document resume title institution pub date · shielded arc electrodes. the guidelines also outline...

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AUTHORTITLEINSTITUTION

PUB DATENOTEAVAILABLE FROM

EDRS PRICEDESCRIPTORS

DOCUMENT RESUME

VT 020 499

Fordyce, H. L.; Doshier, taleInstructional Guidelines. Welding.Department of Justice, Washington, D.C. FederalPrison Industries, Inc.[73]218p.Supervisor of Education, Federal correctionalInstitution, Lompoc, CA 93438 (free until presentsupply is exhausted)

MF-$0.65 HC-$9.87Correctional Rehabilitation; *CorrectiveInstitutions; *Educational Programs; Metals; MetalWorking Occupations; Prisoners; *Teaching Guides;*Trade and Industrial Education; *Weldifig

ABSTRACTUsing the standards of the American Welding Society

and the American Society of Mechanical Engineers, this weldinginstructional guidelines manual presents a course of study inaccordance with the current practices in industry. Intended for usein welding programs now practiced within the Federal Prison System,the phases of the program are designed for beginning and advancedstudents or metal workers interested in welding as a supplement totheir trade. She guidelines are based on accepted practices ofwelding_ instruction, and encourage manipulative skills in usingshielded arc electrodes. The guidelines also outline the process ofoxyacetylene welding and cutting, gas tungsten-arc, and gas metal -arcwelding. The lesson plans include suggested time allotment, anintroduction to and illustration of the type of joint and weldingposition covered in the lesson, equipment and materials needed, andstep-by-step procedures for accomplishing the lesson. (SB)

FILMED FROM BEST AVAILABLt. COPY

U S DEPARTMENT OF HEALTH.EDUCATION A WELFARENATIONAL INSTITUTE OF

EDUCATIONTHIS OfrUMENT HAS BEEN REPROOUCEP C"1CTLV AS RECFIVZO PROMTHE PERSON: OR ORGANIZATION ORIGi%ATING IT POINTS OF VIEW OR OPINIONSsrA Ito DO NOT hECESSARMY REPREsets; r OFFICIAL NATIONAL INSTITUTE 0I-LOUCATION POSI.04 CT POLICY

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U. S. DEPARTMENT OF JUSTICEBUREAU OF PRISONS

FEDERAL PRISON INDUSTRIES, INC.WASHINGTON, D.C. 20537

7,

FOREWORD

IThe social and economic value of training offenders in

career occupations is well known among teachers and other per-sonnel in correctional institutions. Of equal value is thedevelopment of instructional materials which are pertinent tothe real world of work. Both of these criteria are met in thiswelding guideline because its content relates to the actualtechnical skills required for working in the welding industryand allied fields.

This guideline is .representative of what can be achievedby school staffs who are interested in maintaining up-to-dateinstructional techniques in their professional areas of work.What is more important, however, is the fact that the offenderwill be able to seek and hold employment because he was taughtthe right kind of skills to match the skill requirements of thejob. Productive work skills are important for upward mobilityin the job market place and the opportunity to share in thisprocess is essential to the success of the offender when he isreleased to the community.

This publication is a timely contribution to the field ofvocational education in the correctional setting and'shouldserve as a reference for teaching staffs who are engaged in thedevelopment of instructional activities.

Norman A. Carlson, DirectorBureau of PrisonsU.S. Department of Justice

AMERICAN WELDING SOCIETY2501 NORTHWEST 7th STREET MIAMI, FLORIDA 33125 (305) 642-7090

The American Welding Society is pleased to endorse thismanual which represents a significant factor in the effortsof the United States Bureau of Prisons to establish a uniformapproach to the training of welders.

The rapid strides being made in all types of welded fab-ricatioh require greater skills and competence of the crafts-men. Good, qualified welders are-and for the immediate futurestill will be-in short supply. The program of the UnitedStates Bureau of Prisons, which concerns the standardizationof the training and qualification of welders to recognizedwelding codes, including the AWS Structural Welding Code, ap-pears to be a sound and worthwhile approach.

The American Welding Society wishes to extend its bestwishes to the United States Bureau of Prisons for a most suc-cessful program of welder training.

Sincerely yours.

RR.D. StoutPresident, AWS

E.A. FentonExecutive Director, AWS

A NON-PROFIT ORGANIZATION FOUNDED IN 1919 TO ADVANCE THE ART AND SCIENCE OF WELDING

PREFACE

Using the standards of the American Welding Societyand the American Society of Mechanical Engineers, thiswelding instructional guidelines manual presents a courseof study in accordance with the current practices in in-dustry. .

It has been planned for use in welding programs nowpracticed within the Federal Prison System. Years of usewith these procedures has shown to increase a man's advantages in acquiring code certification as a welder.

The phases are designed for beginning and advancedstudents or metal workers interested in welding as a supple-ment to their trade.

The guidelines are based on accepted practices of weld-ing instruction, and encourage manipulative skills to stu-dents interested in becoming certified welders using shieldedarc electrodes. The guidelines also outline the process ofoxyacetylene welding and cutting, gas tungsten-arc welding(TIG), and gas metal-arc welding (MIG). The type of jointand welding positions are described in the lesson plan andincludes an illustration of the text.

The author has prepared this manual and arranged thelessons so that the student is introduced to new experienceswhile reviewing the lessons he has previously learned.

The procedures liste4 account for the author's tredand tested methods, and he does not imply that individualpreferences should not be used when desired.

While this manual deals only with the skills of welding,other factors of the trade are equally important. It shouldnot be overlooked that safety and good work habits are taughtparallel to every project, and that pride in workmanship isbasic to craftmanship.

iii

INTRODUCTION

In April of 1971 the Institutional Visitation ofWelding Instructors met at Lompoc, CA and Englewood, COunder the co-ordinated management of Shelvy Johnson,Supervisor of Vocational Training.

The purpose of these meetings resulted in determiningstandards and guidelines for use in vocational welding pro-grams that are operational within the federal prison serv-ice. If the welding programs were to use the same recog-nized standards, it would be possible to establish uniform,measurable objectives for all programs. It would also bepossible to determine the number of training hours requiredfor a student to reach each phase of a uniform standard.Thus, it would be adaptable to all programs regardless oftheir course length or geographical area.

Using Section IX Welding Qualification of the Amer-ican Society of Mechanical Engineers Boiler & Pressure Codeas the recognized standard, and the testing to be performedin a reputable testing laboratory, a survey was developedand mailed to each welding instructor. The results of thesurvey are shown in the table below.

Procedures, material specifications, and method of testing were extractedfrom Section IX of the American Society of Mechanical Engineers Boiler &Pressure Code

Procedure & Material Method of *No. ofName & Position of Test Specifications Testing Training Hrs

Flat Fillet 1F Fig. Q-9-A Q-9-A 58Horizontal Fillet 2F Fig. Q-9-A Q-9-A 78Vertical Fillet 3F Fig. Q-9-A Q-9-A 122overhead Fillet 4F Fig. Q-9-A Q-9-A 177Glat Groove 1G Fig. (Q-23)(QN-23A) F19(Q-7-2)(Q-8) 356Horizontal Groove 2G Fig. (Q-23)(QN-23A) P19(Q-7-2)(Q-8) 389Vertical Groove 3G Fig. (Q-23)(QN-23A) F19(Q-7-2)(Q-8) 453Overhead Groove 4G Fig. (Q-23)(0-23A) P19(Q-7-2)(Q-8) 573

*Recommended by field survey of welding instructors in Bureau of Prisons

iv

ACKNOWLEDGEMENTS

This writer is grateful toMr. Shelvy E. JAnson,Supervisor of Vocational Training, UnitedStates Bureauof Prisons, for inspiration, co-operation, and guidancewithout whose farsightedness these welding guidelineswould not have been possible.

Gratitude is also due to F.F. Kenton, Warden andD.R. Scott, Supervisor of Education for providing theresources and encouragement to produce this work.

Credit is also due to all the welding instructorsin the Federal Bureau of Prisons for their support andcontributions of data and instructional material.

The author has drawn freely from the code books ofthe American Welding Society and the American Societyof Mechanical Engineers, and is especially indebted toboth organizations.

H.L. FordyceSenior Welding InstructorFederal Correctional InstitutionLompoc, California

Dale Doshier, AdvisorWelding InstructorFederal Youth CenterEnglewood, CO

v

CONTENTS

Phase I Shielded Metal-Arc Welding

I. Surfacing Weld

A. Starting the arcB. Full width beads

Multiple pass pads (C thru G)

II. Lap Weld Sets

A. Lap welds

III. Fillet Weld Sets

A. Flat position.B. Horizontal position (thru D)E. Vertical up positionF. Overhead position (thru G)H. 4 position fillet weld test

125 hrs

IV. Oxyacetylene Cutting

A. Use of the oxyacetylene cutting torch

-V. Arc-Air Gouging

A. Understanding & using the process

Phase II Shielded Metal-Arc Welding 275 hrs

I. Surfacing Weld

A. Whip BeadB. Weave Bead -C. Whip Bead -D. Weave BeadE. Whip BeadF. Whip Bead

II. Fillet Weld Sets

flat positionflat position

horizontal positionhorizontal position

vertical positionoverhead position

A. Horizontal position - AWS-E-6010B. Horizontal position - lacing beadC. Horizontal position - pipe to plate

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D. Horizontal position - multiple corner 59E. Horizontal position - AWS or ASME test 61F. Vertical position - weave bead AWS-E-6010 69G. Vertical position - weave bead AWS-E-7018 71H. Vertical position - weave bead pipe to plate 79I. Vertical position - AWS or ASME test 81J. Vertical down position 91K. Overhead position - AWS-E-6010 99L. Overhead position - AWS-E-7018 101M. Fixed position - multiple corner 103N. Overhead position - AWS or ASME test 105

III. Groove Weld Sets

A. Flat position - corner 43B. Flat position - AWS-E-7024 45C. Flat position - w/back-up 47D. Flat position - open 49E. Horizontal position - w/back-up 63F. Horizontal position - open 65G. Vertical position - corner 75H. Vertical position - 21 passes 77I. Vertical position w/back-;up 83J. Vertical position - weave bead AWSE-6010 85K. Vertical position - weave bead AWS-E-7018 87L. Vertical position - open 89

f M. Vertical down position - open AWS-E-6010 931 N. Vertical position - soundness test AWS-E-7018 &

AWS-E-7024 95( 0. Overhead position - gdundness test AWS-E-7018 &1 AWS-E-7024 107

P. Overhead position - w/back-up AWS-E-6010 109Q. Overhead position - w/back-up AWS-E-7018 111R. Overhead position - open AWS-E-6010 113S. Four position test 115

I

1 Phase III - Shielded Metal-Arc Welding Certification 180 hrs

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I. A.S.M.E. Test Groove Weld

A. Horizontal position w/back-up 119B. Vertical position w/back-up. 121C. Overhead position w/back-up 123

vii

II. City of Los Angeles Field Certification - Groove Weld(or city applicable to area)

A. Horizontal position w/back-up 127B. Vertical position w/back-up 129C. Overhead position w/back-up 131D. Vertical position soundness test 133E. Overhead position soundness test 13S

Phase IV - Oxyacetylene Welding & Cutting 8S hrs

I. Process Familiarization and Equipment Use

A. Stringer beads without filler rodB. Edge weld without filler rod

II. Groove Weld

139141

A. Flat position - corner 143B. Flat position - forehand technique 147C. Flat position - backhand technique 1SSD. Vertical up position - corner 157

III. Fillet Weld

A. Lap weld 14SB. Horizontal position 153C. Vertical position 159

IV. Oxyacetylene Cutting

A. Use of the handcutting oxyacetylene torch 149B. Use of the automatic cutting machine 1S1

V. Braze Welds

A. Flat position - groove weld 161B. Horizontal position - fillet weld 163

VI. Pressure Vessel

A. Final test - oxyacetylene welding 16S

viii

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Phase V-a - Gas Tungsten-Arc Welding (TIG) 135 hrs

I. Familiarization with the Process

A. Stringer beads on aluminum 169B. Stringer beads on stainless steel 181

II. Fillet Weld

A. Horizontal position, lap weld on aluminum 171B. Horizontal position, fillet weld on aluminum 173C. Horizontal position, lap weld on stainless steel 183D. Horizontal position, fillet weld on stainless steel 185

III. Groove Weld

A. Flat position, corner weld on aluminum 175B. Flat position, square butt weld on aluminum 177C. Flat position, corner weld on stainless steel 187D. Flat position, square butt weld on stainless steel 189

IV. Pressure Vessel'

A. Multiple position on aluminum 179B. Multiple position on stainless steel 191

Phase V-b - Gas Metal-Arc Welding (MIG)

I. Fillet Veld

A. Flat position (spray method) 195B. Vertical-down position (short circuiting method) 197C. Flat position on aluminum (spray method) 199D. Vertical-down position on aluminum (short circuiting

method) 201

II. Groove Weld

A. Flat position 203B. Vertical-down position 205C. Flat position on aluminum (spray method) 207D. Vertical-down position on aluminum (short Circuiting

method) 209

III. Flux Cored Electrode Welding

A. Flat position, fillet weldB. Flat position, groove weld

ix

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COURSE: VOCATIONAL TRADE WELDING

BASIC SHIELDED METAL-ARC WELDING

PHASE I OBJECTIVE

Those trainees participating in the 125 hour course

will develop the skills of arc welding, flame cutting,

and arc-air gouging. Practice in shielded metal-arc

welding will be limited to fillet welds made in all

positions. Use of the cutting torch will be limited

to cutting simple shapes from steel plate one inch or

less in thickness. The arc-air tool will be used to

gouge out welds.

The trainee in this course can expect to develop a level

of skill that will enable him to obtain employment as a

limited welder on steel structures. He also may find use

for this skill in other mechanical trades.

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NAME

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MILESTONE A

STARTING AN ARC

MODULE NO. I

FIGURE NO. I

ELECTRODE SIZEW

I TYPEDIA. DC/RP AWS E- 6010

MATERIAL SPEC. AMT SIZE

STEEL MILD 1-.-3 X 8 X 70

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Module I. Surfacing Weld

Milestone A, Starting the Arc

Project 1; Time: 3 hours.

INTRODUCTIONThe student will establish an arc between the electrode andthe work surface using a scratching motion. After the arcis started he will deposit shcirt beads, 1-1/2 inches long,five times in succession without sticking the electrode.

EQUIPMENT REQUIREDDirect current welding machine, slag hammer, wire brush,tongs, face shield and gloves.

MATERIAL NEEDEDScrapped steel plate or used butts, surface weld plates, 1/8inch E6010 electrodes.

PROCEDURE1. Clean plate surface with wire brush, place in the flat

position for welding.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on jacket, face shield and gloves.S. Put electrode in holder.6. Drop face shield, contact plate with electrode, raise

slightly, in a continuing motion.7. Lower electrode to the proper arc length, as directed.8. Deposit a short weld bead, as demonstrated.9. Use all electrodes down to a stub end 1-1/2 inches long.10. Raise flip front, place holder in its rest.11. Clean all slag from the weld bead using the chipping

hammer and wire brush.12. Repeat this procedure until arc starting can be done

without trouble.13. Secure equipment as directed.

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MILESTONE 9

RUNNING FULL WIDTH BEADS

MODULE NO. /

FIGURE NO. 2

ELECTRODE SIZE DIA DC/RPTYPE STEEL AWS-E-6010

MATERIAl. SPEC. AMT. SIZE

STEEL MILD I 3/8 X 8 X 7



Milestone B, Full Width Beads

Project 2; Time: 6 hours

INTRODUCTIONThe student will demonstrate, to the satisfaction of theinstructor, his ability to make full width beads. Eachweld bead will overlap the previous bead by 50% of itswidth. This will be done with straight line travel. Eachbead should have uniform height, width, and ripple.

EQUIPMENT REQUIREDDirect current welding machine, slag hammer, wire brush,tongs, face shield, jacket, and gloves.

MATERIAL NEEDEDScrapped steel plate or used butts and surface weld projectplates, 1/8 inch E6010 electrodes.

PROCEDURE1. Clean plate with wire brush, place for welding in the

flat position.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on jacket, face shield, and gloves.5. Put electrode in holder.6. Drop face shield, establish an arc, raise electrode

slightly, move to the starting point.7. Lower electrode to proper arc length.8. Hold the electrode at 90° to the plate, this is the

work angle. Hold an angle of 20° in direction oftravel, this is the lead angle.

9. Feed electrode into puddle at a controlled rate,maintaining a constant arc length.

10. Establish rate of travel by maintaining a uniformpuddle and bead width.

11. Deposit weld bead from left to right, if right handed,as demonstrated.

12. Use all electrodes down to a stub end 1-1/2 inches long.13. Lift flip from on face shield, place holder in its hanger.14. Chip and wire brush the bead to remove all slag.15. Inspect weld bead, discuss its quality with your instructor.16. Repeat this procedux3 until satisfactory welds are pro-

duced.17. Secure equipment.

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NAME

SURFACING WELD

MILESTONE CMULTIPLE PASS PAD /FIRST LAYER

MODULE NO. I

FIGURE NO. 3

ELECTRODE SIZEj8 DIA. DC/ RP TYPE STEEL. AWS- E- 6010

MATERIAL SPEC. AMT. SIZE

STEEL. MILD I X 8 X 7

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Milestone C, Multiple Pass Pads/First Layer


INTRODUCTIONThe student will make a surfacing weld on one side of asteel plate using 1/8 inch E6010.electrodes. The weldbeads should be straight, of uniform height and width,with an overlap of 50% of each bead.

EQUIPMENT REQUIREDDirect current welding machine, slag hammer, wire brush,tongs, face shield, gloves, and jacket.

MATERIAL NEEDED1 piece 3/8 x 7 x 8 inch steel plate, 1/8 inch E6010 electrodes.


flat position.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on jacket, face shield, and gloves.5. Put electrode in holder.6. Drop face shield, establish an arc, raise electrode

slightly, move to the starting point.7. Lower electrode to the proper arc length.8. Hold the electrode with a leading angle of about 750.9. Feed electrode into puddle at a controlled rate, holding

a constant a:c length as demonstrated.10. Establish rate of travel by maintaining a uniform puddle

and bead width.11. Deposit weld btad in a straight line from left to right,

if right handed, as demonstrated.12. Use all electrodes down to a stub end 1-1/2 inches long.13. Raise flip front, put holder in its rest.14. Clean off all slag with hammer and brush.15. Inspect bead, discuss its quality with your instructor.16. Repeat this procedure until the weld beads are consistent.17. Secure equipment.

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PENETRATION

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NAME .

SURFACING WELD

MILESTONE DMULTIPLE PASS PAD/

SECOND LAYER WHIP BEAD

MODULE NO. I

FIGURE NO. 4

ELECTRODE SIZE TYPEDC/RP STEEL AWS E 6010MATERIAL SPEC. AMT. SIZE

STEEL MILD I X 8 X 7

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Milestone D, Multiple Pass Pad/Second Layer - Whip Bead


INTRODUCTIONUsing the reverse side of the pliiiTrom Project 3, the stu-dent will make a surfacing weld with electrode manipulation(Whip Bead). This is a forward and back motion in incrementsof about 3/8 and 1/4 inch. The arc length must be held con-stant. Overlap the weld beads by 50% of their width. Thecompleted surface must be uniform in depth and appearance.

EQUIPMENT REQUIREDDirect current welding machine, slag hammer, wire brush,tongs, face shield, gloves and jacket.

MATERIAL NEEDEDUse the plate with a surface weld from Project 3, 1/8 inchelectrodes type E6010.


flat position.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on jacket, face shield and gloves.5. Put electrode in holder.6. Drop face shield, establish an arc, raise the electrode

slightly, move to the starting point.7. Lower electrode to the proper arc length.8. Practice the forward and back manipulation described and

demonstrated. Observe how this is an aid to depositbeads of the desired shape and size.

9. Use all electrodes down to a stub end 1-1/2 inches long.10. Open flip front, place holder in its rest.11. Clean off all slag with hammer and brush.12. Discuss your results with instructor.13. Save plate for further work.14. Secure equipment.

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C. LEAVE I" OF SECOND BEAD SI4OWING

NAME

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MILESTONE EMULTIPLE PASS PAD /

THIRD LAYER

MODULE NO. I

FIGURE NO. 5

ELECTRODE SIZE/I DIA DC/SP

TYPESTEEL AWS -E- 6013


STEEL MILD 1 48 X 8 X 7

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Milestone E, Multiple Pass Pad/Third Layer


INTRODUCTIONThe student will change the current from reversed to straightpolarity, explaining to the instructor why this is done. Thestudent will make a surfacing weld with 1/8 inch E6013 elec-trodes over the surfacing weld of Project 4. Each weld beadmust be overlapped 50% of the preceeding bead. Even spacing,uniform height, ripple, and width are the objectives.

EQUIPMENT REQUIREDDirect current welding machine, slag hammer, wire brush,tongs, face shield, gloves and jacket.

MATERIAL NEEDEDSurfacing weld plate from Project 3. and 4, 1/8 inch E6013electrodes.

PROCEDURE1. Clean plate with wire brush, place for welding in theflat position.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on jacket, face shield and gloves.5. Put electrode in holder.6. Drop face shield, establish an arc, raise electrode

slightly, move to the starting point.7. Lower electrode to proper arc length.8. Hold the electrode with a leading angle of about 80°,feed into puddle at a controlled rate, holding a constantarc length.9. Establish rate of travel by maintaining a consistent

puddle and bead width.10. Move from left to right, if right handed.11. Weld beads must be parallel and overlapping by 50%, as

demonstrated.12. Use all electrodes down to a stub end of 1-1/2 inch.13. Lift flip front, place holder in its rest, chip off

all slag, use wire brush as directed.14. Inspect work, discuss the results with your instructor.15. When a satisfactory weld is completed, save plate for

the following project.

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PENETRATION

NAME

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MILESTONE FMULTIPLE PASS PAD /

FOURTH LAYER

MODULE NO. I

FIGURE NO. 6

ELECTRODE SIZE TYPEDIA DC/RP AWS - E- 7018



12



Milestone F, Multiple Piss Pad/Fourth Layer


INTRODUCTIONFor this project the student will use reverse polarity,electrode positive. He will make a surfacing weld on theplate used in Project 5. The beads must be uniform inheight, width, with uniform ripple. Use 1/8 inch E7018electrodes.

EQUIPMENT REQUIREDDirect current welding machine, slag hammer, wire brush,tongs, face shield, gloves, and jacket.

MATERIAL NEEDEDPlate from Project 5, 1/8 inch E7018 electrodes.

PROCEDURE1. Clean the plate with wire brush, place for welding in

the flat position.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on jacket, gloves and face shield.5. Put electrode in holder.6. Drop face shield, establish an arc, raise the electrode

slightly, move to the starting point.7. Lower electrode to the proper arc length.8. Hold the electrode with a leading angle of about 80°.9. Feed electrode into puddle at a controlled rate while

holding a constant arc length.10. Establish rate of travel by maintaining a consistent

puddle and bead width.11. Deposit a straight bead from left to right, if right

handed.12. Beads must be parallel and have a SO% overlap.13. Use all electrodes down to a stub end 1-1/2 inches long.14. Lift flip front, place holder in its rest, clean off

slag with hammer and wire brush.15. Inspect weld beads, discuss the results with your instructor.16. When a satisfactory surfacing weld is produced, save it for

the next project.

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....,...., ...,,,..v..,............mica

PENETRATION


B. FLAT POSITION

C. LEAVE IN OF OURTH BEAD SHOWING

NAME

SURFACING WELD

MILESTONE GMULTIPLE PASS PAD /

FIFTH LAYER

MODULE NO. .1

FIGURE NO. 7

ELECTRODE SIZE TYPEDIA DC/RP AWS E 7024



14



Milestone G, Multiple Pass Pad/Fifth Layer


INTRODUCTIONThe student will cover the surfacing weld of Project 6 with anadditional layer of weld metal using 1/8 inch E7024 electrodes.The beads must be overlapped 50%. They will have a uniformsurface and ripple, with an even buildup.

EQUIPMENT REQUIREDDirect current welding machine, slag hammer, wire brush,tongs, and safety equipment.

