Operator’s Circular Welding Theory and Application

Operator’s Circular Welding Theory and Application
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
Training Circular
No. 9-237
TC 9-237
HEADQUARTERS
DEPARTMENT OF THE ARMY
Washington, DC, 7 May 1993
You can help improve this circular. If you find any mistakes or if you know
of a way to improve the procedures, please let us know. Mail your letter or
DA Form 2028 (Recommended Changes to Publications and Blank Forms), located
in the back of this manual, direct to: Commander, US Army Ordnance Center
and School, ATTN: ATSL-CD-CS, Aberdeen Proving Ground, MD 21005-5201. A
reply will be furnished to you.
Table of Contents
Paragraph Page
CHAPTER 1. INTRODUCTION
Section I. General 1-1 1-1
II. Theory 1-3 1-1
CHAPTER 2.
Section I.
SAFETY PRECAUTIONS IN WELDING OPERATIONS
General Safety Precautions
Safety Precautions in Oxyfuel Welding
Safety in Arc Welding and Cutting
Safety Precautions for Gas Shielded Arc Welding
Safety Precautions for Welding and Cutting
Containers That Have Held Combustibles
Safety Precautions for Welding and Cutting
Polyurethane Foam Filled Assemblies
2-1
2-6
2-12
2-17
2-19
2-30
2-1
2-14
2-22
2-27
2-28
2-38
CHAPTER 3. PRINT READING AND WELDING SYMBOLS
Section I. Print Reading 3-1 3-1
II. Weld and Welding Symbols 3-4 3-3
CHAPTER 4. JOINT DESIGN AND PREPARATION OF METALS 4-1 4-1
CHAPTER 5.
Section I.
II.
III.
IV.
V.
VI.
WELDING AND CUTTING EQUIPMENT
Oxyacetylene Welding Equipment
Oxyacetylene Cutting Equipment
Arc Welding Equipment and Accessories
Resistance Welding Equipment
Thermit Welding Equipment
Forge Welding Tools and Equipment
DISTRIBUTION RESTRICTION: Approved for public release; distribution is
unlimited.
iTC 9-237
Table of Contents (cont)
Paragraph Page
CHAPTER 6. WELDING TECHNIQUES
Section I. Description 6-1 6-1
II. Nomenclature of the Weld 6-7 6-14
III. Types of Welds and Welded Joints 6-10 6-20
xv . ricxvxxiAy ruaxLiuili O“1 / 6“JU
V. Expansion and Contraction in Welding Operations 6-25 6-38
VI. Welding Problems and Solutions 6-29 6-47
CHAPTER 7. METALS IDENTIFICATION
Section I. Characteristics 7-1 7-1
II. Standard Metal Designations 7-4 7-37
III. General Description and Weldability of Ferrous
Metals 7-10 7-45
IV. General Description and Weldability of Nonferrous
Metals 7-17 7-66
CHAPTER 8. ELECTRODES AND FILLER METALS
Section I. Types of Electrodes 8-1 8-1
II. Other Filler Metals 8-4 8-14
CHAPTER 9. MAINTENANCE WELDING OPERATIONS FOR MILITARY
EQUIPMENT 9-1 9-1
CHAPTER 10. ARC WELDING AND CUTTING PROCESSES
Section I. General 10-1 10-1
II. Arc Processes 10-8 10-23
III. Related Processes 10-15 10-102
CHAPTER 11. OXYGEN FUEL GAS WELDING PROCEDURES
Section I. Welding Processes and Techniques 11-1 11-1
II. Weldina and Brasri’ncr Fat-taiid Met-alc 11—17 11-07
III. Related Processes 11-17 11-32
IV. Welding, Brazing, and Soldering Nonferrous Metals …. 11-19 11-41
CHAPTER 12. SPECIAL APPLICATIONS
Section I. Underwater Cutting and Welding with the Electric
Arc
: 12-1 12-1
II. Underwater cutting with Oxyfuel 12-4 12-5
III. Metallizing 12-6 12-6
TV rs.4-4-^
J.V. 1XO11C xuLujjiy — Ol_eex r; 1 cuma xxun T 1Z-1O . -> . r- IZ-lb , ,
V. Flame Treating Metal 12-20 12-24
