CRO-MAGNON

CORPORATION
SEMINAR ON
FUNDAMENTALS IN
MAINTENANCE WELDING
TECHNOLOGY

Speaker:

Homer J. Camon

Marketing Manager

FUNDAMENTALS IN
RECONSTRUCTIVE
MAINTENANCE WELDING
Module
I

SEMINAR OUTLINE

I. Definition of Welding Terms

II. A Review on the Concepts in the Manufacture and
Applications of the Maintenance Engineered
Welding Alloys
III. Welding Problems: Defects and Failures Commonly
Encountered in the Maintenance Welding Industry
IV. A simplified Approach to the Base Metal Preparations
and Removal of Defects
V. An Up-date on the Latest Maintenance Welding
Techniques and Practices
VI. Safety Rules in Maintenance Welding
VII. Open Forum

DIFFERENT WELDING PROCESSES

SMAW Shielded Metal Arc Welding
Stick Welding
Arc or Electric Welding
Sub Process
CAW Carbon Arc Welding
e.g. Arc - Air
OAW/OFW Oxy-Acetylene Welding/Oxy-Fuel
Welding
OTHER GASES USED

A. Propane / Methane / Butane Gases

B. Natural Gas
C. Methylacetylene Propadience stabilized
(MPS) excellent for cutting than acetylene but requires about
twice as much as oxygen to support same flame temperature.

THREE KINDS OAW FLAMES

1. CARBURIZING FLAME For soft metal application.
TEMPERATURE: 5,700oF

2. NEUTRAL FLAME
TEMPERATURE: 5850oF

3. OXIDIZING FLAME
TEMPERATURE: 6,300oF

 TIG / GTAW Tungsten Inert Gas/Gas

Tungsten Arc Welding

SHIELDING GASES
A. Argon
B. Helium
C. Carbon Dioxide
D. Helium - Argon Mixture
E.Carbon Dioxide Argon

Mixture

 TIG / GTAW Tungsten Inert Gas/Gas

Tungsten Arc Welding

TORCH
A. Air Cooled It has a single cable /
connection.
B. Water Cooled It has 3 cable
connections for water
and gas
connections and water return line.

 TIG / GTAW Tungsten Inert Gas/Gas

Tungsten Arc Welding

WELDING POWER
A. Air Cooled For low current capacity T
Torches up to 275
AMPS.
B. Water Cooled For high current
capacity TIG Torches
up to
500 AMPS.

ELECTRODE

AWS
CLASSIFICATION

A. Red
(All Purpose) 2% Thorium (EWTH 2)
B.Yellow
(All Purpose) 1% Thorium (EWTH 1)
C. Green
(Aluminum/Magnesium)
(EWP)
99.5% Pure Tungsten
D. Brown
(Mixed of Pure & Thoriuted Tungsten)
(EWZR-1).25% Zirconium

 ELECTRODE

AWS
CLASSIFICATION

E. Black
(Similar to Thoriuted Tungsten (EWLA-1
1% Lanthanum
F. Orange
(Very successful in AC or DC) (EWCE-2)
2% Cerium
G. Gray
(Assigned for Alloys not covered by above
(EWG) Classes) Unspecified

 MIG / GMAW Metal Inert Gas/Gas

Metal Arc Welding
SHIELDING GASES

A. Argon
B. Carbon Dioxide (CO2) Preferred over
Argon due to the ff:
B1. Less Expensive
B2. Superior Heat Conductivity

 MIG / GMAW Metal Inert Gas/Gas

Metal Arc Welding
SHIELDING GASES
C. 75% CO2 and 25% Argon mixture
premixed in one cylinder where high quality
welds are required in 4130 steel.

D. Flux Cored Wire (0.045 Dia.)

No gas shielding is required similar to stick
welding. Can weld thicker metals at higher
volts and AMP. setting.