MATERIAL NEEDEDUse the surfacing weld plate from Project 6, 1/8 inch E7024electrodes.


flat position.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shied and gloves.5. Put electrode in holder.6. Drop face shield, establish an arc, raise electrode

slightly, move to starting point.7. Lower electrode to the proper arc length.8. Hold the electrode with a leading angle of about 80°.9. Feed electrode into the puddle at a controlled rate,

maintaining a c.:tirtant arc length, as demonstrated.10. Establish the rate of.travel by controlling the width of

puddle and bead.11. Deposit straight beads from left to right, if right handed.12. Beads should have a 50i overlap.13. Use all electrodes down to a stub end 1-1/2 inches long.14. Raise flip front, put holder in its rest, chip and wire

brush weld to remove all slag.15. Inspect .beads, discuss results with your instructor.16. Save those properly made surface weld plates for projects

following.

15

6*1 0 ((. ( ,tt, .A..(3ry sri ,"k(: i , Til ZIN(11W1'.( flr.Cf1 ' a

Nal i(( di (((10(1 f (IGLOO

DIRECTION OF TRAVEL_.0.

316 h.

6r

elmigh k ( (,(e40,,(4fratoorruovitmocooT(at,ta v --7Alit(Vil (NAV ,( (i,(irt .,WIMI16,

3

iA. WELD ON BOTH SIDES

Alift -

lk,,,..1.1411

PENETRATION

NAME

LAP WELD SE TS

MILESTONE ALAP WELDS

MODULE NO.=

FIGURE NO. 8

ELECTRODE SIZE TYPEDIA. DC/RP AWS E- 6010


STEEL MILD 6 16 I X 6


Module II. Lap Weld Sets

Milestone A, Lap Welds


INTRODUCTIONThe student will make a lap set to contain 10 welds. Thesewill be finished on alternate sides until the set is complete.Each weld should have a leg length equal to plata thickness,with a flat face and uniform ripple. There should be no ex-cess reinforcement on top plate or undercut. Use 1/8 inchE6010 electrodes with a forward and back (Hot Whip) motion.


MATERIAL NEEDED6 pieces 3/16 x 1-1/2 x 6 inch steel plate, 1/8 inch E6010electrodes.

PROCEDURE1. Clean plate with wire brush.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on safety equipment.5. Put electrode in holder.6. Overlap plates 3/4 inch and tack weld at each end of the

joints. Place for welding in the horizontal position.7. Drop face shield, establish an arc, raise electrode

slightly, move to the starting point.8. Lower electrode to the proper arc length.9. Hold electrode about 45 to the work inclined 60° in the

leading direction.10. Deposit weld with a forward and back manipulation in small

increments, as demonstrated. Hold a constant arc length.11. Use all electrodes down to a stub end of 1-1/2 inch.12. Raise flip front, place holder in its rest, clean off

slag with ahmmer and wire brush.13. Inspect bead, discuss results with your instructor.14. Repeat, this procedure until the desired weld is produced.

17

t

,.. -LO: ,-1

.A)e.-.Z.C..

`-' .. :'t%

ABC

A.

R

C.

'figaminafillarill(110Y galciarilor1USC);,

maUMW

lacake.,MO quaNS

6

VW'N.

/16

I 312/ gr

PENETRATION

WELD ALL FOUR CORNERS

FLAT POSITION

WELD SEQUENCE

N.111011P4C,V

4

NAME

FILLET WELD SETSMILESTONE A

FILLET WELDSIN THE FLAT POSITION

MODULE NO.111

FIGURE NO. 9

ELECTRODE SIZE I73- DIA. DC/RP TYPE AWS E- 6010

MATERIAL STEEL SPEC.MILD

T SIZE 37g X ti X 6

STEEL MILD I376 X 24-X6

18

I


Module III. Fillet Weld Sets

Milestone A, Fillet Welds in the Flat Position


INTRODUCTIONThe student will make a fillet weld set to contain four,6 pass welds. The beads will be deposited to make filletsof 1/4, 3/8, and 1/2 inch leg lengths progressively. Eachfinished weld should have equal leg lengths, a flat face,with uniform ripple. Use E6010 electrodes with reversepolarity, electrode positive.


MATERIAL NEEDED1 piece 3/16 x 2-1/4 x 6 inch, 2 pieces 3/16 x 1-1/2 x 6 inchsteel plate, 1/8 inch E6010 electrodes.

PROCEDURE1. Clean plate with wire brush.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves.5. Put electrode in holder.6. Tack weld plates at 90° to form a cross; place for

welding in the flat position.7. Drop face shield, establish an arc, raise electrode

slightly, move to the starting point.8. Lower electrode to the proper arc length.9. Deposit weld, holding electrode at various angleS,

depending on position of the bead.10. After each bead is complete, clean off slag with hammer

and wire brush.11. Follow instructor's demonstrated procedure.12. Repeat this procedure until the desired weld is produced.13. Check fillet size with gage.14. Save material for square butt weld.15. Secure equipment.

x

41,.,

,....1/4,

\,...,,,.4"----

"'is ...m Laill1(110«

....

DIRECTION OF TRAVEL---0,,ok,o,t cionii«t(fimooffic c "fir/ fIdGVA.CG1:oriut 0 I,Cl, ' ,- ,' ' ' ,...11(1,;(.Cct,I al qt.11aaaCC0

Ai , B- C

6

"AT,,, twit, Hi ,c, ,,,,i. 61l f,/III, , (II , t III, I; tl . ,C.. t t,t.ille!' dt(i(MO

OF 1

A

I

I I

A16

tkkitit

PENETRATION

A. WELD ALL FOUR CORNERS

B. HORIZONTAL POSITIONi Iin=

MI"C

ill'

C. WELD SEQUENCE

NAME

FILLET WELD SETSMILESTONE B

FILLET WELDSIN THE HORIZONTAL POSITION

MODULE NO.111

FIGURE NO. 10

ELECTRODE SIZE TYPEDIA. DC/RP AWS E- 6010

MATERIALSTEEL SPEC.

MILDAMT2

SIZE i X ii X 6STEEL MILD I i X 24- X 6

20



Milestone B, Fillet Weld in the Horizontal Position


INTRODUCTIONThe student will make a fillet weld set to contain four,six pass welds. The beads will be deposited to make filletsof 1/4, 3/8, and 1/2 inch leg length progressively. Eachfinished weld should have equal leg lengths, a flat face,with uniform ripple. Use E6010 electrodes, weld in thehorizontal position.



PROCEDURE1. Clean plate with wire brush.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves.5. Put electrode in holder.6. Tack weld plates at 90° to form a cross, place for

welding in the horizontal position.7. Drop face shield, establish an arc, raise electrode

slightly, move to the starting point.8. Lower electrode to the proper arc length.9. Deposit weld, holding electrode at various angles,

depending on position of the beads.10. After each bead is complete, clean off slag with hammer

and wire brush.11. Follow instructor's demonstrated procedures.12. Repeat this procedure until the desired weld is produced.13. Check fillet size with gage.14. Save material for square butt weld.15. Secure equipment.

21

,k 6. '

1/4*.'"',,

DIRECTION OF TRAVEL

, k S' ..'" (,,,,,,,,,, ( ,- ((((((((((((((((, ((((((( (,,,,,,,..(,..,,,,.(,,,,,,,,w,c,...N

1

L..___,

.A -B -C

6

ARAmiu)

I, 111011 ',0 n , 4,i1ll1l h(1 WlW, MC:0if4/C 0 1((0 ((w,,,

'IIIII

w-/ -00

I i%

PENETRATION


a HORIZONTAL POSITIONI

MI"C"

I2

C WELD SEQUENCE

NAME

FILLET WELD SETSMILESTONE C


MODULE NO.III

FIGURE NO. II

ELECTRODE SIZEibI TYPEDIA. DC/SP AWS E- 6013

MATERIALSTEEL .SPA CILD AMT

2SIZE Ti X I X 6

STEEL MILD 13 24rg X 24 X 6

22



Milestone C, Fillet Weld in the Horizontal Position UsingE6013 Electrodes


INTRODUCTIONThe student will make a fillet weld set to contain four,6 pass welds. The beads will be deposited to make filletsof 1/4, 3/8, and 1/2 inch leg lengths progressively. Eachfinished weld should have equal leg lengths, a flat face,with uniform ripple. Use E6013 electrodes with straightpolarity, electrode negative.


MATERIAL NEEDED1 piece 3/16 x 2-1/4 x 6 inch, 2 pieces 3/16 x 1-1/2 x 6inch steel plate, 1/8 inch E6013 electrodes.

PROCEDURE1. Clean plate with wire brush.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves.5. Put r'lectrode in holder.6. Tack weld plates at 90° to form a cross, place for

welding in the horizontal position.7. Drop face shield, establish an arc, raise electrode

slightly, move to the starting point.8. Lower electrode to the proper arc length.9. Deposit weld, holding electrode at various angles,

depending on position of the beads.10. After each bead is complete, clean off slag with hammer

and wire brush.11. Follow instructor's demonstrated procedures.12. Repeat this procedure until the desired weld is produced.13. Check fillet size with gage.14. Save material for square butt weld.15. Secure equipment.

23

N(,4c,

-ti,'.4 DIRECTION OF TRAVEL0\1\

t!;'1..\0 \'4

.----...I, t tCr' 0 Q'if ,JT.f rote, u. 1.. ,, k (,114111, c Mil, C , k I ( , , ( ( k,((1 41111111iAlk( .., .. L , Lil ill 111'1W,Iiii,q) ,...

A B C-D-E

r6

merik....1,

,,,,!;: ,,,,,, .,,,,,,,,, ,, ,. cii, ,,,,,, .,,,,(,, Ili a ,c,-.(21:(C .,,.

41

1.II

;14\41tieta4itiuttrtt

CV

L__

PENETRATION

A. WELD ALL FOUR CORNERS.

a HORIZONTAL POSITION

C. WELD SEQUENCEgorilla

1

411

"C "

4 I D. FIRST SIX BEADS 6013

E. LAST SEVEN BEAD-7024

NAME

FILLET WELD SETS

MILESTONE DFILLET WELDS

IN THE HORIZONTAL POSITION

MODULE NO. 71L

FIGURE NO, 12

ELECTRODE SIZE13I TYPEDIA. DC/RP AWS - E- 7024 6013

MATERIALSTEEL SPEC.

MILDAIAT. SIZE - X I X 6

16

STEEL MILD I X 24-it X 6

24

)f



Milestone D, Fillet Welds in the Horizontal Position UsingE7024 Electrodes.


INTRODUCTIONThe student will use a completed weld set from Project 11,to add seven passes with 1/8 inch E7024 electrodes. Thesewill be deposited as follows: first, 3 beads; second, 4beads. This will increase the fillets from 1/2 inch to 3/4inch size. The finished weld will have a flat face, equal leglengths:, and a uniform ripple.


MATERIAL NEEDEDCompleted sets from Project 11, 1/8 inch E7024 electrodes.

PROCEDURE1. Clean welds with wire brush, place for welding in the

horizontal position.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves.5. Put electrode in holder.6. Drop face shield, establish an arc, raise electrode

slightly, move to the starting point.7. Lower electrode to the proper arc length.8. Electrode angle will change with each bead, depending

on its position.9. Clean off all slag after completing each pass.10. Practice as demonstrated.11. Repeat this procedure until the desired weld is produced.12. Check work with fillet gage, as directed.

25

.

PENETRATION

'AB CD

AO6A90O

411W

OA

.1(

#&

\\PI

#1.

5

ccI A. WELD

ta-0B. VERTICAL

0.- 1

C. WELDes

D. DIRECTION

v -

. ,

ALL FOUR

POSITION

SEQUENCE

OF TRAVEL

CORNERS

JP

9.,eli

to

I

c.:'io

:-- -.;...,

_ i

6- '-...

.__ _.,... _.

-4.--:-;

NAME

FILLET WELD SETSMILESTONE E

FILLET WELDSIN THE VERTICAL UP POSITION

MODULE NO.=

FIGURE NO. 13

ELECTRODE SIZE 1,s DIA. DC/RP TYPE AWS E- 6010

MATERIALSTEEL SPEC.

MILDAMT2

SIZE it X 1-1- X 6

STEEL MILD I ii, X 24- X 6

26

O



Milestone E, Fillet Welds in the Vertical-Up Position


INTRODUCTIONThe student will make a fillet set to contain four, 6 passwelds. These will be deposited to make fillets of 5/16, 1/2,and 5/8 inch leg lengths progressively. These welds will havea flat face, equal leg lengths and a uniform ripple.

EQUIPMENT REQUIREDDirect current welding machine, slag hammer, wire brush,tongs, positioner, and safety equipment.

MATERIAL NEEDED1 piece 3/16 x 2-1/4 x 6 inch, 2 pieces 3/16 x 1-1/2 x 6 inchsteel plate, 1/8 inch E6010. electrodes.

PROCEDURE1. Clean plate with wire brush.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves.5. Put electrode in holder.6. Tack weld plate at 90° to form a cross, place in positioner

for vertical welding.7. Drop face shield, establish an arc, raise electrode

slightly, move to the starting point.8. Lower electrode to the proper arc length.9. Deposit bead moving upward with an up and down manipulation.

Follow demonstration procedures.10. The increments of motion are about 3/8 inch up and 1/4 inch

down, holding a constant arc length.11. Clean off all slag from each completed bead.12. Repeat this procedure until the desired weld produced.13. Check fillet dimension with gage.

27

I41.k

we DIRECTION OF TRAVEL

ir ,I

. PENETRATION"

A

ill

r - :

10,11itryII/co


B. OVERHEAD POSITION

C. WELD SEQUENCE

NAME

FILLET WELD SETS

miasma! FFILLET WELDS

IN THE OVERHEAD POSITION

MODULE NO.III

FIGURE NO. 14

ELECTRODE SIZE ! e DIA DC/RP TYPE AWS-E- 6010

MATERIAL STEELSPEC.

MILDAM T.2

SIZE 1.i. x 1 6

STEEL MILD 1 iixzixe

28



Milestone F, Fillet Welds in the Overhead Pc:ition


INTRODUCTIONThe student will make a fillet set to contain four, sixpass welds. These will be made in the overhead position,using E6010 electrodes. The beads will be deposited tomake fillets of 1/4, 3/8, and 1/2 inch leg size progressively.The finished welds will have a flat face, with uniform ripple.



PROCEDURE1. Clean plate with wire brush.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves.5. Put electrode in holder.6. Tack weld plates at 90° to form a cross, place in

positioner for overhead welding.7. Drop face shield, establish an arc, lower electrode

slightly, move to the starting point.8. Raise electrode to the proper arc length.9. Practice as demonstrated, use a slight "C" motion for

better puddle c)ntrol and penetration. Hold a constantarc length.

10. Clean off slag after completing each pass.11. Repeat this procedure until the desired weld is produced.12. Check fillet size with gage.

29

miIi -O. I7

3Id 6

1Iilk wte DIRECTION OF TRAVEL

MU MIVri ,, «1111141111 MI (WIC/ r, ''''', i (11((lOCI, ill

. irwai(ilf(ain '((((f(tC,ivunia,PENETRATION/

A. WELD

B. OVERHEAD

C. WELD

ill

iefi1

r A-B-C

2-

,41.7

ALL FOUR CORNERS

POSITION

SEQUENCE

.,,..,..,,,,....

NAME

FILLET WELD SETSMILESTONE G

FILLET WELDSIN THE OVERHEAD POSITION

MODULE NO. III

FIGURE NO. 15

ELECTRODE FAZE ii.. TYPE'8' D/ A. DC/SP A WS E 6013


AMT.2

SIZE 1 X li X 6

STEEL MILD I 136 X 24 X 6

30



Milestone G, Fillet Welds made in the Overhead Position.

Project 15;. Time: 6 hours

INTRODUCTIONThe student will make a fillet set to contain four, sixpass welds. These will be made in the overhead positionusing E6013 electrodes. The beads will be deposited tomake fillets of 1/4, 3/8, and 1/2 inch leg size progressively.The finished welds will have a flat face, with uniform ripple.



PROCEDURE1. Clean plate with wire brush.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves.5. Put electrode in holder.6. Tack weld plates at 90° to form a cross, place in

positioner for overhead welding.7. Drop face shield, establish an arc, lower electrode

slightly, move to the starting point.8. Raise electrode to the proper arc length.9. Practice as demonstrated, use a slight "C" motion for

better puddle control and penetration.10. Clean off slag after completing each pass.11. Repeat this procedure until the desired weld is produced.12. Check fillet size with gage.

31

r2 -12--ft.

-2

or.th

.I

rIlh rep

#0 ,,,, ,,, , ... . ...,,12,, ,.,nduirtrerroi4fuo^,11(''' :(/')'!(,100INow. --kt

Oa417 T.U

.,:ivtiana 1 loa,viaaa,fc am...7, r r evc0((r,c,'. 'u147(114(2"[(104 I-011.1 4 11(01(;)

PENETRATION 6

ABCDF

E

F

A. WELD ALL

B. WELD SEQUENCE

C. FLAT POSITION

D. HORIZONTAL

E. VERTICAL

F. OVERHEAD

2

Al.RimolIlmoo

r

1kafatiIsom

D

-,,re'cii,k,Illra P,Va

FOUR CORNERS

POSITION

POSITION

POSITION

qe:

NAME

FILLET WELD SETSMILESTONE H

FILLET WELDS TESTIN THE FOUR POSITIONS

MODULE NO.III

FIGURE NO 16

ELECTRODE SIZE I TYPE77- DIA DC/RP AWS -E- 6010


AMT2

SIZE 3T-6 X Ii X 6

STEEL MILD I i X 241 X 6

32

JBASIC SHIELDED METAL-ARC WELDING


Milestone H, Fillet Weld Test in 4 Positions

Project 16; Time: 80 minutes

INTRODUCTIONThe student will make a fillet weld set to contain four, sixpass welds. These will be made in the flat, horizontal, ver-tical-up, and overhead positions using 1/8 inch E6010 elec-trodes. The finished welds will be to specified size withflat face, equal leg lengths with a uniform appearance.Original plates issuerwill be returned to instructor in 80minutes for grading./

EQUIPMENT REQUIRDirect current' iding machine, slag hammer, wire brush,tongs, positioner, and safety equipment.


PROCEDURE1. Clean plate with wire brush.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves.S. Put electrode in holder.6. Tack weld plates at 90° ,to form a cross.7. Place for welding in the flat position, deposit a 6 pass

1/2 inch f-llet weld.8.' Place for welding in the horizontal position, deposit a

6 pass 1/2 inch fillet weld.9. Place for welding in a vertical position, deposit a 6 pass

5/8 inch weld.10. Place for welding in an overhead position, deposit a 6

pass 1/2 inch weld.11. Cool and clean welds.12. Present your work to the instructor for inspection and

grading.

33

co

V

NOTE:

1. FLAME CUT INTO I" STRIPS

2. ALTERNATE EDGE CUTS AT 90 a 45

g

.

CUTTINGLINE

o

7"

"~45'

I I v 1 1

NAME

OXYACETYLENE CUTTINGMILESTONE A

USE OF THE OXYACETYLENECUTTING TORCH

MODULE NO.=

FIGURE NO. /7

ELECTRODE SIZE TYPE


AMTI

SIZE 3y X 8 x 7


Module IV. Oxyacetylene Cutting

Milestone A, Use of the Oxyacetylene Cutting Torch


INTRODUCTIONThe student will demonstrate his ability to assemble theoxyacetylene cutting torch, select the proper tip size forthe metal thickness being cut, and test for gas leaks in thesystem. He will use this equipment to cut one inch stripsfrom used butt weld plates. A successful cut is made todimension, with a clean kerf. Separation must be complete.

EQUIPMENT REQUIREDOxyacetylene pressure regulators, cutting torch, tips, wrench,hose, flint lighter, goggles, gloves, square, tongs.

MATERIAL NEEDEDUsed butt weld plates.

PROCEDURE1. See that the hose and fittings are in good servicable

condition.2. Hold torch with valve wheels upward, attach hose, usewrench on union nuts.3. Select proper sized tip, attach to torch; use wrench on

union nut.4. Close torch valves.5. Turn regulator adjusting screws counterclockwise until

tension is released.6. Open line or cylinder valves.7. Turn regulator adjusting screws clockwise, adjust for the

required pressures.8. Close line or cylinder valves, watch for any pressure drop

which indicates leakage. Correct for any leaks.9. Reopen line or cylinder valves.10. Put on cleaned goggles.11. Open oxygen and acetylene torch valves about 1/4 turn,ignite with flint lighter.12. Adjust to a neutral condition with the proper flame length.13. Hold torch in left hand, guide and work oxygen valve withright hand.14. Hold flame at edge of plate on guide line with the flame

tips touching plate.15. When plate becomes red, slowly depress oxygen cutting valveto full open; raise torch slightly.16. Immediately move along guide line at a constant rate,

.maintain good clearance between flame and plate.17. Rate of travel is governed by cutting effect. Too slowresults in oxide buildup; too fast will stop burning action;proper rate makes a clean cut with parallel sides.18. Repeat this procedure until good cuts are produced.19. Secure equipment.

35


Module V. Arc-Air Gouging

Milestone A, Understanding and Using the Process


INTRODUCTIONThe student will assemble the arc-air equipment, and useit for removing the weld deposit from fillet and butt weldsets. After gouging the weld from the joints, the piecesshould separate and have edges that can be rewelded withoutfurther work.

EQUIPMENT REQUIREDDirect current welding machine, compressed air outlet, arc-air equipment, slag hammer, wire brush, tongs, and safetyequipment.

MATERIAL NEEDEDFillet and butt weld sets from previous projects,. carbonelectrodes.

PROCEDURE1. Clean welds with wire brush.2. Adjust the amperage and polarity as directed.3. Attach power cable and air hose to the arc-air fittings,

open the air valve at source.4. Start welding machine.5. Put on face shield and gloves.6. Put carbon electrode in holder so that about 3 inches

extends from the grooved button to the pointed end.This will leave 9 inches above the button.

7. The air discharge holes must be below the carbon so thatair passes to plate at point of arcing.

8. Open air valve on holder.9. Drop face shield.10. Make contact to establish the arc, move immediately along

the weld at a rapid rate. Hold the electrode at an angleof 10 degrees from the plate.

11. Remove metal in small amounts of about 1/4 inch deep foreach pass.

12. Repeat gouging until the desired depth is reached. Movethe electrode down in the holder as it is burned away.

13. Chip away all slag from the edges of the gouge.14. Secure equipment.

36

COURSE: VOCATIONAL TRADE WELDING

ADVANCED SHIELDED METAL-ARC WELDING

PHASE II OBJECTIVE

After the successful completion of the basic shielded

metal-arc welding course the student has the option to

continue to practice in the Advanced Course.

Of those electing to participate in Phase II of the pro-

gram, 80% of the students will have taken and passed the

fillet weld tests, and are familiar with the groove weld

plate test similar to the A.W.S. D1-0-72, Welding in

Building Construction or Section IX of the American So-

ciety of Mechanical Engineers Boiler & Pressure Vessel

code test.

This standard .is equal to, or surpasses, the requirements

commonly used by industry for evaluating shielded metal-arc

weldors. Eighty-percent of the students completing the

course will possess a marketable skill.

37

.,CAt( gC;;-

' .kl..4 .1(k,kt,t4: ,.!.`..`-

S'.?:-

Co

I

A 'la iffwawaroive6maiwalalt:j6.(e' caleaccayeggaoaasgaCGO

DIRECTION OF TRAVEL

7

REINFORCEMENT

'OW

--ic0

A B

-

c:,:,:.-,..:.... ;L.:, -,,,,, .1,-........w :-......,,,,t,.....:,....&:..N....

tr)103

PENETRATION

A WELD BOTH SIDES.

B. FLAT POSITION.

NOTE: REFERS TO BEAD WIDTH

NAME

SURFACING WELD

MILESTONE ASURFACING WELDS

WHIP BEAD

MODULE NO. I

FIGURE NO. I

ELECTRODE SIZE %2 DIA. DC/RP TYPE AWS E- 6010



1

I

I

I



Milestone A, Surfacing Welds in the Flat Position withElectrode Manipulation (Whip Beads)


INTRODUCTIONThe student will deposit stringer beads with a SO% overlap.To cover the surface of a steel plate, use S/32 inch E6010electrodes with a forward and back motion. This manipulationis made in small increments while holding the arc to a con-stant length. The completed deposit should be uniform inthickness and appearance.

EQUIPMENT REQUIREDDirect current welding machine, slag hammer, wire brush,tongs, face shield, and gloves.

MATERIAL NEEDED1 piece 3/8 x 7 x 8 inch steel plate.


flat position.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves.S. Put electrode in holder.6. Drop face shield.7. Establish the arc, raise electrode slightly, move to

the starting point.8. Lower electrode to proper arc length.9. Make beads with forward and back motion in the direction

of travel while holding a constant arc length.10. Use electrodes down to 1-1/2 inch stub.11. Chip and wire brush the deposit until it is'completely

cleaned.12. Arc should be directed at the edge of each previously

deposited bead for the SO% overlap.13. Save this specimen for the following project.