VI. Cutting and Hard Surfacing with the Electric Arc 12-27 12-27
VII. Armor Plate Welding and Cutting 12-33 12-31
VIII. Pipe Welding 12-41 12-54
LX. Welding Cast Iron, Cast Steel, Carbon Steel,
and Forgings 12-46 12-65
X. Forge Welding 12-48 12-71
XI. Heat Treatment of Steel 12-50 12-72
XII. Other Welding Processes 12-60 12-80TC 9-237
Paragraph Page
CHAPTER 13. DESTRUCTIVE AND NONDESTRUCTIVE TESTING
Section I. Performance Testing 13-1 13-1
II. Visual Inspection and Corrections 13-4 13-2
III. Physical Testing 13-12 13-8
APPENDIX A. REFERENCES … A-l A-l
APPENDIX B. PROCEDURE GUIDES FOR WELDING … B-l B-l
APPENDIX C. TROUBLESHOOTING PROCEDURES … C-l C-l
APPENDIX D. MATERIALS USED FOR BRAZING, WELDING, SOLDERING,
CUTTING, AND METALLIZING …D-l D-l
APPENDIX E. MISCET.1ANEOUS DATA … E-l E-l
GLOSSARY . …G-l G-l
INDEX 1-1 Index-1TO 9-237
LIST OF ILLUSTRATIONS
Figure Title Page
2-1 Welding helmet and hand-held shield 2-2
2-2 Welding helmets and shields 2-4
2-3 Safety goggles 2-5
2-4 Protective clothing 2-5
2-5 Welding booth with mechanical ventilation 2-10
2-6 Process diagram for air carbon arc cutting 2-25
2-7 Circuit block diagram AAC 2-26
2-8 Safe way to weld container that held combustibles 2-37
3-1 Construction lines 3-3
3-2 Standard locations of elements of a welding symbol 3-4
3-3 Basic and supplementary arc and gas welding symbols 3-5
3-4 Process or specification references 3-5
3-5 Definite process reference 3-6
3-6 No process or specification reference 3-6
3-7 Weld-all-around and field weld symbols 3-8
3-8 Resistance spot and resistance seam welds 3-8
3-9 Arrow side fillet welding symbol 3-8
3-10 Other side fillet welding symbol 3-8
3-11 Plug and slot welding symbols indicating location and dimensions
of the weld 3-9
3-12 Arrcw side V groove welding symbol 3-9
3-13 Other side V groove welding symbol 3-9
3-14 Welds on the arrow side of the joint 3-10
3-15 Welds on the other side of the joint 3-10
3-16 Welds on both sides of joint 3-10
3-17 Spot, seam, and flash or upset weld symbols 3-10
3-18 Construction of symbols, perpendicular leg always to the left .. 3-12
3-19 Construction of symbols, arrow break toward chamfered member … 3-12
3-20 Construction of symbols, symbols placed to read left to right .. 3-13
3-21 Combinations of weld symbols 3-13
3-22 Complete penetration indication 3-13
3-23 Construction of symbols, special types of welds 3-14
3-24 Multiple reference lines 3-14
3-25 Supplementary data 3-14
3-26 Supplementary symbols 3-14
3-27 Dimensions of fillet welds 3-15
3-28 Combined intermittent and continuous welds 3-16
3-29 Extent of fillet welds 3-16
3-30 Dimensions of chain intermittent fillet welds 3-17
3-31 Dimensions of staggered intermittent fillet welds 3-17
3-32 Application of dimensions to intermittent fillet weld symbols .. 3-17
3-33 Surface contour of fillet welds 3-18
3-34 Plug and slot welding symbols indicating location and dimensions
of the weld ‘ 3-19
3-35 Surface contour of plug welds and slot welds 3-20
3-36 Surface contour of plug welds and slot welds with user’s
standard finish symbol 3-20
3-37 Slot weld dimensions 3-20
3-38 Dimensions of arc spot and arc seam welds 3-21
3-39 Extent of arc spot welding 3-21
ivTC 9-237
3-40 Number of arc spot welds in a joint 3-22
