. Fig. 56. Lincoln Arc Welder in Rock Island R. R shops, Silvis, 111., showing the black canvas screen with which the Welder is surrounded, thus protecting the eyes of other workmen from glare. Fig. 57. Lincoln Arc Welder (Portable Type). This is oni ol twenty-three Arc Welders in use on the Rock Island R. R. 23 mm iimmmiiiiiiii ELECTRIC ARC WELDING i (nil n iininminin i i i ' minium ■ i inn inn mi in mini .nnin nun n mnnnnni Miscellaneous Kiiitkio Welding No. of Description. operations Bumper Beam 1 Brake Shoe Heads 102 Brake Hanger Bracket 1 Crossheads — Piston 1/ Crossheads — Valve 22 i 'rosshead Pins 3 Deck Castings 7 Driving Boxes 4 Driving Box Lugs. 10 [•"rallies 2 Frame Cross Brace 1 Eccentric Blades 5 Eccentric ( rank 1 Guide Hay-. 69 Guide Yoke ... 1 I .r\ ii- ( omhinatii m 17 Links Link Hangers 12 Link Saddles Miscellanei ius 6 Quadrants Teetli 3 Rods Main 9 Rods— Side- -Grease Plug Holes 106 Rods- Side Spade I'm Holes 1 Rod Straps Reverse Lever Heels Kc\ it-c I ,<-\ ei I - 1 1 1 hes Spring Saddles ... Spokes -I )ri\ ing Wheel •shop I in 1 . and Machinery Pail Sheet Tumbling Shall . Pender Truck Equalizers Transmission Hangers Total 487 Net saving foi month. .$1,375 IN Locomotive Shop — Name Withheld -One Labor $ 1.41 11.79 .33 12.96 J 39 .S3 30.23 2.10 KIS 5 11 2 59 .96 .19 99.52 66 2 66 .144 1.36 59 1.48 .28 2.4S 20.61 -t 16 57 2.19 mm .72 .33 3.13 4.18 Material $ 0.33 2.48 .il. 1 3.29 .55 .18 6.90 4.20 .33 1.25 60 21 .05 28.91 .lit 60 89 .in in .19 i ; 75 2.70 23 1.10 .15 13 i,ii .13 0£ 85 si I in $60.62 1916 I an ua i . February \1 .ii i I \pril Maj 1 uni li.lv No of operations 461 . 453 584 525 487 57') . 525 . i oi s Jobs. 1 ,abi ir 253 57 172.92 228.22 210.09 165.97 Material $47 88 59.89 64.57 42.62 60.62 54.94 41.12 Current $155.70 187.70 199.13 ] 14.20 175.52 175.5-' 135.62 Current $ 1.35 9.55 .08 10 53 1.95 .53 20.70 1.80 .88 4.20 1 .80 .86 .15 86.33 .30 1.75 _' 55 .90 .45 .50 .23 2.18 10 05 08 3.30 .45 .53 1.80 4.20 .50 .15 1.00 3.15 .38 Total cost $ 3.09 23.82 .43 26.78 4.89 1.54 57.83 8.10 2.29 10.56 4.99 2 05 .59 214.76 1 oo i.99 6.68 2.56 1.14 -'17 56 5.41 55 54 1.56 8.56 1.17 1.32 4.59 11.71 1.35 .55 4.98 8 15 1.05 Month. Other method $ 5.00 80.58 1 25 133.06 13.95 4.47 484.32 105.48 6.90 57.84 21.75 5.44 12.74 423.03 ■'.74 3257 36.41 324 8.52 4 St. 2.45 9.99 89.04 12.29 53.78 7.S0 11.55 22.99 42 5(1 6.00 1.50 49.21 78.30 1.38 Saving $ 1.91 56.76 .82 106.28 9.09 2.93 426.49 97.38 4.61 47.28 16.76 3.41 12.35 208.27 8.68 27.58 29.73 .68 7.18 2.69 1.87 4.58 55.70 10.73 45.22 6.63 10.23 18.40 30.70 4.65 .97 44.23 70.17 .33 $175.52 $464.36 $1,839.54 $1,375.18 Total ei ,-t $386.65 4*<. per engines engine 42,640 2,811' 15" $990 77 $181 09 $843.72 $2,015.58 222' 45" $80.39 $2,093.97 $8.48 5,034 1,473' 45" 520 01 s. : -17 442 If, 1,047.64 24' 00" 10.08 1.056.12 5.J9 24 'i iiiimiiutii illlHIMIItHI 111:1111. !|IIIINIi:< ■ ■' .:lli.;:,' Illlllllllllllllllflllllllllljllll ' COSTS AND SAVINGS ... . .. iniiiiiriiiiiiii niiiimiiiiiiiiiiin .1 111 inn 1111 mm 1111 1111 mini Table -Comparison of Electric Weldini; vs. Old Methods and < l >• scription of parts Cost old method \ alvt steins $16.28 Eccentric straps 1 7.95 Cylinder cocks 1.36 Cross heads 355 40 Piston heads 47.93 Motion saddles g.32 Frame braces 99.50 Crank arms IS.s ] Rocker box castings 4 59 Transmission bar 2.80 Reach rod [.25 Rocker arms 20.75 Eng. truck equalizers 7.70 Truck frame 15.70 Trailer jaws ' ~,t. Extension piston cross head 6.30 Brake beams 1 ,59 I '.rake hangers 5.10 Smoke arch brace 3.511 Air pump valves 2,50 Lugs on valve yoke : 32.45 Push car wheels 6.Q0 Stilson wrench 1 ,60 Drill chuck 15 mi Driver brake fulcrum 5.52 Wheel spokes 1 ,276.80 Main rod blocks ._, 15.88 Triple valve gage 20.00 Link blocks 72.24 Lift shafts 23.98 Quadrant 7.43 Wedges 55.94 Chafing castings g 30 Plugging and building up holes J49.69 Tire rim keys 3.22 Throttle stem I 50 Reverse lever support 3.38 Smoke box 61.38 Hub liners I J 5 1 Strip on cross heads 2'~> $2 Fire door handle 1.75 Boiler casings 63.21 Frame buckle 4.90 Trailer yokes 5.25 Motion frame 9.10 Combination lever 1.03 Lugs nn trailer bub 4.50 Center castings 76.81 Spring bli icks 1.15 Guide blocks 5 52 Hinder 5.19 Steam pipes 3.79 I lat Spots on tires 99.86 Cylinder bushings 35.65 Building up side rods 93.48 * irease cups 1 1.79 Stationary fire door 8.00 Cracks iii tanks 372 69 Petticoat pipes 140.52 Filling worn spots 2,677.80 Pins 70.66 Reverse lever parts 103.02 fntal $6,434.10 Ias Welding Made on Ro< k Island Lines Saving ( ost gas ^ ..M . lei . over "1.1 Saving No welding welding method over gas engs. $15.26 $4.76 $11.52 $10.50 6 7 63 2.38 15.57 5.25 2 1.04 .34 1.02 .70 1 120.23 37.73 318.67 X2.50 13 32.74 ln.24 37.69 22.50 4 10.94 3.44 4.88 7.50 1 48 "(I 15.00 84,50 33.00 10 26.14 S.14 10.67 18 00 7.29 2.04 2.55 5.25 1 4.33 1.38 1.42 3.00 9 1.09 .34 .91 .75 1 1.1.24 4.24 16.51 9.00 6 17.24 5.24 2.46 12.00 9 13 04 4.04 1 1.66 9.00 3 4.38 1.36 1 4" 3.02 1 4.36 1.36 4.94 3.00 1 2.18 .68 1.01 1.50 1 7.45 3 4ii 1.70 4.05 3 6.25 2.14 1.36 4.11 1 1.33 .53 L.97 .80 1 21.80 6.80 25.65 15.00 6 10.56 3.05 2. ')4 7.50 4 1.09 .34 1.26 .75 1 2 18 .68 14.32 1.50 1 8.72 2.72 2 xo 6.00 1 113.08 35.08 1,241.72 78.00 15 28.34 0.84 7.04 19.50 9 3.27 1.02 18.98 2.25 1 51.49 15 4'' 56.75 36.00 20 4 02 1 02 :: 96 3.00 1 11.09 3.59 3.84 7.50 3 69.69 21.69 33.35 48.00 25 10.70 3 20 5.10 7.50 1 280.94 141) 47 209 22 140.47 70 5.38 2.38 .84 3.00 ! 09 .34 1.16 .75 1 4 36 1.36 2.02 3.00 -> 32.43 9.03 51.45 22.50 13.11 4.11 8 411 9.00 3 31.00 12.66 12.66 18.34 3 1 09 .34 1.41 .75 I 30 30 •i 32 53.89 20.92 1 2.41 .91 3.99 1.50 1 6.45 1.95 3.30 4.50 1 10.17 4.17 4.93 6.00 1 1.75 .55 48 1.20 1 4.52 1.52 2.98 3.00 i 28 56 9.06 (.7.75 19.50 3 1.09 .34 .81 - z 1 4.29 1.29 4.23 3.00 1 13.10 4.10 1.09 9 mi 2 5.12 2.12 1.67 3.00 1 95.77 29. 77 70.09 6l 4 9.40 3.40 32.25 6.00 1 81.1 6 31.16 62 32 50 00 -i 11.43 3.93 7.86 7.50 ^ 8.72 2 7 i 5.28 6.00 1 113.62 36 16 337.53 78.4,-, 14 52.37 16 37 124.15 36 mi 18 1,064 60 329.60 2. 348 20 735.00 128 87.23 2 7.2.1 43.43 60.00 74.04 2 3. '14 $921 -.1 7". '18 51.00 38 $2,755.74 $5,512.49 $1 Table II. — Comparison of Elei rRic Welding vs. Other Methods. ( '..St of Cost of Description of parts other methods elec. weld Pedestals $645.00 $45.24 Tank frames 9.03 1.36 Shop tools 14 36 3 4ii Piston rods 78.64 16.37 Sharp flange drivers 165.40 20.28 Truck side 194.00 10.20 Building up dr. axles.... 121.50 4.90 Steel car underframe. . . . 11.34 1.71 Building up car axles 515.00 25 24 Hushing stavholt holes... 294.96 73.74 Welding flues 2,607.65 521.53 Frames 931.00 133 28 Cracks in fire boxes 2,431.27 297 17 Total $7,839.15 $1,154.42 No Savings engs $599.76 5 7.67 1 30 96 4 62.27 10 145.12 3 183.80 4 1 16 60 1 9.63 1 289.76 -. i ] n 26 2,086.12 102 797.72 1 1 2.134.10 92 $6,684.73 Table III. Summary. ists and Savings Per Month Cost of other in. tit. ids $6,434.10 7.S39.15 Cost of Eras welds $2,7 55 74 3, (.'17. 42' I ost Of electric welds $•121 61 1,154.42 Saving over other methi ids $5.512 4" 6,684 71 Saving over eras weld $1,834.13 .' 143 00* $14,575 2 5 $77,209.20 94.069.80 $6,453.16 i 'osts am 1 1 068 84 44,369 04 $2,075.03 Sazings — P $1 1,059 S2 13.853.04 $12.19; ' 'r Year $66.14'i 88 S0.21t,,76 $4,377 1 < $22,8fl».56 30.516 90* $171.27'' in $77,437.88 $24,912.36 $146,366 04 $52,525. 5. •Figures show cost of gas weld if work could have been weWed with gas. nil iiiMinii ii i i i) i! ii i .i in : iiiimiiiiiiiiiwiimii ELECTRIC ARC WELDING I iiMimini iimiiiii fn Ship Building and Repairing Kig. 58. Electric . I motor tru ["his F The Boom Roller & We Clevi Ohio, and is doing limit worl the largesl steamer on I equipmi H. P Novo Engine hell connecti I Lincoln A Weldei ["hi engine also atcs ,,, hammer. I carries the welding entei i ip through tl : in the sid: Closely allied to it^ use in railroad shops is the use of arc welding in shipbuilding and repairs. Here again tremendous developments have taken place in the year since the United States entered the war. Very wide use is now being made of electric welding in the actual construc- tion of >liips, where it not only costs less than riveting, but makes a very vital saving in time Unfortunately censorship rules will not permit the photographing of this work or the givii detailed information concerning it. Ship build- ers who are interested, however, can obtain all the data from the Emergency Fleet Corporation, ami the wonderful possibilities of this process in ship building will be substantiated by any one who takes the pains to thoroughly investigate it. At the present time the insurance rules do not permit the welding of any strength members on the vessel, that is, the welding of plates ,,,- ribs. or the welding of the plates to the ribs. Regarding this use of electric welding, James G, Dudley, Research Engineer, has the follow- ing to say, in a recent issue of International Marine Engineering: "bur more than five years past, railways of the United State- have employing metallic electrode welding in largely increasing amounts and with astonishing tech- nical and economic gains in securing practicall) leakless conditions of tubes and furnace sheets i if the 1< ii omi 'live In liters. " ['lie technical literature of railways and weld- in- demonstrates beyond successful controver- sion that jointures of mure than 100 percent effi- ciency can be readily and commercially secured by electric welding means. Even the truly re markable results secured under the punishing conditions of steam locomotive service have not as yet overcome the friction and inertia of "standard practice" in so far as the design and fabrication of a complete locomotive is con- cerned, but eventually the insurance and inspec- tion interests must voluntarily "approve" or be compelled by the march of events to "permit" the fullest possible use of electric welding in this field of transportation. 26 SHIP BUILDING AND REPAIRING mil : minimi "Passing to marine practice, it is more or less common knowledge in marine circles that elec- tric welding has been successfully and economic- ally employed for main- years past in man) ports of many countries in repairing of parts of ships, winch otherwise must have been tied up for costl) periods." At present the rules permit the welding of the following parts, and these after all are of very great importance because they are the parts on which riveting takes the must time and on which the greatest saving can be made: The classification societies have so far con- sidered and approved the application of electric welding to the following parts of vessels: Deck Rail Stanchions to plating. Clips for Detachable Rail Stanchions. Continuous Railing Rods (Joints). Attaching Deck Collars (1,. Kings i around ven- tilators. Attaching Deck Collars (L Rings) smoke stack. Attaching cape rings, smoke stack pipes, etc. Attaching Galley Fixtures to Plating. Attaching Bath and other Fixtures in officers' quarters. Attaching Cowl Supporting Rings to Ventilators. Bulwark Top Splicing and End Fitting. Skylight^ over I ialley. (a) Engine Room Stairs and Gratings. (b) Boiler Room Stairs and Gratings. Attaching (A) and (B) to Plating Grab Rods on Casing. All Stairs and Ladders including Rail Attach- ments. Door Frames to Casing, Hinges, Catches lh>ld Coach-hooks, etc. Clips f"r attaching Interior Wood Finish to '• S ing. Entire Screen Ubd. Coal Chutes. Butts of W. T. and O. T. Boundary Bars on Bhds. or floors in double bottom. Ventilator ( owls. Stacks and Uptakes. Bulkheads (that are not structural parts of the ship), partition bulkheads in accommodations. Framing and Supports for Engine and Boiler Room Flooring or Gratings. Cargo Batten Cleats. Pig. 59, The sketches show pieces which can he made with the i lectric arc in ship yards. No 1 is a very difficult and expen- sive job for the angle smith, but can he made for a few cents with the electric arc weider, No. 2 is a boat davit made from an 8 inch I beam split and rewelded. The cost of this from the angle smith would be $6.00 or $7.00. whereas it can be ,1- , li i, «< 1 . 1, . 1 for $1-00. Fig. 60. Welding a sky light on a steel vessel. Tic 61 Sky light c pli ti Ij v i Ided. urn u urn' ■linn: mil .iM ■ ■ '■ - ■ i ! ELECTRIC ARC WELDING iiii. ":. i m iiii , Fig. 62. Model -i I- li < trie Weld, d K I I il-- ...lih i .1 t : • Tanks (that arc not structural parts). Shaft Alley Escapes. Steel Skylights over accommodation spaces. Engine Room Skylights. Grab Rods on exterior anil interior of Deck I louses. Deck Houses noi covering unprotected openings through weather decks. Reinforcing and protecting angles round man- holes. [oints of \Y. T. \ngle Collars at frames in wav of W T Flats. < >ther parts of a vessel in which electric welding is proposed must be submitted for considers tion. March 2^, 1918, Llo\d's Register of Shippin i j Battery Place. .V. Y. ('. It i- the < >i >mi> 'ii hi' experts on the "Electric Welding ( ommittee of the Emergency Fleet Corporation." thai four welded ships can be built for the cost of three riveted ships and tin- welded ship will require about half the time for complete fabricate »n. The British Admiralty have already launched a channel barge of some 200 tons dead weight built completely by the electric welding process. Plans have been submitted to the Fleet Cor- poration for a 7500 ton electrically welded mer chant ship of standard construction which would make use of the steels already on order and would he built in a yard designed especially for the construction of electrically welded ship- It is estimated that on continuous welding — side and down welding, an average speed of 4 feet per hour could he maintained and that on overhead or intermittent welding a speed ot 2 feet per hour could he averaged. To give an idea of the work involved, a ship of this character would require the equivalent of about 186,000 lineal feet of welding in half inch plate, and the number of rivets to lie driven in the yards and on the ways would he reduced to about 17, (hh). Tin's i- an extremely important development in view of the difficulty ot obtaining riveters and the unusually high wages paid for this class of work. Hue to the saving in steel weight resulting from a re-distrihutioii ot mate rial and a substitution of welding lor riveting joints, it is estimated that a welded vessel would have 500 ions more cargo capacity than a riveted ship of the same dimensions. According to the best available information the cost of welding on such a ship Would he ,-ihi >ut $41.00 per ton of steel. Figuring the high- est possible prices for labor, material, etc., and that this figure might fairly be expected to he reduced to $29.50 per ton. added to ibis would he the o >st of shop preparation for welding, erect ing and fitting the plates in place, which would give a total cost of $87.00 per ton t not including steel), at a maximum, with a fair chance ni average- cost as low as $75.50 pel ton Inasmuch as there are only 2300 ton- o! steel in the welded ship as compared with 2800 tons for the riveted ship, the total cost of all work- should he considered in making comparisons and not the Ci ist tier ton. \ recent issue of the Welding Kngineci tains some valuable suggestions for arc welding mi ship building work. Especial mention is made of the fact that steel foundries are now working at full capacity and that the linn- c m sumed in sending hack defective castings to them is wasted. Electric welding equipment for im- mediate repair of these castings should he in- stalled in the ship yards and the transportation conserved. A number of pieces which can be welded •- g 1 advantage are shown in the sketch here- with, reproduced by the courtesy of the Welding Engineer. All of these pieces can be welded and are bein' r welded in some vards. Such welds an 28 iiiiliimwiiitiiimiini, iiinnmmiiuii mini HlltllllllttllllllllllltltlllllllllimilllHIIIIIIIIIIIIIIIIIIIIIIIIII! uiiiihuin, :: . in in iiMiiiniiii nun in, Miiinj'iiiimiiin inn; :n ■ . mi miiiiii SHIP BUILDING AND REPAIRING mm vim'. in milium perfectly reliable, providing the operator is care- ful and good material is used, precautions