39

....,-..........-

Hop

S N.; .....---,,,

...-_-,.............-.................,...., ,,--,

REINFORCEMENT

im1110iittl%04tImwl,\hittitihOkMW11\A\k\

iNFPN:ViiiiewilummIlliiWhit itto

DIRECTION OF TRAVEL

.

co

B

4(gLeiLMENLZiaMag

7

...Fr A

mi03

PENETRATION

A. WELD BOTH SIDES

a FLAT POSITION

NOTE, REFERS TO BEAD WIDTH

NAME

SURFACING WELD

MILESTONE BSURFACING WELDSWEAVE BEAD

MODULE NO. I

FIGURE NO. 2

,DIA. DC/RP TYPEELECTRODE SIZE 5.3 AWS-E- 6010 :MATERIAL SPEC. AMT SIZE

I


40

i

1



Milestone B, Surfacing Welds with a Weaving Manipulation inthe Flat Position


INTRODUCTIONUse the plate from Project 1 to make a second surfacingweld deposit. This will also be done in the flat positionusing S/32 inch E6010 electrodes. Make a deposit of from2 to 3 times the width of a stringer bead by weaving theelectrode from side to side. A short dwell time at eachside with rapid motion across the d6posit will make a flatweld with even ripple. Advance each time by 50% of thewidth of the deposit.


MATERIAL NEEDEDUse the plate from Project 1.

PROCEDURE1. Clean plate with wire brush.2. Position for welding in the flat position.3. Set amperage and polarity as directed.4. Start welding machine.S. Put on face shield and gloves.6. Put electrode in holder.7. Drop face shield.8. Establish the arc, raise electrode slightly, move to the

starting point.9. Lower electrode to the proper arc length.10. Practice the use of a side-to-side motion in straight lines

across the direction of travel. Keep the puddle narrowwhile it overlaps the preceding deposit.

11. This manipulation should make a well about 3/4 to 1 inchwide.

12. Use electrodes down to a stub 1-1/2 inches long.13. After completing each pass, open flip front of face

shield and chip and wire brush the weld.14. Repeat this procedure until the desired weld is obtained.1S. Save this plate for use in other surfacing weld practice.

41

to

,

1/4..,..._..

_.,,...,;....._,_

%.

/1 \c,...:5

.

ON ONE SIDE ONLY.

POSITION.

FOR NEXT PROJECT.

I

I

I

I

1

1

1

1

1-I16

_

4-

\-- TACK

c--- igi PENETRATION

,Tg

A B

k REINFORCEMENT

A. WELD

>12'

B. FLAT

NOTE: SAVE

dr

ROOT GAP ft--

NAME

GROOVE WELD

MILESTONE A.CORNER WELDS

IN THE FLAT POSITION

MODULE NO. /II

FIGURE NO. 3

ELECTRODE SIZE 5. TYPE/32 DIA. DC/RP AWS-E- 6010

MATERIAL SPEC. ANT SIZE

STEEL MILD 3 I X ih- X 6

42


Module III. Groove Weld

Milestone A, Corner Weld in the Flat Position


INTRODUCTIONThe student will make a corner weld in the.flat position. Thedeposit sequence will be: first, a single 100% penetrationbead; second, two filler beads; third, a weave bead coverpass. The surface should be slightly convex with a uniformripple with no excessive reinforcement on either side of joint.


MATERIAL NEEDED3 pieces 3/8 x 1-1/2 x 6 inch steel plate, 5/32 inch E6010electrodes.

PROCEDURE1. Clean the plate with the wire brush.2. Set amperage and polarity as directed.3. Start welding machine,4. Put on face shield and gloves.5. Put electrode in holder.6. Stand the plates on end at 90%, making an outside corner.

Drop face shield and tack weld.7. Place this assembly for welding in the flat position.8. Establish the arc, raise electrode slightly, move to the

starting point.9. Lower electrode to the proper arc length.10. Deposit penetration bead with forward and back motion;

hold constant arc length.11. Chip and wire brush after each pass.12. Make the succeeding passes with two filler beads and the

weave bead cover.13. Repeat this procedure until a satisfactory weld is pro-

duced.14. Save this weldment for use in the next project.

43

A- B

i i: jj 11LtO

r °a

.ac Y,5,,- .*:-.7,V,;=,.., .2 0.

'?'"""!..f....i'''.7,;:i'"".?,,, Z:7

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0,1:7Yo... "'-..,,,7 ...'- .., , ,...v -''',--"'

swap, mew a:sinso---.;

A. WELD ON ONE

B. FLAT POSITION

gg V-,r. . ,

.e. a

.;..5,i ,..ye,

....".., - -.0.-

" -?:'=---..'"'

Y7

-..

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fade IN,t....:V.'41,....:,",...,,......v.,....", 44.,"-,a,,,r2:',..1-:...416.1^,-7.,.. , ,t::,,

... W

PENETRATION

I

I

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,( c ,, ,la

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..........

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SIDE

''.."..."',

-1.-I6

: --.x.r--

NAME

GROOVE WELDMILESTONE B

"V" GROOVE WELDIN THE FLAT POSITION

MODULE NO. III

FIGURE NO. 4

ELECTRODE SIZE t DIA. DC/RP TYPE AWS E - 7024MATERIAL SPEC. AMT. SIZE

STEEL MILD 3 1 X I i X 6

44

1



Milestone B, 'V' Groove Weld in the Flat Position


INTRODUCTIONThe student will make a flat groove weld by using a cornerweldment salvaged from Project 3. He will invert thisassembly to weld on the root side. Use 1/8 inch E7024electrodes for multiple passes until this back side isfilled. The deposit must be free from slag inclusions,undercut, and pinholes. The deposit should fill out toplate ends.


MATERIAL NEEDEDSalvaged weldment from Project number 3, 1/8 inch E7024electrodes.

PROCEDURE1. Clean the plate with the wire brush.2. Support the weldment for welding in the flat position.3. Set amperage and polarity as directed.4. Start welding machine.5. Put on face shield and gloves.6. Put electrode in holder.7. Drop face shield.8. Establish the arc, raise electrode slightly, move to

starting point.9. Lower electrode to the proper arc length.10. Make all the beads in a straight forward motion; hold

a leading angle on the electrode of about 20°.11. Clean off the slag after each pass; continue depositing

beads until groove is filled.12. Repeat this procedure until the desired weld is produced.13. Secure the equipment.

45

, TA.

.,..).

.

-<..,4-

EC i f :KW (Dome -( .c ,

., H,....N

8 .60°LI --60°

alIkk -103

6

mo Mlqa i j

2

REINFORCEMENT

PENETRATION INTO

II.1 BACK-UP STRIP.

A. FLAT POSITION

ROOT GAP

NAME

GROOVE WELD

MILESTONE C.I'V' GROOVE BUTT WELDS W/ BACK UP


MODULE NO. III

FIGURE NO. 54

ELECTRODE SIZE32_5_ DIA. DC/RP TYPE

AWS E 6010

MATERIALSTEEL SPEC.

MILDAMT2

SIZE 1 X 1 X 7

STEEL MILD 3 X 2 X 6

46

i

I

1

I

I

I

I



Milestone C, 'V' Groove Butt Welds with Backing Strip inthe Flat Position


INTRODUCTIONThe student gill make a groove weld with backing strip inthe flat position. The beads will be placed as follows:Root bead fuses the three pieces together, the bevelededges to the backing strip; second, a weave bead; third,a weave bead; fourth, a weave bead cover pass that isslightly convex with a uniform pattern and tight ripple.

EQUIPMENT REQUIREDDC welding machine, slag hammer, wire brush, tongs, andsafety equipment.

MATERIAL NEEDED3 pieces 3/8 x 2 x 6 inch, and 2 pieces 1/8 x 1 x 7 inchsteel plate, 5/32 inch E6010 electrodes.

PROCEDURE1. Clean the plate with the wire brush.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves.5. Put electrode in holder.6. Assemble plates face down, the beveled edges gapped

3/16 inch, cover with the backing strip and tack weldat each side.

7. Turn this assembly face up for welding in the flatposition.

8. Make the first bead fusing both beveled edges and thebacking strip.

9. Clean away slag completely after each pass.10. Weave additional beads, pass across quickly and dwell

at each side for good fusion.11. The completed reinforcement should not be higher than 1/8

inch above plate thickness or wider than 1/16 inch ateach side of the groove.

12. Repeat the procedure until a satisfactory weld is produced.13. Show work to your instructor; discuss the results.14. Save this material for practice beads.

47

A-8

. .., .,_-,

0°

REINFORCEMENT

PENETRATION

aust 13'ANKAA:feco& ,c,,z.

D

60°1/4.1

6

elAIMEMTIMMER i .\

ROOT

IN/332-i L 2

FLAT POSITION.

B. WELD FROM ONE SIDE ONLY.

Alik

GAP

tverA.

FACE ROOT

NAME

GROOVE WELDMILESTONE D

"V" GROOVE BUTT WELDSIN THE FLAT POSITION

MODULE NO. 311

FIGURE NO. 6

ELECTRODE SIZE TYPE3-2 DIA. DC/RP AWS -E 6010


STEEL MILD 3 X I- X 6

48

I



Milestone D, 'V' Groove Butt Welds in the Flat Position(When available, substitute pipe for plate)


INTRODUCTIONThe student will make a groove weld without a backing strip.This is done in the flat position. The first stringer beadmust penetrate the root completely. Two filler beads aredeposited over this root pass. The cover is a weave bead,slightly convex, without undercut.

EQUIPMENT REQUIREDDC welding machine,. slag hammer, wire brush, tongs andsafety equipment.

MATERIAL NEEDED3 pieces 3/8 x 1-1/2 x 6 inch steel plate beveled on one sideto 30°, 5/32 inch E6010 electrodes.

PROCEDURE1. Clean plates with wire brush.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves.5. Put electrode in holder.6. Put the plate face down with the beveled edges aligned

and gapped to 3/16 inch'. Tack weld.7. Turn this assembly face up for welding in the flat

position.8. Establish an arc, raise electrode slightly, move to

the starting point.9. Lower electrode to the proper arc length.10. Deposit the first bead with full penetration. Use a

forward and back motion; concentrate arc at the root gap.11. Clean each pass completely with chipping hammer and wire

brush.12. Place the two filler beads, then the weave bead cover.13. The reinforcement must not be more than 1/8 inch above.

plate thickness, or wider than 1/16 inch at each sideof the groove.

14. Repeat this procedure until the desired weld is produced.15. Show work to your instructor; discuss the results.16. Save the material for practice welding.

49

REINFORCEMENT

,P-

, A!o 0cP Sa

, `',ite, (S iLt.,t-;.4t,,,I.4.

p . tckvi

A. WELD BOTH SIDES

B. HORIZONTAL POSIT ION


rolco

PENETRATION

(.WRIAMLWRIUMNaiNglaaa e6N

0

cn

co

ti1

INco

MI GI li MUMMICIMIWO

(I IMAM Web

7

NAME

SURFACING WELD

MILESTONE CSURFACING WELDS


MODULE NO. I

FIGURE NO. 7

ELECTRODE SIZE 5/32 DIA. DC/RP TYPE AWS * E - . 6010


STEEL MILD I 3i X 8 X 7

50



Milestone C, SurfaCing Welds in the Horizontal Position

Project 7; Time 6 hours

INTRODUCTIONThe student will make surface weld beading on steel platein the horizontal position using 5/32 inch E6010 electrodes.A forward and back (whip) motion will be used to depositthese beads. Make a 50% overlap. Cover both sides of theplate to a uniform depth.

EQUIPMENT REQUIREDDC welding machine, slag hammer, wire brush, tongs,positioner and safety equipment.

MATERIAL NEEDED1 piece 3/8 x 7 x 8 inch steel plate, 5/32 inch E6010electrodes.

. PROCEDURE1. Clean the plate with wire brush, place in position for

horizontal welding.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves.5. Put electrode in holder.6. Establish an arc, raise electrode slightly, move to

the starting point.7. Lower the electrode to the proper arc length.8. Hold electrode at about 5° slope upward while welding.9. Make a small forward and back motion, move along the

length of the bead with a constant arc length.10. Use all electrodes down to a stub end 1-1/2 inches long.

1

11. Clean slag away completely after each pass.12. Continue this procedure until the entire plate has beencovered with weld metal.

1

13. Save material for surface weld in the vertical position.

I

.L.

( ,c:...

c> (:-

V- ....47TY0.0.

(4=`,.i?:1(2,>"1',T_ u.'" '1""u(-c,',,,-:',l citiIL u,,,,.. , 1,, ,,,,, .!(,,.., ..4

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Li.2

38 PENETRATION


ik B. HORIZONTAL POSITIONtilltfir'MillII

nC

n I411

C. WELD SEQUENCE

NAME

FILLET WELD

MILESTONE AFILLET WELDS


MODULE NO.=

FIGURE NO. 8

ELECTRODE SIZE _§... TYPE32 DIA. DC/RP AWS E 6010

MATrRIAL STEEL SPEC.MILD

AMT. SIZE2 -1---X 64

STEEL MILD 2 X I i X 6

52

1

1

i.

I


Module II,, Fillet Weld

Milestone A, Fillet Welds in the Horizontal Position


INTRODUCTIONThe student will make a fillet weld set for welding in thehorizontal position. This set will contain four welds withsix beads in each. The first bead will make a 5/16 inch,the second and third beads will make a 1/2 inch and beadsfourth, fifth and sixth will complete-the fillets to 5/8inch. These should have a flat face, equal leg length anduniform ripple.



PROCEDURE1. Clean the plate with the wire brush.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves5. Assemble and tack weld pieces to form a cross; place in

the positioner for horizontal welding.6. Drop face shield.7. Establish an arc, raise electrode slightly, move to the

starting point.8. Lower, electrode to the proper arc length.9. Make the weld as demonstrated, use a small forward and

back motion, holding a constant arc length.10. Clean away slag completely after each pass.11. Continue depositing and overlapping beads until the

fillets are of the proper size.12. Repeat this procedure until the desired weld is produced.13. Check dimension of the fillet with gage.14. Save this material for the next project.

53

, ,

. F----4-4N

liti.d,pymilou , 8 ,'

_

1111,11111111010, ,, -3

A B C

._ r--..4....

yt,111)19,))111A1' ,, 'Iiiilillitil,i1111 ,,r .( 4 'I1 '.7 i ''') r)nimmilliAz_ a

MII

8

I

i___

se-

Al1

PENETRATION


B. HORIZONTAL POSITIONN.,lidIRIMEN

P.MI"C" i

WELD SEQUENCE

NAME

FILLET WELDMILESTONE B FILLET WELDS

IN THE HORIZONTAL POSI TIONWITH LACING BEADS

MODULE NO. IL

FIGURE NO. 9

ELECTRODE SITE m_5_ TYPEDIA. DC/RP AWS -E 6010

MATERIAL STEEL SPIREDAMT. SIZE 3v X 21 X 6

STEEL MILD 2 4 X I4- X 6

54


Module II. Fillet Weld

Milestone B, Fillet Welds in the Horizontal Position withLacing Bead


INTRODUCTIONThe student will use the stringer bead fillet welds ofProject 8 to practice this lacing bead in the horizontalposition. This cover pass is deposited on the down stroke,only. The upstroke is made quickly, no metal is deposited,and the electrode is advanced to the position for the nextdown stroke. Overlap about 50% each time down. The com-pleted weld will have a 3/4 inch leg dimension with a flatface, and a smooth surface.


MATERIAL NEEDEDCruciform from Project 8, S/32 inch E6010 electrodes.

PROCEDURE1. Clean the Project 8 welds with hammer and wire brush,completely.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves.S. Put electrode in holder.6. Establish an arc, raise electrode slightly, move to thestarting point.7. Lower electrode to the proper arc length.8. Make welds as demonstrated by your instructor. Keepthe ripples close together.9. Repeat this procedure until the desired weld is produced.10. Use gage to measure depth of deposit.11. Save material for square groove butt joint.

55

A A

* filt it(.1

-(i-B-C

..}

re :i

03

C

r r

4&N.

4 .

r-- 2 4 2 SECTION - A - A

1

I1

I

tI

1

iIt

I

7 MlaoA. HORIZONTAL POSITION

11111101I

PENETRATIONB. WELD ALL FOUR PIPES

kIliti%C. WELD SEQUENCE

111/li 41

NAME

FILLET WELD

MILESTONE CPIPE TO PLATE FILLET WELDS


MODULE Nair

FIGURE NO. 10

ELECTRODE SIZE TYPEDIA. DC/RP AWS E 6010

MATERIAL STEEL SP ECILD.

MILDAMTI SIZE X 8 X 8

STEEL PIPE MILD 4 '.?° X 1

.1--

56



Milestone C, Pipe to Plate Fillet Welds in the HorizontalPosition


INTRODUCTIONThe student will make a pipe to plate fillet weld set byjoining four pipe nipples to each side of a steel plate.Welding will be done with the pipe nipples in the verticalposition. Six beads will be required to make a fillet witha 5/8 inch leg. The fillets should have a flat face, equalleg length and no undercut.


MATERIAL NEEDEP1 piece 3/8 x 8 x 8 inch steel plate, 4 pipe nipples 2 x 1-1/2inches long, 5/32 ihch E6010 electrodes.

PROCEDURE1. Clean material with wire brush.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves.S. Put electrode in holder.6. Tack weld four pieces of 2 inch pipe to the plate 2 inches

in from the plate edges. See drawing No. 10.7. Place assembly for welding in the horizontal position.8. Establish an arc, raise the electrode slightly, move to

the starting point.9. Lower the electrode to the proper arc length.10. Weld half way around pipe in one pass, clean off slag,

weld second half to complete root bead.11. Complete these root beads on each nipple before completing

any single fillet.12. Clean off slag, continue welds until six beads have been

deposited on each weld.13. Practice as demonstrated; use a small forward and back

motion.14. Repeat this procedure until the deiired weld is produced.15. Use gage to check weld size.16. Show work to your instructor; discuss the results.

57

$

DETAIL A

I

!!,

V44.k:;:::!!!!!!! ::

41011111(Aer

tift

.....--.:1:o,

I ii-÷DETAIL 8

24 a

41 8

111111Pr

r C D E

i-!iVii: gli

C. WELD ALL EIGHT CORNERS

IR li I II I I Ii D. WELD ALL AROUND

E. HORIZONTAL POSITION

PENETRATION

NAME

FILLET WELD

MILESTONE DMULTIPLE CORNER FILLET WELDS


MODULE NO. IE

FIGURE NO. II

ELECTRODE SIZE 5_ TYPE3-2 DC/RP AWS-E 6010

MATERIAL STEELSPEC.

MILDMr SIZE A-$ X 8 X 8

STEEL MILD I i- X Ik X 6

STEEL MILD 4 i X 1 f X 21

r

I



Milestone D, Multiple Corner Fillet Welds in the HorizontalPosition


INTRODUCTIONThe student will make a multiple corner set to contain sixoutside corner welds, four unobstructed corner, and fourobstructed corner welds. Each will require six passes tomake fillets with 5/8 inch legs, a flat face, uniform ripples,and no undercut.

EQUIPMENT REQUIREDDC welding machine, slag hammer, wire brush, tongs, filletweld gage, positioner and safety equipment.

MATERIAL NEEDED1 piece 3/8 x 8 x 8 inch, 1 piece 3/8 x 1-1/2 x 6 inch, 4pieces 3/8 x 1-1/2 x 2-1/2 inch steel plate, 5/32 inch E6010electrodes.

PROCEDURE1. Clean plate with wire brush.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves.5. Put electrode in holder.6. Tack weld 3/8 x 1-1/2 inch bars to the 3/8 x 8 x 8 inch

plate as shown in the drawing. A model is kept on dis-play board.

7. Position this assembly for horizontal welding.8. Establish an arc, raise electrode slightly, move to the

starting point.9. Lower electrode to the proper arc length.10. Deposit root bead in all corners on both sides of the

plate before completing any single weld.11. After completing each fillet, clean off all slag.12. Weld as demonstrated, use a forward and back motion with

a constant arc length.13. Repeat this procedure until the desired weld is produced.14. Show the work to your instructor; discuss the results.

59

AXIS OF WELD

407111". ot)4..7

--"--4'''N

F.>Zcd

WW

zz,wV

eVPLATE IS IN HORIZONTAL

POSITION FOR TEST.-3

3 I41-11 nr

Ir A-B

M I,......Ifik ....._

skt

%IOW A. TEST, FILLET WELDWB. HORIZONTAL POSITION

PENETRATION

NAME

FILLET WELDMILESTONE E

FILLET WELD TESTAWS - ASME

MODULE NO. 1I

FIGURE NO. 11-A

ELECTRODE SIZE 1 TYPE32 DIA. DC/RP AWS E 6010MATERIAL SPEC. AMT SIZE

STEEL MILD 2 Ig- X 12 X 3



Milestone E, Fillet Welds Performed According to ASME-AWSSpecification.

Project 11-A

INTRODUCTIONThe student will demonstrate his ability to pass the filletweld test as described in the ASME Fired and Unfired PressureVessel Code, Section IX. The test illustrated in FiguresQ-4 (6). The AWS also illustrates this test in D1.0-72,Figure A-3, 2F (b).

EQUIPMENT REQUIREDDC welding machine, slag hammer, wire brush, tongs, filletweld gage, and safety equipment.

MATERIAL NEEDED2 pieces 1/4 x 3 x 12 inch ASTM A-36 steel plate, 5/32 inchelectrodes.

PROCEDURE1. Clean plate with wire brush.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves.5. Put electrode in holder.6. Tack weld plates to form a 'T' joint, position for

horizontal welding.7. Establish an arc, raise electrode slightly, move to

the starting point.8. Lower electrode to the proper arc length.9. Deposit a 1/4 inch fillet weld. Each weld must be stopped

and restarted at the midpoint of the bead.10. There is no wrap around or return around corner deposit.11. Test weld according to the ASME procedure.

61

(4rtr40i144VZrn4hle6

," I,,,N4t riirok,,ow .

. I.wwwwweimmir, ,,,,,,,,,,wo, - c,leakwati.:1ammoc- --- 11/

_ec,u)

K.403

11N

co

2

A. HORIZONTAL POSITION

B. WELD SEQUENCE

2

CIAION)0

NAME

GROOVE WELDMILESTONE E

nV" GROOVE BUTT WELDS WI BACK UPIN THE HORIZONTAL POSITION

MODULE NO. EL

FIGURE NO. 12

ELECTRODE SIZE TYPEDIA. DC/RP AWS- E- 6010

MATERIALSTEEL SPEC.

MILDAMT.2

SIZE IwX 7 XISTEEL MILD 3 X 6 X 2

62



Milestone E, 'V' Groove Butt Welds with Backing Strip inthe Horizontal Position


INTRODUCTIONThe student will make a groove weld with backing strip. Use5/32 inch E6010 electrodes and stringer beads. These willbe deposited in this order; first, root bead fusing the threepieces; second, pass a single filler bead; third, pass threeoverlapping beads; fourth, a three bead cover. The coverpass will be free of undercut, and have a flat or slightlyconvex face.


MATERIAL NEEDED3 pieces 3/8 x 2 x 6 inch steel plate beveled to 30° on oneside, 2 pieces 1/8 x 1 x 7 inch steel for backing, 5/32 inchE6010 electrodes.

PROCEDURE1.. Clean pla-1-1 with wire brush.2. Set ampei ,e and polarity as directed.3. Start weld ag machine.4. Put on face shield and gloves.5. Assamble plate for a groove butt joint with a 3/16

inch root opening against the backing strip. Placethis assembly face down so that tack welding can bedone on back side.

6. Position for welding in the horizontal position.7. Drop face shield, establish an arc, raise the electrode

slightly, move to the starting point.8. Lower the electrode to the proper arc length, make the

root bead.9. Move along the joint to fuse the beveled edges and the

backing strip together.10. Clean away slag by chipping and brushing.11. Deposit the additional beads as directed by your

instructor.12. The three bead cover pass should not be more than 1/8 inch

above the plate thickness, or wider than 1/16 inch beyondeach side of the groove.

13. Repeat this procedure until the desired weld is produced.14. Show your work to your instructor, discuss the results.15. Save material for beading practice.

