Workmanship Project STUDENT

Transcription

1 GMAW Workmanship Project STUDENT T N E D U T S E D I GU Lincoln Electric Workmanship Project 1

2 Guide for Safe Arc Welding STEP 1 Please refer to the E205 Safety Guide that was included in your kit and review Arc Welding Safety Practices before starting this project. You can also view this guide online at: Now, that you have reviewed and understand your safety practices, begin by laying out the pieces of metal below. Arc Welding Safety E.205 Part 1A (x2) Part 1B 2 Lincoln Electric Workmanship Project

3 STEP 2 Read over the attached blue print and understand the entire project before continuing. Additional information on reading blue prints can be found in the How to read shop drawings book from the JFLF foundation. f.org Lincoln Electric Workmanship Project 3 GMAW STUDENT Workmanship Project

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5 STEP 3 Layout parts that need to be cut according to the blueprint. STEP 4 Oxyfuel cut parts that are called out in the blueprint. Lincoln Electric Workmanship Project 5 GMAW STUDENT Workmanship Project

6 STEP 5 Clean the edges of the plate with a hand grinder. STEP 6 Following the blueprint, file a land on the beveled edge. File the land according to the print specifications. 6 Lincoln Electric Workmanship Project

7 STEP 7 Position plates together and tack weld both ends of the joint as shown in the fi gures below. STEP 8 Position the triangle on the plates and tack weld both ends, following the blueprint measurements. Lincoln Electric Workmanship Project 7 GMAW STUDENT Workmanship Project

8 STEP 9 Weld your project together using the GMAW spray process. 8 Lincoln Electric Workmanship Project STEP 10 After welding, clean your welds with a wire brush.

9 BACKGROUND INFORMATION Tape measure reference: Measurements above are not to scale. Lincoln Electric Workmanship Project 9 GMAW STUDENT Workmanship Project

10 BACKGROUND INFORMATION Carburizing Flame Neutral Flame Neutral Flame with Oxygen Cutting Stream 10 Lincoln Electric Workmanship Project

11 BACKGROUND INFORMATION Oxy/Acetylene cutting procedures Before Lighting Oxy/Fuel Gas Torches Make sure all valves are closed and regulator adjusting screws are backed out. Set gas pressures according to the manufacturers tip charts. Open then close each gas valve independently to bleed the system. Set pressures at fl ow Lighting an Oxy/Acetylene Torch Slighting open acetylene valve and light with an approved device. Root fl ame and clear smoke. Open oxygen valve and set fl ame to neutral. - Sharp defi ned inner cone Never light torch with both oxygen and acetylene fl owing. Welding Flame Types Carburizing fl ame Neutral fl ame Oxidizing fl ame Turning off an Oxy/Acetylene Torch Proper sequence checks integrity of torch valves Close oxygen valve fi rst Close acetylene valve second If acetylene valve is leading a small fl ame will continue burning If oxygen valve is leaking, torch will pop as acetylene valve is closed. If either valve is leaking, repair before further use. ALTERNATIVE FUEL CUTTING PROCEDURE Before Lighting Oxy/Fuel Gas Torches Make sure all valves are closed and regulator adjusting screws are backed out. Set gas pressures according to the manufacturers tip charts. Open then close each gas valve independently to bleed the system. Set pressures at fl ow. Lighting Equal Pressure Torches Using Alternate Fuel Gases Open torch valves 1/8 to 1/4 turn. Ignite fuel gas with approved igniter and adjust fl ame. Introduce oxygen and adjust to the desired fl ame. - Tip edge touching plate - Star pattern or sound It is permissible to light the fl ame with both gases fl owing. - Sometimes necessary Adjusting for large or heating tips. - Increase fuel then oxygen in successive steps Turning Off Alternate Fuel Torches Close fuel gas valve fi rst. Close oxygen valve second. This sequence can prevent the operator from being burned. If fuel pressure is great enough - check valves at initial light up by turning oxygen off fi rst. Lincoln Electric Workmanship Project 11 GMAW STUDENT Workmanship Project

12 BACKGROUND INFORMATION 12 Lincoln Electric Workmanship Project

13 BACKGROUND INFORMATION Lincoln Electric Workmanship Project 13 GMAW STUDENT Workmanship Project

14 BACKGROUND INFORMATION Parts of a weld: TERMS & DEFINITIONS Toe: The junction of the weld face and the base metal. Leg: The distance from the joint root to the toe of the weld Face: The exposed surface of a weld on the side from which welding was done. Theoretical Throat: The minimum distance minus any reinforcement between the joint root and the face of a fillet weld. Effective Throat: The minimum distance minus any reinforcement between the weld root and the face of a fillet weld. Actual Throat: The shortest distance between the weld root and the face of a fillet weld. Reinforcement: Weld metal in ex Heat Affected Zone: That portion of t microstructure h Weld Root: The points at wh Joint Root: That portion of a In cross section TERMS & DEFINITIONS. nd the face of a fillet weld. nd the face of a fillet weld.. Reinforcement: Weld metal in excess of the quantity required to fill a joint. Heat Affected Zone: That portion of the base metal that has not been melted, but whose mechanical properties or microstructure have been altered by the heat of welding, brazing soldering, or cutting. Weld Root: The points at which the root surface intersects the base metal surfaces. Joint Root: That portion of a joint to be welded where the members approach closest to each other. 14 Lincoln In cross Electric section, the joint Workmanship root may be a point, Project a line, or an area.

15 BACKGROUND INFORMATION BASIC GMAW SETTINGS: Digital WFS and Voltage Controls Weld setting chart under welders door Lincoln Electric Workmanship Project 15 Reference additional GMAW settings in Lincoln Electric s C4.200 GMAW welding guide at GMAW STUDENT Workmanship Project

16 BACKGROUND INFORMATION Helpful GMAW Techniques: Work Angle Contact Tip To Work Distance (CTWD) Travel Angle 16 Lincoln Electric Workmanship Project

17 BACKGROUND INFORMATION Troubleshooting welds: Lincoln Electric Workmanship Project 17 GMAW STUDENT Workmanship Project

18 Torchmate Growth Series 2x2 CNC Prototyping System / Tomahawk 625 One-Pak The Torchmate SeriesWELDING 2x2 Prototyping System changes the way you THE Growth ARC BOOKSHELF make Books, parts in your home, school or small fabrication shop. Delivering enhanced Texts, Charts, control and repeatability over manual operations, this compact multi-use platform DVDs Teaching is designed to bringand CNC plasma cutting, routing,aids drilling, milling and engraving to those who could not previously afford to enter the world of CNC technology. We included what s required to operate the system for CNC plasma cutting expand with secondary tooling as your needs and expertise grow. Books DVDs Videos The James F. Lincoln Arc Welding Foundation The James F. Lincoln Arc Welding Foundation was created in 1936 through a deed of trust, to encourage and stimulate scientific interest in and scientific study, research The Lincoln Electric andcompany education in respect of the development of the arc welding industry through advance in the knowledge and practical application of the arc welding process. As St. Clair Avenue Cleveland,and OHdesign U.S.A. a contribution to scientific progress and to promote industrial progress through education, PH: the Foundation produces and publishes the books listed here as a non-profit service to industry.