 MIG / GMAW Metal Inert Gas/Gas

Metal Arc Welding
MACHINE / ACCESSORIES
A. Welding Gun
In place of TIG Torch or Arc Welder Stinger.
B. Power Supply
Almost all wire feed welders supply DC
current but can be applied with AC by
using transformer rectifier. Output can
range from 15 to 1,200 AMPs. But
most often ranges from 10 to 220/230
volts, or up to 575 volts depending on
machine output.

 MIG / GMAW Metal Inert Gas/Gas

Metal Arc Welding

MACHINE / ACCESSORIES

C. Wire

Drive Mechanism / Control Unit

Consist of a wire spool and DC-Motor powered
drive rolls (two wheels that run against each
other with the wire in between. Control unit
regulates Arc starting and stopping, as well as
wire feed, gas flow and sometimes water flow
rates.

Properly adjusted MIG machines Arc sounds like

frying bacon when in use.

D. Water Cooling System - For some heavy-duty units.

 PAW Plasma Arc Welding

Gas is heated to extremely high, temperature
and ionized so it becomes electrically conductive.
It uses such a gas to transfer an electric Arc to the
work piece and to constrict or contain the Arc for
welding. Plasma Arc is up to 20 times faster than
oxy-acetylene.

A. Electrode Non-consumable
Tungsten Electrode located
within the torch Nozzle.

 PAW Plasma Arc Welding

B. Plasma Temperature Range 50,
000F (27,760C) (Hot enough to melt
any metal) This is cthe temperature of
Plasma Arc emerging from the orifice.

 PAW Plasma Arc Welding

C. Two modes of penetration in
Plasma Arc Welding
C1. Melt-In For conventional,
manual and mechanized fusion
welding advantages are better
operator control of Torch to
work distance and elimination of
Tungsten electrode contamination
because electrode is protected
inside the nozzle. Filler metal can
be used.

 PAW Plasma Arc Welding

C2. Keyhole
Gives a long narrow arc that
completely penetrates the workpiece to form
a keyhole at the center of the weld puddle.
Filler metal is not required, in close fitting.
But-Type Weld-Seam Welding. The complete
penetration of the workpiece thickness and
movement of the molten metal purges
impurities and gases from weld prior to
solidification. This gives the highest possible
weld quality. Done with metals up to
inches thick.

 PAW Plasma Arc Welding

D. Power Supply Initiates the Arc and
contains the Gas Supply and Water Cooling
System.

E. Direct current/straight polarity

usually used current Reverse polarity/
positive electrode is used with a water
cooled copper electrode.
F. Filler Rods Usually added the same
as in TIG Welding, Mechanized Wire feed
Systems can also be used for Industrial
applications.

 PAW Plasma Arc Welding

F. Gas Supply same gas used in
TIG Welding but two gas supplies are
required with Plasma Welding.
a. Orifice Gas Plasma Gas.
b. Shielding Gas Any gas as in TIG Welding.
c. For cutting use Nitrogen as Shielding Gas.

NOTE: Which gas should be used depends

on the type of welding technique
and type of metal to be weld.

Examples:
1. Argon For welding steel, carbon,
low alloy or stainless and
aluminum using any technique.
2. 75% helium / 25% Argon Mixture
If material is over 1.8 inches thick
using melt-in technique.
3. For reactive metals such as titanium
use argon if the material is less than
inches thick.
4. Other Applications Argon / Helium
mixture of 50-75% Helium
for keyhole and 75% Helium
for melt-in.

d. Non-Oxidizing feature of Plasma Arc

makes it natural for cutting stainless
steel, and non-ferrous metals
such as aluminum, copper and brass.

SAW Submerged Arc Welding

Is a process in which the Electric Arc
is submerged in a powder flux thereby
protecting the weld from atmospheric
contamination. The system is usually
automatic feed and travel, and a base
metal rod is used. Its used where high
accuracy and weld quality are desired.

SPOT WELDING
welding Method.

A production

To join sheet metal.Electrical resistance heating

and clamping pressure are used to fuse panels
together with a series of small Spots, filler metal is
NOT used. It is also called resistance welding.