63

I r033,--6 j

ualQ

,t.

mt t)+

IrignMal:( 4(KCCIS .6 Ca® mil 6

321

NIREINFORCEMENT PENETRATION

111

ROOT GAP

ROOT FACE&NAME

GROOVE WELD

MILESTONE F"V" GROOVE BUTT WELDS


MODULE NO. Br

FIGURE NO. 13

ELECTRODE SIZE TYPEDIA. DC/RP AWS-E- 6010


STEEL MILD 3 + X 2 X 6

ADVANCED SHIELDED METAL-ARr WELDING


Milestone F, 'V' Groove Butt Welds in the HorizontalPosition


INTRODUCTIONThe student will make a groove weld, without backing strip,in the horizontal position. This will require 4 beads tocomplete. The first bead should have consistent rootpenetration; the 2 filler beads should fill the plate almostflush. The lacing bead cover pass will have no undercut andno sag at the bottom of the bead.

EQUIPMENT REQUIREDDC welding machine, slag hammer, wire brush, tongs,positioner, and safety equipment.

MATERIAL NEEDED3 pieces 3/8 x 2 x 6 dnch steel plate with 30° bevel on oneside, 5/32 inch E6010 electrodes.

PROCEDURE1. Clean plate with wire brush.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves.5. Put electrode in holder.6. Put:the plates face down with the beveled edges paralleland gapped to 3/32 inch. Tack weld on the back side.7. Place this assembly in the positioner for horizontalwelding.8. Drop face shield, establish an arc, raise electrode

slightly,move to the starting point.9. Lower the electrode to the proper arc length.10. Deposit the root bead with a forward and back motion,

concentrate the arc at the gap. Hold a constant arclength.11. Clean away slag after each bead is completed.12. Use lacing manipulation for completing the weld.13. The reinforcement should not be more than 1/8 inch above

plate thickness, or wider than 1/16 inch at each side ofthe groove.14. Repeat this procedure until an acceptable weld is produced.15. Show work to your instructor for a discussion of results.16. Save material for beading practice.

65

. .

I P

. (r.e'

...w16

PENETRATION

REINFORCEMENT

CO

lil>IMP CC

eV I--errInvrUiP lt.0..r....rer...ear, 20orO., C..)

aew CUCC4ES..

..r.

A. WELD BOTH SIDES

B. VERTICAL POSITION

NAME

SURFACING WELD

MILESTONE D SURFACING WELDS

IN THE VERTICAL POSITION -WEAVE BEADS

MODULE NO.1

FIGURE NO. 14

ELECTRODE SIZE j_32 DIA. DC/RP TYPE AWS-E- 6010

MATERIAL SPEC. ANT SIZE




Milestone'D, Surfacing Welds with Weave Beads in the VerticalPosition


INTRODUCTIONThe student will make weave beads, vertically, on steel plate.These beads will alternate in width, one of 1/2 inch widefollowed by a 1 inch bead until the plate is covered. Beadswill be straight with a tight uniform ripple and pattern.


MATERIAL NEEDED1 piece 3/8 x 7 x 8 inch steel plate, 5/32 inch E6010 electrodes.

PROCEDURE1. Clean plate with wire brush and place in the positionerfor vertical welding.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves.5. Put electrode in holder.6. Drop face shield, establish an arc, raise electrode

slightly, move to the starting point.7. Raise electrode to the proper arc length.8. Deposit the weave bead moving upward.9. Make the beads 1/2 inch and 1 inch wide, the rippling mustbe uniform, each weave should overlap the preceding pass.10. Use all electrodes down to a stub end 1-1/2 inch long.11. Clean off slag after completing each bead.12. Show work to your instructor for a discussion to the

results.

67

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NAME

FILLET WELD

MILESTONE F FILLET WELDSIN THE VERTICAL POSITION -

WEAVE BEADS

MODULE NO. 3/

FIGURE NO. 15

ELECTRODE SIZE 5 TYPE32- DIA. DC/RP AWS E 6010


AMT SIZE i X 2 4- X 6

STEEL . MILD 2 4 x ii X 6



Milestone F, Multiple Pass Fillet Welds in the VerticalPosition


INTRODUCTIONThe student will make a fillet weld set to contain four welds.These will be made with weave beads 5/16, 1/2, 5/8 & 7/8 inchleg dimensions. Welding will be in the vertical position,travel up. All welds will have equal leg lengths, flat face,and no undercut.

EQUIPMENT REQUIREDDC welding machine, slag hammr.tr, wire brush, tongs,positioner, and safety equipment.


PROCEDURE1. Clean plates with wire brush.2. Set amperage and polarity to specification.3. Start welding machine.4. Put on face shield and gloves.5. Put electrode in holder.6. Tack weld plates at 90° to form a cross, place in the

positioner for vertical-up welding.7. Drop face shield, establish an arc, raise electrode

slightly, move to the starting point.8. Lower electrode to the proper arc length.9. Deposit the first bead with an up and down motion in

small increments.10. Clean away all slag after completing each pass.11. Use weave motion, crossing in the upward direction, to

complete the weld.12. Repeat this procedure until a weld of specified size and

shape is produced.13. Check the results with fillet weld gage.14. Secure the equipment.

'69

PENETRATION

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FILLET WELitMILESTONE G FILLET WELDS

IN THE VERTICAL. POSITION -WEAVE BEADS

TYPE AWS -E -7018

MODULE NO..

FIGURE NO. 16 1

ELECTRODE SIZE i DIA. DC/ RP

MATERIAL STEEL SPEALDAMT. SIZE 73 X 2+ X 6

STEEL MILD 2 ii X 4 x 6



Milestone G, Multiple Pass Fillet Welds in the VerticalPosition


INTRODUCTIONThe student will make a fillet weld set to contain fourwelds. These will each be made with 4 weave beads in thevertical position. Use 1/8 inch E7018 electrodes. Thewelds will measure 5/16-1/2-5/8-7/8 respectively. Allwelds will have a flat face,, uniform ripples, no undercut,and equal leg lengths.


MATERIAL NEEDED1 piece 3/8 x 2-1/4 x 6 inch and 2 pieces 3/16 x 1-1/2 x 6 inchsteel plate, 1/8 inch E7018 electrodes.

PROCEDURE1. Clean plate with wire brush.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves.S. Put electrode in holder.6. Tack weld the platesat 90° to form a cross, place in

positioner for vertical-up welding.7. Drop face shield, establish an arc, raise slightly,

move to the starting point.8. Lower electrode to proper arc length.9. Use weave motion to deposit bead upward.10. Clean slag from weld after each pass.11. Continue welding until the fillet is of the specified

size and shape.12. Repeat this procedure until a proper weld is produced.13. Check weld with the fillet gage.14. Secure the equipment.

71

PENETRATION

REINFORCEMENT

A B

co

7 J

A . WELD BOTH SIDES


NOTE : - * REFERS TO BEAD WIDTHNAME

SURFACING WELDMILESTONE' E SURFACING WELDS

IN THE VERTICAL POSITION -WHIP BEADS

MODULE NO. I

FIGURE NO. 17

ELECTRODE SIZE 1. DI A . DC/ RP32TYPE AWS E 6010

MATERIAL

STEEL

SPEC. AMT. SIZE

MILD I 1 X 8 X 7



Milestone E, Surfacing Welds in the Vertical Position


INTRODUCTIONThe student will make a surfacing weld with stringer beadsin the vertical position. Use an 8-inch square steel plate,cover both sides with-be-ads with over lapping of SOS. Makeis uniform thickness of deposit with even ripple.

EQUIPMENT REQUIREDDC welding machine, slag hammer, wire brush, tongs,positioner, and safety equipment,

MATERIAL NEEDED1 piece 3/8 x 7 x 8 inch steel plate, 5/32 inch 56010electrodes.

PROCEDURE1. Clean plate wich wire brush, put in positioner for

vertical-up welding.2. Set amperage and polarity as directed.3. Put on face shield and gloves.4. Start welding machine.S. Put electrode in holder.6. Drop face shield, establish an arc, raise electrode

slightly, move to the starting point.7. Lower electrode to the proper arc length.8. Practice vertical welding manipulation. This is a short

up and down whip motion while holding a constant arclength.

9. Deposit the beads with a 50S overlap so that the newwelded surface is uniform in appearance and depth.

10. Clean away slag after finishing each bead.11. Repeat this procedure until the desired-weld is produced.12. Show work to your instructor, discuss the results.13. Save this plate for Project 20.

73

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NAME

GROOVE WELDMILESTONE G

CORNER WELDSIN THE VERTICAL POSITION

MODULE NO.=

FIGURE NO. 18

ELECTRODE SIZE TYPEDIA. DC/RP AWS E 6010 _


STEEL MILD 3 I X 6

74



Milestone G, Corner Welds in the Vertical Position


INTRODUCTIONThe student will make a corner weld with four beads. Thefirst, root bead; second and third, 2 filler beads; fourth,a weave bead cover. This weld will be made in the verticalposition; it should have a slightly convex face with auniform appearance, and no excessive reinforcement on eitherside of the joint.


MATERIAL NEEDED3 pieces 3/8 x 1-1/2 x 6 inch steel plate, S/32 inch E6010electrodes.

PROCEDURE1. Clean plate with wire brush.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves.S. Put electrode in holder.6. Tack weld plates for a 90° corner weld, place in posi-

tioner for vertical-up welding.7. Drop face shield, establish an arc, raise electrode

slightly, move to the starting' point.8. Lower electrode to the. proper arc length.9. Make first bead using an up and down motion in small

increments. Hold a constant arc length.10. This bead should fully penetrate the join"..11. Clean away all slag after each nass.12. Place the two overlapping beads over the root pass.

Finish with a weave bead:13. Repeat this procedure until a proper weld is produced.14. Secure the equipment.

75

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Module III. GroOve Weld

Milestone H, 'V' Groove Welds in the Vertical Position


INTRODUCTIONThe student will make a multiple bead 'V' groove weld onthe reverse side of the corner weld project, number 18.This will require a minimum of 20 beads. There should beno evidence of slag inclusions, pinholes, or porosity.The ends of the joints must be full and straight. Use5/32 inch E6010 electrodes. Weld in the vertical position.


MATERIAL NEEDEDUse reverse of Project 18 weldment, 5/32 inch E6010 electrodes.

PROCEDURE1. Wire brush the plate, pie In positioner for vertical

welding.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves. _-5. Put electrode- in holder.6. Drop face shield, establish an arc, raise electrode

slightly, move to starting point.7. Lower electrode to proper ar length.8. Place the root bead; use alt and down motion in the

direction of travel.9; Up 3/8 and down 1/4 inch are the approximate increments

of movement. Hold a close arc.10. Clean off slag after depositing each bead.11. Repeat this procedure until the desired weld is produced.12. Have the instructor see your work, discuss the results

with him.

77

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PENETRATION

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C. WELD ALL FOUR PIPES

cati) D. WELD SEQUENCE

MIIIIIIIM,IIIIIW

NAME

FILLET WELDMILESTONE H FILLET WELDS

IN THE FIXED POSITIONPIPE TO PLAYE

MODULE NO. Ir

FIGURE NO. 20

ELECTROW SIZE A TYPE32 DIA. DC/RP AWS E - 6010MATERIAL

STEEL SPEC.MILD

AMT.I

SIZE 2 X 8 X C8STEEL PIPE MILD 4 20 X.,, I'



Milestone H, Fillet Welds in the Fixed Position - Pipe toPlate


INTRODUCTIONThe student will make a pipe to place set. He will tackweld four pipe nipples to each side of a steel plate.With this plate held in vertical plane, the fillet weldsformed will be welded with 6 passes, each. The weld willmeasure-5/8 inch, have a flat face, and equal leg lengths.

EQUIPMENT REQUIREDDC welding machine, slag hammer, wire brush, tongs,positioner, fillet gage, and safety equipment.

MATERIAL NEEDED1 piece 3/8 x 8 x 8 inch steel plate, 4 pieces 1-1/2 x 2 inchsteel pipe, 5/32 inch E6010 electrodes.

PROCEDURE1. Clean the material with wire brush.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves.5. Put electrode in holder.6. Tack weld the 4 pieces of pipe on one side of the plate

1 inch in from the edge, and on 4 inch centers. Placein positioner for vertical welding.

7. Drop face shield, establish an arc, raise electrodeslightly, move to the starting point.

8. Lower electrode to the proper arc length.9. Start each bead at position 7 o'clock, move vertically

upward to position 12 o'clock in a clockwise direction.10. Clean off slag.11. Start second half of this bead at the beginning of the

first half, at position 7 o'clock. Move counterclockwiseunder and up to position 12 o'clock.

12. Repeat this procedure until consistent results are obtained.13. Check work with fillet gage for the proper weld contour and

size.14. Show work to your instructor for a discussion of the

results.

79

PENETRATION

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NAME

FILLET WELDMILESIONE I

FILLET WELD TESTAWS ASME

MODULE No. 71

FIGURE NO. 20-A

ELECTRODE SIZE 532

TYPEDIA. DC/RP AWS -E 6010

MATERIAL SPEC, AMT SIZE

STEEL MILD 2I

q--- X 12 X 3

. .



Milestone I, Fillet Weld Test in the Vertical Position

Project; 20-A

INTRODUCTIONThe student will demonstrate his welding ability by performingthe ASME fillet weld test shown in Fig. Q-4 (C) in the ASMEFired and Unfired Pressure Vessel Code, Section IX. This isalso shown in AWS code D1.0-72, Fig. A-3, 3F (C).

EQUIPMENT REQUIREDDC welding machine, slag hammer, wire brush, tongs,positioner, fillet weld gage, and safety equipment.

MATERIAL NEEDED2 pieces 1/4 x 3 x 12 inch ASTM A36 steel plate, 5/32 inchE6010 electrodes.

PROCEDURE1. Clean plate with wire brush.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves.5. Put electrode in holder.6. Tack weld plates in a 'T' joint for fillet welding.7. Place in positioner for vertical-up welding.8. Drop face shield, establish an arc, raise electrode

slightly, move to the starting point.9. Raise elect ode to the proper arc length.10.(Weld from tne bottom up; use the technique practiced in

Project 18.11. Each pass mast-be stopped and restarted at the midpoi::t.12. Clean away slag before restarting the weld.13. There is no weld around the plate ends.14. See the ASME testing procedure; make this test on the weld.

81

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ROOT GAP

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NAME

GROOVE WELD .4'.MILESTONE II,-

"Ii" GROOVE* BUTT WELDS W/ BACK UPIN THE '`VERTICAL POSITION

MODULE NO. -III

FIGURE NO. 21

ELECTRODE SIZE DIA. DC/RP TYPE AWS ' E 6010iMATERIAL STEEL SPEC

MILDAMT.2

SIZE I X I X 7

STEEL MILD 3 131- X Ii X 6

......

82



Milestone I, 'V' Groove Butt Welds with Backing Strip,in the Vertical Position


INTRODUCTIONThe student will make a 'V' groove weld with a backingstrip in the vertical position. Use 5/32 inch E6010electrodes to make this 6 pass weld. 'First, pass in rootto fuse backing and beveled edges; second, a single bead;third, two filler beads complete with a two bead cover pass.The cover pass will have a uniform ripple and no evidenceof undercut.


MATERIAL NEEDED3 piece:, 3/8 x 1-1/2 x 6 inch steel plate, beveled to 30°on on6 side, 2 pieces 1/8 x 1 x 7 inch plate, 5/32 inchE6010 electrodes.

PROCEDURE1. Clean plate with wire brush.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and. gloves.5. Place beveled plates face down with parallel alignment

and a root opening of 3/16 inch. Put backing stripover this joint. lack weld.

6. Place in positioner for welding in the vertical-upposition.

7. Establish an arc; raise the electrode slightly, move tothe starting point.

8. Lower the electrode to the proper arc length.9. Make the rcot bead, fusing the beveled edges and the

backing strip10. Chip and wiry brush to completely remove slag after

finishing eacH pass.11. Place ad,liticaal beads as directed.12. The finished reinforcement should not be more than 1/8

inch above base metal thickness, or wider than 1/16 inchat each side of the groove.

13. Repeat this procedure until an acceptable weld isprodliced.

14. Show work to your instructor, discuss the results.15. Save material for beading practice.

83

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ROOT GAP

TACK 1._16Mk

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PENETRATION

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NAME

GROOVE WELD

MILESTONE J"V" GROOVE BUTT NELDS W/BACK UP

IN THE VERTICAL POSITION

MODULE No. lirFIGURE NO. 22

ELECTRODE SIZE _5,_ TYPE32 DIA. DC/RP AWS -E - 6010

MATERIAL STEEL SPEC,MILD

AN T2 SIZE -Ig-XIX 7

, STEEL MILD 3 11 X I-I X 6

84



I Milestone J, 'V' Groove Butt Welds with BaCking Strip inthe Vertical Position

Project 22: Time: 6 hours

INTRODUCTION'Me student will make a groove weld with backing strip in-he vertical position. Place the beads as follows: First,root bead fusing, the beveled edges to the backing strip;second, two filler beads; third, a weave bead cover. Thecover pass will have a uniform pattern with a flat lightripple and no undercut.

EQUIPMENT REQUIREDDC welding machine, slag hammer, wire brush, tongs,positioner, and safety r nipment.

MATERIAL NEEDED3 pieces 3/8 x 1-1/2 x 6 inch steel plate beveled on oneside to 30°, 2 pieces 1/8 x 1 x 7 inch steel strip, 5/32inch E6010 electrodes.

PROCEDURE1. Clean plate with wire brush.2. Set amperage and polarity as directed.3. Put on face shield and gloves.4. Put electrode in holder.5. Assemble plate by placing the beveled pieces face down,

the edges parallel with a 3/16 inch gap. Place backingstrip over this gap, tack weld to each side.

6. Position for vertical-up welding.7. Drop face shield, establish an arc, raise electrode

slightly, move to the starting point.8. Lower electrode to the proper arc length.9. Make root pass using an up and down mot:on, hold a

constant arc length.10. Clean away slag after each bead is completed.11. Place additional stringer beads, the cover bead is a

weave pass.12. The reinforcement should not be more than 1/8 inch

above plate thickness, or wider than 1/16 inch ateach side of the groove.

13. Repeat this proceare until an acceptable weld isproduced.

14. Save material for beading practice.

85

ROOT GAP

TACK 2lay 16

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A.

B.

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NAME

GROOVE WELD .*

MILESTONE K"V" GROOVE BUTT WELDS W/BACK UP


MODULE NO. MI

FIGURE NO. 23

ELECTRODE SIZE 1

DIA. DC/RPTYPE

AWS -E- 7018MATERIAL

STEEL SPECMILD 2

AMT. SIZE wi X I X 7

STEEL MILD 3 if X If X 6

86



Milestone K, 'V' Groove Butt Welds with Backing Strip inthe Vertical Position


INTRODUCTIONThe student will make a groove weld with backing strip inthe vertical position. Use 1/8 inch E7018 electrodes todeposit beads as follows: first, a root pass fusing the 3plates together; second and third, 2 filler beads; fourth,a weave bead cover pass. The cover pass will have a uni-form pattern with tight flat ripples and no evidence ofundercut.


MATERIAL NEEDED3 pieces 3/8 x 1-1/2 x 6 inch steel plate beveled to 30° onone side, 2 pieces 1/8 x 1 x 7 inch steel for backingstrip, AWS 1/8 E7018 electrodes.

PROCEDURE1. Clean plate with wire brush.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves.5. Put electrode in holder.6. Tack weld 3/8 inch beveled plates to backing strip in

parallel alignment leaving a root opening of 3/16 inch.Place in positioner for vertical-up welding.

7. Establish an crc, raise electrode slightly, move to thestarting point.

8. Lower electrode to the proper arc length.9. Make the root pass with a small weave motion. Concentrate

arc to fuse the three plates together.10. Remove slag after each pass is completed.11. Weave additional beads as directed.12. Make the cover pass. It should not be more than 1/8 inch

above plate thickness, or wider than 1/16 inch at eachside of the groove. -

13. Repeat this procedure until an acceptable weld is produced.14. Show work to your instructor, discuss the results.15. Save material for beading practice.

Note: The root opening may vary according to local practiceor design. This may require a greater number of beadsfor completion of the joint.

87

ROOT GAP

32

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PENETRATION

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SUBSTITUTE

IF AVAILABLE

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GROOVE WELD

MILESTONE L"V" GROOVE BUTT WELDSIN THE VERTICAL POSITION

MODULE NO. Xi

FIGURE NO. 24'

ELECTRODE SIZE 32 DIA. DC/RP TYPE AWS E 6010


STEEL MILD 3 X IT X 6

88



Milestone L, 'V' Groove Butt Welds in the Vertical Position(When available, substitute 6 inch pipe)


INTRODUCTIONThe student will make a 'V' groove weld without a backupin the vertical position. Use 5/32 inch E6010 electrodes.Place the beads as follows: first-, a root pass with fullpenetration; second pass, single bead; third, two over-lapping beads; fourth, two bead cover. The cover will havetight uniform ripples and no evidence of undercut.

EQUIPMENT kEQUIREDDC welding machine, slag hammer, wire brush, tongs,positioner and safety equipment.

MATERIAL NEEDED3 pieces 3/8 x 1-1/2 x 6 inch steel plate beveled on oneside to 30 , 5/32 inch E6010 electrodes.

PROCEDURE1. Clean the plate with wire brush.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves.5. Put electrode in holder.6. Tack weld the beveled plates with a root opening of 3/32

inch, place in positioner for vertical-up welding.7. Drop face shield, establish an arc, raise electrode

slightly, move to the starting point.8. Lower electrode to the proper arc length.9. Deposit root bead, use an up and down motion with a

short arc.10. Clean off slag completely after each pass.11. Whip the remaining passes as demonstrated.12. The cover bead must not exceed the plate thickness by

more than 1/8 inch or be wider than 1/16 inch at eachside of the groove.

13. Repeat this procedure until the required weld is produced.14. Secure the equipment.

89

PENETRATION

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NAME

FILLET WELDMILESTONE J

FILLET WELDS

IN THE VERTICAL DOWN POSITION

MODULE NO. 31

FIGURE NO. 25

ELECTRODE SIZE 375TYPE

DIA. DC/RP AWS E- 6010


AMTI

SIZE 3 1-g X2TX 6

STEEL MILD 2 3 X I2-Ifa X 6

90



Milestone J, Fillet Welds in the Vertical Down Position


INTRODUCTIONThe student will make a fillet weld set to contain four,four pass welds. These will be deposited as weave beadsin thevertical down position. Use 5/32 inch E6010 elec-trodes. The beads will have a fine, smooth texture, flatface, and no evidence of pinholes or porosity.



PROCEDURE1. Clean plate with wire brush.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves.5. Put electrode in holder.6. Tack weld plate to form a cross, place in the positioner

for vertical welding.7. Establish an arc, raise electrode slightly, move to the

starting point.8. Lower electrode to the proper arc length.9. Hold electrode to a 60° angle downward from the joint,

make a rapid weave motion while moving down.10. Clean away all slag after each pass is completed.11. Continue weaving beads for 3 more passes to fill the

joint to the required dimension.12. Repeat this procedure until the desired weld is produced.13. Show work to your instructor, discuss results.

91

ROOT

32

1 db. 12'1

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NAME

GROOVE WELDMILESTONE M

"V" GROOVE BUTT WELDSIN THE VERTICAL DOWN POSITION

MODULE NO. XI

FIGURE NO. 26

ELECTRODE SIZE 5 TYPE32- DIA. DC/RP AWS E 6010

MATERIAL SPEC AMT SIZE

STEEL MILD1w 12- X 6

92



Milestone M, 'V' Groove Butt Welds in the Vertical DownPosition


INTRODUCTIONThe student will make a groove butt weld in the vertical downposition. This four pass weld consists of two stringer beads,finished with two weave beads. Use S/32 inch E6010 electrodes.The cover pass will have a fine smooth ripple and no evidenceof pinholes, porosity, or undercut.


MATERIAL NEEDED3 pieces 3/8 x 1-1/2 x 6 inch steel plate beveled to 30° onone side, S/32 inch E6010 electrodes.

PROCEDURE1. Clean plate with wire brush.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves.5. Put electrode in holder.6. Tack weld plates with 3/32 inch gap between the beveled

edges, place in the positioner for vertical welding.7. Establish an arc, raise electrode slightly, move to the

starting point at the top of the joint.8. Lower the electrode to the proper arc length.9. Hold electrode at a 60° angle downward from joint, move

down with a fast weave bead.10. Clean away slag completely after each pass.11. Make a weave bead for each succeeding pass until groove

is filled.12. Repeat this procedure until the desired weld is produced.13. Show work to your instructor, discuss the results.

93

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AWS-E- 7024

AWS-E- 7018 FILLET WELDVERTICAL POSITION.