which must be observed on any kind of mechanical work. The metal electrode is the only suitable method for welds of this character. Repairs The most important work done bj the arc welding process on board ships is in the reoair of the ship's boiler. Owing to the strain which is brought to bear upon the shell and fire box of the boiler, due to the heaving, rolling and pitching of the ship, there is a greater tendency for the riveted joints and stay bolts to leak than in the case of a stationary boiler. Also, as a general proposition marine boilers work harder for their nominal rating than stationary boilers. This means greater corrosion and more rapid deterioration. In general, the two classes of defects which occur are cracks in the furnace and leaks in the riveted seams and stav holts. The United States government has very strict rules regarding the application of the process to the welding of marine boilers, but the defects just named can be repaired by the arc welding process. Tn the case of a riveted seam which leaks due to the fact that the caulked edge has worked away from the plate a reinforcing strip is usually put on the seam, extending from the extreme edge of the caulked edge to a point beyond the heads of the rivets. This will effectively stop all leaks either around the rivets or at the caulking edge. Where the edge beyond the line of rivets has been eaten away by the corroding action of leak- ing steam a whole new edge is built up. all work- being done by the metal electrode process Leaky stay bolts are repaired by reinforcing and welding clear over the top of the stay bolts. Cracks in the fire box are first located and holes drilled in the shell at each end of the crack to be sure that the end of the crack has been reached. Then the intermediate space is chipped out giv- ing two beveled edges. The electric arc process is used almost ex- clusively for this work, for the reason that it is almost impossible to do the work with the oxy-acetylene, and a good many United States fcrn>/-«rfrnAi»-t- \ Fig. 63. Repair Tug, Carrie A Ryerson, property of A. F Mitchell & Son, Chicago This tug carries a 200 ampere Lincoln Arc Welding outfit in the small housi on the deck. This Welder is driven by a Novo Gasoline Engine and by actual test it performed th< same amount of wink on 6 gallons of gasoline as a constant voltage type of welder owned by t Fie same company, driven by a strain turbine and consuming 2 tons of coal. (See page 50 52 for description of Constant and V i Voltage Welders, > I ig. 64. Broken stern post on S. S. Cygnus before weld- Note that the break has been chipped out to a "V" shape for welding. Pig. 65. Stern post on S. S, Cygnus (set Fig, 64) The weld was made with a Lincoln Arc Welder and was practically com- pleted when this photograph was taken. 29 ELECTRIC ARC WELDING in iiiii mini nil in Government steamboat inspectors refuse to pass the work of the oxy-acetylene operator for this purpose. Tin- trouble arises from the wide dis- tribution of the heat i if the oxy-acetylene flame which causes contraction difficulties in the plate i if the hoiler. \nother serious defect < if the oxy- acetylene process is that it is almost impossible to weld overhead with the use of the gas flame. Vbout one operator out of fifty can do success- ful work in the overhead position. Since a large part of the boiler work encountered in marine practice is overhead, this practically eliminates the oxy-acetylene process. The fire rule- pro- hibit it-- use in mi ist instances. A great deal of welding is done on the 'leeks and deck houses of boats. Most of this work at the present cine is in the nature of repair work rather than new construction. On board the ship- of the Great I .tikes a great deal of welding is done about the hatches which become damaged from loading and unloading. Miscel- laneous small jobs are done about a boat when it is laid up f"t repairs, winch mean a great saving of time and money. While at the present time there is very little welding' done on the outer shell of the hull there is considerable work being done about the engine room, .ami on the arches and tank tops. < hie of the latter applications is in burning off rivets where certain plates are to be taken off and new plates put on. Where a rivet is to be driven it is necessan to gel one head of the ri before it can be taken out. Burning off the head of the rivel and then driv- ing it through is the quickest iv; i ed up to the present time for doing this job. Another application of arc welding when the boat 1- in drydock is the repairing of what is known as the rudder shoe. This 1- the heavj steel casting which extends from the -tern end oi the keel of the ship to support the rudder post. It is ther frequent occurrence for this -hoe to be- come broken and it is necessary to drydock the ship m order to repair it. This job was formerly done with the thermit process, but has been done successfully a number of times with the carbon arc process. The rudder frame is usually a steel casting with boiler plate riveted on it. In col- lision- and wrecks the rudder frequently sutlers and repair- are made using the arc welding process, While a great many applications of the arc welding process have been made up to the pres- ent time in shipbuilding and repair practice, there 1- no doubt but that only a few of the possible applicatii ins have been made. Equipment Up to the present time the equipment used for arc welding purposes in marine practice has Keen n! three types The engine driven unit. direct connected to a reciprocating engine: the belt driven engine type unit, and the turbine driven engine type unit. The equipment is usually mounted on a boat which is self-pro pelled by its own -team engine. The boat must carry a licensed engineer in addition to one or more boiler makers and one or more operatoi the arc welding plant. The charge for the ervices of the repair boat varies somewhat in different localities. ( >n the Great Lakes a great deal of contract work is done, that is, a price is given on each proposed job, and there really is Hi 1 standard price. The arc process is used rather than the oxy- acetylene process for marine work because the most important part of the work — boiler repairs — can be done only by the arc process. The cost of producing the heat for welding is certainly igh with most electric outfits now in opera- tion as it would be if the gas could be used. This high cost of producing the electric power is due to the high investment in the repair boat, the emergency character of the service rendered, which mean- that the boat lies idle a good per- centage of tin- time, and the practice of using m driven equipment on a -elf-propelling boat. But "wing to the fact that boiler repairs cannot be successfully done by the gas process and the enormous saving resulting from the application of welding in repair work, the electric welding outfit ha- become a recognized ami indispensable part of the ship repair company's equipment. The actual cosl per hour per operator mi a -team driven outfit which include- air tool equipment varies of course with the continuity of the work. ( )n the Great Lakes the actual cost per operator 30 SHIP BUILDING AND REPAIRING ■ li 1 ■ iiimi::i mmm 1 :■ : [hum si ■ i' ■ in! 1 ■ ■ ■ ■ ■ ■ n ■ ! i 111 ii mum minim i in minimum iiiiiiiiiiiiimiiminm Fig, 66. Welding a coal shovel in the Great Lakes district. Arc Welding can be (lone at any point where an electric cable can be carried. t Fig. 67. Lincoln Arc Welder direct geared to a 10 H. P. Novo Gasoline Engine, making an ideal outfit for ship building and repair work, where a portable outfit is required per hour, considering investment and the varia- tion in the amount of work dune is probably not less than $2.50 per operator (1916). The cost of operating the air compressor is an addi- tion to this figure. The cost of operation in harbors on the sea coast probably does not ex- ceed one half the above figure on the average, due to the greater amount of work. Gasoline or oil driven equipment can he operated at a figure in the neighborhood of $1.00 per operator per hour, owing 1" the fact that a licensed engi- neer is not required. Tins type of equipment is to be recommended for small welding repair companies in all eases. The steam equipment is economical however, for large ship repair com- panies i in the sea coast. Regarding what to specify for marine work, it is recommended that in all cases individual units he used; that is, an individual unit for each operator. Unless the individual units are used, a machine of considerably greater capacity must he installed in order that there will be no interference of one operator with another. Since a large part of the work done on board ships is done with the metal electrode process, 150 ampere capacity represents the unit capacity required. Equipment A description of the various types of arc welder adapted to shipbuilding and repair will be found i in pages 5' l-5< i. 31 II I..IM..-.MM. -in: .-:■■■ - ■•■■: -in Mil Mlliili II mil ■■ M '■ IN ■ ■■: ELECTRIC ARC WELDING ■ '! ri '■ : :. 'Hi 'Hi ■ llllimilll II I .:■ ■ J IIIIIIUHIH ■ Boiler Plate Work w general Welder at I Ohio. This Coi \ \ md. In locomotive shops of the large railway sys- tems of the country, the arc welding process has been used for a period of from six to eight years and in many shops the process is used not onI\ in the repairing of old boilers, but in the manu- facturing of new "ins. The work in repairing "Id boilers may be grouped under the head of welding in lines, welding in tube sheel and • ing cracks in the fire 1» ex. See "Suggestive Applications," Page 49. It lias also been widely used for general tank i - ork The American Machinist, in a recent issue, presents quite a discussion on this use of arc welding, stating: "Nowhere is the saving of are welding exemplified to a greater e? than in tin- manufacture "i steel tanks. Not only have the actual manufacturing operations been simplified and cheapened hv the elimination hi riveting and caulking, hut the resistance of the finished weld to leakage or rupture is much greater than that of the riveted joint." At a recent meeting of the Boiler Code Com- mittee of The American Society of -Mechanical Engineers, the following fact- were presented li\ speakers before thai committee bearing par- ticularly on the use (if welding for boiler and similar high pressure vessels. "The recent improvements in the an uf weld- ing in the apparatus and in methods of testing" the product, notably in the electric are pro* have made it possible t work, electric arc welding comes into direct competition with riveting and for that reason a comparative cost of the two processes i- of interest Cost of Welding and Riveting In order to compare the cost of riveting with the cost of welding we max lake the amount of ivork accomplished under given conditions bv the riveting gang, analyze the cost of the work and compare it with the cost of doing the work with the arc welding process. Taking the thicki the plate as ,',, -inch, spacing the rixcts at l'j-iiicli. the size of the rivets at ii li in diameter, we can safely estimate that the riveting gang will put in 60 of these rixcts in ne hour, under ordinary shop conditions. The analysis of the a >st is as f< ill i\x - : ' es base 1 i >n o inditii ms in 1' '16. RIVETING maker's time, ■ $ .45 ne In mi ,.<5 Mix et heater's nine i me hi mi .21 1 lr 'in ( Ine lax '"" man's I ime, hi mi .2 ! |)unchmen's i ime, ' j In nir .17 r 1 1 " ii i .20 i >)11 men's timi . . hi mi .20 Total Labor $2.03 I ength ' if rix eted seam, 7 ft 6 in. I 'i mn I ets i equin i ■ rivets, 1 Power required to drive pneumatic hammer and ioI, appri iximately In K. VV. Imurs. Investment per riveting gang, in air compressors, motor drive, storage tanks, distributing svstem, air hammers, and other rna- • I' U i Ming. ncoln \rc Weldei a .ii the shop of Tin * leveland. In the foreground are stiffening mil;-- for boilei work made with the Lincoln Arc Wi ised in this ^hop for a wide varietj of work 34 COMPARED WITH RIVETING urn [ I ' .1. iimiiiiimiiiii i ' i mi Iii order to get a comparative cost of the arc welding process, we will analyze the cost of doing the same work, namely making a seam 7 feet 6 inches long, which is a lap joint, welded inside and out. The following is an analysis of the cost, also on 1916 conditions. ARC WELDING One operator at 45c per hour for l'.j hours $ .56 No bucker required Xo heater required. One man with a chipping hammer, ' _■ hour 2.3 i )ne layout man. '.J hour 11 Two punchers, % hour. 08 Two erectors, ',, hour .Ill T\\ i 1 p ill men : j hi iur Jn Total Labor $1.28 Pounds of electrode required. 2.S. Cost of electrode, 12.5c. Kilowatt hours required to run the welder, ap- proximately 5. Investment in welding machine for one man. .. .$860.00 Labor has advanced considerably since this time but riveting gangs wages have gone up far more than welders' waives so thai the com- parison is very fair. It is to be noted from the above analysis that the labor cost item in the manufacture of boiler plate construction by riveting is approximately 75% greater than in the case of the welded con- struction. The amount of power required fur riveting is double the amount required for welding. The investment required by the arc welding appara- Fig. 78. Annealing Pot made with the Electric Arc Welde Fig 79 Storage tank made complete bj elect rii arc welding. The flanged end is welded into the sides by melting its edges tog« thei « ith ill-- < dgi - of the side sheets * /*?< '* .*> k« v j ■»•»»<»■»> ■I I ig\ 80. This conical sheet was welded at the point shown, in order to avoid a double lap at the edge of tin work which would have been difficult to rivet Fig. 81. Cylindrical Tank in process of welding, Tins shows an ingenious method of mounting the tank on a "horse" and clamping the. edges of the sheets by m ans of two plates secured together by bolts. 35 iL. i unit!] iiiimiiiiiiiiiiiiiiiiimimiimiiiiiiiiiinii ELECTRIC ARC WELDING mini nun ii i - < i ■ ■■ .. -., l a ck nf i b^^4r h &*?£ &}£ i switches ami hard centers at cross-overs, reclaiming worn joint plates, building compromise joints, cutting orn -<■. : i> ins, cutting ■ iff bi 'lis. -v r Cupped J units Fig. 89. Guard for trai Welder I his was foi dotted lines in the ski ■■ ^J' V Cupi ^^5***— • The necessity for repairing a joint b\ the process arises from the fact that on track where the cars pass in one direction only the wheels, in from one rail to the adjacent rail, pound nut a cup mi the second rail. This comes about as a result of a breaking down of the road bed which makes the joint rest on an insecure f dation. The constant pounding loosens the bolts which hold the fish plates so that in time the jar in passing from one rail to the next becomes noticeable to passengers. Once such a cup has been formed there are only two way- in which the difficulty can he eliminated; either the rail ..in be taken uin and a new rail put in. or it can In- repaired 1>\ the arc process. The former method cannot always he used, because it' the i rack i- ill bad condition ami all of the rails are pretty well worn, the introduction of a new rail. which is mil worn, will make conditions a- bad a- they were before. The usual procedure where the arc process is nut used, is to take up all of the track where the trouble occurs and relax rails Tlie expense of doing tin-, of course, is very high Then Lre man) cases on reci >nl where line- (if track have been kept m service by the use of the arc welder fur three or four years in addition to the ordinary life of the track. The saving in cases of this kind runs into thousands of dollars and the cost of the equipment is a negligible fact' r. Corrugated Rail I ig 91 ; built up b> stood 1 1 Another defect which occurs mi the electric- railway track is known as corrugation. The causes assigned for this difficulty are numerous. 