FUSION WELDING The only true

kind of welding.
The metal pieces to be welded are heated to a
liquid state along the weld seam and usually filler
metal of the same or similar type is added to the
molten puddle and allowed to cool, forming one
continuous piece of metal, thus, the weld should
be stronger than the added filler metal.

I. DEFINITION OF WELDING TERMS

A. PROCESSES
1. SMAW
2. OAW
3. GTAW
B. WELD DEPOSITS
1. Penetration/Fusion Zone
2. HAZ (Heat Affected Zone)
3. Width
4. Height

C. WELDING FUMES smoke/vapor, that are

produced during
welding.
D. RADIATION - natural response of an

element when subjected to

heat (emission of rays).

II. A Review on the Concepts in the Manufacture and

Applications of the Maintenance-Engineered Welding
Alloys.
Variables
1. Purpose

Production
Welding
To fabricate a
design

Maintenance
Welding
To restore work or
broken parts into its
original design as
rapidly as possible.

2. Time Element Ample of time Now situation.

for planning to
ensure success.

Variables

Production
Welding

3. Nature of Work

Limited number of
work.

4. Human Factors

Planning is done
by Engineers,
Metallurgist,Consu
ltants &
Specialists.

Maintenance
Welding
Every repair
is unique.

Maintenance
Engineers/Super
visors
Maintenance
Welders &
Machinists.

Work are done by expert production Welders.

Variables

5. Facilities/
Equipment

Production
Welding

Complete
production
welding
equipment
(SMAW,OAW,
GTAW,etc.)

Maintenance
Welding

Whatever
equipment
available at
the time of
breakdown.

Variables

6. Base
Metal

Production
Welding

Clean,
New,
Known
exact
analysis

Maintenance
Welding

Dirty (greasy, oily,

rusty, painted, dusty, &
contaminated with
chemicals).
Worked (rolled,
forged, heat
treated, fatigued).
Seldom knows
the analysis.

Variables

7. Welding

Rods/Alloy

Production
Welding

Ordinary
production rods
to match
standard base
metal analysis.

Maintenance
Welding

Highest possible
alloying element
content
to
compensate for all
the difficulties
in
maintenance
welding.

Should provide users with

GREATER
VERSATILITY,
GREATER
PHYSICAL
PROPERTIES
AND
GREATER EASE OF
APPLICATIONS.
8. Quality

Safety is taken into

design

100% successful
weld requirement.

Allowed 3-6%
Bad Welds
9. Value

Profit

Savings through
time & money.

III. WELDING PROBLEMS: Defects and

Failures commonly encountered in the
Maintenance Industry.
A. Porosity
B. Hard Spots

- cause by blowholes and the

releasing of gases.
- carbon reaction with other
elements.

Examples:
1.) IRON + CARBON = IRON CARBIDES
2.) CHROMIUM + CARBON = CHROMIUM CARBIDES
3.) MOLYBDENUM + CARBON = MOLYBDENUM
CARBIDES

C. Cracking - Fracturing and fissuring of a

material.
c.1. Multi-axial stresses
c.1.1. expansion
c.1.2. contraction
c.2. Elemental Reaction
c.2.1. Sulfur hot- cracking
c.2.2. Phosphorous cold cracking

D. Rod Selection - does not contain:

d.1.
d.2.
d.3.
d.4.
d.5.

Cleansers
Neutralizers
Stabilizers
Deoxidizers
Etc.

Exampl
e:

6 0 1 3

tensile strength
welding position

welding
current/chemical
composition of
flux covering

1.

(One) Flat (F), Horizontal (H),

Vertical (V), Overhead (OH)

2.