AWS-E- 7024 GROOVE WELDOPTIONAL POSITION.

1....1

NAME

GROOVE WELD

MILESTONE NWELD SOUNDNESS


MODULE NO. mr

FIGURE NO. 27

ELECTRODE SIZE I TYPETi- DIA.. DC/RP AWS-E- 7018 / AWS -E- 7024

MATERIALSTEEL SPEC.

MILDAMT

ISIZE 3 I73- X ly X 7

STEEL MILD 23

11- X 3 X 6

94



Milestone N, Weld Soundness, Vertical Position


INTRODUCTIONThe student will make a weld on square cut plates tackwelded to a backing strip so that there will be two filletwelds at each side of the groove. These will be made in thevertical position, using E7018 electrodes. The remainingweld beads are deposited in the flat position using E7024electrodes until the fillets are covered and the groove isfilled.


MATERIAL NEEDED2 pieces 3/8 x 3 x 6 inch, 1 piece 3/8 x 1-1/2 x 7 inch steelplate, 1/8 inch E7018 and E7024 electrodes.

PROCEDURE1. Clean plates with wire brush.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves.5. Put electrode in holder.6. Assemble plates for a double lap joint with a 15/16 inch

opening between the plates. Tack weld these to thebacking strip on the backside.

7. Place in the positioner for vertical welding.8. Use 1/8 inch E7018 electrodes to make two fillets at each

side of the groove.9. Place in the flat position, remove slag completely.10. Use 1/8 inch E7024 electrodes to fill the groove with over-

lapping beads. There should be ro evidence of slag in-clusions, pinholes, or porosity. The ends of the jointsmust be full and straight.

11. Repeat this procedure until the desired weld is produced.12. Save the material for practice welding.

95

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NAME

SURFACING WELD .

MILESTONE FSURFACING WELDS

IN ME OVERHEAD POSITION

MODULE NO. I

FIGURE NO. 28

ELECTRODE SIZE.3715 TYPEWA. DC/RP AWS - E 6010


STEEL MILD 13-if X T X 8

96



Milestone F, Surfacing Welds in the Overhead Position

Project 28: Time: 6 hours

INTRODUCTIONThe student will deposit surfacing welds on both sides of asteel plate. This will be done in the overhead position,using S/32 inch E6010 electrode, overlap each bead by 50%.The surface should be uniform in buildup and appearance.


MATERIAL NEEDED.1 piece 3/8 x 7 x 8 inch steel plate:, 5/32 inch E6010 electrodes.

PROCEDURE1. Clean plate with wire brush, place in positioner for

overhead welding.2. Set amperage and polarity ass directed.3. Start welding machine.4. Put on face shield and gloves.5. Put electrode in holder.6. Establish an arc, lower the electrode slightly, move to

the starting point.7. Raise electrode to proper arc length.8. Hold electrode 90° to the plate, the work angle, and with

a leading angle of 45°.9. Use a forward and back motion in small increments, arc

length should not change.10 Use all electrodes down to a stub 1-1/2 in,:hes long.11. Clean off all slag after each pass is completed.12. Repeat until plate is covered with a uniform surface.13. Show work to your instructor for a discussion of the

results.14. Save material for further projects,

97

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C. WELD SEQUENCE

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NAME

FILLET WELD

MILESTONE KFILLET WELDS


MODULE NO. Z

FIGURE NO. 29

ELECTRODE SIZE 1... TYPE32 DIA. DC/RP AWS -5..-- 6010


AMT.2

SIZE a6 X Iri X 6

STEEL MILD 1 116 X 24-1 X 6

8



Milestone K, Multiple Pass Fillet Welds in the OverheadPosition


INTRODUCTIONThe student will make a fillet weld set for welding in theoverhead position. This set will contain 4 welds with sixbeads each. The first bead will make a 5/16 Inch weld.The second and third beads will make a 1/2 inch weld. Thefourth, fifth, and sixth beads will complete the filletsto 5/8 inch. These should have a flat face, equal leglength, and uniform ripple.


MATERIAL NEEDED2 pieces 3/16 x 1-1/2 x 6 inch, 1 piece 3/16 x 2-1/4 x 6 inchsteel plate, 5/32 inch E6010 electrodes.

PROCEDURE1. Clean plate with wire brush.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves.5. Put electrode in holder.6. Tack weld plates to form a cross, place in positioner for

overhead welding.7. Establish an arc, lower electrode slightly, move to the

starting point.8. Raise electrode to the proper arc length.9. Deposit beads with a forward and back motion in small

increments, hold a constant arc length.10. After each bead is completed remove all slag.11. Continue welding, overlapping each bead, until the 5/8

inch leg length is reached.12. Repeat this procedure until a proper weld is produced.13. Check the weld dimension with gage.

99

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NAME

FILLET WELD

MILESTONE LFILLET WELDS


MODULE NO. E

FIGURE NO. 30

ELECTRODE SIZE 1DIA. DC/RP TYPE AWS-E- 7018

8MATERIAL STEEL SPEC.

MILDAMT.2

SIZE ii X ii. X 6

STEEL MILD I -11- X 24. X 6

100



Milestone L, Multiple Pass Fillet Welds in the OverheadPosition


INTRODUCTIONThe student will make a fillet weld set for welding in theoverhead position. This set will contain 4 welds with sixbeads each. The first bead will make a 5/16 inch weld.The second and third beads will make a 1/2 inch weld. Thefourth, fifth, and sixth beads will complete the filletsto 5/8 inch. These should have a flat face, equal leglength, and uniform ripple.


MATERIAL NEEDED2 pieces 3/16 x 1-1/2 x 6 inch, 1 piece 3/16 x 2-1/4 x 6 inchsteel plate, 1/8 inch E7018 electrodes.

PROCEDURE1. Clean plate with wire brush.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves.5. Put electrode in holder.6. Assemble and tack weld pieces at 90° to form a cross,

plate in the positioner for overhead welding.7. Establish an arc, lower electrode slightly, move to the

starting point.8. Raise electrode to the proper arc length.9. Practice as demonstrated by the instructor using a "C"

motion for better puddle control and penetration.10. After each bead is completed, remove slag completely.11. Continue welding, overlapping each bead until the 5/8

inch leg dimension is reached.12. Repeat this procedure until a proper weld is produced.13. Check fillet dimension with gage.

101

PENETRATION

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C. WELD ALL EIGHT CORNERS

D. WELD ALL AROUND

E. VERTICAL FIXED POSITION41- li-÷-8

NAME

FILLET WELD

MILESTONE M

CORNER WELDSIN THE VERTICAL FIXED POSITION

MODULE NO. I

FIGURE NO. 31

ELECTRODE SIZE 5.2 DIA. DC/RP TYPE AWS-E-60I0

MATERIAL STEELSPE

MILDAMT SIZE ..B-- X 8 X 8

STEEL MILD I a X 1k X 68

STEEL MILD 4 I X I X 2'8

102



Milestone M, Corner Welds in the Vertical Fixed Position


INTRODUCTIONThe student will make a multiple corner fillet weld set. Thiswill have six outside corner welds, four unobstructed cornerwelds, and four obstructed corner welds. Use six passes foreach weld with 5/32 inch E6010 electrodes. All welds willhave equal leg lengths of 5/8 inch with a flat face and noundercut.


MATERIAL NEEDED1 piece 3/8 x 8 x 8 inch, 1 piece 3/8 x 1-1/2 x 6 inch, 4pieces 1/8 x 1-1/2 x 2-1/2 inch steel plate, 5/32 inch E6010electrodes.

PROCEDURE1. Clean plate with wire brush.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves.S. Put electrode in holder.6. Tack weld the pieces together as shown in the drawing. A

sample is on the display board.7. Place this assembly in the positioner for vertical welding..8. Establish an arc, raise the electrode slightly, move to

the starting point.9. Lower the electrode to the proper arc length.10. Deposit the root beads in all of the joints on both sides

of the plate before completing any one weld.11. Chip and wire brush the welds to completely remove slag.12. Practice welding as demonstrated by your instructor, use

an up and down motion in small increments.13. Repeat this procedure until consistent welds are produced.14. Show work to your instructor for a discussion of the

results.

103

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POSITION

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A. TEST, FILLET WELD.

B. OVERHEAD POSITION.

NAME

FILLET WELDMILESTONE N

FILLET WELD TESTAWS - ASME

MODULE NO. Z

FIGURE NO. 31 -A

ELECTRODE SIZE 325 TYPEDIA. DC/ RP AWS E 6010MATERIAL SPEC. AMT SIZE

STEEL MILD X 12 X 3

104



Milestone N, Fillet Weld Test, Overhead Position

Project 31-A

INTRODUCTIONThe student will demonstrate his ability t, pass the ASMEfillet weld test as it is described in the ASME Fired andUnfired Pressure Vessel Code, Section IX, Fig.Q4(d), or theAWS fillet weld test described in the D1.0-72, Fig.A-3, 4F(d).


MATERIAL NEEDED2 pieces 1/4 x 3 x 12 inch ASTM A36 steel plate, 5/32 inchE6010 electrodes.

PROCEDURE1. Clean plate with wire brush.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves.5. Put electrode in holder.6. Tack weld plate to form a 'T' joint, place in positioner

for overhead welding.7. Establish an arc, lower electrode slightly, move to the

starting point.8. Raise electrode to the proper arc length.9. Weld from left to right, using a forward and back motion,

with a constant arc length. Each bead must be stoppedand restarted at the midpoint of the bead.

10. The completed weld should have equal leg length of 1/4inch.

11. There is no wrap around weld or return at the corners.12. Test this weld as shown in the ASME procedure.

105

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B. AWS-E- 7024 GROOVE WELD

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Li2

NAMEGROOVE WELD

MILESTONE 0WELD SOUNDNESS


MODULE NO. IID

FIGURE NO. 32

ELECTRODE SIZE ./.. TYPEDIA. DC/RP AWS E- 7018 / AWS -E- 7024MATERIAL'

STEELSPEC.

MILDAMT

ISIZE A 1

8 X 12 X 7


106



1

Milestone 0, Weld Soundness, Overhead Position


INTRODUCTIONThe student will make a weld on square cut plates which aretack welded to a backing strip. This forms a groove for twofillet welds at each side. These will be made in the overheadposition using E7018 electrodes. The remaining weld beadswill be deposited in the flat positon using E7024 electrodesto complete filling the groove.


MATERIAL NEEDED1 piece 3/8 x 1-1/2 x 7 inch, 2 pieces 3/8 x 3 x 6 inch squarecut steel plate, 1/8 inch E7018 and E7024 electrodes.

PROCEDURE1. Clean plate with wire brush.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves.5. Put electrode in holder.6. Tack weld the plates to form a double lap joint with the

backing strip. Leave an opening of 15/16 inch betweenthe square cut pieces.

7. Place in the positioner for overhead welding.8. Weld the two fillets using E7018 electrodes. Direct the

arc to the corners for good penetration.9. Place in the flat position, clean away all slag, complete

the weld by filling the groove with overlapping beads.Use E7024 electrodes for this.

10. Repeat this procedure until the desired weld is produced.11. Save material for weld practice.

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PENETRATIONHB,,

A. OVERHEAD POSITION

B. WELD SEQUENCE

NAME

GROOVE WELDMILESTONE P

"V" GROOVE BUTT WELDS W/ BACK UPIN THE OVERHEAD POSITION

MODULE NO.=

FIGURE NO. 33

ELECTRODE SIZE _5_ TYPE3-2 DIA. DC/RP AWS E 6010


AMT4

SIZE 3 Iir X 12- X 6

STEEL MILD 3 I7i- X I X 7

108

1-



Milestone P, 'V' Groove Butt Welds with Backing Strip, inthe Overhead Position


INTRODUCTIONThe student will make a 'V' groove with backing strip inthe overhead position. Use S/32 inch E6010 electrodes.Place beads in the following order: first, root bead;second, single bead; third, two overlapping beads; fourth,three bead cover. The cover pass will have a uniformappearance and no undercut.


MATERIAL NEEDED4 pieces 3/8 x 1-1/2 x 6 inch steel plate beveled to 30°on one side, 3 pieces 1/8 x 1 x 7 inch steel strip, S/32inch E6010 electrodes.

PROCEDURE1. Clean plate with wire brush.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves.S. Put electrode in holder.6. Assemble the plates for a 'V' groove butt joint with

a 3/16 inch root opening. Tack weld these to thebacking strip. Place in the positioner for overheadwelding.

7. Establish an arc, lower electrode slightly, move to thestarting point.

8. Raise electrode to the proper arc length.9. Make the first bead, fusing the two beveled edges to

the backing strip. Use a forward and back motion witha constant arc length.

10. Clean away slag completely when each pass is finished.11. Continue depositing stringer beads for the succeeding

passes and the cover.12. The reinforcement should be slightly convex, uniform

in appearance. It should not be more than 1/8 inchthicker than the plate or more than 1/16 inch widerat each side of the groove.

13. Repeat this procedure until the desired weld is produced.14. Show work to your instructor, discuss the results.1S. Save material for weld practice.

109

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B. WELD SEQUENCE

ir4.0.1,

PENETRATION"B"

NAME

GROOVE WELD

MILESTONE 0 R

"V" GROOVE BUTT WELDS W/ BACK UPIN THE OVERHEAD POSITION

MODULE NO. AL

FIGURE NO. 34

ELECTRODE SIZE Ir DIA. DC/RP TYPE AWS - E- 7018


AMT.4

SIZE ... x 48 2 X 6


110



Milestone Q, 'V' Groove Butt Welds with Backing Strip, inthe Overhead Position

Project 34; Tine: 9 hours

INTRODUCTIONThe student will make a 'V' groove butt joint with backing'strip weld in the overhead position. Use 1/8 inch E7018electrodes in the following sequence: first, root bead;second, single bead; third, two overlapping beads; fourth,three bead cover. The cover will have a uniform appearanceand no undercut.


MATERIAL NEEDED4 pieces 3/8 x 1-1/2 x 6 inch steel plate bevel,pd to 30° onone side. 3 pieces 1/8 x 1 x 7 inch steel for the backingstrip, 1/8 inch E7018 electrodes.

PROCEDURE1. Clean plate with wire brush.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves.5. Put electrode in holder.6. Assemble plate for a groove joint with 3/16 inch root

opening, tack weld to backing strip. Place in the po-sitioner for overhead welding.


8. Raise electrode to the proper arc length.9. Make root bead, fusing the beveled edges together and

to the backing strip. Use a small weaving motion witha constant arc length.

10. After completing each bead, clean all slag from metal.11. Place additional beads as directed until the groove is

filled.12. The reinforcement should not be more than 1/8 inch

thicker than the plate, or wider than 1/16 inch at eachside of the groove.

13. Repeat this procedure until an acceptable weld is produced,14. Show work to your instructor for a discussion oZ results.15. Save material for welding practice.

Note: The root opening may vary according to local practiceor design. This may require a greater number of beadsfor completion of the joint.

111

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1 1 1

A ROOT FACE

AllakEir:41 i 1 If t b t ta


B. WELD SEQUENCEREINFORCEMENT

leC. SUBSTITUTE 6 IN. PIPE

IF AIIAILABLE

NAME

GROOVE WELD.---;

MILESTONE R"V" GROOVE BUTT WELDS


MODULE NO. liE

FIGURE NO. 35.

ELECTRODE SIZE _§.. TYPE32 DIA. DC/ R P AWS E 6010


AMT4

SIZE 3 I6 X If X 6

112

I



Milestone R, 'V' Groove Butt Welds in the Overhead Position(When availare, substitute 6 inch pipe)


INTRODUCTIONThe student will make a groove butt weld without backupstrip in the overhead position. Use 5/32 inch E6010 elec-trodes. Beads will be placed: root bead with full pene-tration; second, single bead; third, two overlapping beads;fourth, three bead cover. Inspect the sample weld on thedisplay board for guidance.


MATERIAL NEEDED4 pieces 3/8 x 1-1/2 x 6 inch steel plate beveled to 30° onone side, 5/32 inch E6010 electrodes.

PROCEDURE1. Clean plate with wire brush.2. Set amperage and polarity as directed.3. Start welding machine.4. Put on face shield and gloves.5. Put electrode in holder.6. Assemble the plates and tack weld together with a root

opening of 3/32 inches. Place in the positioner foroverhead welding.


8. Raise electrode to the proper arc length.9. Deposit a root bead with full penetration, drag electrode

on plate edges.10. After each pass is completed remove all slag.11. Deposit succeeding beads as directed. The reinforcement

should not be more than 1/8 inch above plate thickness,or wider than 1/16 inch at each side of the groove.

12. Repeat this procedure until the desired weld is produced.13. Show work to your instructor, discuss the results.14. Save material for practice welds.

113

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A. FLAT POSITION

B. HORIZONTAL POSITION

C. VERTICAL POSITION

D. OVERHEAD POSITION

/40144/i11),'';17'

.2/ ,Ii/41

NAME

GROOVE WELD

MILESTONE S"V" GROOVE BUTT WELDS

TEST IN FOUR POSITIONS

MODULE NO. .TIL

FIGURE NO. 36

ELECTRODE SIZE 328 TYPEDIA. DC/RP AWS-E- 6010

MATERIAL STEEL S PEC.MILD

AMT5

SIZE 18 X Ik X 6

STEEL MILD 41

8 X I X 7

114



Milestone S, 'V' Groove Butt Weld Test in Four Positions


INTRODUCTION

IThe student will prepare beveled plates for welding fourgroove welds with backing strips. These are described inSection IX of the ASME Code, Fig. Q23, 1G(a), 2G(b), and

1

4G(c). After completing the welds, they will be machinedto plate dimension; 1-1/2 inch coupons will be taken forbend testing. One face and one root bend will be made for

I

each welding position. The student will prepare and bendthese specimens. This project is only for training andnot for certification.

IEQUIPMENT REQUIREDDC welding machine, slag hammer, wire brush, tongs, andsafety equipment. The use of a shaper and bending presswill also be required.

MATERIAL NEEDED4 pieces 1/8 x 1 x 7 inch, 5 pieces 3/8 x 1-1/2 x 6 inchsteel plate with a 30° bevel on each side, 5/32 inch E6010electrodes.

PROCEDURE1. Clean plate with wire brush.2. Set amperage and polarity to specifications.3. Start welding machine.4. Put on face shield and gloves.5. Put electrode in holder.6. Tack weld the plates to form 4 'V' groove butt weld joints

with 3/16 inch root opening. Place consecutively in thepositioner for flat, horizontal, vertical and overheadwelding.

7. Weld each joint with stringer beads at the root; cleanand complete following the specifications shown on thedrawing. Full fusion of the beveled and backing stripsis required. Guard against slag inclusions, and pinholing.

115

SHIELDED METAL-ARC WELDING

CERTIFICATION

PHASE III PART A OBJECTIVE

Foliating the completion of both the basic and advanced

arc welding programs, the trainee is given the opportunity

to participate in arc certification practice for 180 hours

(Part A). Eighty-percent of those students who take part

in this work will have the ability to pass the American

Society for Mechanical Engineers groove weld with backing

strip test. The procedure is described in section IX

Figure Q-23 (A) and Figure Q-3 position 2G, 3G, and 4G of

the ASME boiler and pressure vessel code. The American

Welding Society also describes the test in the AWS Manual

D1.0-72, Code for Welding in Building Construction, Figure

A-14, and positioned according to Figure A-2, 2G(b), 3G(c),

4G(d).

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NAME

ASME -AWS GROOVE WELD TESTSMILESTONE A

"V" GROOVE W/ BACK UPIN THE HORIZONTAL POSITION

MODULE NO. I

FIGURE NO. /

ELECTRODE SIZE 5 DIA. DC/ RP TYPE AWS- E 601032MATERIAL STEEL SPEC.

MILDA2 TM. SIZE

83 X 4 X 8

STEEL MILD I X I X 9

118


CERTIFICATION TEST

Module I. ASME or AWS Groove Weld Tests

Milestone A, 'V' Groove with Backing Strip in the HorizontalPosition


INTRODUCTIONThe student will make a 'V' groove weld with backing stripin the horizontal position, using 5/32 inch E6010 electrodes.The beads to be deposited as follows: first pass, penetration;second pass, single bead; third pass, three beads; fourth pass,three bead cover. The finished weld must be of test quality tobe used for qualifying the weldor's skill.

EQUIPMENT REQUIREDDC welding machine, slag hammer, wire brush, tongs, safetyequipment, and shaper.

MATERIAL NEEDED2 pieces 3/8 x 4 x 8 inch steel plate, beveled on one side to30°, 1 piece 1/8 x 1 x 9 inch for the backing strip, 5/32 inchE6010 electrodes.

PROCEDURE1. Clean the plates with wire brush.2. Set the amperage and polarity to specification.3. Start welding machine.'4. Put on face shield and gloves.5. Place electrode in holder.6. Drop face shield.7. Tack weld the back side of the plates to the backing strip

with a root opening of 3/16 inches.8. Place this assembly in the positioner for welding in the

horizontal position.9. Establish an arc, raise electrode slightly, move to the

starting point.10. Power electrode to proper arc length.11. Place the first pass using a forward and back motion in

small increments.12. After each pass is completed, chip and wire brush the weld

so that it is completely clean of slag.13. Place the succeeding beads as directed by your instructor.14. Concentrate the arc on the edges of the previous bead.15. Place the cover beads so that the total reinforcement will

not exceed the plate thickness by more than 1/8 inch, norbe wider than 1/16 inch at each side of the groove.

16. Show work to your instructor for a discussion of the results.17. Prepare for testing; remove all metal at the face and root

of the weld down to plate thickness. Cut out 1-1/2 inchcoupons for the bend test.

119

8

316

il

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co

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co

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A. VERTICAL POSITION

B. WELD SEQUENCE

l IAM

AndAlf.."

4:1111.>NON

NAME

ASMEAWS GROOVE WELD TESTSMILESTONE B

"V" GROOVE W/ BACK UPIN THE VERTICAL POSITION

MODULE NO. I

FIGURE NO. 2

ELECTRODE SIZE 5 DIA. TYPEI A. DC/RP AWS - E 601032MATERIAL STEEL SPEC.

MILDAMT.2

SIZE 3-8- X 4 X 8

STEEL MILD I ir x I x 9

120


CERTIFICATION TEST


Milestone B, 'V' Groove with Backing Strip in the VerticalPosi'ion


INTRODUCTIONThe student will make a 'V' groove weld with backing strip inthe vertical position, using 5/32 inch E6010 electrodes. Thebeads will be deposited as follows: first pass, penetration;second pass, single bead; third pass, two beads; fourth pass,two bead cover. The finished weld must be of test quality tobe used for qualifying the welder's skill.

EQUIPMENT REQUIREDDC welding machine, slag hammer, wire brush, tongs,, safetyequipment, and shaper.

MATERIAL NEEDEDi pieces 3/8 x 4 x 8 inch steel plate, beveled on one side to30°, 1 piece 1/8 x 1 x 9 inch for backing strip, 5/32 E6010electrodes.

PROCEDURE1 thru 6. Repeat equipment & safety procedures.7. Tack weld the back side of the plates to the backing

strip with a root opening of 3/16 inches.8. Place this assembly in position for vertical welding.9. Establish an arc, raise electrode slightly, move to the

starting point.10. Close the arc gap to the proper dimension.11. Place the first pass using an up and down motion in small

increments.12. After each pass is completed, chip and wire brush the

weld so that the bead is completely clean of slag.13. Place the succeeding beads as directed by your instructor.

Concentrate the arc on the edges of the previous bead.14. Place the cover beads so that the total reinforcement does

not exceed the plate thickness by more than 1/8 inch abovethe plate thickness, nor wider than 1/16 inch at each sideof the groove.

15. Repeat this procedure until a weld is produced to thespecification.

16. Show work to your instructor for a discussion of results.17. Prepare for testing; remove all metal at the face and

root of the weld down to plate thickness. Cut out 1-1/2inch coupons for the bend test.

121

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NAME

ASME-AWS GROOVE WELD TESTSMILESTONE C

"V" GROOVE WELD W/BACK UPIN THE OVERHEAD POSITION

MODULE NO. I

FIGURE NO. 3

ELECTRODE SIZE 5_ TYPE32 DIA. DC /RP AWS- E 6010

MATERIAL STEEL .SPEMOLDLD

AM T2

SIZE 1 X 4 X 88


122


CERTIFICATION TEST


Milestone C, 'V' Groove with Backing Strip in the OverheadPosition


INTRODUCTIONThe student will make a 'V' groove weld with backing strip inthe overhead position, using 5/32 inch E6010 electrodes. Thebeads will be deposited as follows: first pass, penetration;second pass, single bead; third pass, two beads; fourth pass,three bead cover. The finished weld must be of test qualityto be used for qualifying the welder's skill.