38 inn it iiinmiii!! i iiiimiiiiiiiiiiiiiiiiiiiiiiiiiiiimiiiiiimiimiiiiiimiiiimimii ....I. MMI I... I Mill It 1:1111111111111. ,i STREET RAILWAY WELDING iililililiiliiiiliiiliiiiiiiiiminiiijiiiiimii "i:'i::iiiimiiiiiiimiimmiimi but the corrugated rail looks as if the metal on the top of the rail had Keen slipped into cor- rugations. A car passing over a corrugated rail makes considerably more noise than when passing over a perfect rail and a distinct vibration and jar is felt by the passengers. < )nce a rail begins to show corrugation, the deterioration is rapid. In the case of corrugated rails and cupped joints, the metal electrode process is used to fill in the low spots. After the metal has been filled in the excessively high spots may be ground off with a grinder. Grind i /is* There is some variation in the practice oi grinding off the excess metal. Some companies use the reciprocating grinder only, while others use both the hand grinder and the reciprocating grinder. The latter process seems to be prefer- able because it is undoubtedly the most eco- nomical. The rate of grinding with a hand grimier is rather low, and where the filled in sec- tion is considerably higher than necessary, an unreasonable length of time is required to bring it down to the proper surface. Coin promise Joints Where "T" rail section joins girder rail a compromise joint can lie made getting a g 1 body of steel at the rail ends by building up with the electric arc. Electrodes The kind of electrode used depends a great deal upon the work. So far as actual resultsgo, the basic steel electrode or even Swedish iron will give results which are entirely satisfactory on ordinary rail section. The ordinary rail sec- tion may contain as much as .-Ml',' carbon while the basic steel electrode usually does not contain any more than .12',.' carbon. It would seem that the metal in the welded section therefore. would be considerably softer than the rail. This however, does not seem to be the case The cast steel which is put on the rail by die metal electrode process is not a normal cast steel due to the oxidation and sudden cooling at the instant it is deposited on the rail. It has been found that by forging metal so deposited, or in other words giving it a mechanical treatment, when cold, increases its hardness to a consider- able degree, so that after the repaired rail has Lincoln Arc Welder mounted repaii si n ice iu 93. Truck Side Frame repaired by Electric Arc Welding. Breaks in the- frami 01 worn boll holes can he repaired m this way. The holes are till..! in with new material then re-drilled. Fig, 94. A badly worn armature shaft h n c w elder. This i-. aftenvai ds mai hined ilt up with [own to pro electric ri Size. Broken parts <>f truck frame repaired by arc weMiti] 3') L iHiiiiriiiiiiiiiiiniii mil ■ ELECTRIC ARC WELDING i mm "mm 'mini liiltn' pei bar, •■ . Fig. 99. This worn gear case was repaired by using a dis- et car gong, and welding it over the portion of th< fhe case was made as good as new at a cost of about 4?c. been in service fur a short time, the action of the wheels in giving the metal this mechanical treat- ment probably renders the metal considerably er than the metal of the original rail. For high carbon rails, that is rails which contain as high as .90% carbon, and for manganese center special work the special slag coated electrode should be used. < Ine street railway company buys ordinary spring steel for this purpose which pos- sesses about 1',' carbon. The results they obtain b) the use of this steel on manganese center and high carbon rails are perfectly satisfactory. The building up of broken tongues in switch con- struction is also a frequent application. The — metal here, of course, is ground "ft' bv tin- use i if the hand grin Shop Welding The application of arc welding in the electric railway repair shop has not proceeded with the same rapidity as the application on track work has proceeded, although the saving which can be nplished is quite as great. The operation of electric car- over the track produces excessive wear on practically every part of the truck and under-framing. The wear and tear on electric car- i- probabl) greater in pro- portion to the value of the equipment than is the wear On a -team I . c, resulting from it- travel over the rails The sudden starting and ping with the consequent reversal of -trains in all the members, mean- that at every point where the car is fastened together with rivets :r occurs. Where one part rubs over another, the deterioration i- extremely rapid. When a part becomes worn there are only two things that can be done; either new metal can be added and the part repaired, or it must be scrapped and a new part put on the car. !t is obvious that the repair of the part by adding new metal produces a large saving. Where a part can be repaired without taking ar apart or taking the truck out from under the car. by the use of the welding process, an additional saving is made. Owing to the ease of application of the arc process, this can frequently be done and in this case the Master Mechanic can credit himself with saving the price of a new part, le-s the cost of welding — the saving in labor represented by the amount of time saved by not taking the car apart, and the additional saving 4- '" wniwiiiMHHi mi limn ' Hiiiuiiin I mum iiiniiinirii ninri mini m n i n | „ , mm,, minin tililliri iiiiiimmiiiiiin mmiiii muni iiiiEimiiiL :: . niiimiiiiiiiiimiiiin STREET RAILWAY SHOPS resulting from keeping the car in service rather than having it lying idle in the repair shop. The following parts are some of the principal cue-, which are repaired : Truck frames 1 )raxv heads Brake hangers Spring hangers Body bolsters Gear cases Armature shaft Gears Journal boxes Resistance grids Truck bolsters Channel iron underframins Arc Welding vs. Oxy-Aceytlene The only way in which the metal can be filled in the worn parts is by the oxy-acetylene welding process, or by the arc process. The relative cost of the two processes is much the same as in other applications. The cost of operating an oxy-acetylene torch for repair work of this na- varies from 60 cents to $1.50 per hour. An aver- age cost of operation per hour is probably in the neighborhood of $1.00. This takes into account a considerable amount of preheating on steel work by the use of kerosene torch of a preheat- ing furnace. Without the preheating arrange- ment the average cost per hour of operating the torch is probably in the neighborhood of SI. 50 per hour. The following table shows some com- parative costs on typical miscellaneous jobs en- countered in an electric railway repair shop. Cost Based on Conditions of 1916 Descriptii ■ Cost of :>t Job Replace ment Bearing Housing made of cast steel. Repair job $ 8.60 Axle cap. Renewing dowel pin holes. . 11.15 Repairing Armature shaft, pinion seats and Key way 55.00 Journal boxes re- paired by use of chafing plate .... 6.90 Truck Frame 60.00 Resistance grids. Typical repair job 3.00 Reducing bore of gear. This job impractical with oxy-actelyene. Re- duction too small for use of bushing 30.00 Cost Oxy Acety- Cost Electric ls nt- Torch \n Welding £2 60 $ .75 70 .25 7.20 .80 3:00 1.75 .20 1.10 .20 4.10 Fig. 100. Miscellaneous repair jobs on street railway work maile with the Lincoln Arc Welder by The Harrisburg Rail- ways Co.. Harrisburg, Pa. The metals encountered in the repair of cars include cast steel, cast iron, wrought iron, and mild steel. All of these metals can be success- fully handled in the railway repair shop. A large percentage of the work can be "bench work" and preheating furnaces and torches can be used to a good advantage. There is one peculiarity to the application ot the process for the repair of cars that does not exist on many other arc welding applications. There are many jobs of exactly the same nature since the car equipment is standardized to a large extent. This justifies a considerable amount of time spent in the solution of a given problem since that it is certain that a number of similar jobs will re-occur from day to day. The capacity of the equipment required for each operator is 200 to 300 amperes. This per- mits the use of the machine for either carbon or metal electrode on any kind of a job that will arise. There are few cases where it would be necessary to couple two of the units together to get a higher capacity. Equipment for Arc Welding Complete description of arc welding equip- ment for use on Electric Railroads will he found on page 57. 41 wt . 111 : : . ELECTRIC ARC WELDING Drop Forge Shops bv R. I'". Kinkead, before \n 1 101 R The arc welding process is being used sue fully a) the present tunc in the repair ol de in drop forgings before the forging leaves the shop. Tin- work is done to improve the ap] ance of the forging rather than in improve its strength, although the correction of certain de ili ics increase the strength i if the pii I he must important class of forgings which quire the correction of small defects is aut bile forgings The defect- corrected are low spots, parts not properly filled out, an kinds of o >1 the very great localization of the heat, although if the piece is annealed after weld ing, the pi lint at \\ hich the o n 1 1 ■■. as made cannot be located. The work can be done very rapidly owing to tin fact that the instant the operator strikes the arc. he can start filling in the metal. \*o preheating is necessary. The lowest priced man in the shop can do the weld ing. The designation of the forgings to be o n re< ted by welding should be dune by a competent fore- man or the superintendent of the shop. Know- ing that the metal to be added will have a certain tensile strength and ability to resist shearing stress and that it will have a very small degree of elasticity due to the fact that it is cast steel, there is little room for difference of opinion as to where to apply the welding process. fhe on the forging at which the defect occurs, has an important bearing on the question of whether or not it can he corrected. The service ected of a forging also affects the application of the welding process. It is evident that a defect of certain dimensions can be corrected if it occurs on an automobile lamp bracket which ould not be safelv corrected if it occurred on cvlindei crank shaft The fun-man of the shop, or the superintendent knows what to weld, it should not be left to the welding operator. ■since there are only two welding proo applicable to the correction oi flaws in drop t ings, electric arc and oxy acetylene, a comparison may be interesting. The cost of producing a unit of heat by the gas process is approximately six times the cost of producing a unit of heat b\ the arc process I Kving to the great loi ili tion of the heat in the arc process, approximately three times the welding can be done with a given amount of heat as can be done with the same tint of heat produced by the gas process. l', v actual test, the co t of gas for general work on automobile front axles runs from twenty i M twenty-five times the cost of electric power to dn the same work. < )ne operator with the elec trie- arc can do at least twice as much work in a da\ as an oxv-acetylene operator. The advantage has been claimed for the oxy icetvlene process that it enables the operator to hum down to the bottom of a cold shut and thus till in the whole defect. This practice is also possible using the carbon arc process, but the practice is dangerous. A forging which shows evidence of having a deep cold shut in a part ected to heavy stress should not be welded. \ forging which has .1 cold shut which will not materially affect the usefulness of the forging will actually be in poorer condition after the defect has been burned out and filled in than if the defect were not corrected tit all. The appli- cation of the gas flame in such a case will over heat a large amount of metal around the •!- while the burning out is being done. After the irea is sufficiently burned out. a comparatively large amount of cast metal will be filled in which is known to be inferior to the metal of the orig- inal forging. There is no heat treatment which will bring the forging hack to a condition equal 42 mil iii|i;iiillliili[i!llill:!|||ii!lllllii iiiitiiiiiiiiiiiiiiiiiiiiiiiniii i i /mi.- mi .' i i iin i ' ' ' ■■ '. mi minimi iiniiiiimiiiiiiiiiiiiiiiiiiiiiiii DROP FORGE SHOPS " minium iiiiiiiiiiiiii i II mi minium I.. its condition before the welding was done. It is much better to simply till the defect in a depth uf approximately a sixteenth of an inch with the metal electrode process which will nut materially affect the metal surrounding the defect Overheating the metal in a drop forging is always undesirable, particularly in the case of the allo-\ steels used fur certain automobile drop forgings. The high temperature reached in the gas flame and the electric arc affect the structure uf the steel to such an extent that it can never he made identical to the structure which has not been affected by the welding process. It i- evi- dent therefore, that the heat used fur welding should he localized as much as possible. The oxy-acetylene flame will heat from three to five time- the volume of metal in performing a given welding operation that will be heated when the arc process is used. The arc produces heat in the metal at exactly the point where it i- needed, while the gas flame produces the heat external to the metal ami blows it over a large area The welding uf defects on drop forgings is a delicate matter among some manufacturers at the present time. This condition of affairs appear- In he <\uv to the fact that the process is new rather than that it is immoral. When the -teel foundries first started to correcting de- fects in important locomotive castings there was the same feeling prevalent. In tact must uf the welding was done in the dead uf night and behind carefully guarded doors, 'fin's was only five or six years ago. \'<>w practically every steel foun- dry has one or more arc welders, and every kind of a steel casting is welded in the presence of the inspectors. Defects in gun carriages fur the Yaw Department are corrected in and out uf the Navy Yards. The responsibility fur a drop forging rests with the manufacturer. If he can make forgings at a price at which they can be sold at a profit and the forgings stand the service he can stay- in business. If the manufacturer sends out bad forgings, he loses his business. As long as a manufacturer must scrap forgings with insignifi- cant defects on them which his competitor can save, his price on the product will be high or his profit low. The present tendency uf prices of automobiles dues nut permit the quotation of fancy prices on drop forgings. The welding of small defects on drop forgings therefore is a matter of business economics, and will undoubt- edly lie solved in exactly the same manner as it has been solved in the case of the steel foundries. I t *w. :&*U ^^fewi n " l'u; 102, Lincoln Arc Wi i gi Drop Forging plant. 43 ii ilillililiiiiiiiiiiiiiiiiiimiiiimiilllllliiiii i! .i.ii! ii iinii'. in dliiilli iiiniiiiiiiii ELECTRIC ARC WELDING III!; ■ ::■---- I ■ 1 1 1 ■ ■ s - -S ■ I ■ I r i i iwiii i w mil ■ ii ■ IIIIIIIIIIHIII Commercial or Job Welding '9 ' .