4
1 SAFETY IN WELDING . . . . . . . . . . . . . . . . . . . . 9
1.01 Introduction . . . . . . . . . . . . . . . . . . . . . . . . 10 1.02 How to use the handbook . . . . . . . . . . . . 11
1.03 Welding instructions and training . . . . 12 1.04 Personal protection . . . . . . . . . . . . . . . . . 13
1.04.01 Arc welding face shields . . . . . 14 1.04.0 Protective goggles . . . . . . . . . . . 18
1.04.03 Welders protective clothing . . 0
1.05 Work site protection . . . . . . . . . . . . . . . . 22
1.05.01 Welding curtain . . . . . . . . . . . . . . 1.05.0 Welding blanket . . . . . . . . . . . . .
1.05.03 Fire extinguisher . . . . . . . . . . . . . 3
1.06 Welding fumes . . . . . . . . . . . . . . . . . . . . . 24
1.06.01 Welding fumes . . . . . . . . . . . . . . 6 1.06.0 Fume extraction . . . . . . . . . . . . . 8
1.07 Safety check list . . . . . . . . . . . . . . . . . . . 30
1.07.01 Equipment . . . . . . . . . . . . . . . . . . 30 1.07.0 Work place . . . . . . . . . . . . . . . . . . 31
1.07.03 Hot work procedure . . . . . . . . . . 3 1.07.04 Operator protection . . . . . . . . . . 3
2 SOLUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 2.01 Introduction . . . . . . . . . . . . . . . . . . . . . . . . 36
.01.01 Quick reference for cutting . . . 39 .01.0 Quick reference for joining . . . . 40
.01.03 Quick reference for rebuilding, hardfacing and coating . . . . . . . 43
.01.04 Quick reference to cold repairs . . . . . . . . . . . . . . . . . 45
2.02 Filler material consumption . . . . . . . . . . 47 2.03 Metal identification . . . . . . . . . . . . . . . . . 50
2.04 Unalloyed low alloyed steel . . . . . . . . 55
.04.01 Introduction . . . . . . . . . . . . . . . . . 55 .04.0 Unalloyed steel . . . . . . . . . . . . . . 55
.04.03 Low alloyed steel . . . . . . . . . . . . 55 .04.04 Heat resistant steel . . . . . . . . . . 55
.04.05 Low temperature steel . . . . . . . . 56 .04.06 Weathering steel . . . . . . . . . . . . 56
2.05 Problem steels . . . . . . . . . . . . . . . . . . . . . 62 2.06 Stainless steels . . . . . . . . . . . . . . . . . . . . 65
.06.01 Introduction . . . . . . . . . . . . . . . . . 65 .06.0 Austenitic Stainless Steel . . . . . 66
.06.03 Ferritic Stainless Steel . . . . . . . . 68 .06.04 Martensitic Stainless Steel . . . . 69
.06.05 Duplex Stainless Steel . . . . . . . . 70 .06.06 Clad Steel . . . . . . . . . . . . . . . . . . . 71
.06.07 Stainless Steel corrosion types 7 .06.08 Storing and handling of
Stainless Steel onboard . . . . . . 74 .06.09 Grindingcutting consumables
for Stainless Steel . . . . . . . . . . . 75
2.07 Cast iron . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
.07.01 Introduction . . . . . . . . . . . . . . . . . 78 .07.0 Grey cast iron . . . . . . . . . . . . . . . 79
.07.03 White cast iron . . . . . . . . . . . . . . 80 .07.04 Malleable cast iron . . . . . . . . . . 80
.07.05 Ductile cast iron . . . . . . . . . . . . . 81 .07.06 High alloy cast iron . . . . . . . . . . 8
.07.07 Identification of cast iron . . . . . 83 .07.08 Preparation of the
work piece . . . . . . . . . . . . . . . . . . 84 .07.09 Arc welding of cast iron . . . . . . 87
.07.10 Braze welding of cast iron . . . . 95 .07.11 Cold repair on cast iron . . . . . . . 97
2.08 Copper and copper alloys . . . . . . . . . . . 104
.08.01 Introduction . . . . . . . . . . . . . . . . . 104 .08.0 Brass . . . . . . . . . . . . . . . . . . . . . . . 104
.08.03 Aluminium brass Yorcalbro . . 105 .08.04 Bronze . . . . . . . . . . . . . . . . . . . . . . 106
.08.05 Nickel bronses Cunifer . . . . . . 107
2.09 Aluminium . . . . . . . . . . . . . . . . . . . . . . . . 112 2.10 Evaluation of welds . . . . . . . . . . . . . . . . . 114
.10.01 Typical welding faults . . . . . . . . 114 .10.0 Inspection of welded joints . . . 118
.10.03 Crack detection . . . . . . . . . . . . . . 13
3 CONSUMABLES . . . . . . . . . . . . . . . . . . . . . . . . . 125 3.01 Coated Electrodes . . . . . . . . . . . . . . . . . . 126
3.01.01 Introduction . . . . . . . . . . . . . . . . . 17 3.01.0 Types of electrodes . . . . . . . . . . 18
3.01.03 Storing and re-drying . . . . . . . . . 134 3.01.04 Classification and approvals . . 140
3.01.05 Welding positions . . . . . . . . . . . . 148
5 3.01.3 NIFE-334 N
Nickel Iron Electrode for Cast Iron . . . . . . . . . . . . . . . . . . . . 184
3.01.4 NICKEL-333 N Nickel Electrode for Cast Iron 186
3.01.5 TINBRO-341 Electrode for Copper Alloys . . . 188
3.01.6 ALBRONZE-344 Electrode for Copper Alloys . . . 190
3.01.7 ALUMIN-351 N Electrode for Aluminum . . . . . . . 19
3.01.8 CH--38 Electrode for Chamfering . . . . . 194
3.01.9 ACA-384 Electrode for Air Carbon Arc
Gouging . . . . . . . . . . . . . . . . . . . . 196
3.02 Tig welding rods and fluxes . . . . . . . . . 199