EQUIPMENT REQUIREDDC welding machine, slag hammer, wire brush, tongs, safetyequipment, positioner, and shaper.

MATERIAL NEEDED2 pieces 3/8 x 4 x 8 inch steel plate, beveled on one side to30°, 1 piece 1/8 x 1 x 9 inch for the backing strip, 5/32 inchE6010 electrodes.

PROCEDURE1 thru 6. Repeat equipment & safety procedures.7. Tack weld the back side of the plates to the backing strip

with a root opening of 3/16 inches.8. Place this assembly in the positioner for overhead welding.9. Establish an arc, raise electrode slightly, move to the

starting point.10. Close the arc gap to the proper dimension.11. Place first pass using a forward and back motion in small

increments.12. After each pass is completed, chip and wire brush the

weld so that it is completely clean of slag.13. Place the succeeding beads as directed by your instructor.14. Concentrate the arc on the edges of the previous weld.15. Place cover beads so that the total reinforcement will not

exceed the plate thickness by more than 1/8 inch, nor bewider than 1/16 inch at each side of the groove.


17. Show work to your instructor for a discussion of results.18. Prepare for testing; remove all metal at the face and root


123

1

I


CERTIFICATION

PHASE III PART B OBJECTIVE

Following the completion of shielded metal-arc welding

certification in Part A of this program, the trainee

is given the opportunity to participate in Part B. This

module uses the construction code tests of city or state

inspection agencies where the student will have residence.

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NAME

CITY OF LOS ANGELESSHOP AND FIELD CERTIFICATION

MILESTONE A"V" GROOVE W /BACK UP


MODULE NO. I

FIGURE NO. 4

ELECTRODE SIZE 5 TYPEDIA. DC/ RP AWS- E 601032MATERIAL STEEL SPEC.

MILDAMT..2

SIZE I X 4 X 88STEEL MILD I X I X9

126


CERTIFICATION TEST

Module II. City of Los Angeles Shop and Field Certification

Milestone A, 'V' Groove with Backing Strip in the HorizontalPosition


INTRODUCTIONThe student will make a 'V' groove weld with backing strip inthe horizontal position, using E6010 electrodes. The beadsto be deposited in the following manner: first pass, pene-tration; second pass, single bead; third pass, three beads;fourth pass, three bead cover. The finished weld must beof test quality to be used for qualifying the welder's skill.

EQUIPMENT REQUIREDC welding machine, slag hammer, wire brush, tongs, safetyequipment, and shaper. Al,:o the use of a positioner.-

MATERIAL NEEDED2 pieces 3/8 x 4 x 8 inch steel plate, beveled on one site to30°, 1 piece 1/8 x 1 x 9 inch steel for backing strip, S/32inch E6010 electrodes.


to form a butt weld with a root opening of 3ilb inch's.8. Place this assembly in the positioner for welding in the

horizontal position.9. Establish the arc, raise the electrode slightly, move to

the starting point.10. Lower electrode to proper arc length.11. Place the first pass using a forward and back motion in

small increments.12. After each pass is completed, chip and wire brush the

weld so that is is completely clean of slag.13. Place succeeding beads as directed by your instructor.14. Concentrate the arc on the edges of the previous bead.15. Place cover beads so that the total reinforcement will

not exceed the plate thickness by more than 1/8 inchabove the plate thickness.

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NAME


MILESTONE B"V" GROOVE W/ BA :K UP

IN THE VER'ICAL POSIT:ON

MODULE NO. If

FIGURE NO. 5

ELECTRODE SIZE 5 TYPEDIA. DC/RP AWS E 601032MATERIAL STEEL SPEC.

MILDAMT. SIZE _Ir X 4 X 8

STEEL MILD I 8 X I X 9

. .

128


CERTIFICATION TEST


Milestone B, 'V' Groove with Backing Strip in the VerticalPosition


INTRODUCTIONThe student will make a 'V' groove weld with backing strip inthe vertical position, using E6010 electrodes. The beads tobe deposited in t e following manner: First pass, penetration;second pass, single bead; third pass, two beads; fourth pass,two bead cover. The finished weld must be of test quality tobe used for qualifying the welder's skill.

EQUIPMENT REQUIREDDC welding machine, slag hammer, wire brush, tongs, safetyequipment, and shaper.

MATERIAL NEEDED2 pieces 3/8 x 4 x 8 inch steel plate, beveled on one side to30 , 1 piece 1/8 x 1 x 9 inch steel for backing strip, 5/32inch E6010 electrodes.

PROCEDURE1 thru 6. Repeat equipment & safety procedures.7. Tack weld the back side of the plates to the backing stripto form a butt weld with a root opening of 3/16 inches.8. Place this assembly in position for vertical welding.9. Establish the arc, raise the electrode slightly, move to

the starting point.10. Lower electrode to proper arc length.11. Place the first pass using an up and down motion in small

increments.12. After each pass is completed, chip and wire brush the weld

so that it is completely clean of slag.13. Place succeeding beads as directed by your instructor.14. Concentrate the arc on the edges of the previous bead.15. Place cover beads so that the total reinforcement will not

exceed the plate thickness by more than 1/8 inch, nor morethan 1/8 wider than the groove.


17. Show work to your instructor for a discussion of results.18. Prepare for testing; remove all metal at the face and

root of the weld down to plate thickness. Cut out 1-1/2inch coupons for the bend test.

129

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NAME


MILESTONE C"V " GROOVE W/ BACK UP


MODULE NO. II

FIGURE NO. 6

ELECTRODE SIZE 5 TYPEDIA. DC /RP AWS-E- 601032MATERIAL STEEL SPEC.

MILDAMT2

SIZE 3 X 4 X 88

STEEL MILD I8 X 1 X 9


CERTIFICATION TEST


Milestone C, 'V' Groove with Backing Strip in the OverheadPosition


INTRODUCTIONThe student will make a 'V' groove weld with backing strip inthe overhead position, using E6010 electrodes. The beads tobe deposited in the following manner: first pass, penetration;second pass, single bead; third pass, two beads; fourth pass,three bead cover. The finished weld must be of test qualityto be used for qualifying the welder's skill.


MATERIAL NEEDED2 pieces 3/8 x 4 x 8 inch steel plate, beveled on one side to30 , 1 piece 1/8 x 1 x 9 inch steel for backing strip, 5/32inch E6010 electrodes.

PROCEDURE1 thru 6. Repeat equipment & safety procedures.7. Tack weld the plates to the backing strip on the back side

to form a butt weld with a root opening of 3/16 inches.8. Place this assembly in the positioner for overhead welding.9. Establish the arc, drop the electrode slightly, move to

starting point.10. Raise electrode to the proper arc length.11. Place the first pass using a forward and back motion in

small increments.12. After each pass is completed, chip and wire brush the weld

so that it is completely clean of slag.13. Place succeeding beads as directed by your instructor.14. Concentrate the arc on the edges of the previous bead.15. Place the cover beads so that the total reinforcement will

not exceed the plate thickness by more than 1/8 inch, normore than 1/16 inch at each side of the groove.


17. Show work to your instructor for a discussion of results.18 Prepare for testing; remove all metal at the face and root


131

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AWS-E- 7018

AIMil11111=111111

AWS-E- 7024

A. AWS-E- 7018 FILLET WELDVERTICAL POSITION.

B. AWS- E-7Q24 GROOVE WELDOPTIONAL POSITION.

NAME


MILESTONE 0WELD SOUNDNESS TEST


MODULE NO. X

FIGURE NO. 7

ELECTRODE SIZE 1 TYPE--a- DIA. D 17/RP AWS-E-70I8 / AWS-E-7024

MATERIALSTEEL

STEEL

SPEC.MILD

MILD

AMT SIZE83

I X 2 X 10

2 if31X 32- X 8

132


CERTIFICATION TEST


Milestone D, Weld Soundness Test in the Vertical Position


INTRODUCTIONThe student will make a weld soundness test in the verticalpositon. This will be made with a backing strip, using bothE7018 and E7024 electrodes. The square cut plates are tackwelded to the backing strip so that the first beads are filletwelds in the vertical position with the E7018 electrodes, Theassembly is then placed for welding in a flat position;the remaining groove is filled using the E7024 electrodes.The finished weld must be of test quality to be used for quali-fying the welder's skill.


MATERIAL NEEDED2 pieces 3/8 x 3-1/2 x 8 inch steel plate, squart cut, 1 piece3/8 x 2 x 10 inch steel for the backing strip, 1/8 inch E7018and 1/8 inch E7024 electrodes.


to form a butt weld with an opening of 15/16 inches.8. Place this assembly in the positioner for vertical welding.9. Establish the arc, raise the electrode slightly, move to

the starting point, using the E7018 electrodes for thesefillets.

10. Lower the electrode to proper arc length.11. Place the fillets using a small weave motion. Concentrate

the arc in the corners for good penetration.12. Chip and wire brush the beads after each pass.13. Place the weldment in the flat position and continue to

fill the groove with the E7024 electrodes. Make overlappingstringer beads without manipulation.

14. Repeat these procedures until a consistent, sound weld isproduced.

15. Prepare for testing; remove the backing strip and facereinforcement to the plate thickness. Cut out 1-1/2 inchcoupons for the bend test.

133

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A. AWS-E-70I8 FILLET WELD

OVERHEAD POSITION

AWS-E- 7024 GROOVE

OPTIONAL POSITION

WELD

2

NAME


MILESTONE EWELD SOUNDNESS TEST


MODULE NO. 11

FIGURE NO. 8

ELECTRODE SIZE b DIA. DC/RP TYPE AWS-E- 7018/ AWS-E-7024

MATERIAL STEEL SPEC. A2MT. SIZE r3 X 4 X 8

STEEL MILD I1- I T x ix 9

134


CERTIFICATION TEST


Milestone E, Weld Soundness Test in the Overhead Position


INTRODUCTIONThe student will make a weld soundness test in the overheadposition. This will be made with a backing strip, using bothE7018 and E7024 electrodes. The square cut plates are tackwelded to the baking strip so that the first beads are filletwelds made in the overhead position using the E701R electrodes.The assembly is then placed for welding in a flat position;the remaining groove is filled using the E7024 electrodes. Thefinished weld must be of test quality to be used for qualifyingthe welder's skill.


MATERIAL NEEDED2 pieces 3/8 x 4 x 8 inch steel plate, square cut, 1 piece1/8 x 1 x 9 inch steel for the backing strip, 1/8 inch E7018and E7025 electrodes.

PROCEDURE1 thru 6 Repeat equipment & safety procedures.7.' Tack weld the back side of the plates to the backing strip

to form a butt weld with an opening of 15/16 inches.8. Place this assembly in the positioner for overhead welding.9. Establish the arc, lower the electrode slightly, move to

the starting point, using the 1/8 inch E7018 electrodesfor these fillets.

10. Raise the electrode to the proper arc length.11. Place the fillets using a small "C" motion. Concentrate

the arc in the corners for good penetration.12. Chip and wire brush the beads after each pass.13. Place the weldment in the flat position and continue to

fill the groove with the 1/8 inch E7024 electrodes. Makeoverlapping stringer beads without manipulation.

14. Repeat these procedures until a consistent, sound weld isproduced.

15. Prepare for testing; remove the backing strip and facereinforcement to the plate thickness. Cut out 1-1/2 inchcoupons for the bend test.

135

1

1

I

I

OXYACETYLENE WELDING AND CUTTING

PHASE IV OBJECTIVE

By taking part in the practice of oxyacetylene

welding and cutting the student will learn how

to assemble and use this equipment, while famil-

iarizing himself with the processes.

A second objective in learning oxyacetylene welding

is to prepare the student for use of the gas tung-

sten-arc torch. Each system uses a hand held torch

while filler metal is hand fed.

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B. FLAME NEUTRAL4.1-

C. DO NOT PENETRATE (THREE EACH)

D. DO NOT PENETRATE (THREE EACH)

E. PENETRATE (THREE EACH)

NAME

PROCESS FAMILIARIZATIONAND EQUIPMENT USE

MILESTONE A

RUNNING STRINGER BEADSWITHOUT FILLER RODS

MODULE NO. I,

FIGURE NO. i

ELECTRODE SIZE TYPEN/A N/A

MATERIALSTEEL SPEC.

MILDAMT

ISIZE 18 GA.X 24 X 6

IOXYACETYLENE WELDING

Module I. Process Familiarization and Equipment Use

Milestone A, Running Stringer Beads Without Filler Rod


INTRODUCTIONThe student will make weld beads across a piece of 18 gagesteel. The purpose for this exercise is to learn torchcontrol, flame adjustment, and rate of travel. There willbe three sets of three beads, the first bead should bestraight and narrow with a fine ripple. The second shouldbe twice the width of the first, with the same appearance.The third bead should be the same size as the second, butwill have uniform penetration on the back side.

EQUIPMENT REQUIREDOxyacetylene torch, tips, regulators, flint lighter, wrench,tongs, goggles, vise grip-pliers.

MATERIAL NEEDED1 piece of 18 gage steel 2-1/2 x 6 inches.

PROCEDURE1. Inspect hose and fittings to see that they are servicable.2. Attach hose to torch, use wrench for a leak tight union.3. Select proper tip size for the metal thickness being

welded; attach to torch barrel, finger tight.4. Close torch valves.5. Turn regulator adjustment screws counterclockwise until

tension is released.6. Open oxygen and acetylene source valves.7. Turn regulator adjustment screws clockwise until the

specified pressure is raised.8. Close oxygen and acetylene source valves; watch for any

pressure drop at regulators. Correct for any leaks.9. Clean work and put on goggles.18. Open torch valves about one quarter turn; light with

flint lighter.11. Adjust flame to a neutral condition with a cone length

as directed.12. Hold torch as a pencil, the flame pointed with a 45°

leading angle, the tip of cone 1/8 inch from metalsurface.

13. Hold at metal edge until melting starts, then move thispuddle slowly across.

14. For beads 2 and 3 use some torch side motion to increasepuddle, and bead width.

15. Practice this procedure until the desired results areproduced.

16. Secure equipment.

139

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A. FLAT POSITION

B. FLAME NEUTRAL

C. WELD ALL FOUR EDGES

D UNIFORM RIPPLE

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NAME

PROCESS FAMILIARIZATIONAND EQUIPMENT USE

MILESTONE B

EDGE WELD W1THOVT FILLER ROD

MODULE NO. I

FIGURE NO. 2

ELECTRODE SIZE N/A TYPE N/A

MATERIAL STEEL SP.MECILD

AM T2

SIZE 12 GA. 12.1 X 3

140

OXYACETYLENE WELDING

Module I. Process Familiarization and Equipment Use'

Milestone B, Edge Welds Without Filler Rod


INTRODUCTIONThe student will clamp together two pieces of 12 gage steelto form an edge joint. This assembly will be positioned forflat position welding. The edges will be fused without theuse of filler rod. The weld should have a fine and uniformripple and a convex face.


MATERIAL NEEDED2 pieces 12 gage steel 1-1/2 x 3 inches.

PROCEDURE1 - 8. Repeat equipment & safety procedures.9. Clamp the metal pieces together with vise grip-pliers,

the edges aligned. Position for flat welding.10. Open torch valves about one quarter turn; light with




13. Hold flame steady at edge of joint until fusion starts;move from right to left with a steady motion, meltingdown the edges consistently. Join all four edges.

14. Repeat this procedure until the desired results areproduced.


141

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B. FLAME NEUTRAL

C. PENETRATE

OAWA-B-C32

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ROOT GAP32

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REINFORCEMENT

PENETRATION

NAME

GROOVE WELDMILESTONE A

CORNER WELD!N THE FLAT POSITION

MODULE NO. Z

FIGURE NO. .3

ELECTRODE SIZE16 DIA. TYPE COPPER COATED AWS-ASTM CLASS 1 TYPE C

MATERIALSTEEL SPEC. A2 MT.

MILDSIZE12 X 3

142

I

;Ly

1


Module II. Groove Weld



INTRODUCTIONA corner weld will be made by joining two pieces of steel at60°. This joint will be welded in the flat position withfull penetration. Use filler rod and one pass. The weldface will have uniform ripple and convex face.

EQUIPMENT REQUIREDOxyacetylene torch, tips, regulators, flint lighter, wrench,tong:, goggles, vise grip-pliers.

MATERIAL NEEDED2 pieces 12 gage steel, 1-1/2 x 3 inches, 1/16 inch steelfiller rod.

PROCEDURE1 8. Repeat equipment & safety procedures.9. Clamp two pieces of steel together to form a corner

joint of 60° with a root opening of 1/32 inch. Positionfor flat welding.

10. Open torch valves about one quarter turn; light withflint lighter.

11. Adjust flame to a neutral condition with a cone lengthas directed.

12. Hold torch as a pencil, the flame pointed with a 45°leading angle, the tip of cone 1/8 inch from metalsurface.

13. Hold on metal edge until melting starts, then move thispuddle slowly across.

14. Add filler metal in center of puddle to fill out beadsize.

15. Travel from right to left at a rate resulting in auniform bead in height and width.


143

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NAME

FILLET WELDMILESTONE A

LAP WELDMODULE NO. III

FIGURE NO. 4

ELECTRODE SIZE I i Y PEDIA.16 COPPER COATED /WS -ASTM CLASS I TYPE C

MATERIAL STEEL SPEC.MILD 2

AMT SIZE 12 GA. If X 3

144

I

1


Module III. Fillet Weldi

1 Milestone A, Lap Weld

IProject 4; Time: 6 hours

INTRODUCTIONThe student will overlap two pieces of steel to form filletweld joints. These two joints will be welded, using fillerwire. They should have a flat face, no undercut and withoutexcessive deposit above the upper piece of steel.


I

I

MATERIAL NEEDED2 pieces 12 gage steel, 1-1/2 x 3 inches, 1/16 inch steelfiller.

PROCEDURE1 - 8. Repeat equipment 4 safety procedures.9. Overlap two pieces of steel 1/2 inch and clamp with the

vise grip-pliers. Place for welding in the flat position.10. Open torch valves about one quarter turn; light with


as directed.12. Hold torch as a pencil; the flame pointed with a 450


13. Hold flame in joint so that top and bottom pieces arefused; add filler metal as required to form a uniformfillet.

14. Move along joint at a uniform rate to form a fillet witha flat face and even ripple.

15. Repeat this procedure until the desired results areproduced.


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REINFORCEMENT

GAP

PENETRATION) L

ROOT

NAME

GROOVE WELD

MILESTONE B

'IV" GROOVE WELDIN THE FLAT POSITION

MODULE NO. II

FIGURE NO. 5

ELECTRODE SIZE rel DIA. TYPE COPPER COATED AWS -ASTM CLASS I TYPE C

MATERIALSTEEL SPMILDEC.

2ANT SIZE I2 GA. X12 X 3

146



Milestone B, 'V' Groove Weld in the Flat Position


INTRODUCTIONThe student will make a single pass forehand butt weld witha 1/32 inch root opening for full penetration. The beadshould have a uniform build-up and ripple.


MATERIAL NEEDED2 pieces 12 gage steel 1-1/2 x 3 inches, 1/16 inch steelfiller wire.

PROCEDURE1 8. Repeat equipment & safety procedures.9. Lay pieces of steel flat with parallel edges and a gap

of 1/32 inch; tack weld at each end.10. Hold flame at beginning of weld with filler wire close.

When fusion starts this must be quickly added.11. Move along the joint, watching for melt through at root,

then adding filler to the amount that gives the properbuild-up.

12. Continue this procedure until the required weld isproduced.


147

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NAME

OXYACETYLENE CUTTING

MILESTONE A

HAND CUTTING / OXYACETYLENE TORCH

MODULE NO. Tir

FIGURE NO. 6

ELECTRODE SIZE TYPEN/ A N/A


STEEL MILD I -- X 8 X 10

148



Milestone A, Learning to Use the Hand Cutting OxyacetyleneTorch


INTRODUCTIONThe student will demonstrate his ability to assemble anduse the manual oxyacetylene cutting torch. He will layoutsimple patterns on steel plate, then cut to these lines.The cuts should be square edged, have a smooth surface witha minimum amount of slag.

EQUIPMENT REQUIREDCutting torch and hose, tips, flint lighter, wrench, tongs,goggles, gloves, scale, dividers, center punch, scribe.

MATERIAL NEEDEDSteel plate with a surface suitable-for layout work. Referto drawing #6.

PROCEDURE1 - 8. Repeat equipment &_safety procedures.9. Clean plate with wire brush; layout shapes according to

the drawing; place on the burning table.10. Open torch valves about one quarter turn; light with

flint lighter.11. Adjust flame to a neutral condition with preheat flame

of the proper length, as directed.12. Hold flame at edge of plate on the guide line; when

color changes to red slowly open cutting oxygen valve,depress fully.

13. Immediately move along the guide line. Move at aconstant rate determined by the condition of the cut.Too fast will lose the cut, and too slow will fill thekerf with slag.

14. Repeat this procedure until the desired cuts can bemade.


149

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A. CUT INTO 81. SO

NAME

OXYACETYLENE CUTTING

MILESTONE 8

MACHINE CUTTING/AUTOMATIC CUTTING MACHINE

MODULE NO. 17

FIGURE NO. 7

ELECTRODE SIZE N/A TYPE N /A


MAT. SIZE i X 8 X 40

- 150

T



Milestone B, Learning to Use the Automatic Cutting Machine


INTRODUCTIONThe student will demonstrate his ability to assemble anduse the automatic cutting torch. He will cut severalsquare pieces from steel plate.

EQUIPMENT REQUIREDCutting torch for automatic use, tractor, track, tips, flintlighter, wrench, electric cable, pressure regulators, hose,wire brush, scale, straight edge, square, tongs, goggles,and gloves.

MATERIAL NEEDEDSteel plate. Refer to drawing #7.

PROCEDURE1. Place steel plate on the cutting table, clean with wire

brush, put track on the plate 12 inches in from andparallel to its edge.

2. Place tractor on track, engage clutch to lock in place,put motor switch to off, then plug in cable to currentoutlet.

3 8. Repeat equipment & safety procedures. Select, attachappropriate sized cutting tip.

9. Move tractor to one end of the cut and adjust torch to8-1/16 inches in from the plate edge.

10. Lift the torch about one inch above the plate and traceout the cut.

11. Return to the starting edge of the cut, lower torch to1/4 inch above plate, put on goggles.

12. Open oxygen and acetylene torch valves one quarter turn;light torch with flint lighter; adjust to a neutralcondition, with preheat flames of the proper length asdirected.

13. Heat the plate edge to a red spot, slowly open cuttingoxygen valve to full, and immediately close the tractorswitch to on.

14. Watch the condition of the cut; hold one hand on the speedregulator; change faster or slower when indicated.

15. Watch for any change in the flame clearance and makeadjustment to maintain at about 1/8 inch above plate.

16. Repeat this procedure to produce five steel squares of8 inches each.


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PENETRATION

NAME

l'ILLET WELD

MILESTONE B


MODULE NO. 1TE

FIGURE NO. 8

ELECTRODE SIZE I DIA. TYPE COPPER COATED AWS ASTM CLASS 1 TYPE C16


AMT2

SIZE 12 GA. X lf X 3

1

I OXYACETYLENE WELDING

1

1

1

I

I

I

I

I

1

Module III. Fillet Weld

Milestone B, Fillet Welds in the Horizontal Position


INTRODUCTIONThe student will make a fillet weld by joining two piecesof steel in a "T" joint. This will be welded on each sidein one pass. There will be full penetration, flat face,equal leg length, and no undercut.


MATERIAL NEEDED2 pieces 12 gage steel 1-1/2 x 3 inches, 1/16 steel weldingrod.

PROCEDURE1 - 8. Repeat equipment & safety procedures.9. Hold steel pieces with tongs and tack weld at 90° in a

"T" form; place for horizontal welding.10. Direct flame into root of joint so that full penetration

is obtained.11. Move across weld slowly with a slight forward and back

motion; add filler on back motion.12. Completed fillet must have a flat face and equal leg

length.13. Repeat this procedure until the desired weld is produced.14. Secure equipment.