<£ Wf a- ■ 1 Every city of am size has a number of small shops where welding of all sorts is done. For a long time acetyleiu weldin chief process in use in these shops. l"he\ were started, mostly, b\ men who had done acetvlene welding in various manufacturing plants until the) had become very expert in its application to all sorts of work. < > 1 1 starting business for themselves, they nat- urally adopted the process with which they were familiar. They were prompted not only by this, but by the fact that it required only a very small capital to buy the necessary equipment for acety- lene welding. fhese early shops have grown in number and have increased in size remarkably in the past ten years. Hie larger ones have now come to the point where there is a continuous stream of work passing through their plants and they have been obliged to look very carefully into methods of reducing production cost. ( ompetition has grown keen in proportion to the success which the early shops made of their business. ' Iwing to tin- condition, main- of the shops have carefully investigated and have been [Hit- ting in arc welding apparatus t< weld thinner material successfully. Reinforcing of sheets or plates by angles, rims, presents another possibility fot arc welding. It has been successfully applied fur welding angle supports on tank wagons, reinforcing rims in large storage tanks and other worl< of this general nature. Pipe Welding The advantages of welding for pipe construc- tion have been a subject of careful investigation by The Xational lube Co., ami others interested in this sub It has been found that welding gives a more permanent joint in pipe than the couplings ordi narily used, that n gives a strength equal to that of the solid pipe and reduces the tendency to leakage at joints by eliminating couplings, the whole being practically one unbroken length of pipe. _ sen 5 made I i] shaft. : steel Fig 111. Welding door hang* I firepi tee] doors. The square tubes on the horse arc also arc welded on the -..tin-. -!.i liiimmiiiimiiiMiiii. "i .mm nin :imi ■ i mi i inn in inn in mi i . . ; mi GENERAL MANUFACTURING These advantages are of special importance in the construction of superheaters and similar ma- terial made from pipe products. An especially good instance of superheater welding is illus- trated. A development of this process is the welding of flues in locomotive boilers which has been very widely practiced in railroad shops and locomo- tive manufacturing plants. It is the present theory that welded pipe lines reduces electrolytic action and corrosion. The welded pipe presents a continuous conductor in which the resistance is lower than in coupling pipe thus reducing the tendency of the current to jump joints and set up electrolytic action. This use of welding is applicable not only in shop manufacturing work, but in laying of pipe lines and can be taken care of to good advantage by a portable arc welding set, which either takes current from the trolley or electric supply line. A Portable Welding set, driven by a gasoline engine or mounted on a truck and driven by a truck engine will accomplish the same result. $*--■■- Kig. 11? Lincoln Arc Welders in the plant of The Standard I'nrts Co., large manufacturers of automobile parts. Fig. 113. Steam Superheater. Every joint made by electric arc welding. manufactured Lincoln Arc Welder. 47 Hilliiillllliiilllllillillim .inn. miiiiiiiiiiiiuniiii ' .:,;.. .::. i mini miiimillllmiiiiini ELECTRIC ARC WELDING mi ■■ Repairs Repair Fig. USA. 1 ig 117, I incoln Arc Welder in plant of Aultman & Tayloi M Co., Mansfield, Ohio, used foi general manui and repair work on agricultural implemi Ilk' repair oi defects in manufactured pieces has already been discussed under the subject of steel castings and forgings, where arc welding lias thus far bad its greatesl application. There is undoubtedly another wide field in building up of pressed metal parts which come mperfeel from the dies and which have cracks, "short sides" or similar minor defects, which could be readily repaired b) adding new metal. The repair of broken machinery or parts can be made quickly and at low cost b) the arc weld ing process. Unless the plant is a large one and would have a considerable amount of this work, acetylene would be cheaper than arc welding, but where there is enough such work to keep an operator busy a great portion of the time, the arc welding would be found most economical. The general nature of such repair work, fol- lows under several headings. Rolt holes often become worn and necessitate replacing the worn puce with a new casting. This can be avoided by filling the worn hole with new metal then redrilling it. Bearing surfaces on slides, cams, eti . are repaired by somewhat similar processes. Patches are applied on ladles, tanks, and ve used in different manufacturing processes. Steel mills have found it economical to install arc welders for the purpose of repairing wobbler in the rolling mill. The ends of these wobblers are built up with new steel to original shape, sav- ing the cost of a new roll casting, which is much i expensive than the ordinary casting steel. Work is also being done successfully on the w i irking surface of the roll. Steel shafts are built Up ill somewhat the same manner, new material being welded on to the worn end, and the shaft then being put into the lathe and then turned d' >w n. Fig us. Steel parts incorrectl) machined built up 1> the aic weldei and ifterwards re-machined to pi pi 48 iiiiiiiimiiirminmi:ii ..:. , mi illllimilllliilllliiiilliiim niiilliilili , i) i. ii in minim is ■. ELECTRIC ARC WELDING Suggestive Applications Fig. 118A. FLUE WELDING 2" Flue Locomotive Back Flue Sheet. Actual Time: 2 minutts 2" Flu..-; 7 minutes 5" Flui Electrode 2" Flue— V— 00-100 Amp. 5" Flue — 5/32" — 120-130 Amp. The total time U) weld a complete set of flues de- pends on the condition of the flues and flue sheet. A fair average may he calcu- lated from the above figures by adding 50% to the total time for rest periods. Fig ] 1811. FLUE WELDING 1. Pul flue in as it" ii were nol to be welded. 2 Send the engine out fnr a few trips to lit the tubes take their set. ::. Sand blast the flue sheet. 4. Weld flues A heavj bead of welded metal around the flue is nm . ,i put on the smallest bead that can be thorough!? welded to both flue and sheet Fig. 118D FLANGED HEAD BACKED INTO SHELL. ill I LANGED HEADS- BOILER PLATE. %" Plate— Speed— 7 Ft, per hour. 5/32" Electrode L30 Amperes. Fnr High Pressure, joints should be welded inside and out. Kig. use. PIPE wi LDING See "Build- ing I'ji Operation" for speed of work. The Welded ioint is stronger than the threaded iotnt. Steel or wrought iron pipe onls mas be welded. i:uILi;n PLATE Si i p ( i T 1 r Electrode *%" Ahoy. only, no Amps 120 Amps. 150 Amps 6 %-3/16 Bgures include straight welding time Loss of time in handling the job must taken into account on each job. Vertical <>r overhead welding speeds are at least 50% l>elow speeds given above. -V wire Is used to fill in bottom of seam. 1 ig ] 18.1 WELDING IN PLACE 01 CALKING speed of work depends on amount of metal added. Strength of joint may be raised 25 doing the work at three times the welding speed given in table, page 6, for any thickness plate above *4". This makes a single riveted joint equivalent to a double riveted joint and makes a double riveted ioint as strong as the original plate. Joints welded in this man- ner stand nun-It abuse without leaking. 49 Fig. 118K. BUILDING UP OPER VTIONS (Note that the weld Is oasil) machined! 5 32" Electrode, 1 10 Amp.. 20 Volts will deposit one pound of metal in ap- proximately 30 minutes. 3/16" Electrode, 1T5 Amp., 22 Volts will deposit one pound of metal in approximately 20 minutes I ' ' Electrode, one cubic inch of stool may be deposited In about 7% minutes. The metal when deposited on mild steel bj the metal elec- trode process will always be sofl and easily machined, The carbon electrode process should be used for build- ing up operations only when the built up piece can be later annealed to take out contraction -.train. ii iii mill ELECTRIC ARC WELDING * * Current for Electric Arc Welding The successful commercial use of electric arc welding on the scale indicated in this book re- quires direct current. Alternating currenl does not produce an arc which can be controlled to a sufficient degree for such welding. The voltage id the current must be from IS to 30 volts metal electrode welding and from 30 to 45 volts for carbon electrode welding. These voltages are lower than are supplied by any power com- pany and are lower than those used for almost any other manufacturing process. The current most universally used in manufacturing estab- lishments is alternating current because it is easily transmitted and can be produced at lower cost. For these reasons electric arc welding al- ways demands a special equipment to produce suitable direct current at the proper voltage for welding. Equipment for Electric Arc Welding There are several distinct types of electric arc welding equipment now manufactured. A thor- ough understanding of each of these i, necessary before an intelligent application of the process can be made. Resistance Welder When electric arc welding was ti i^t used direct current was more common than it is i The first welding was done by inserting a heavy re- sistance in the regular direct current supply line in the shop. This line usualh supplied current at 110 to 220 volts. The resistance served to cut tin's \ , iltage d< >wn t< < fn >m 15 to 20 v< 'Its, thus making it adapted for welding purposes. The extra power used in overcoming this resistance was of course wasted The saving elicited however in repairing steel castings and in making repairs in railroad shops was so great compared to former methods that the waste of electric current was a minor matter. This re- sistance was usually made either by passing the current through a barrel of water or by passing it through a cast iron grid resistance. This resistance served two purposes, first to cut down the voltage, second to prevent a great rush of current when the electrode was first touched to the piece to lie welded. Motor Generator Sets This type of equipment was made necessary by the fact that alternating current is now in such wide use. Some means had to he devised to transform alternating current into direct. In the motor generator set a motor is used which is arranged to be driven by the electric current supplied to the shop. This motor in turn drives a generator which delivers direct current for welding purpi ises. economj of tlii- method over the resist- ance method is at once apparent because the cur- rent taken from the supply line is not wasted but used directly in driving the generator. Even in plants where direct current is available, a motor generator set is used, the motor, of course, being a direct current machine. In the gradual refinement of the motor gen- erator for welding purposes, two distinct types quipment were produced. For want of a better term, these have been called constant voltage welders and variable voltage welders Constant Voltage If ciders This type of motor generator set has a gen- erator which delivers current at a constant VOlt- N'ote; In plants where no electric current at all is available. it l- still possible to do welding work by means of a generator belted to the engine or line shaft. Such an - qui pment is shown mi page 54. 50 ARC WELDING EQUIPMENT iiiiiiiiniii age of about 75 volts. This voltage, however, is still too high for welding purposes and has to be reduced by introducing a resistance in the circuit. The power consumed in this resistance is of course wasted just as it was in the old type of resistance welder, the only difference is that in the constant voltage welder, the waste is con- siderably less. Variable Voltage Welder It should be understood that in arc welding the voltage of the current actually used is con- tinually changing. For instance, when starting the weld, the operator touches the welded piece with the electrode, then as the current begins to flow, he draws it away a short distance establish- ing the arc between the electrode and the welded piece. At the moment he touches the electrode to the piece, the voltage in the circuit is nearly zero and as he draws the electrode away, the voltage constantly increases as the arc lengthens. For this reason, an arc welder cannot be truly economical in use of current unless it gives ex- actly the right voltage for the work at every instant of operation. To produce this result a generator has been designed which always delivers the exact volt- age required at the arc at any particular moment. This is the chief characteristic of the Welder manufactured by The Lincoln Electric Co., of Cleveland, and this principle is responsible for the remarkable success this welder has made in every field. Expert Opinion Engineers in industries where welding is widely used have made a very thorough investi- gation of these two types of welder, realizing the importance of choosing the right one for their particular work. The Railway Mechanical Engineer in an editorial in their November. 1916 issue have the following to say in reference to these two types of equipment : "Two distinct types of motor generator sers are available for arc welding, different manufac- turers championing differenl systems. In one type the current is delivered at an approximately constant pressure of 75 volts and an adjustable resistance is used in series with the arc to vary the arc voltage to suit the work in hand. "The second type of motor generator set is so-called constant current or variable voltage equipment. In this system the generator de- livers a variable voltage, maintaining an approxi- mately constant current flow. Tt is therefore effective in affording constancy and uniformity of the arc and inasmuch as no ballast resistance is required, this system is more efficient than the previous one." The Association of Railway Electrical En- gineers appointed a special committee on the subject of arc welding and their report of Octo- ber 31, 1916, gives a valuable comparison on this point. "There are two types of equipment in the market which may be described as constant voltage type and variable voltage type. "The constant voltage type is a motor gen- erator set which takes power from the shop mains and delivers on the generator end a prac- tically constant low voltage. A resistance ballast is used between the generator and the welding- arc to limit the current at short circuit. The power used in the resistance ballast is of course wasted. The low voltage direct current power is carried over the shop on heavy cable- to the welding outlets. "The variable voltage type is a motor gener- ator set which takes power from the shop mains and delivers on the generator end the voltage required for welding without the use of re- sistance ballast. The inherent characteristic of the generator is such that the short circuit is limited without the use of resistance ballast. Inductive ballast is used to stabilize the arc. This 51 ii' i. ■ :i i ■■ mi . iiimm:i nin . . mini mi i iiii ■ . . nil ELECTRIC ARC WELDING ii ;n i :, Ill " I i\ pe of equipment is made only in single opei units. Willi this type of equipment the low voltage distribution system may he elimi- nated, riie mol • : fed directh from the -Imp line? Com partitive Costs The question again resolves itself hum 01 the comparative cost of the two types of equip- ment, llourh co system can he readily figured. hor this ] ci mdii \ . iltage aetuall Cost < if cun cut per K. \\ . hi iir . . I 'nder these condit ider fii • if electi i by the i >ld resistant i of welding. Second the cost n 75 volt constant voltage motor generator. Hiird the cost with a variable voltage In using .1 ;enei at< >r set, it is neci -nine a J? per cent loss owing to power required to run the machine. We then havi following figures: CUITI til Vv, ] 50 Amp 1 ; ii Anip Kilowatt llOUl S pel ! Cost .it I'l i \M I I |i I 111 HI of welding 7 ; cents 28 cents \ 'i i uli re- Motoi gi neratoi - \ lilt- I Motoi ' Var- .V II- fi gu res a n on ■imislv. As a matter of fact it would not he usi half of the time I the same r< pet ation fai tor. Ease of Operation I he difference in operation oi the two tvpes of machine is equalh a- important as the cost, characteristic of the variable voltage welder is the ease with which the arc is controlled thus preventing the frequent make and break of the arc which results in imperfect work. \11 complicated switches and solenoids are eliminated on this type of apparatus and one simple knife switch, together with a small rheo- stat handle for regulating the current, is all that is necessary. Importance of Equipment I lu- selection of the right equipment for arc welding work is of the utmost importance. The consideration given to the subject b\ the two authorities quoted above indicates this. Both the results obtained and the cost of op- eration depend entirely upon the type of equip- ment selected. 