(Two) Flat (F), Horizontal Fillet

3. (Three) Flat (F), Horizontal (H),

Vertical Down (VD), Overhead (OH)
4. (Four) Flat (F), Horizontal (H), Vertical
Down (VD), Overhead (OH)

IV. A Simplified Approach to the Base

Metal Preparations and Removal
of Defects
A. Build-up (wear and tear)
B. Crack
C. Sleeve/patches
Things to consider:
1. Identification of causes
2. Identification of base metal
3. Know the possible effect of heat

1) Wear - remove at least 0.5mm (grinding, machining,

filing)
- use of degreaser
- pre-heat
- searing (preheat + wire brushing
3x)

2) Cracking
- drill a hole at crack ends
- use proper curve
- find the root

V. AN UPDATE ON THE LATEST MAINTENACE

WELDING TECHNIQUES AND PRACTICES

Motto:
The human skill
is a vital factor in
the success of every
repair process.

A. GAP To avoid multi-axial stresses & lock-in

stress.
1.) Root Gap (between 1/16 to 1/8)
2.) Shim (1/16 soft wire)
3.) Pre-straining

B.WELD BEADS
1.) Stringer joining and filling up of cracks and for
sensitive and brittle metals.
W= 3x MAX

2.) Weave Advisable for build up.

W= 5x and not less than 3x

Directions Of Weaving

C.) BEAD SEQUENCES

1.) Back-step- to avoid warping.

2.) Skip-3/4-1 (to balance the distribution of heat

in the entire portion to be welded).

D.) COUNTER DISTORTION AND MISALIGNMENT

1.) Tack

2.) INTERMITTENT

3.) LOCK

4. STRONG-BACK

5. WEDGE OR KALSO

D. HEAT TREATMENT
1.) Preheating
2.) Post heating
3.) Normalizing
4.) Tempering
5.) Annealing

E. PEENING
F. BUTTERING

H. ANCHORING

I. BUFFER LAYER
J. HARD SURFACING FOR WEAR & TEAR
IF THE BASE METAL IS SUBJECTED TO:
1)

IMPACT

2)

METAL TO METAL CONTACT

EROSION-SEDIMENTS+PRESSURE+LIQUID+
TEMPERATURE

4)

ABRASION

5)

CORROSION

K. OTHER PRACTICAL
TECHNIQUES
1.)
2.)
3.)
4.)
5.)
6.)
7.)
8.)
9.)

Striker Plate
Avoid Crater Cracks
Patching
Drill holes at Crack Ends
Clamping
Welding in Compression
Expansion Joint
Close Arc Length
Proper Polarity Adjustment for DC
Welding Machines
10.) Gemini Process

L. ALTERATION/MODIFICATION OF `
ORIGINAL DESIGN
M. METAL-STITCH AND WELDING COMBINED

N. PROPER BASE METAL PREPARATION

O. PROPER USE OF MATERIALS

VI. SAFETY RULES IN MAINTENANCE

WELDING
WELDING HAZARDS
A. Radiation (Rays):
1.) Ultra-violet rays
2.) Infra/ultra red rays
3.) Visible lights
B. Fumes

C. Explosion = combustibles + oxygen + ignition

1. Guards against Explosion
A. Use no oil (oxygen regulators & fittings)
B. 15 psi maximum (acetylene pressure)
C. Proper handling of gas cylinders
D. Empty cylinders should be marked MT and
properly closed
E. Protection against any source of heat - including
sunlight on cylinders, regulators and
hoses.
F. Avoid flashback
G. Remove unnecessary combustibles within the

1. Guards against Explosion (cont . . . )

H. Steaming process (using inert gas like nitrogen)
before welding vessels
containing combustibles materials.
I. Use of gas detector.

J. Availability of fire extinguishers

2. General Precautions when Welding Vessels

Containing Combustibles:
A. Remove all fluids.
B. Steam at least one (1) hour per 200 gallons
vessel capacity using inert nitrogen
C. Always test after steaming with gas detector
D. Use lighted torch from behind an explosion
proof shield to test around the vents of freshly
steamed gas tank.

2. General Precautions when Welding Vessels

Containing
E.

Combustibles: (cont.)

Weld immediately after steaming. Steam

should continue to clean the vessel while
welding is done.