153

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REINFORCEMENT B. FLAME NEUTRAL

IC. R ROOT OPENING

WV' D. 30 BEVEL

I32

ROOT

E. BACKHAND SCALETECHNIQUE\--- PENETRATION

OPENING

NAME

GROOVE WELDMILESTONE C


MODULE NO. rFIGURE NO. 9

ELECTRODE SIZE rgi DIA TYPE. COPPER COATED AWS -ASTM CLASS I TYPE C

MATERIALSTEEL MI

SPEC.LD 2

AM T. SIZEI2 GA. X If X 3

1

154

9XYACETYLENE WELDING


Milestone C, 'V' Groove Welds in the Flat Position


INTRODUCTIONThe student wil) make a two pass backhand butt weld withfull penetraion on 12 gage steel plate. The bead surfacemust be convex and uniform in appearance.



PROCEDURE1 - 8. Repeat equipment & safety procedures.9. Tack weld pieces in a butt joint without gapping; place

for flat position welding.10. Orym torch valves about one quarter turn; light with


as directed.12. Hold torch with a dragging angle of about 45° at the

left end of joint; hold tip of cone clear of steel by1/8 inch.

13. Move to the right cone of flame directed backward intopuddle.

14. Add filler material to make a full bead.15. Follow technique as demonstrated.16. Repeat this procedure until the desired weld is produced.17. Secure equipment.

155

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a FLAME NEUTRALINPENETRATION

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OPENING k

NAME

GROOVE WELD

MILESTONE D

CORNER WELDIN THE VERTICAL POSITION

MODULE NO. .T1

FIGURE NO. ID

ELECTRODE SIZE 1 1 YPEre DIA. COPPER COATED AWS -ASTM CLASS I TYPE CMATERIAL

STEEL MSPEC.

ILDAMT.2

SIZE12 GA. 1 X 3

156



Milestone D, Corner Weld in the Vertical Position


INTRODUCTIONThe studert will make a vertical -up corner weld joint byjoining two pieces of 12 gage steel at 60°. This is a onepass weld with full penetration. Bead surface should beconvex and uniform in appearance.



PROCEDURE1 - 8. Repeat equipment & safety procedures.9. Clamp steel pieces together at 60° to form a corner

joint; with a 1/32 inch root gap. Position for verticalwelding.

10. Open torch valves about one quarter turn; light withflint lighter.

11. Adjust flame to a neutral condition with a cone lengthas directed.

12. Hold torch as a pencil, the flame pointed with a 45°leading angle, the tip of cone 1/8 inch from metalsurface, puddle slowly across.

13. Hold tor;11 steady at base of the joint until fusionstarts.

14. Add filler in puddle as torch is moved upward.15. Repeat this procedure until desired result is obtained.16. Secure equipment.

157

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C. WELD BOTH SIDESor--PENETRATION

NAME

FILLET WELD

MILESTONE CFILLET WELDS

IN THE VERTICAL POSITION.

MODULE NO. mr

FIGURE NO. II

ELECTRODE SIZE I_ TYPE COPPER COATED AWS-ASTM CLASS I TYPE C16 "MATERIAL STEEL SPEC.

MILDAMT.2

_

SIZE 112 GA. X 1--2 X 3

158


Module III. Fillet Weld

Milestone C, Fillet Welds in the Vertical Position


INTRODUCTIONThe student will make a 'T' joint to be welded in the verticalposition. This is a one pass fillet; there should not be anyvoids at the root. It will have a flat face and equal leglength.



PROCEDURE1 8. Repeat equipment & safety procedures.9. Hold steel pieces with tongs and tack weld at 90° in a

'T' form; place"for vertical-up welding.10. Open torch valves about one quarter turn; light with

flight lighter.11. Adjust flame to a neutral condition with a cone length



13. Hold torch steady at base of the joint until fusionstarts.

14. Add filler in puddle as torch is moved upward.15. Repeat this procedure until desired result is obtained.16. Secure equipment.

159

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D. 30° BEVEL

IllgrAtI

ROOT

E. FOREHAND TECHNIQUE

REINFORCEMENT

OPENING

NAME

BRAZE WELD

MILESTONE A


MODULE NO. 3t

FIGURE NO. 12

ELECTRODE SIZE 1 DIA. TYPE GAS BRAZING ROD

MATERIALSTEEL SPECMIL.

D 2AMT. SIZE12 lit

X

160

416


Module V. Braze Welds

Milestone A,- 'V' Groove Weld in the Flat Position


INTRODUCTIONThe student will form a groove butt joint with 2 pieces of12 gage steel having a root gap of 1/32 inch. These pieceswill be jointed by braze welding, using brass filler withflux. There should be full penetration with uniform rein-forcement at face and root.


MATERIAL NEEDED2 pieces 12 gage steel 1-1/2 x 3 inch, 1/8 inch brazing rod,brazing flux.

PROCEDURE1 - 8. Repeat equipment & safety procedures.9. Tack weld pieces to form a butt joint with a 1/32 inch

root gap.10. Open torch valves about one quarter turn; light w.



leading angle, the tip of cone 1/8 inch from metalsurface'.

13. Heat the brass rod, dip into flux for a -2 to 3 inchcoating.

14. Heat joint end to the melting point of the brass, 1651°F.There will be little color change of the steel, and nomelting of the steel.

15. Move along joint with torch motion back and forth orcircular, deposit brass on back motion. Do not allowbead to flow away from the joint over the steel surface.

16. Repeat this procedure until the desired weld is produced.17. Secure equipment.

161

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PENETRATION

NAME

BRAZE WELDMILESTONE B


MODULE NO. IIZ

FIGURE NO. 13

ELECTRODE SIZE TYPEDIA. GAS BRAZING ROD8MATERIAL STEEL SPEC.

MILDAMT.

2SIZE 12 GA. X If X 3

162


Module V. Braze Welds



INTRODUCTIONThe student will make a 'T' joint to be braze welded in thehorizontal position. This is a single pass weld with a flatface and equal leg length.


MATERIAL NEEDED2 pieces 12 gage steel 1-1/2 x 3 inch, 1/8 inch brazing rod,brazing flux.

PROCEDURE1 8. Repeat equipment & safety procedures.9. Tack weld steel plate pieces to for a 'T' fillet joint.10. Open torch valves about one quarter turn; light with




13. Heat the brass rod, dip into flux for a 2 to 3 inchcoating.

14. Heat joint end to the melting point of the brass, 1651°F.There will be little color change of the steel, and nomelting.

15. Move along joint with torch motion back and forth orcircular, deposit brass on back motion. Do not allowbead to flow away from the joint over the steel surface.


163


OAK> B. HORIZONTAL POSITIONA

0 AW 0 AW OAW C. FLAT POSITIONB A C

ftet*

D. 2 IN FLAT POSITION

1 2 IN VERTICAL POSITION

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NAME

PRESSURE VESSEL

MILESTONE AOXYACETYLENE WELDING

FIN, L TEST

MODULE NO. V/

FIGURE NO. 14

ELECTRODE SIZE I TYPET-6 DIA. COPPER COATED ASW ASTM CLASS I TYPE C


AMT.8

SIZE 12 GA. Ii X 3STEEL MILD I 12 GA. 4 X 6STEEL MILD I 12 GA. 4 X 4STEEL MILD I 12 Gi 4. 24- X 2

164

1


Module VI. Pressure Vessel

Milestone A, Final Test - Oxyacetylene Welding


INTRODUCTIONThe student will make a pressure vessel from lap weldedprojects. These pieces will be joined by corner welds toform a cube on a base. This can be given a pressure test.

EQUIPMEf REQUIREDOxyacetylene torch, tips, regulators, flint lighter, wrench,tongs, goggles, vise grip-pliers.

MATERIAL NEEDED8 pieces 12 gage steel 1-1/2 x 3 inch, 1 piece 4 x 4 inch,1 piece 4 x 6 inch, 1 piece 2-1/4 x 2-1/4 inch.

PROCEDURE1 - 8. Repeat equipment & safety procedures.9. Make 4 lap welds to join 8 pieces of 1-1/2 inch steel.

Overlap 1/2 inch, weld in the horizontal position.10. Join these pieces to form a square; make 2 corner welds

in flat and 2 in the vertical position.11. Make a base plate by centering the 4 x 4 inch piece on

the 4 x 6 inch piece. Join with 2 edge welds and 2fillets.

12. Center the square box on this base and join with 2 filletwelds in the horizontal and 2 in the vertical position.

13. Close the box by welding the 2-1/4 x 2-1/4 inch piece atthe top. Make 2 corner welds in the horizontal and 2 inthe vertical position.

14. Repeat these operations until all welds are properlymace. It may be an advantage to tack weld the entirestructure together before making any one weld. Thiswill reduce distortion and loss of dimension.

15. This vessel may be pressure tested by melting an openingin the top to receive a small pipe nipple. Connect thisto a water supp.: source, not air, inspect for leaks.

165

1

GAS TUNGSTEN-ARC WELDING (TIG)

PHASE V, PART A OBJECTIVE

In this course the student will learn the character-

istics of the gas tungsten-arc welding system and

how to use it. He will become familiar with air

cooled and water cooled torches. He will weld tLin

gage ferrous and non-ferrous metals.

The skill developed through this experience will make

the student employable as a welder using gas tungsten-

arc welding equipment except for that work covered by

codes or demanding advanced experience.

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PENETRATION

A." FLAT POSITION

B. WELD BOTH SIDES

NOTE, REFERS TO BEAD WIDTH

NAME

FAMILIARIZATION WITH THE PROCESSMILESTONE A

STRINGER BEADSIN THE FLAT POSITION

MODULE NO. I

FIGURE NO. 4-1

ELECTRODE SIZE 1 TYPE-8- DIA. AC/HF ALUM. 1100 0


ALUM. PLATE 1100 0 I 1 X 4 X 44

168

J


Module I. Familiarization with the Process

Milestone A, Stringer Beads


INTRODUCTIONWith TIG equipment and aluminum plate the student will as-semble the torch, set proper argon gas pressure and flowrate. Using filler wire he will hand feed this to weldbeads on both sides of the aluminum plate. These beadsmust be consistent in width, be straight and have uniformwidth and rippling.

REQUIRED EQUIPMENTAlternate-direct current welding machine with high fre-quency current, foot control, pressure regulator, flowmeter, TIG torch complete, tongs, and safety equipment.

MATERIAL NEEDEDAluminum plate 1/4 x 4 x 4 inches, type 1100-0 filler wire.

PROCEDURE1. Clean plate surface with steel wool, pull the filler wire

through the steel wool to remove oxide.2. Set current controls: amperage, high frequency intensity,

polarity and remote control as required.3. Open argon gas valve, set pressure and flow rate as

required.4. Open cooling water valve.5. Assemble torch with the proper sized tungsten, collet and

collet body, cup. The electrode may require grindinb toa tapered end.

6. Start welding machine.7. Put on face shield and gloves..8. 'Hold torch as though it is a pencil, drop face shield.9. Depress foot switch to start arcing on copper backing.10. Move arc to the plate, hold until melting starts.11. Start across plate, adding filler material, establish

rate of travel by maintaining uniform puddle width.12. Move from right to left, with a forward and back motion

in small increments, add filler back movement.13. Stop arc by pressing on foot control with heel, do not

lift torch until arc is extinguished.14. Repeat this procedure until uniform beads are produced.15. Inspect beads, discuss their quality with your instructor.16. Secure equipment.

169

00 6

17 Ififf1(11011;qiflidt .10


B. WELD BOTH SIDES

NAME

FILLET WELD

MILESTONE ALAP WELDS


MODULE NO. 1E

FIGURE NO. A-2

ELECTRODE SIZE DIA. TYPE ALUM. 1100 0MATERIAL SPEC. AMT. SIZE

ALUM. SHEET 1100 -0 2 .060 X 6 X 1

170



Milestone A, Lap Welds in the Horizontal Position


INTRODUCTIONThe student will make a lap weld set by overlapping two piecesof sheet aluminum 1/2 inch. He will make a fillet weld oneach side of this assembly. These welds must have equal leglength and a flat face.

EQUIPMENT REQUiREDAC-DC welding machine with high frequency current, foot control,pressure regulator, flow meter, TIG torch complete, tongs, visegrip pliers, welding jig and $,ifety equipment.

MATERIAL NEEDED2 pieces .060 x 1-1/2 x 6 inch sheet aluminum, type 1100-01/8 inch diameter filler wire.

PROCEDURE1 - 6. Repeat equipment safety procedures.7. Put on face shield and gloves.8. Clamp the aluminum pieces in the vise grip with a 1/2 inch

overlap. Drop face shield.9. Hold torch as though it is a pencil, depress foot control

to start the arc on the aluminum, hold uhtil melting starts.10. Arc should be directed against the bottom piece, in the

corner of the fillet. Move forward and back with constantarc length. Control heat with foot.

11. Dip filler wire in puddle on back stroke of torch.12. Avoid melting the top edge too deeply.13. Rate of travel will control size of the weld.14. Repeat these procedures until the specified weld is produced.15. Secure equipment ,

171

w

GTAW

060 g A El

1. .

0w0.

_

gartardatin

t---


B. WELD BOTH SIDES

NAME

FILLET WELDMILESTONE B


-...MODULE NO.11.

FIGURE NO. A-3

ELECTRODE SIZE I TYPE8 DIA. AC/HF ALUMINUM 1100 - 0


ALUMINUM SHEET 1100-0 2 .060 X I- X 6

172





INTRODUCTIONThe student will make a fillet weld set with two pieces ofaluminum, tack welding them in a 'T' form. The two weldswill be made i. the flat position and must have equal leglengths and flat faces. This type of joint does not allowfor penetration through the vertical member.

EQUIPMENT REQUIREDAC welding machine with high frequency current, foot control,pressure regulator, flow meter, TIG torch complete, tongs,welding jig and safety equipment, vise grip pliers.

MATERIAL NEEDED2 pieces .060 x 1-1/2 x 6 inch sheet aluminum, 1/8 inc type1100-0 aluminum filler wire.

PROCEDURE1 6. eat equipment & safety procedures.7. Put on face shield and gloves.8. Form a 'T' joint by supporting the vertical piece with,

the vise grip pliers at the center of the base piece.Drcp face shield.

9. Depress foot control to initiate the arc to the coppergrounding plate.

10. Move arc to the joint and tack weld each end.11. Make the fillet welds; direct the arc in the corner with

the greate'st amount of heat against the base plate. Moveforward and back in small increments, deposit filler onback stroke.

12: Welds must be equal in leg dimension, have flat facewithout undercut.

13. Repeat this procedure until welds are to specification.14. Secure equipment.

173

.060

....

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.003

I

1

1

1

1

1

1

1

i

w

/ G TAWA El

90

REINFORCEMENT

.\\\i PENETRATION

.060

A.

B.

A\11P

deLAP

FLAT POSITION

JIG WITH BACK UP

NAME

GROOVE WELDMILESTONE A

CORNER WELDMODULE NO. MI

FIGURE NO. 4-41

- ELECTRODE SIZE DIA. AC/HF TYPE ALUM. 1100 08MATERIAL SPEC. AMT. SIZE

ALUMINUM SHEET 1100 -0 2 .060 X li X 6

174





INTRODUCTIONThe student will tack weld tliJ pieces of sheet aluminum toform a corner weld. Welding will be done in the flat positionin one pass. The weld should fully penetrate the joint, havea slight convex surface with even ripple.

EQUIPMENT REQUIREDAC-DC welding machine with high frequency current, foot control,pressure regulator, flow meter, TIG torch complete, tongs,welding jig and safety equipment.

MATERIAL NEEDED2 pieces .060 x 1-1/2 x 6 inch aluminum sheet, 1/8 fillerwire type 1100-0.

PROCEDURE1 - 6. Repeat equipment & safety procedures.7. Place pieces in the welding jig to form a corner joint.8. Put on face shield and gloves.9. Hold torch as though it is a pencil, drop face shield.10. Depress the foot control to initiate the arc to the jig

backing.11. Move the arc to the joint, make the weld with a forward

and back motion in small increments; add filler wire onthe back stroke.


175

1co

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. ..7.:_,

N14.'rc.4'14444,.

G TAW.060 A-B

0co0

REINFORCEMENT

1-21 --01

. fi

3PENETRATION

A. FLAT POSITION

B. JIG WITH GAS BACK UP

NAME

GROOVE WELDMILESTONE 9

SQUARE BUTT WELDSIN THE FLAT POSITION

MODULE NO. iEr

FIGURE NO. A-5

ELECTRODE SIZE 1 DA ATYPE

a I. C/ HF ALUM. 1100-0 -0


ALUMINUM SHEET 1100-0 2 .060 X li X 6

it



Milestone B, Square Butt Weld in the Flat Position


INTRODUCTIONThe student will make a single pass butt weld with fullpenetration. The weld will have a convex face with evenripple. There should be no undercut.

EQUIPMENT REQUIREDAC-DC welding machine with high frequency current, foot control,pressure regulator, flow meter, TIG torch complete, tongs,welding jig, and safety equipment.

MATERIAL NEEDED2 pieces .060 x 1-1/2 x 6 inch aluminum sheet, 1/8 inchfiller wire type 1100.0.

PROCEDURE1 6. Repeat equipment & safety procedures.7. Place pieces in the welding jig to form a tight butt joint.8. Put on face shield and gloves.9. Hold torch at though it is a pencil, drop face shield.10. Depress foot control to initiate the arc to the jig backing.11. Move the arc to the joint, make the weld with a forward and

back motion in small increments; add filler wire on theback stroke

12. Repeat this rocedure until the desired weld is produced.13. Secure equipment.

177

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A. HORIZONTAL POSITION-

B. FLAT POSITION

NAME

PRESSURE VESSEL

MILESTONE A

ALUMINUM PRESSURE VES :LMODULE NO. II'

FIGURE NO. A-6ELECTRODE SIZE 8 DIA. AC/HF TYPE ALUM. 1100-0MATERIAL ALUMINUM SHEET SPEC.

1100-0AMT

ISIZE

.060 X 4.75 X 4ALUMINUM SHEET 1100 -0 I .060 X 4.75 X 6ALUMINUM SHEET 1100 -0 I .060 X 3.25 D.ALUMINUM SHEET 1100 -0 I .060 X 10.25 X 2

178


Module IV. Pressure Vessel

Milestone A, Aluminum Pressure Vessel

Project 6; Time: 3 hours,

INTRODUCTIONFollow the instructions in the drawing to construct a vesselusing the prepared materials. This structure will be joinedby 1 butt, 1 corner, 2 lap, 2 edge, and 1 fillet weld. Thisis the final project of this module; the vessel may be pres-sure tested.

EQUIPMENT REQUIREDAC-DC welding machine, with high frequency current, foot control,pressure regulator, flow meter, TIG for .1 complete, tongs,welding jig, and safety equipment.

MATERIAL NEEDED.Pre-cut aluminum pieces listed and shown on drawing A-6.

PROCEDUREUse the drawing to determine the assembly and welding routine.Duplicate all operations shown.

179

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= .urAstimmmi

froPENETRATION

A. FLAT POSITION

B. WELDWELD BOTH SIDES


NAME

FAMILIARIZATION WITH ThE PROCESS

MILESTONE 8STRINGER BEADS

IN THE FLAT POSIT ION

MODULI_

FIGURE NO. A-7

ELECTRODE SIZE i_ DIA. DC/ SPTYPE

/6 S. S. 308


STAINLESS STEEL PLATE 308 1 X 4 X 4, A

180

4

I

GAc TUNGSTEN -ARC WELDING (TIG)

Module I. Familiarization of Process

Milestone B, Stringer Beads in the Flat Position


INTRODUCTIONThe student will make stringer beads to form a pad coveringboth sides of a stainless steel plate. The beads, made with1/16 inch filler wire, must be uniform in width, straight,and have a 25S overlap on each bead.

EQUIPMENT REQUIREDAC-DC welding machine with high frequency current, foot control,pressure regulator, flow meter, torch assembly, tongs, andsafety equipment.

MATERIAL NEEDED1 piece 1/8 x 4 x 4 inch stainless steel plate, 1/16 inchfiller wire of a type that will match the base metal.

PROCEDURE1 - 6. Repeat equipment & safety procedures.7. Hold the torch as though it were a pencil, drop face shield.8. Depress foot control to initiate the arc to the copper

backing, move the arc to the plate and hold until meltingstarts.

9. Move at a constant rate with forward and back motion insmall increments.

10. Add filler metal on the back motion of the torch.11. Control fate of travel by keeping a constant bead width.12. When a bead is completed, raise face shield to evaluate

results.13. Repeat this procedure until an acceptable bead is produced.14. Secure equipment.

,...,.....


B. WELD BOTH SIDES

NAME MILESTONE C

FIL LET WELD

ELECTRODE SIZE Ft1_DIA .

TYPEDC/SP

MATERIAL

STAINLESS STEEL

LAP WELDSIN THE HORIZONTAL POSITION

MODULE NO. IL'

FIGURE NO. A-8

STAINLESS STEEL 308

SPEC. AMT SIZE

308 2 I.060 X Ii X 3

182



Milestone C, Lap Welds in the Horizontal Position


INTRODUCTIONThe student will overlap two pieces of stainless steel by1/2 inch. He will weld both sides of this lap joint withtwo single pass fillet welds. These must have a flat faceand legs of equal dimension.

EQUIPMENT REQUIREDAC-DC welding machine with high frequency current, foot control,pressure regulator, flow meter, torch assembly, vise grip pliers,tongs, and safety equipment.

MATERIAL NEEDED2 pieces .960 x 1-1/2 x 3 inch stainless steel, 1/10 inchfiller wire of a type matching the base metal.

PROCEDURE1 - 6. Repeat equipment & safety procedures.7. Set amperage, high frequency start only, and remote control

as directed.8. Hold the torch as though it is a pencil, drop face shield,9. Depress foot control to initiate the arc to the copper

backing, move arc to the joint and hold until meltingstarts. Direct the arc into the corner of the joint withthe major heat against the bottom plate.

10. Move at a constant rate with forward anC back motion insmall increments.

11. Add filler metal on the back motion of the torch.12. Control the rate of travel by keeping a constant bead

width.13. Repeat this procedure until the desired well is produced.14. Secure equipment.

183

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HORIZONTAL POSITION

WELD BOTH SIDES

.

NAME

FILLET WELD

MILESTONE 0 itFILLET WELDS


MODULE NO. IC

FIGURE NO. i. -9

ELECTRODE SIZE I TYPEDIA . DC/ SP STAINLESS STEEL 308

16


ST4INLESS STEEL SHEET 308 2 .060 X If X 3

,ss

GAS TUNGSTEN-ARC WELDING GIG)


Milestone D, Fillet Welds in the Horizontal Position


INTRODUCTIONThe c*tudent will make a 'T' joint and weld the fillets inthe flat/horizontal position. These will be made in onepass, must have a flat face and equal leg length. Theymust not have undercut, or penetration through the verticalplate.

REQUIRED EQUIPMENTAC-DC ,elding machine with high frequency current, pressureregulator, flow metcr, torch assembly, vise grip pliers,tongs, and safety equipment.

MATERIAL NEEDED2 pieces .060 x 1-1/2 x 3 inch stainless steel, 1/16 inchfiller wire of a type to match. the base metal.

PROCEDURE1 - 6. Repeat equipment & safety procedures.7. Put on face shield and glov^s.8. Form a 'T' joint by supporting vertical piece with vise

rip pliers at the center of the base plate.9. Drop face shield.10. Depress foot control to initiate C.e a:(.. to the copper

grounding plate.11. Move arc to the joint and tack weld each end.12. Make tile fillet welds; direct the arc in the corner

with the greatest amount of heat against the base plate. rMove forward and back in small increments, deposit filleron back stroke.

13. Welds must be equal in leg length, dimension, have a flatface without undercut.

14. Repeat this procedure until welds are to specifications.15. Secure equipment.

185

A\0

.003

I

I

I

I

I

I

I

I

Iro

1

I

I I

./ GTAW..060 A- B90

REINFORCEMENT\\e( PENETRATION

.060

A.

B.

41,LAP

FLAT POSITION

JIG WITH BACK UP

NAME

GROOVE WELD

MILESTONE cCORNER WELDS


MODULE NOTIC

FIGURE NO. A -10

ELECTRODE SIZE I DIA. DC/ SP TYPE STAINLESS STEEL 308; ig

MATERIALr

SPEC. AMT. SIZE

; STAINLESS STEEL SHEET 308 2 1.060 X 17 X 3

186



Milestone C, Corner Weld in the Flat Position


INTRODUCTIONThe student will make a corner weld set by tack welding twopieces of stainless steel at an angle of 90 °. This jointwill be welded in the flat position. Make a full penetrationbead in one pass. Weld face should be slightly convex andhave even ripple.

EQUIPMENT REQUIREDAC-DC welding machine with high frequency current, pressureregulator, flow meter, torch assembly, tongs, and safetyequipment, welding jig.