52 LINCOLN ARC WELDERS i»i "in" mi mi ii ■ iiiiii mini i ii i ■ ii tiiiimiiiiiiiiiiiimiiimit iiiiii n Minimum liiiimiiiiiiiiniii in i I ig I 19. Line nating ( hi rent i Weld, i foi In Arc Welde Suppl} . This i Ik a\ \ stei 1 f. for Alter- a 400 \ui indn work 1 1 I h \ Control Panel Lincoln Arc Welders The Lincoln Electric Co. have been engaged in the manufacture of arc welding apparatus ever since its first successful application in this country. Welders manufactured by this Com- pany, at that time, are still in daily use in spite of the improvements effected by the long study of the subject. Lincoln engineers are not only thoroughly familiar with the proper design and construction of welding equipment, but what is more impor- tant to the prospective user, they are skilled in the application of the work in every field where it has been used. Variable Voltage Equipment The Lincoln Arc Welder is a variable voltage equipment — the type referred to by the Railway Electrical Engineers Association in their report, part of which is reproduced on page 51. This welder will do welding work at lower cost than any other method or process. This assertion The Lincoln Electric Co. are ready to pmve by direct comparative test on any class of work. Simple Examination of the illustration itself is suffi- cient to convince any prospective buyer of the simplicity of Lincoln equipment. There is an entire absence of the complicated clapper switches, solenoids, circuit breakers and other devices, which add to the cost and which are bound to require considerable expert attention. Reliable The reliability of Lincoln equipment is di- rectly due to its simple construction and to the high grade materials used. S3 ■ ■ Him in .i mini' in n : mini i . : m n i X LINCOLN ARC WELDERS ■ nun mum mi i i Miinii mil linn i mmii n li miiiuiiililllllim Ill ■ Su ppl y fi; I li 8 Fig. 121. Lincoln Arc Weldei 1""' Vlti i nal Cm rent Supplj it j i ■ Individual I nits The standard Lincoln Welder is intended to supply current for one operator only. The ad- vantages of this plan are obvious. The user of arc welding can in this way begin with the small- est possible initial investment and can add to it whenever he requires and in any amount to suit his needs. The investment is always propor- tional to the aim mnt of work done. Another advantage of this arrangement is that it allows each operator to be independent of the others and to use current only when he is engaged in actual welding work. In case of trouble with the welding plant, only one man would be affected. Adjustable for Heavy Work In most cases, the single unit is amply large for any work that occurs. In large steel foun- dries or railroad simps, where an occasional large job of carbon electrode welding is necessary. two or more Lincoln Welders can be connected in parallel to do the work, furnishing ample power for any welding purpose whatever. This connection can be made in five minutes' time by any welding operator and the plants can be separated again with even le-.s work. " liM '^?s* Stabiliz C .mi il i icne rato i The Lincoln Arc Welder as illustrated above is adapted for use everywhere, where electric cur- rent supply is available. An exception might be made of the railroad shop and street railway service for which special types of electric welder have been designed. This Welder consists of four simple units: 1. — A Standard Lincoln Motor arranged to be driven by the regular shop current supply. Fig. 122. Lincoln Arc Wilder, Belt Driven foi usi where no electric power is available. 54 LINCOLN ARC VVKLDFRS Arc Welder direct - gasoline engine. 2. — A Variable Voltage Generator delivering current of the proper kind for welding purposes. 3. — A Control Panel mounting simple knife switches and connections together with a wheel switch for regulating current and a small am- meter and volt meter for measuring same. 4. — The Lincoln Arc Stabilizer. This is practically an electro magnet which acts as a reservoir in which power accumulates exactly as it would in a reservoir on a water line. Whenever any extraordinary demand for power is made, the stabilizer supplies the extra power, without disturbance of the line. Two types of Lincoln Arc Welders, one for direct and the other for alternating current sup- ply mains, are shown in Figs. 120 and 121. Arc welding can be also used where electric- current supply is not available. In this case, the motor is not supplied and the generator is belted or direct connected to a gasoline engine, steam turbine or line shaft. This equipment can be supplied with a horizontal panel switch which makes it convenient for mounting on auto truck. (See Figs. 122 and 123.) This type of arc welding set is intended for use in places where neither mechanical nor elec- trical means are available for driving the welding generator. It consists of the generator of a standard Lin- coln Arc Welder direct coupled to a gasoline en- gine designed especially for driving electrical ma- chinery. It is equipped with control board and stabil- izer, the entire apparatus being mounted on a light but substantial lied plate which may be readily placed upon a flat railroad freight car, an automobile truck, a ship or wherever may be most convenient for the work in hand. Numerous uses for this type of arc welding machine readily suggest themselves, among them are shipyard and boiler work, the welding of pipe-lines in oil districts, steam railroad repairs, etc. 55 In .1 ■ . i ■ iin iiiiiiiii ■ ■ ii r LINCOLN ARC WELDERS i i i ' i i miimiinn I ' Lincoln Arc Welder for Railroad Shops This equipment is the same m all respects a^ the standard welding outfits described in page 54. For convenience in railroad shop operation, however, it is mounted on especially designed trucks which permit it to be moved readily about the shop Special . idvantages of Lincoln Welders This outfit is intended to take care of one ator and can be placed at any point in the shop where the regular electric wiring is installed. The Lincoln Welder can be plugged in on any power socket anywhere where a five horse-power motor will operate, [n other words there need be no special provision for the welding outfit and no special wiring and re arrangement ol the shop. Other types of welder are designed to take care of several operators from one machine. The disadvantage of this system is that it requires a low tension distributing system carried from the welding machine to any station where weld- ing is to be done. Such a system requires large copper wire and i- a eery expensive installation tn make, and it does not offer any advantage w hatever. The Lincoln Arc Welder can always be taken to the place where the locomotive is standing and welding work can go on at the same time with other repairs. With other systems, the loco- motives all have to be brought to special stations for welding work or a low tension wiring system lias to be carried over the entire shop. Instead of moving the heavy locomotive about, the Lincoln Arc Welder, on its light truck can he taken anywhere even for a few minutes work. This is an important advantage of the Lincoln n i ie of equipment. With the Lincoln Arc Welder any number of operators desired can work on the same engine without interference, something which should not be overlooked. Should occasion arise to use carbon arc weld- ing, needing a welder of greater capacity, this can be provided by connecting two or three indi- vidual units as described on page 54. Occasion for this will practically never arise in the railroad shop. .. :i;.iiiii;iinii.i.:,i. WELDERS FOR STREET RAILROAD USE i Portable Lincoln \rc Welder for Streel Kai way use. Lincoln Arc Welder for Street Railroads This Welder has a motor designed to be oper ated by the power direct from the trolley line and this motor in turn drives the generator, de- livering the electric current at the proper voltage for welding. The type of welder formerly used for this work, consisted simply of a cast iron resistance. The current was taken directly from the trolley line, the resistance being used to reduce it to the proper voltage for welding purposes. This method was neither economical nor safe ami is rapidly being replaced by the Lincoln special equipment. Economy The Lincoln Arc Welder for street railway work takes only from 6 to 8 kilowatts from the trolley line and' gives 150 to 200 amperes weld- ing current. The resistance welder takes from 80 to 100 kilowatts to do the same work. With the resistance welder the large amount of power taken from the line frequently results in burning of the trolley wire, in such a way that it either breaks or is weakened so that it breaks down in the first heavy storm. Safety With the resistance type of welder, the elec- trode in the operators hand carries the full volt- age of the trolley line. The slightest carelessness in handling may result in his getting the full current through his body, which would almost certainly result in death. Many serious accidents of this kind have occurred. Rail is Always Hot With the Lincoln Arc Welder, the rail is made the positive electrode of the system and the elec- trode which the operator holds is the negative. This insures that the rail will always be hot at the point where welding is done. The melted metal from the electrode will adhere to it readily. In the resistance type of welder, the rail is the negative electrode and there is frequently trouble in getting the metal to adhere properly. Shop Welding The Lincoln Arc Welder above is especially adapted for shop repairs on broken or worn parts, as it is exactly the same type of machine as is used for that purpose in other plants. Power For Grinder The motor on the Lincoln Welder is provided when desired, with an extended shaft to which a portable hand grinder can be connected by means of a flexible shaft. This provides motor drive for the grinder, when the operator is not welding:. 57 nun :i mi ELECTRIC ARC WELDING The following sections '>n Design of Welded Joints and "Ten Lessons in Electric Welding" are offered a< an aid in acquiring the knowledge and skill necessary to make successful applica- tions of the electric arc welding process. It would be impossible to write an) text book on this sub- ject which would include all of the things which n is necessary fi ir an i gineer t( i know in order to always make a successful ap plication of the process. The application of the process is a new science that has been explored in only a few of the directions in which it will eventually prove successful The arl of welding with an electric are is like any other mechanical art which may profitably be studied, but which only experience can perfect. The manual training idea has been foil out in the lessons on welding to a certain extent so that the operator may learn to weld by weld- ing according to definite instructions. The op- erator should follow the instructions to the best of his ability. It has been found by actual ex perience that if the operator merely "plays" with (he apparatus ami follows no definite plan dur- ing bis training period, little is accomplished so far as the learning of the fundamental princi pies involved is concerned. The operator must trv to make the samples required in the ievin- as g< " id as possible l'\ so doing, he will acquire a knowledge of the fundamental principles in- volved in any welding application. It is impor taut that tin- operator cut the welds as required in tbi' lessens and criticise his own workmanship and allow other competent workmen to criticise it for him. so that in the end he will know beyond question whether or not he is making t weld while he is i iperating the arc. It will be found much cheaper in the long run to have the operator spend enough time to be- come thoroughly familiar with the fundamental principles of welding during bis training period than to put him on commercial work and allow him to get his experience there. It should be thoroughly understood that the operator will not he an expert by any means when he has com pleted the samples required in these lessons. It requires a large amount of experience to become an expert operator and owing to the rapidity with which the process and apparatus are being developed, it is impossible for one man to know all there is to be known about electric arc weld- ing. The operator should continually study ways of improving his practice and if possible study the practice which has been developed by other experienced operators. Design of Welded Joints From an engineering point of view, even metallic joint whether it he riveted, bolted or welded, is designed to withstand a perfectly definite kind and amount of stress. \ n example of this is the longitudinal seam in the shell of a horizontal tire tube riveted boiler. This joint is designed for tension and steam tightness only and will not stand even a small amount of trans- verse bending stress without failure by leaking. If a joint performs the function for which it was designed and no more, its designer has ful- filled his responsibilities and it is a good joint economically. Regardless of how the joint is made the design of joint which costs the least to make and which at the same time performs the functions required of it. with a reasonable factor of safety, is the perfect joint. The limitations ,,f the several kinds of me- chanical and welded joints should be thoroughly undersl 1 A bolted joint is expensive, is difficult to make steam or water pressure tight, but has the distinguishing advantage that it can be disas- sembled without destruction. Bolted joints which are as strong as the pieces bolted together are usually impracticable, owing to their bulk. Riveted joints are less expensive to make than bolted joints but cannot be disassembled without destruction to the rivets. A riveted joint, sub- ject to bending stress sufficient to produce ap- preciable deformation, will not remain steam or water pressure tight. Riveted joints can never lie made as strong as the original sections be- 58 I MINI 1 1- fill III .11 .11 III Ill III ■ ii in .iiiii' .' ' ■ ' .mm: mi. . DESIGN OF WELDED JOINTS I : MM -HI- .Mill II II MM .ii MII'IIM NINNl ■ Hill i cause of the metal punched out to form the rivet holes. There is no elasticity in either riveted, holted or autogenously welded joints which must re- main steam or water pressure tight. Excess material is required in the jointed sections of bolted or riveted joints, owing to the weakness of the joints. Autogenously welded joints have as a limit of tensile strength the tensile strength of cast metal of a composition identical to that of the joined pieces. The limit of the allowable bending stress is also set by the properties of cast metal of the same composition as that of the joined pieces. The reason for this limitation is that on the margin of an autogenous weld adjacent to the pieces joined, the metal of the pieces was heated and cooled without change of composition. Whatever properties the original metal had, due to heat or mechanical treatment, are removed by this action, which invariably occurs in an auto- genous welding process. Regardless of what physical properties of the metal used to form the joint may be, the strength or ability to resist bending of the joint, as a whole, cannot exceed the corresponding properties of this metal in the margin of the weld. Thus assuming that an autogenous weld be made in boiler plate, having a tensile strength of 62,000 lbs. Assume that nickel steel, having a tensile strength of 85,000 lbs. be used to build up the joint. No advantage was gained by the excess 23,000 lbs. tensile strength of the nickel steel of the joint since the joint will fail at a point close to 62,000 lbs. If appreciable bending stress be applied to the joint it will fail in the margin referred to above. The elastic limit of the built-in metal is the same as its ultimate strength for all practical pur- poses but the ultimate strength is above the elas- tic limit of the joined sections in commercial structures. In spite (if the limitations of the autogenously welded joint referred to above it is possible and practicable to build up a joint in commercial steel which will successfully resist any stress