F.

Open all vents.

D. Electric Shock
1. 008 amps .

- Shock Sensation

2. .015 amps.

- Painful Shock

3. .020 amps.

- Loss Control

4. .100 amps.

- Possible Heart
Failure

5. .200 amps.

- Fatal

E. Fires (Classified According to

Origin)
1. Class A (wood, paper, clothing)
2. Class B (oil, grease, paints)
3. Class C (electrical fires-motor, switches,
appliances)
4. Class D (burning flammable metals like
mercury

F. Burns
1.Minor Burns (affects only the outer layer
of the skin; fiery red; may blister)
2. Deep Burns (penetrated beyond skin and
flesh; destroys not only the skin but the
underlying muscles and fats)

 Touch Wounds Only if Absolutely Necessary.

Do Not Apply Salves or Lotions to the Burns.
Leave Burned Clothing on the Burns.
Dont Break Blisters.
Cover all the Affected Areas with Dry Dressing.

Use Shock Preventive Treatment.

Get Proper Medical Help.

*Recommended By American Optical

(AO)
Gas Torch Cutting and Welding
Shade No:
Soldering

1.7**

Brazing

3 or 4

Cutting:
Light (up to one inch)

3 or 4

Medium (one to six inches)

4 or 5

Heavy (one-half inch and up)

5 or 6

Welding:
Light (up to one-eight inch)

4 or 5

Medium (one-eight to one-half inch) 5 or 6

Heavy (one-half inch and up)

6 or 8

** Medium Calobar
Electric Welding and
Cutting
Shielded Metal Arc
Welding (SMAW

Rod Diameter
1/6 to 3/32
1/8 to 5/32
3/16 to
5/16 to 3/8

Shade No:
8
10
12
14

Electric Welding and

Cutting

Rod Diameter

Shade No:

Atomic Hydrogen

10 to 14

Inert Gas Shielded Arc

(GTAW/GMAW)
Carbon Arc Welding (CAW)

10 to 14

Plasma Arc Welding:

Spraying
Cutting
Welding

14
5 to 8
8 to 12
8 to 12

FUMES

EFFECTS

Iron Fume

- causes lung cancer and

disease known as siderosis.

Zinc Fume
Lead Fume

- causes metal fume fever.

- extremely dangerous and
accumulative type of poison that
can resolve paralysis, anemia,
stomach and colon problems,
tiredness and nervous disorder.

Cadmium Fume

- causes kidneys, livers and

lungs disease.

FUMES

EFFECTS

Chromium Fume

- affects primarily skin and lungs.

Some chromium fumes are
carcinogenic and can cause cancer.
Hexavalent Chromium (Cr6) is
very dangerous.

Nickel Fume

- very poisonous and carcinogenic can

causes Pneumonia

Copper Fume

- causes fever, chills and nausea.

FUMES

EFFECTS

Manganese Fume

- affects lungs and central

nervous system.

Beryllium Fume

- very low exposure are

poisonous and causes
pneumoconiosis.

Silica

- contain some Nuisance dust

that can cause nausea.

Fluorides

- can irritates eyes, noses and

throats.

FUMES
Solvents

EFFECTS
-

can irritate the mucous membrane

and drowsiness.

Nitrogenous Gases - affects lungs causing pulmonary

edema and produces toxic
poisoning. Lethal when welding
in confined spaces.
Ozone
- irritates mucous membranes and
Causes throat dryness, headache and
fatigue. Extreme exposure causes
pulmonary edema and bleeding
in the lungs.

FUMES

EFFECTS

Carbon Monoxide -

Carbon Dioxide

causes internal suffocation. Causes

headaches and dizziness. Extreme
exposure is fatal.

- effect is stimulation of breathing

causing increase in absorption of
other welding fumes.

Use Gas Mask

Install Exhaust Fan (extraction of fumes)
Use of welding alloys which produces
shielding gas.
Use of Close Arc
Proper Base Metal Preparation