MATERIAL NEEDED2 pieces .C60 x 1-1/2 x 3 inch stainless steel, 1/16 inchfiller of a type to match the base metal.

PROCEDURE1 6. Repeat equipment & safety procedures.7. Place pieces in jig to form a corner joint.8. Put on face shield and gloves.9. Hold torch as though it is a pencil, drop face shield.10. Depress foot control to start arcing to the jig, move

to the joint.11. Direct arc so that edges of metal fuse. Add filler when

torch is moved back in the forward and back procedure.12. Repeat this procedure until a satisfactory weld is produced.13. Secure equipment.

187

114.11111114.4°'4..

A _ B REINFORCEMENT

i

0c)°.

.060GTAW

i_____IIIIIMILf

A. FLAT

B. JIG WITH

PENETRATION3

POSITION

GAS BACK UP

NAME

GROOVE WELDMILESTONE D

SQUARE BUTT WELDSIN THE FLAT POSITION

MODULE NO. XL

FIGURE NO. AII

ELECTRODE SIZE ITh- DIA. DC/ SP TYPE

S. S. 308MATERIAL . SPEC. AMT. SIZE

STAINLESS STEEL SHEET . 308 2 .060 X I X 3

188

I

t

I

I



Milestone D, Square Butt Weld in the Flat Position


INTRODUCTIONThe student will make a single pass butt weld with fullpenetration. The finished weld should be convex, of uniformwidth and shope. There should be no undercut.

EQUIPMENT REQUIREDAC-DC welding machine with high frequency current, pressureregulator, flow meter, torch assembly, tongs, welding jig,and safety equipment.

7" MATERIAL NEEDED2 pieces .060 x 1-1/2 x 3 inch stainless steel, 1/16 inchfiller wire of a.type matching the base metal.

1-

PROCEDURE1 - 6. Repeat equipment & safety procedures.7. Place the pieces in a jig so that edges are flush and

touching.8. Put on face shield and gloves.9. Hold torch as though it is a pencil, drop face shield.10. Depress foot control to start arcing to the jig, move

to the start of the joint.11. Hold torch so that both edges fuse. Add filler metal

when torch is moved back, in the forward and backprocedure.

12. Repeat this procedure until a satisfactory weld is produced.13. Secure equipment.

189

.060GTAW.060 8

6'

IIIN1 .

GTAW8 .060 400 '.1_,....._.......4

.

el. :o :

t.0

ttti

3.370:

3.25

GTAWTAW8

r. GTAWA

060 GTAWA

0to0

0to0

al- 6 A. HORIZONTAL POSITION

c

B. FLAT POSITION

NAME

PRESSURE VESSEL

MILESTONE ePRESSURE VESSEL

IN A MULTIPLE POSITION

MODULE. NO. 1Z

FIGURE NO. A-12

ELECTRODE SIZE16

DIA. DC/ SP S. S. 308MATERIAL

STAINLESS STEEL SHEET SPEC.308

AMT.I

SIZE.060 X 4.75 X 4

STAINLESS STEEL. SHEET .308 I .060 X 4.75 X 6STAINLESS STEEL SHEET 308 I .060 X 3.25 D.STAINLESS STEEL SHEET 308 I .060 X 10.25 X 2

190


Module IV. Pressure Vessel

Milestone B, Pressure Vessel in a Multiple Position


INTRODUCTIONThe student will construct a vessel. to the specificationsshown in the drawing. Use the precut and rolled materialprovided. This assembly will contain 1 butt, 1 corner, 2lap, 2 edge, and 1 fillet weld. This vessel is the finalproject of this module, kt....pay be pressure tested.

EQUIPMENT REQUIREDAC-DC welding machine with high frequency current, foot control,pressure regulator, flow meter, tongs, welding jig, and TIGtorch, safety equipment.

MATERIAL NEEDEDPrepared stainless steel pieces shown in the drawing, 1/16inch filler metal of a type matching the base metal.

PROCEDUREUse the drawing to determine the assembly and welding routine.Duplicate all operations shown.

191

1

GAS METAL-ARC WELDING (MIG)

PHASE V, PART B OBJECTIVE

In this section of phase V the student will learn

to use the semi-automatic equipment of the gas

metal-arc process. He will become familiar with

the different methods of metal transfer, as in

spray, short circuiting, and flux cored electrode

welding.

The skill developed through this experience will

make the student employable as a welder using gas

metal-arc welding equiPMent except for that work

covered by codes or demanding advanced experience.

.J193

00g,*-4.--

PENETRATION -

.. .,

4#WELD SEQUENCE

SPRAY ARC

D. WELD ALL SIDES

1

.17.---"

.._..;.-- ,..z__-_-

W. ..'4...-t.-.--, , _ --

C.

G MAWABCD 4

A.

B.

r

FLAT POSITION

M.1. G. PROCESS

NAME

FILLET WELD

MILESTONE A

FILLET WIFLDSIN THE FLAT POSITION

MODULE NO. I

FIGURE NO. B-1

ELECTRODE SIZE TYPE.035 DIA. DC/CP WIRE SPOOL MO -1313 STEEL


AMT.I

SIZE 1- X 2 X 244

STEEL MILD 2 - X I X 24

194


Module I. Fillet Weld

Milestone A, Fillet Welds in the Flat Position


INTRODUCTIONThe student will make a fillet weld set of steel plate thatwill contain four 3/4 inch fillet welds 24 inches long. Hewill use the spray method of metal transfer, depositing thenumber of passes that will Make a fillet of the desireddepth. Weld will be made in the flat position.

EQUIPMENT REQUIREDDC constant potential welding machine, wire feeder with gun,gas mixing manifold, tongs, wire brush and safety equipment.

MATERIAL NEEDED1 piece 1/4 x 2 x 24 and 2 pieces 1/4 x 1 x 24 inch steelplate.

PROCEDURE1. Clean the plate as required.2. Select the proper size and type of fil- wire, wire

guides drive rolls, contact tube, and ga. cup.3. Thread wire through the system with 1 inch of stick out

below the contact tube.4. Select the proper shielding gas mixture and set pressures

and flow rates.5. Set proper amperage, voltage, slope, and wire feed rate.6. Start welding machine.7. Open cooling water valve.8. Put on face shield and gloves.9. Hold gun, drop face shield, and tack weld the pieces to

form a cross.10. Direct the gun so that the wire points to the corner of

the joint.11. Close contactor switch, move gun along the joint.12. Use a leading angle and a small weave motion.13. On thin gage material do not use weaving, and hold gun

with a drag angle.14. Make the required width of bead by controlling the rate

of travel.15. Repeat this procedure until a uniform weld is produced.16. Secure equipment.

195

4..

4

/GM

StWELD

A WA-8- C-D

SEQUENCE

PENETRATION

.- 1--

.- 7: :::

16

0 7it0A

WO

1

\

...."---

7-Na0----;

I I Opli 41

....?"

7 I

I

1

-1ILIAFA. VERTICAL DOWN POSITION

13. MI.G PROCESS

C. SHORT ARC

D. WELD ALL SIDES

NAME

FILLET WELDMILESTONE 8

FILLET WELDSIN THE VERTICAL DOWN POSITION

MODULE NO. 1

FIGURE NO. 0-2

ELECTRODE SIZE TYPE.035 DIA. DC/CP WIRESPOOI MO -1313 STEEL

MATERIALSTEEL

SPEC,MILD

AMT1

j_SIZE X 2 X 244

STEEL MILD 2 I X 1 X 24..

196

I



Milestone B, Fillet Welds in the Vertical Down Position


INTRODUCTIONThe student will make a fillet weld set with steel plateto hold four S/8 x 24 inch fillet welds. He will use theshort circuiting arc method of metal transfer, making thenumber of passes that will produce the desired depth ofweld. This is made in the vertical down position.

EQUIPMENT REQUIREDDC welding machine with constant potential, wire feederwith gun assembly, ,gas mixing manifold, tongs, wire brush,and safety equipment.

MATERIAL NEEDEDI piece 1/4 x 2 x 24 and 2 pieces 1/4 x 1 x 24 inchessteel plate.

PROCEDURE1 - 8. Repeat equipment & safety procedures.9. Hold pieces with tongs, drop face shield, tack weld

plate to form a cross for the four fillet welds.10. Place this assembly in the positioner for vertical

welding.11. Drop face shield, point gun so that wire is at top

center of the joint.12. Close contactor switch, pull or drag gun down with a

slight weave pattern. Move at a uniform rate to formthe bead of the desired width.

13. Repeat this procedure until a uniform weld is produced.14..Secure equipment.

197

\2/

SPRAY ARC

D. WELD ALL

,t V C"

g-,

16

SEQUENCE

lr 34-

III 1111111

I

I

'.!I

II

I

I

1

.

;\i

C.

6 MAWABCD 7

*

\A.

B.

Pr

\2

ill

FLAT POSITION

M. I. G. PROCESS

PENETRATION

WELD

SIDES

NAME

FILLET WELD

MILESTONE C

FILLET WELDSIN THE FLAT POSITION

MODULE NO. I

FIGURE NO. 8-3

ELECTRODE SIZE Ig DIA. DC/CP WIRESPOOLTYPE

4043 ALUM.

MATERIALALUMINUM PLATE SPEC.

4043AMT.

1

SIZE I ,X4- c 24 24

ALUMINUM PLATE 4045 2 Iw X I X 24

!98



Milestone C, Fillet Welds in the Flat Position


INTRODUCTIONThe student will make a fillet on aluminum by making aset to contain four 3/4 x 24 inch welds. The spray metaltransfer method will be used to. deposit the needed fillermetal to make the required depth of deposit. This will bedone in the flat position.

EQUIPMENT REQUIREDDC welding machine with constant potential, wire feederwith gun assembly, pressure regulator and flow meter,tongs, and safety equipment.

MATERIAL NEEDED1 piece 1/4 x 2 x 24, 2 pieces 1/4 A 1 x 24 inch aluminumplate.

PROCEDURE1 - 9. Repeat equipment & safety procedures.10. Hold pieces with tongs, drop face shield, tack weld

plates to form a cross for the four fillet welds.11. Point the gun so that wire is directed to the corner

and starting point of the fillet.12. Close contactor switch, push gun along with a slight

lead angle, use a small weave motion.13. Move at a uniform speed that will deposit the desired

amount of filler metal.14. Repeat this procedure until a uniform weld is produced.15. Secure equipment

199

2

GMAWA-B-C-D

N400116WELD

1141\1111k4"

PENETRATION

., ..,.--.,

-. kaaw,

---. i 00. 1

_....it

SEQUENCE

tOt<lb.,--

CO

r. . - - ,.... ...,,- 4....,,,-. ....O ....... ....eai ^If-- 7.

ji)0

I

I

I

I

MIME

A. VERTICAL DOWN POSITION

B. M.I.G. PROCESS

C. SHC"T ARC

D. WELD ALL SIDES

NAME

FILLET WELD

MILESTONE to FILLET WELDSIN THE VERTICAL DOWN POSITION

W/ SHORTCIRCUITING METAL TRANSFER

MODULE NO. I

FIGURE NO. 8-4

ELECTRODE SIZE I16 DIA. DC/CP WIRESPOOL TYPE 4043 ALUM.MATERIAL

ALUMINUM PLATE PESC,4043

AMT.I

SIZE -iIf X 2 X 24ALUMINUM PLATE 4043 2 1 X I X 24

200

I

1

I



Milestone D, Vertical Down Welding with Short CircuitingMetal Transfer

Project 4;- Time: 2 hours

INTRODUCTIONThe student will make a fillet weld set of aluminum tocontain four 5/8 inch welds. The short circuiting metaltransfer method will be used, welding in the vertical downposition. Deposit the number of beads needed to completethe weld to dimension. Equal leg length and a flat faceshould be produced.

EQUIPMENT REQUIRED1 DC constant potential welding machine, wire feeder, with1 gun complete, pressure regulator, flow meter, tongs, and

safety equipment.

MATERIAL NEEDED1 piece 1/4 x 2 x 24 inch, 2 pieces 1/4 x 1 x 24 inchaluminum plate, filler wire type 4043.

PROCEDURE1 8. Repeat equipment & safety procedures.9. Hold gun, drop face shield and tack weld plate in the

form of a cross for fillet welds.10. Place this assembly in the positioner for vertical

welding.11. Point the gun at the top of the joint with a slight

drag angle.12. Use a small weave motion, move down at a rate to form

the proper sized bead.13. Continue' welding until the 5/8 inch dimension is

reached; overlap and fuse each bead added.14. Repeat this procedure until the desired weld can be

produced.15. Secure equipment.

201

cm

i

N

I

O

:.---

re).

; Z--:1..."%:'Z

....-ate-c/

rA

`.-

ga,,.sAc_l?--

V..,"

illiktg`:

60°

REINFORCEMENT

GMAWA-B-C

3260°

ROOT FACE1161,

MC=%I

_ iiim1 Ir3

32L 2

ROOT GAP

PENETRATION

A. FLAT POSITION

B. M.I.G PROCESS

C. SUBSTITUTE STEEL PIPEIF AVAILABLE

NAME

GROOVE WELD

MILESTONE A"V" GROOVE BUTT WE LDS


MODULE NO. IC

FIGURE NO. B-5

ELECTRODE SIZE TYPE.035 DIA. DC/CP WIRESPOOL MO-1313 STEEL


STEEL MILD 2I2 X 2 X 24

202



Milestone A, 'V' Groove Butt Weld in the Flat Position(when available, substitute pipe)


INTRODUCTIONThe student will make a butt weld on steel plate in theflat position: This weld can be made with either fourweave passes or seven stringer beads. The reinforcementshould be slightly convex, uniform in width but withoutundercut or pinholes. Penetration should be complete.

EQUIPMENT REQUIREDDC constant potential welding machine, wire feeder withgun complete, gas mixer manifold, tongs, and safetyequipment.

MATERIAL NEEDED2 pieces 1/2 x 2 x 24 inch steel plate beveled to 30°.

PROCEDURE1 - 7. Repeat equipment & safety procedures.8. Place the plate in the jig for butt weld with a root

opening of about 1/8 inch.9. Point the gun at the centerline of the joint, drop face

shield.10. Close trigger switch, push gun along the joint at about

15° from vertical in the direction of travel.11. Use either the weave or stringer procedure.12. Move at a uniform rate and-repeat until the groove is

filled.13. Reinforcement should not exceed plate thickness by more

than 1/8 inch; it should be uniform in appearance.14. Repeat the procedure until an acceptable weld is produced.15. Secure equipment.

203

352 2 ROOT FACE

PENETRATION

-IN IIIIIIVA

G MAWA-B-C

"M.arsim

REINFORCEMENT

2

60°....,

60°

Soo.14:1

WI'....Z'41 1§

V-.;15',

O ":;

4.


B. M. I.G. PROCESS

C. SUBSTITUTE STEEL PIPE

IF AVAILABLE .

NAME

GROOVE WELD

MILESTONE B"V" GROOVE BUTT WELDS

IN THE VERTICAL DOWN POSITION

MODULE NO. Zr

FIGURE NO. B-6

ELECTRODE SIZE .035 DIA. DC/CP WIRESPOOL TYPE MO-13I3 STEEL


STEEL MILD 2 -L X 2 X 24

204



Milestone B, 'V' Groove Butt Weld in the Vertical DownPosition (when available, substitute pipe)


INTRODUCTIONThe student will make a butt weld on steel plate in thevertical down position. This weld can be made usingshort circuiting arc method of metal transfer, makingthe number of passes that will produce the desired weldsize. The reinforcement should be slightly convex, uni-form in width,but without undercut or pinholes. Pene-tration should be complete.

EQUIPMENT REQUIREDDC constant poi..c.ntial welding machine, wire feeder withgun complete, gas mixer manifold, tongs, and safetyequipment.

MATERIAL NEEDED2 pieces 1/2 x 2 x 24 inch steel plate beveled on one sideto 30°.

PROCEDURE1 - 7. Repeat equipment $ safety procedures.8. Place the plate in the jig for a butt weld with a root

opening of about 1/8 inch.9. Position this assembly for vertical welding.10. Point the gun at the center line of the joint, hold a

slight dragging angle down. Drop the face shield.11. Close trigger switch, move downward with a small weave

motion, or hold steady to make stringer beads.12. Move at a uniform rate and repeat until the groove is

filled.13. The reinforcement should not exceed plate thickness by

more than 1/8 inch; it should be uniform in appearance.14. Repeat this procedure until an acceptable weld is produced.15. Secure equipment.

205

itAl

C

6S-;

t.L

.,

1 ''

G) '1W

REINFORCEMENT

1kE- 2

ROOT

iFACE

f\1P,

A 71.- 2

LROOT GAP

PENETRATION

A. FLAT POSITION

a M.I.G. PROCESS

C. SPRAY ARC

D. SUBSTITUTE STEEL PIPEIF AVAILABLE

NAME

GROOVE WELD

MILESTONE G

uVu GROOVE BUTT WELDIN THE FLAT POSITION

MODULE NO. II

FIGURE NO. 8-7

ELECTRODE SIZE Im DIA. DC/CP WIRESPOOL TYPE 4043 ALUM.


ALUMINUM PLATE 4043 2 y X 2 X 24

206



Milestone C, 'V' Groove Butt Weld in the Flat Position(when available, substitute pipe)


INTRODUCTIONThe student will make a butt weld on aluminum plate in theflat position. This weld can be made using spray methodof metal transfer, making the number of passes that willproduce the desired weld size. The reinforcement shouldbe slightly convex, uniform in width, but without undercut.Penetration should be complete.

EQUIPMENT REQUIREDDC constant potential welding machine, wire feeder with guncomplete pressure regulator, flow meter, tongs, and safetyequipment.

MATERIAL NEEDED2 pieces 1/2 x 2 x 24 inch aluminum plate beveled on oneside to 30°; spool of type 4043 filler wire.

PROCEDURE1 - 7. Repeat equipment & safety procedures.8. Place the plate in the jig for butt joint witil a root

opening of about 1/8 inch. Place for flat positionwelding.

9. Put on face shield and gloves.10. Point the gun at the centerline of the joint, drop face

shield.11. Close the trigger switch, push gun along the joint at

about 15° from the vertical in the direction of travel.12. Use either weaving or stringer procedure.13. Move at a uniform rate and repeat until groove is filled.14. Reinforcement should not exceed plate thickness by more

than 1/8 inch; it should be uniform in appearance.15. Repeat this procedure until an acceptable weld is produced.16. Secure equipment.

207

1

332 2 ROOT FACE

PENETRATION

En lira

GMAWA-B-C-D

111141110r 32

60 REINFORCEMENT

0.1

-.- ..--::-..".-,

-*.' ..'---..;-

. 7

a ,

C4

60

14N I

".\ 'NCtC0

.. 440-rc

V:I


B. M. I. G. PROCESS

C. SHORT ARC


i1:?..

I

NAME

GROOVE WELD

MILESTONE D

"V" GROOVE BUTT WELDSIN THE VERTICAL DOWN POSITION

MOOULE NO. Z

FIGURE NO. B-8

ELECTRODE SIZE J_ DIA. DC/CP WIRESPOOL TYPE 4043 ALUM.16


ALUMINUM PLATE 4043 2I

2- X 2 X 24

208



Milestone D, 'V' Groove Butt Weld in the Vertical DownPosition (when available, substitute pipe)


INTRODUCTIONThe student will make a butt weld on aluminum plate in thevertical down position. This weld can be made using shortcircuiting arc method of metal transfer making the numberof passes that will produce the desired weld size. Thereinforcement should be slightly convex, uniform in width,but without undercut or pinholes. Penetration should becomplete.

EQUIPMENT REQUIREDDC constant potential welding machine, wire feeder with guncomplete, pressure regulator, flow meter, tongs, and safetyequipment.

MATERIAL NEEDED2 pieces 1/2 x 2 x 24 inch aluminum plate, beveled on oneside to 30°; type 4043 filler wire.

PROCEDURE1 - 7. Repeat equipment 4 safety procedures.8. Place the plate in the jig for a butt joint with a root

opening of about 1/8 inch. Position for vertical welding.9. Put on face shield and gloves.10. Point gun at the centerline of the joint, drop face

shield.11. Close trigger switch, move downward with a slight drag

angle.12. Use either weaving or stringer welding procedure.13. Move at uniform rate and repeat until the groove is filled.14. Reinforcement should not exceed plate thickness by more

than 1/8 inch; it should be uniform in appearance.1S. Repeat this procedure until an acceptable weld is produced.16. Secure equipment.

209

FLUX CORE

D. WELD ALL

0, ,e: CZ:.

i.k 14"....

l

PENETRATION

ciao?vow.

WELD SEQUENCE

SIDES

!)1'9 0--(41

--f. z:.--

,:-." s-;,.

-V,.#;13;..

/

C.

GMAWABCD

A.

B.

\,..IFLAT POSITION

M. I.G. PROCESS

NAME

FLUX CORED ELECTRODE WELDING

MILESTONE AFILLET WELDS

IN THE FLAT POSION

MODULE NO..IIL

FIGURE NO. B-9

ELECTRODE SIZE .045 DIA. DC/CP WIRESPOOLYPE AWS A5 20 69MATEMAL STEEL SPEC.

MILDAMT.

ISIZE I

4 X 2 X 24

STEEL MILD 2 - X I X 24

210


Module III. Flux Cored Electrode Welding

Milestone A, Fillet Welds in the Fiat Position


MIMM1Di.,=....

INTRODUCTIONThe student will make a fillet weld set of steel plate forwelding in the flat position. Four fillet welds will bemade with 3/4 inch leg dimension. Flux cored electrodeequipment will be used to deposit the metal needed to fillthe fillets to the required depth. These should have a flatface .and equal leg length.

EQUIPMENT REQUIREDDC constant potential welding machine, wire feeder with guncomplete, gas mixing manifold, tongs, and safety equipment.

MATERIAL NEEDED1 piece 1/4 x 2 x 24 inch and 2 pieces 1/4 x 1 x 24 inchsteel plate.

PROCEDURE1 - 8. Repeat equipment 4 safety procedures.9. Hold gun, drop face shield and tack weld the pieces to

form a cross.10. Direct the gun so that the wire points to the corner of

the joint. .

11. Close contactor switch, move gun along the joint.12. Use a leading angle and a small weaving motion.13. Make the required width of bead by controlling the rate

of travel.14. Repeat this procedure until a uniform bead is produced.15. Secure equipment.

211

1

Or)

v

NN

I09

G

0i.:. ir

kt."0,- ....

,.tkk er

001p

.....45

itt

le- 1.1

REINFORCEMENT (---GMAW

A-B-C

60T.L. law

-4. meraffilsI 1

1r

.

OOT GAP

PENETRATION

A. FLAT POSITION

B. M.LG. PROCESS

C. FLUX CORE


NAME

FLUX CORED ELECTRODE WELDINGMILESTONE 0

"Vn GROOVEGROO BUTT WELD W/BACK UPIN THE FLAT POSITION

MODULE NO. Si

FIGURE NO. EI-10

ELECTRe:E SIZE .045 DIA. DC/CP WIRESPOOL TYPE AWS A-5 20 - 69MATERIAL STEEL SPEC.

DMILANT. SIZE i X 2 X 24

STEEL MILD I IiT X I X 25

21

I


Module III. Flux Core Electrode Welding

Milestone B, 'V' Groove Butt Weld in the Flat Positionwith Backing Plate


INTRODUCTIONThe student will make a butt weld with backing strip onsteel plate with a beveled edge. Two or three passes willbe needed to complete this weld, depending on the size ofthe wire used. The reinforcement should be slightly convex,with uniform ripple. Fusion with the backing strip shouldbe complete. There should not be any undercut or pinholes.

EQUIPMENT REQUIREDDC constant potential welding machine, wire feeder with guncomplete, gas mixing manifold, tongs, and safety equipment.

MATERIAL NEEDED2 pieces 1/2 x 2 x 24 inch steel plate with one side beveledto an angle of 300; 1 piece of 1/4 x 1 x 25 inch steel bar.

PROCEDURE1 7. Repeat equipment & safety procedures.8. Place the plates in welding jig to form a butt weld with

the backing strip. The root opening should be about3/16 inches.

9. Put on face shield and gloves.10. Hold gun with wire pointed at the root of the joint.11. Drop face shield, close contactor switch, move along

the root of the joint. Use a small weave motion sothat all three members of the joint are fused.

12. Clean each pass as it is completed, continue depositingbeads until the groove is filled.

13. The reinforcement should be uniform, have a slightlyconvex surface without undercut or pinholes.


213

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