which will be encountered in commercial work. 1 he advantage lies in the built up structure and the inherent steam and water pressure tightness oi a welded joint. The fundamental factor in the strength of a welded joint is the strength of the material added by the welding process. This factor de- pends upon the nature of the stress applied. The metal added by the welding process, when sub- ject to tension, can be relied on in commercial practice to give a tensile strength of 45,000 lbs. per square inch. This is an average condition; assuming that the metal added was mild steel and that the operation was properly done, the metal will have approximately the same strength in compression as in tension. When a torsional stress is applied to a welded joint the resultant stress is produced by a combination of bending, tension and compression, as well as shear. The resistance of the metal to shear may be figured at 8/10 its resistance to tensile stress. The metal added by the welding process, with the present development in the art of welding, will stand very little bending stress. An auto- genously welded joint made by the electric arc process must be made stiffer than the adjacent sections in order that the 1 lending stress shall not come in the joint. An electric weld, when properly made, will Lie steam and water pressure tight so lens as bending of members of the structure dues not produce failure of the welded joint. Little is known at the present time in regard to the resistance of an electrically welded joint to dynamic stress, but there is reason to believe that the resistance to this kind of stress is low. However, owing to the fact that in most struc- tures there is an opportunity for the members of the structure to flex and reduce the strain upon the weld, this inherent weakness of the welded joint docs nut interfere seriously with its usefulness. A few tests have been made of high frequency alternating stresses and it has been found that using the ordinary wire electrode the welded joint fails at a comparatively small number of 59 iiiiini: i! nil ..n. Ill i!l ■ ! ' .1 Hill ' .1- ELECTRIC ARC WELDING Fig. 132 ii alternations. This is of little importance in most structures since high frequency alternating stress is not often encountered. Stresses in Joints The drawings reproduced on pages 60, 61, 62 show several typical metallic joints and the stresses which are brought to bear on them. The method of welding is indicated. In Figure 126 it will be noted that a re-enforc- ing plate is welded to the joint to make the joint sufficiently stiff to threw the bending outside the weld. Figure 127 shows a joint in straight tension. Since ii" transverse stress occurs the heavy re- enforcing of Figure 126 is not required. Just enough re-enforcing is given the joint to make up for the deficient in tensile strength, of the metal of the weld. Figure 128 show another method of building up a joint that is in straight tension. It should be noted that in both Figure 127 and Figure 128 as much re-enforcing is placed on one side ol a center line thru the plates as is placed on the i ither. 129 shows the original form of lap joint such as is used in riveting. The method shown for welding this joint is the only method which can be used. It cannot be recommended because such a joint, when in straight tension, tends to bring the center line of the plate into coincidence with the center line of the stress. In so doing an vsive stress is placed on the welded material. Figure 130 shows the construction iwd in cer- tain tanks where a flanged head is backed into a cylindrical shell. The principal stress to •<■,] by the welded joint is that tending to push the head out of the shell. The .velding process indicated in the figure will successfully do this. Owing to the friction between the weld and the shell, the outer weld would be sufficient to hold the weld in place for ordinary pressure. 60 ■ : ■ INI" ■ IIMM ■' IIHIIM lllllillllimillllimlliiiliiiEiillllinliiliiiillll llllllllllllllllllllllllllllllllll DESIGN OF WELDED JOINTS III Illlllllllllllllillll run: llllllllllllllllllllllllll I'll Mill' Illl Fig. 133 For higher pressures the inside weld should be made in addition. Figures 131 and 132 show another method of welding a flanged head to the cylindrical shell. These methods are preferable t<> the method in- dicated in Figure 130. Figure 132 represents the reci immended practice. Figure 133 shows a plate and angle structure which might he used in ship construction. The particular feature to notice in the welding prac- tice indicated, is that the vertical plates do not reach, the entire distance between the horizontal plates. This is merely a method of eliminating difficulties in welding the plates to the angle. Figures 134A, 1341'.. 134C and 1341* show a method of welding a crack in a locomotive frame. Hie object in this practice is to reduce the amount of metal deposited by the electric welding process. The metal of the plate lami- nated structure is of better quality than the weld- ing process will deposit. And also a large amount of time is saved by this practice. The plates should lie \s or > _. inch in thickness. /;; making any weld, the smallest amount of metal should he added by the welding process which is possible to add with perfect fin Fig. 134A Fig. 1341? I.UD i 1 niiimiiiiiiiiiiiiiinmimim ■ nun n r. hi i mi n .in mi in i ii ■ n mi ■ 'v i [i.iiimilliiiii ELECTRIC ARC WELDING c o o - i II iiiiiiiii I nil ' iiiili : ;: i mi mi: mi Figure 135 shows a method of welding a head into a cylindrical pipe. The thickness of the head should lie approximately twice the thick- ness of the wall of the pipe. The extra thickness plate is to gain sufficient stiffness in the head to make the stress on the welded material purely shear. The pressure from the inside tends to make the head assume a hemispherical shape. This would place a bending stress on die welded material if the head were thin enough to give at the proper pressure Figure 136 shows a method of welding a crack- in a tire In >x sheet. The thin plate backing in- troduced at the weld makes the operation very much easier for the operator and produces the re-enforcing of the water side of the tire box sheet w hich is most desirable. Data for Calculations i cu. inch of steel weighs .28 pounds. 3.57 cu. inch of steel weighs i pound. One pound of 5 32 inch electrode may he de- posited in 27 minutes with 130 amp., 16 volts. 25 to 30'' of all electrode is wasted in "ends." 15 ft. of 5 32 inch electrode weigh one pound. One K. \Y. II. of electric power will produce 3413 B. T. U. of heat. On straight-awav welding the ordinary operator with helper will actually weld 75'' of the time. '.j WELDER PARTS nun mm: i i 'mm I i i i mil' I ' II iMIIIh miiliil mm mm nihil i m M miiiiiniiiiiiil 1,1 No. 1. 8. 9. in 1 1. 12. 13. 14. Xo. I IN. 10. 20. Dust Cap. Inner I lust Cap, i lutei End S.K.F. Bearing Insulating Washer Tube, Brush 1 [older Commutator Bar, M End Bra. k. 1 Brush Holder, Motor End Shaft Commutator ' ap Shrink Collar Armature Coils Eye Bolt Statpr Lamination Xo. Frame Rivet Tubes Pole Coils, Motor End Blower Field Coils, General. u End DIRECT CURRENT SUPPLY N. 19 Armature Lamination Frame Bolt End Plate Mica Ring 29. 31.' 3 2. 33. 34. Commutator Bar, Welder End Brush Holder, Welder End Clamping Washer Rocker Felt Lock Nut Spring Dust Cap, Generator End Lock Nut Spring. Brush Holder Finger Stud Finger Brush Blower Support Brush I ing< : Shaft Commutati i! Cap Mica Ring Felt S K F Bearing Lock Xut I lust Cap, I lut. '. Lock Xut Spring I >ust ( ap, Inn. r i lamping Washer Insulating Wash, i Rocker Finish Holdei Commutator Rracket, Weld. End Tlate. We Ai mature Ci Field Coils FIG. End End No. 21. 23. 24. .In. 31. 138. ALTERNATING CURRENT SUPPLY No 33. End 34. S5. Shrink Collai Frame Bolt, \\ - Id I y, Bolt Frame Rivet Welder End Blower End Plate, M. Si. nor Coils I- 1. mi, Bolt, Frame Rit . I End Rotor Rods Rotor End Ri King Tub. Mot. Tube End I' Mnl 16 38. S9 40 41. 42 4.!. 44. Shrink Collar, Motor End Bracket. Motor End ting Ring, Excite] Grease Cup Exciter Frame Poles Field Coils Armature Ci iils I Mi, a Ring Exciter Commutator E ■ ■ itei Brush Holder Exciter Insulating Washei - Exciter Tube, Brush Holdei 56 57. el. 1.4, Clamping Washer Bracket Exciter End Rocker Exciter End Dust Cap S.K.F. Be.iiiug Exciter End Dust in' Ex. iter End Insula! ion Exc iter Shaft Terminal Block I ■■ ■ it. I End. Pig I ol Clip 1 lust . .us Motni End Connecting I ' i i i l.,.ck Washer. Motor End S K F Bearing lin^t Cap, Inner, Motor End Felt Spring. Brush Holder Connectoi - Stud, Finger Connecting Ring Blower Suppon TEX LESSONS IN ARC WELDING . inn mum niiiiimimimiiiiiiit : mm ■■ iiiiiimiiiiimmiimmmiiiimimm n miimmimm in iiiimii ' ii ■ ii c 200 ! ','. , 1,1. (A) I- lectrodi II i i I ■ ? mil I'it-ld 1 1*1 K , Kin (S) Stal l \\ 1 \\ I LESSON I 'The .Ire Welding Machine It is with the the arc fi >i « reproduced showing the names of parts oi the welder set. It is not nei the names of the detail parts except that he should understand tin !• » atii m and f the es parts as folli i\vs : I >nish, Brushln ilder, i Exciter Commutator. Field Coils, Motor, I- ( Ireas e i 'up, Ball 1 leai ing s, Shal < . ! '■ Poll I See [, , . \ny elect riciai thesi part; is inl- aid, to do so. The arc welding electrical!;, separati from the motm which drives n \ welding generatoi maj be driven b_\ eithei altei n >r or hy a I - asoline engine. Tin source of power to drivi tin welding generator liing whatever to do with tin havior of the weldi provided it is furnished in sufficient quantity and turns the ■ ing generatoi al the propel speed. Hie motor end of the welding machine is like am other motor of the same rating. Tlu- principle of operation of the welding generator i~ very simple to the man who has had some experi- ,,\ it ii direct current generators but is difficult else to understand For the benefit oi man who has had electrical experience, ii is sufficient , that the welding generator is merely a spe< II ateh excited generator with a differen- tia] compound winding and that an inductivt ballast is used in the arc circuit Ii is desirable for the operator to understand the principle ol operation of the welding -, t as well as tin electrician understands it but it is not itely necessan The accompanying cut shows the ill ampere characteristic and the wiring diagram ol , elding g< nei at >r. Iding outfit should alwaj s be install* d electrician. All cables are labeled and the direction of rked so that m i difficult} w ill : " ■ enced in installing the outfit without the use of a wir- ing diagram. The Stabilize! is made up of coils of wire a laminated steel core and it- purpose is to make the .ml r.iM t, , ,pei \u electrician should explain to the operator the method .if starting the < mtfil The control panel contains the apparatus with which the operator controls the behavior of the welding gen- erator, adjusting it to give the proper amount of heat for welding. Two cuts are shown showing two types 64 Illllll TEN LESSONS IN ARC WELDING .' !:. ill, I Hull ii ' llll ' • •I control panel used. The portable type accomplishes the same thing as the stationary type. The voltmeter and ammeter are left off the portable type on account "f the fact that they arc too fragile to stand the rough use to which lhej would lie subjected on portable equipment. Fig. 142 shows the ordinary equipment used by tin operator, and welding table. Referring to Fig. 154. the proper clothing for an operator is shown, — it consists of black cap. unionalls, cotton gauntlet gloves, split leather apron. Adjustment of Machine 1. I (pen main switch and control switch on panel. 2. Start welding set. 3. Turn rheostat as far as it will go to the left. 4. Close control switch into position marked 100. (In this position the current in the arc will be approxi- mately 100 amperes, i 5. Put a piece of .-:/' welding wire in the metal elec- tn ide holder. i). Place a piece of boiler plate scrap or. welding table ti i practice on. 7. Close main switch on panel. 8. Sit down on stool in front of welding table. Take band shield in left hand, metal electrode holder in right hand. With shield held in front of face touch boiler plate with end of welding wire. The result will be a spark and the welding wire will stick to the boiler plate. Let go of electrode holder and open main switch Oil panel. 9 With a new piece of welding wire and face shield in front of face, scratch welding wire sidewisi on boiler plate to get spark, then draw welding wire about an eighth of an inch away from the plate. Hold weld ing wire vertical to boiler plate, otherwise arc will be difficult to start. Repeat the above operatii n until an arc can be main- tained as long as desirable. The beginner should burn from 75 to IOC pieces of welding wire at this practice, observing through the shield what happens in the arc. \s the operator becomes mure skillful he should try to held a shorter arc. The proper length is about an eighth of an inch. The operator should spend about 15 hours on this kind of practice. The amount of current or ampere- required for welding depends prin- cipally upon the sixe welding wire used. Three-six- teenths inch welding wire requires about 150 amperes. (Turn rheostat as far to left as it will go and close control switch into 150 ampere position.) For points in between ltxi and 150 amperes turn rheostat to right with control switch in 150 ampere position. Aninii'tc t'ig I tO, Statiunan Panel Fist. 142. Operator's To 65 L TEN LESSONS IN ARC WELDING ii inn inn in nun in :■ .;i ■ II! ■ iiiiiiiiiiiiii il Ulim limiiil mil in Miimi ii LESSON II Starting the Arc This exercise deals with the proper method of starting and stopping an electric arc. The beginner usually draw- an arc and starts to weld at whatever poinl the arc happens to starl operating properly. In other words, the beginner usually wilds where it is possible for him i" weld rather than welding in a pre- determined place The purpose of tin- exercise is to give the operator sufficient control of the arc t" en able him to weld at any place be may decide 1. Place a piece of scrap hoiler plate on the welding table. With a piece of soap stone marls a line the plate. Now weld a bead as nearly as possibl. to the right of this line. Make the bead as stl as possible. Repeal this operation until a perl gilt l'e. id * " from the pri an be laid down. 2. In tlii- exercise the nperatoi should print bis initials on a piece id scrap boiler plate and weld a bead i >\ er the lines I [a\ ing pi initials in this manner lake annthei piece ol boiler plate and make the initials the san iz< with out previously printing them with soap ston<\ This ild be t . peated until tin i can reproduce bis initials without following the lines. The purpose of tins cxi -or to control an air and had it in a predetermined dip It also invob i 5 [be ii aining of th see where be is leading the arc. I In- will be di at firs! owing to tli,- fact that the operator ran see nothing but the are itself tin ^lass i ator should n and chisel and i ■ of several beads w hii It will lie found that the beginning of the I- usually not -| ],;, is dn.' to the t'.i, i thai I -: .it. : |"hi . ipei ition of weld is m.i. the head. A- The end of the head is quite a- important beginning. In referring to beads which the beginner ha- previously made it will he found tl sider- ahle crater has been left al the point at which th. was broken. The objection to this crater is that it is -tat! welding at this point when it is de- le t.i Continue the head er may be filled : i the are i- finally bi i >ki n by mi wding down the are until the desired amount of metal is added, and breaking the are suddenly by pulling the harply to one side. The operator should practice this operation until be is able to finish a bead leaving a crater of not to exceed Pc of an inch in diameter. 5. Thi .loo,, outlined in the preceding four aphs should occupy at least tin hours of tin- nine The following sample is to be made a- to the record of the operator's ability to start and sti ip an arc pn iperly : Material re. pined: one 12"xl2"xj4" piece of boiler plate; three si es ol electrode are required /<;". ■■'2", \o marking ip stone is to he done 011 the plate. Referring to the photograph reproduced here with, the first three rows of heads are to be made wire using approximately 150 amperes. Each head should be one inch long. ITie beads should be quarters of an inch apart. They should be straight and parallel, Each head should have a per- i.ii weld at it- start and a very small crater at the finish. The next five head- are to he made using -nd the next two. electrode with about 125 and 100 amperi pectively. < hie side ol lit. should he completely welded in accordance the above instructions. The plate should then he turned over and 1 leraticn repeated am! pei on the oilier side of 'he plate. Fig. 143 mm run: mi m : \ inn nun i if i in' n .1 .:.. mm m mill 1 nllih mil i mil TEN LESSONS IN ARC WELDINCI iiiinmiiiiimiimiiiiimiiii Illlllll ■ ■ I! 1 LESSON III Building Up Operation The purpose of this exercise is to show the operator the proper method of building up several layers of welded material. It is assumed that in Lesson II the operator has learned to deposit metal from the welding wire on a piece of boiler plate and have it entirely welded along the line of fusion. Until the operations outlined in Lesson II are completely mastered, it is useless to proceed with the exercise of building-up operations. Material required: One 10".\12"\ ' .." piece of boiler plate. One size of electrode, h of an inch, is re- quired. The current should be about 125 amperes. Referring to the photograph reproduced herewith. three pads are to he built up on the face of the plate. These pads are to be 6" long. 2" wide. 1" high. The first pad starting from the left hand side of the plate is to be built up without any particular design or pat- tern, and without brushing or cleaning of the oxide- covered surfaces. The next pad is to be built up following the definite pattern. First, brush the spot on which the second pad is to be built very thoroughly with a wire brush. Second, build up a single layer of metal the width of the pad using a series of beads laid along the 6" dimension, always starting at one end and finishing at the other end. Having deposited the first laser, the oxide covered surfaces must be brushed thoroughly with a wire brush. Each layer should be brushed at least three minutes. The second layer of the pad should be built up so that the beads run at right angles to the beads of the first layer, i. c, the heads are parallel to the 2" dimension of the pad. This practice is com- monly called "lacing." The second layer to be as thoroughly brushed as is required upon finishing the first layer. Each succeeding layer should be thoroughly brushed. The third pad is to be built up in exactly the same manner as the second pad with the exception that in place of brushing the work with the wire brush onlj between each layer, the oxide must be entirely cleaned off by the use of the hammer and chisel. It will be noted that the oxide may be removed bj comparatively light blows on the chisel. It is not necessary to cut away am metal to knock the oxide from the top of the layer with a chisel. The wire brush may be used to brush the oxide off the metal after it has been cut away with a chisel. The operator has now completed three pads. The first pad illustrates how- welding should not be done. The second pad illustrates a fairly satisfactory practice. The third pad illustrates the best practice. If possible the operator should have this sample sawed diagonally through the three pads. It should then be set up on a grinding machine and a fine surface ground on the cut section of the pads. This can be done in a tool room The ground surface should then he painted with diluted sulphuric acid or tincture of iodine. It will then be easy to compare the quality of the metal in the three pads. The operator should also observe carefully the line of fusion between the pads and the original plate. This fusion must be perfect if the weld is of any value. The photograph reproduced herewith illustrates the appearance of a good line of fusion. Fig. U4 Fig n 67 iii. i<- ii i i i.iiiiiiiiiiimiiiiitiinmi. TEN LESSONS IN ARC WELDING LESSON IV Plate Welding lln- exercise is one oi the rtmsl important of the scries Inf. him- the welding of plate is tin most frequent application "t the electric arc welding process Phe welds which must he made in le ot plate, sue h .1 - tanks, ire in it alw a\ the operator must K irn to weld not onh in the hori . iin.il posh ion bul ei tical and positions. Three samples are to be made as the n of the operator's abilih to weld in the horizontal posi nd the vertical and straight o > il required Six II plate hex eled 45 di i me 12" 125 t" 150 amp i sin mid spend appi - iximati I In mi- in ptili mi i i.i t \ prai i ice. Si \ eral neci boiler plate should be beveled and sin >\\ n in the .ii ' i impam it lid then be set up vei ticallj and w i ldi ttom and weldit hould i, own r in arrivin best ■ . make li w eld in this position, different methods and observing the following p hits Does the weld extend completelj from the inm the < uii-i edges o| tin plate Doi i i oi the ■i e> pan 'ii I 1 affect tin characti i ot the weld ? Does the exp n and 1 1 inti ai tion i aused by I produce wai ping oi bin kling \ i tet H satisfied himself on these points two pi crap boiler plate should be bevi Ii .1 and pi. i i dtion ,,,],■ . peratoi ,i trj to weld them together in this position. « elding from the un I lie i 'pei at .in iii. pieces approximated} one sixteenth ot an fi it this exi .i !-•' I of weldii nsiderable amount of practio to masti i It will be found that the operation « ill I" some" Ii: t i' i-H r ii 150 amperes i trodi rsl In welding be' i Ii -1 ratot should remember that the welding wire >r eleel should be held as nearh perpendiculai welded as possible, and that nly he rt one .\ I,,,,- an a distinct hissing sound. It is impo I weld with such an arc A arc has a rapid lire metallii click which ma\ guished. The operat' i sh mid maintain a 1 classes of welding. Where possible an trii i.in should be asked to connect a low reading volt meter across the arc so thai tin eoltagi ma In read while the operator is welding. The coll metei should read from 15 to 18 volts while the are is in open The greatest amount of beat is obtained on the work whin the electrode holde is negative. This is the proper connection for both metal and carbon electrode work. While the arc is in operation there will be a circular pot oi molten metal upon the work. The operator should concentrate bis attention upon the sun- of this molten spot i i metal which is in the direction of motion of the electrode This may also be described a- the forward edge of the circular spot. Tin should be directed on this point, since it is at this poinl that tin greatest amount of heat is desirable. // in/ elei trii weld only win / from the welding iWn is Tacked l-'iy. 147. Horizontal, Vertical and Overhead S 68 "'in"!- i ; ' ii i i 11 linn minim mi inn ■ ' ...i. iiWHi : ■ - "' . m mil TEN LESSONS IN ARC WELDING iilllllilllllllllllllllililiill Miiiimiiimiilmiitiitiiiiiii mil iiihiiiiiiihiiiiiuii iiiiiiin [nun throicn into molten metal on the piece being welded. If the globule of metal drops on metal which is not molten it may stick but it will not be welded. The operator should study the action of the metal in the heat of the arc very carefully. The operator should begin to realize at this point that merely holding an arc is not necessarily welding but that the art of weld- ing is ninety per cent brain work and ten per cent manual labor. 2. Place the horizontal sample of welding in posi- tion on the welding table. Put a ,n the edges. The operator should then take hammer and chisel and clean the oxide from the surface of the welded metal very thoroughly. The second layer may now he welded into the bevel start- ing at one end and finishing at the other end. This layer should lie thin and should not extend higher than the upper surface of the plates. Chip oxide from surface of welded material and put the third and fin- ishing layer on the weld. The third layer should ex- tend about o. of an inch beyond the edge of the bevel on each plate, and ' s " above the upper plate surfaces The plate should now he turned over and a re-enforce ment of equal width anil thickness put on the other side. The purpose of this practice is to make the sec- tion of the weld equal on both sides of a center line through the metal of the plate. If the weld were re- enforced on one side and not on the other the stress would be concentrated on the side which was not re-en- forced when the weld is put in tension 3. The two plates should be tacked together as in first exercise but in this case the beveled edges are to be set vertical, as shown in Fig. 148. The weld is to he made according to a definite pattern start- ing at the bottom and finishing at the top. This pattern is triangular. The operator should start on the right hand plate at a point of about ;';■. of an inch to tht right of the beveled edge, holding the welding wire as nearly perpendicular as possihle to the surface being welded. The movement should be along the beveled edge of the right hand plate toward the farther edge, then along the beveled edge of the left hand plate toward the nearer edge, extending to a point 1% of an inch to the left of the bevel on the left hand plate, then across to the starting point. Five- thirty-second electrode with about 125 amperes is to he used. The operator must pay particular attention to see that the farther edges of the plates are securely welded together \ considerable amount of metal should he run through the edges to make this certain. 4. For the sample of overhead welding, the plates may he tacked together as shown previousl} except that the opening should be approximately ', of an inch. The two plates are to he welded in the overhead position after they have been tacked. Several pieces oi plate ' s of an inch thick, l'j" wide and 6" long are to be cut, and a ■.'_■" electrode should he stuck on ex- treme edge of one of the corners so that the electrode stands out perpendicular to the piece. The purpose oi the electrode is to serve as a handle. This A" piece is to he pushed through quarter inch opening between the plates front the under side and to he brought into position so that it wall form a backing for '.he weld. Fig. 147 shows the position of this plate. After the plate has been placed in position it may be tacked. The Use of this plate makes the overhead welding somewhat easier than welding with- out its use. Si. hi the overhead weld at the center of the job and weld toward one end. A definite pattern should he followed. Start at the lower edge of the right hand plate at a point ,;. of an inch to the right of the bevel. Continue along the beveled edge of the right hand plate up to the backing plate, across the backing plate and down the beveled edge of the left hand plate to a point ; of an inch to the left of the bevel. This will form the first head. Xou start the second bead at the beveled edge of the right hand plate and on top of the first head, and till in. as far as possihle, the opening formed by the beveled edges of the plates. A third head will he required to complete this operation. The operator now litis two surfaces to weld on, the surface formed by the welding ma- terial, which should he approximately vertical, .and the surfaces of the plates to he welded". Idle pattern of the first pad should he followed out from this point on welding at the junction of the previous!} welded material, and the surface- of the plates being welded together so far as tins is possihle. This make; thi weld more a vertical weld than an overhead weld and considerabl} simplifies the operation. The operator should use about 150 amperes to start with, cutting it down to 125 or less a s the [date warms up. Having completed one end of the weld in this manner the other end may be welded in exactly the same way. It will be found that the backing plate will warp and tend to get out of contact with tin- beveled plates. This will not interfere with the welding and will enable the operator to re-enforce the weld 011 the top side, which is verv desirable. 69 . lill'll! Ill llllllllllllllll IIIIIIIIII1IIIIIIIIIIIIIIIIIII mum miiutii i: ii TEX LESSONS IN ARC WELDING LESSOX r Thin Plate Welding This exercise is to give the operator some experience on thin plate welding. The difficulties encountered in thin plate welding are comparatively simple of solution, and the operator is lett to use his own resources I" a considerable extent in making the sample. The great difficulty in welding thin plate arises from tin tendencj of the arc to burn through the thin plate owing to the great intensity of heat. Practically all thin plate is covered with a heavy scale of blue oxide, and it is necessary to get this oxide cleaned off in order to make a good weld. This may be done with hammer and chisel or a sand blast The operator has already found that it is neces ave clean metal in to make a good weld. The quickest and best wa> of getting clean metal is to sandblast the surfaces to be welded. This applies to metal of all thicknesses. The reason blue oxide gives tin operator trouble is that it is a verj | i conductor of electricity, and it is hard to get the arc started on an oxide-covered surface and also that the oxide gets into the metal of the weld Material required: One piece of 24"x30" sheet steel approximately fa ot an inch in thickness i .node with ''II to HKt amperes. 1. The operator should study the drawing i duced i ippi >site i f ig. 151 i and lay out the pieces to be cut mi order to make the sand blast pot shown. This will leave some scrap material around the edges which should lie cut with a hack saw into pieces approximated _'"x4". The operator should practice welding these scrap pieces In laying them down on the welding table and welding a straight seam. One sample should also lie welded with the two pieces perpendicular to each other as shown in accompanying cut. (Fig. 149.) Ap- proximately two hours should be spent on this practice. _'. The op( i ati ii should iv » cut the plates necessary to form the -and blast pot and weld them together. It is suggested that the heads be made smaller than the shell so that the) fit on the inside. They should set hack from tin of the shell about ' ,". ( hie small hole should be burned i at the location of one of the fittings in order to allow tin heated air to escape while the welding is being done. The fitting can he put on the sand Mast pi it at some later tune b) the operator [,-;„ 14 ,, LESSOX II Pressure Jl'cld'inn This exercise is in the nature of a test of the ability of the operator to make a solid homogeneous weld which is properlj and thoroughl) done. A great null) electric welds are subjected to steam or watei pressure and unless they arc properly ni.uk the) will show leaks. and will fail at a point below the pressure for which they were designed It is very important that the op eratoi should know when he is making weld. If he does not know this Ins work is entirely worth- less, He is as i r a workman as the jeweler who must smash an expensive watch in order to find out how it was made \ skillful operator, who has a reasonable degree of judgment and intelligence, knows when he is making a good weld. If he has made a section of a weld which is not good, he should eithei cut that section out and reweld it or inform the man responsible fur the job of the fact that a particular section is faulty. A man who will lie to himself in regard to the quality of his work, will he to the man wdto is responsible for its quality, and is worse than worthless as a skilled operatoi Material required: (hie 18" section of 8" wrought iron pipe or seamless steel tubing, two plate heads to fit mi tin inside of the pipe or tube. These heads should be beveled 45 degrees on the cir- cumference, o puces ,,i 1" black wrought iron pipe 6" long, one puce of m" or 1" pipe according to the size watei pipe used in the shop where the welding is done. This pipe is to be connected to the water system so that the completed sample may be tested under pres- sure. Six holes are to be drilled at intervals of 2" into the 8" pipe to take the six 1" pipes. One hole is to be cut to take the V or 1" pipe. 1. The heads are to he welded into tl i shown in the accompanying cut. (Fig. 150.) The op- erator must be careful to hold a short arc and so far as possible keep the electrode perpendicular to the surface being welded. The surfaces which are to be welded must an and tin oxide must he removed from each layer of metal before the next layer is welded, h> the use of sand blast or hammer and chisel. The 1" pipes are spaced close enough together so that .some diffi- culty will he experienced in making a good weld be- tween pipes. This is done purposel) because it is a difficulty frequently encountered in pi. nine The up erator should mark with chalk the spots where he believes, owing r • ■ the manner in which he welded the sample, that the leaks will occur Weld the ends of the -ix 1" pipes shut. 2. The operator should connect the sample to the Haln system of the shop and test it fur leakage i It is advisable to pour the sample full of water before the connection is made so that it will be entirely tilled with water when under pressure. I If leak- are found the operator should cut out that part of the weld, examini the weld and find if possible the cause ,i the leak. The defective spots should be rew elded and the test ited. 7" m i i mum i J I ; i : c : h 1 1 1 r ■ 1 1 1 1 1 : j mum „ jiiii : minium" iiiiiumilii : mi i i i : i mm TEN LESSONS IN ARC WELDING 'llllimilllHllllMllll ■ ^ 1 1 1 1 1 1 1 1 1 1 ■ c e ■■ 1 1 1 1 ■ .' ■ - ■ i i r . 1 1 1 1 1 ■ :,., ii. mi in nun ' i mum i mil NORSE Z TAPER i NOZZLE % PIPE NIPPLE 6L0NQ ^COUPLIN^ - d Blast Pot Made by Arc Welding. 71 k ■ mill Hi". 1 ■ II Minimi! 'i mi: mm' ! ■ muim ! mi mi mi n - : TEN LESSONS IN ARC WELDING LESSON III Miscellaneous Jobs mi mini "I 1 I nun The object of this exercise is i - give the opcratoi in idi Few "I tin manj different kinds of ap- plications of thi proce \ gn it deal depends upon ieral t's natural n Iness in planning a job One of the difficulties is in knowing how l about i that it maj be di 'tie u ith tin ire highl\ skilled tl is. the easier will be tin waj which he chooses to pel form the operation, This involves careful planning ol irted. Tl ■ ■• who (Mini- a he is going I the job will have little success in doing it. V has in welding depends the usi rain than upon the use I In- - - .In mid In- able to l - ,i i ei tain job and explain tin ■ - dn ilu- job in that particul; Mati i ial i * quii '-'1 ' me i i\ eti d Fig. I ' 153 not conform I ihould take ilei plate, and tacl -ilu of a lap joint. I In liould then I" -it up in the vertii xvi Idi underside of the lap, similar t< Tins operation should be repeated until the Mr • gi H .1 weld and the fillet has a ui uld i ali ulate 1 1 i if fi - - rk he can do. 1 his work is simil eld i mly oni form Hit 14m to 150 amperi The .Mi and e> gooc< - further. si consist* oi welding two pieces oi ■ without beveling. If possible two pieces oi ' thickness boiler plate should be obtained for the exercise. Each edgi which is to be welded should be set in a horizontal position and a bead welded along the center of the plate. The second bead should then be welded in top of the first, remo\ lie oxide from the first before the second is ap plied. When both edge are thus prepared and put her the operator will have what amounts to beveled edges to weld together, but it will be neces- sar\ to weld from both sides in order to complete tin* job. One weld ol this nature should be made and cut I the operator maj examine it to sec that fusion has taken place mi the entire weld. is the one shown in the cut 152 1 and consists ol w elding the caulking riveted joint and welding around the rivet head. The method of welding the caulking edge has plained. In welding around tin rivet head it is advisable to heat the rivet before weld- ead Witl the plate in a \ ertical the caulking edge i . draw an at c "ii the head of the first rivet, allowing the metal from tin- electrode to fall clear of the rivet head. Tins should be continued for about two ninutes or until Fig 152 I ' ■ I Iflllll I -: nn 'in. >' iiiiitiiiniiiiiiiiii .' i [iiiiiiimiiiiiiinii TEN LESSONS IN ARC WELDING 111 Illl Iimiilliiililiiiillilliiilliin llimiiiiiiiiliiilimiiiii: i '" in the rivet is thoroughly heated, then the fillet should be welded around the rivet. The operator should then skip two rivets and repeat the operation on the fourth The idea of skipping rivets is to keep the heat Fig is.; distributed so that contraction in the metal will nol set up shearing stresses in the rivets. By following the above practice a very tight joint will result when the metal of the rivets and plates cools. The result is similar to the result obtained by putting in a hot rivet and peening ii over. When such a rivet cools it con- tracts and pulls the plates tightly together. The op erator may turn the sample over and repeat the opera- tion on the nther side, perfecting it if possible. 5. The exercise of welding an angle iron section is one which illustrates a type of job which is quite com- mon. The angle may he cut from a straight angle section ami the triangular shape cut out with a hack saw. The triangle is cut out so that the angle may- be bent at right angles. The tip of the triangular. however, must he cut square oft in order to allow a right angle to be bent without the edges coming en tirely together. The distance between the edges after the angle has been benl through 90 degrees should be equal to the thickness of the angle. The operator may then bridge cross the i w o edges from one side allowing as little metal to drop down between the edges as pos- sible. Then the angle should be turned over and the space between the edges completely filled b\ welding in one or more layers. LESSON fill Flue If eld in a This exercise deals with the welding oi lines into the due sheet of a boiler This work is encountered in fire tube hollers of all kinds. The operation re- quires ;i considerable amount of skill in handling the arc. A preparation of the flue sheet for welding in actual practice is usually what makes the job a su or failure. In practice the proper way of preparing a line sheet for welding is to put the hues in exactly as if they were not to he welded Idle boiler should then be fired at least once to allow the tubes to take ig. 154 their permanent set, [Tie line sheet should then be sand blasted to dean the surfaces to he welded. If no s.md blast is available the pneumatic tool should he used to knock the oxide off the surfaces, after which the surfaces should he thoroughly brushed with a wire brush, then the welding may lie done. If the work is prepared in this manner and properly welded the results will he uniformly successful. Material required: Section of _." boiler plate with four 1" flues rolled in as shown in cut; s" electrode with 11.1(1 amperes should he used. 1. Set the sample as shown in the photograph. Use head shield and hold the electrode holder in both hands as shown in the cut. The first flue at the top should be welded starting at the point shown in the cut and welding one-half wa\ around, moving from right to left. Then the other one-half wadded starting at the original point and moving downward to the left. The second flue should then be welded starting at the bot- tom and welding in two halves so that they meet at the top. The operator may then weld the other two tines by either of the two methods illustrated, depending upon which the operator likes the better. One of the lines should then be sawed in half to show the quality of the workmanship. Ih mini en wiiiiiiiiiiiiiuiiiiiii iiiiiiiiiiiimiimiiiiiiimiiiiiniiiiimiiinmiii TEN LESSONS IN ARC WELDING LESSON IX II elding Steel Castings with Carbon Arc Thi~ exercise illustrates the kind of work dune in a steel foundry and in certain n hops. The car- bon arc is used in the same manner as the tl.-.mc of an oxy-acetylene torch. From .->i » ■ to 600 amperes are required for carbon electrode work of this nature. The operator must use both I therefon shield is required The carbon electrode holder is held in the right hand and the welding i id if held in the left hand Carbon electrode welding is usually considered easier than metal electrode welding but there is considerable skill required to handle a . are successfully. Material required: One small steel casting(Fig 1 55 1 carbon electrode holder, carbon electrode '/' in di- ameter sharpened to a point welding capacity in I iere unit is not available, two ISO-ampere units maj be connected i: welding rod 1. For preliminat c practice tin 1 ' use the 300 unpen carbon are and cut into small pieces several pieces i i. For this \\ > irk the arc should he held approximately a quarter long. After the operator lias pi . . this wi Tk to be able ti i make a cl determined line, he should try welding d boiler plate si rap usii d the d to till in with. It will cult to control the arc ami lead it in any di direction. 2. If . " carbon electrodes are available one should be sharpened and placed in the metal electrode holder and some cutting of " plate done using 150 amperes 1'hi rator should be able to cut a straight, clean cut upon completing this exercise. 3. Using the riveted sample which was used in ii VII the operator should use the 300 amperes carbon are to cut out a section of the upper plati tween two rivets. To perform this operation the plate should he set up in the same position in which it was welded s, , thai when the metal is melted by the carhop arc it can run down out of the cut. The sample should then later be welded flush, using the metal electrode process. After working with the carbon are and before working with the metallic arc on this job it will be xide i iff tlii' siirfaei ' lion arc forms a very thick coating ide. 4. This exen with the correction of a flaw m the steel casting due to a sand spot. This .1 ■ii th" steel casting is caused by the crumbling of the ry to burn the sand spi i| ■ iul with are and till in new material from the weld- ere is no sand spot on the casting avail- able ii will be sufficient for the iperator to heat spol ximately r " in diatnetei to the molten state, then quickly break the are and strike the molten metal a alow with a ball-pein hammer. If tin- operator ei ition on a sand spot he would ■ most of tin- sand by the heat of the harp Mow with the hammer throws the of the weld. The next the defect with new material The operation must he per- possible, otherwise the metal added ...- nil as the metal of the easting in the vicinity weld will he ruined hy the extreme heat. The Quid be ined ' short pieces of the weld- tould he melted and puddled in the proper place. In case the arc breaks during aid he started again on •h.t is net molten and the arc brought over into Liickly. If the arc is started bj touching the molten metal with the carbon elect! is very likely that the weld will be hard owing to the n from the electrode has gotten into the weld. \~ soon as the added material has been weld the arc must he broken. There is alw. dency on tin part of a beginner to play the are too long completed weld in an attempt ih finished appearance; thi= • in burning of the metal. In steel casting work a! hard spots two points must he observed: (1> isl I i done around the point at which the weld is 10 Si made with the arc so that it u ill not ' too fuddenly. (2> The carbon electrode must not lie brought in contact with the molten metal a- explained he: Tin- opei iuld he p si i by the operator until ! < can pi iduci a weld which is . to him. and si ag till in the weldinj ■ II) as 74 .i..i !■ mi' ■■..: 'i iiiiniiii; :;ii ii i ttllllltmlllllllllllllllllllllll imiiiii iniiitiiiiiiu TEN LESSONS IN ARC WELDING hi- Miiiiimimiiiiiiiiiiimiiitimiiniiimimiiiitiiiiiiiiiiii : iillllillllllllllll niiiiimiiiii LESSON X Cast Iron Welding The purpose of this exercise is to give the operator an idea of what can be accomplished with the electric arc on cast iron. The operator will frequently hear amazing statements as to what some particular operator has done along the line of welding cast iron but it is a fact that there are only a few commercial applica- tions of the process in the welding of cast iron. The difficulty in welding cast iron with the electric arc is not due to the fact that the metal cannot be properly fused, but is due to the fact that the sudden intense heat of the arc over ? local area results in the production of a hard weld and the introduction of contraction stresses which often result in cracking. Using the carbon welding process, cast iron welding rods may be fused into a cast iron piece. Using the metal electrode process and a soft iron or steel electrode, it is impos- sible to make a reliable weld between the added ma- terial and the cast iron. Using the metal electrode process certain work can be done by the introduction of steel studs in the cast iron pieces to be welded to- gether so that a certain amount of strength is obtained by the bond formed between the steel studs by the welded material. Material required: 300 amperes welding capacity. ft" cast iron welding rod. One small gray iron cast- ing ( Fig. 156). A small gray iron casting should be broken and the edges beveled, using the carbon arc for cutting. The pieces should then be placed in a carbon mold so that the molten iron when it is added will not run away from the joint. This is illustrated in Fig. 156. The carbon arc should be used to preheat the casting. It is not necessary to heat the piece to a red heat. The carbon arc and cast iron welding rod should then lie used to fuse tlie added material to the piece. As in Lesson IX, care should be exercised not to play the arc upon the weld any longer than is neces- sar\ to -ue complete fusion. In case the metal gets too hot and runs badly the arc must be broken and an interval of time allowed for it to cool slightly to eliminate the trouble. After the weld is completed the piece should be wrapped up securely in asbestos paper and allowed to cool slowly for 6 or 8 hours (larger pieces require from IS to 24 hours to cool). As an alternative to wrapping in asbestos paper, the piece may be covered in previously heated slacked lime. The idea of the lime is the same as the asbestos, to cool the casting slowly. If the work is properly pre- heated and welded rapidly and very slowly cooled the material in the weld will be as readily machineable as the balance of the piece. No flux of any kind is re- quired, although borax may be used. 75 LINCOLN MOTORS fhese motors are noted for the extreme rug- gedness and simplicity of their construction. They are insulated with a special compound which resists the destructive action of dust, dirt, chemical fumes, water, heal and cold. i in account of these features the\ arc particu- larly suitable for operating in foundries, steel mills, chemical plants, cotton mills, brick and tile plant-, ship-yards and other places where the working conditions are exceptional^ severe. Specifications Standard voltages II 11 to 2300 \< 'It-. I Uglier voltages can he obtained on special order. Phases- Two and three phase alternating cur- rent only. ( yclcs 01 /' ' equal I M I, 10, , ; i I and ( ii • c\ cles per seci md. < >ther to 500 H. 1'. Temperature Ratings Lincoln Motors are guaranteed to operate at a temperature rise of not over 40 degrees ( . on continuous full load and 5? degrees C. on a 25'i overload for two hours. Ci uaraiitce I .mo >ln Motoi ai anteed tor a period of six months against all defect- of material or workmanship and we agree to replace free of charge f. o. b. Cleveland, parts which prove defective within that time, providing the detective part is returned to us in Cleveland. charm-- prepaid, and that inspection proves the claim. rices and n application. ROTOR STATOR ; ■>-_• ithout damage to '1" winclinj i i of tin reliability of Un< LIBRARY OF CONGRESS 016 091 716 7