3-41 Surface contour of arc spot and arc seam welds 3-22
3-42 Groove weld dimensions 3-22
3-43 Groove weld dimensions having no general note 3-23
3-44 Groove welds with differing dimensions 3-23
3-45 Groove weld dimensions for welds extending through the members
joined 3-23
3-46 Groove weld dimensions for welds extending partly through the
members joined 3-24
3-47 Dimensions of groove welds with specified root penetration 3-24
3-48 Flare groove welds 3-24
3-49 Root opening 3-25
3-50 Back or backing weld symbol 3-25
3-51 Surface contour of groove welds 3-25
3-52 Contours ohtai n^d by welding 3-26
3-53 Flush contour by machining 3-26
3-54 Convex contour by machining 3-26
3-55 Surface contour of back or backing welds 3-27
3-56 Melt-thru weld symbol 3-27
3-57 Surface contour of melt-thru welds 3-27
3-58 Size of surfaces built up by welding 3-28
3-59 Flange weld symbols 3-29
3-60 Size of resistance spot welds 3-30
3-61 Strength of resistance spot welds 3-30
3-62 Spacing of resistance spot welds 3-30
3-63 Extent of resistance spot weld 3-31
3-64 Number of resistance spot welds 3-31
3-65 Contour of resistance spot welds 3-31
3-66 Size of resistance seam welds 3-32
3-67 Strength of resistance seam welds 3-32
3-68 Length of resistance seam welds 3-32
3-69 Extent of resistance seam welds 3-33
3-70 Dimensioning of intermittent resistance seam welds 3-33
3-71 Contour of resistance seam welds 3-33
3-72 Embossment on arrow-side member of joint for projection
welding 3-34
3-73 Embossment on other-side member of joint for projection
welding 3-34
3-74 Diameter of projection welds 3-35
3-75 Strength of projection welds 3-35
3-76 Spacing of projection welds 3-35
3-77 Number of projection welds 3-35
3-78 Extent of projection welds 3-36
3-79 Contour of projection welds 3-36
3-80 Surface contour of lash or upset welds 3-36
4-1 The five basic types of joints 4-1
4-2 Inaccessible welds 4-4
5-1 Stationary oxygen cylinder manifold and other equipment 5-1
5-2 Station outlet for oxygen or acetylene 5-2
5-3 Stationary acetylene cylinder manifold and other equipment 5-2
5-4 Acetylene generator and operating equipment 5-3
5-5 Portable oxyacetylene welding and cutting equipment 5-4
5-6 Acetylene cylinder construction 5-6
5-7 Oxygen cylinder construction 5-8
vTC 9-237
LIST OF ILLUSTRATIONS (cont)
Title Page
5-8 Single stage oxygen regulator 5-9
5-9 Two stage oxygen regulator 5-11
5-10 Mixing head for injector type welding torch 5-12
5-11 Equal pressure type general purpose welding torch 5-12
5-12 Oxyacetylene cutting torch 5-19
5-13 Diagram of oxyacetylene cutting tip 5-19
5-14 Cutting attachment for welding torch 5-20
5-15 Making a bevel on a circular path with a cutting machine 5-20
5-16 Machine for making four oxyacetylene cuts simultaneously 5-21
5-17 Cutaway view of DC welding genera 5-23
5-18 Direct current welding martine 5-24
5-19 Alternating current arc welding machine 5-25
5-20 Gas tungsten-arc welding setup 5-26
5-21 Argon regulator with flowmeter 5-27
5-22 TIG welding torch 5-27
5-23 MIG welding torch 5-29
5-24 Connection diagram for MIG welding 5-30
5-25 Metal-arc welding electrode holders 5-35
5-26 Atomic hydrogen welding torch 5-35
5-27 Chipping hairmer and wire brush 5-35
5-28 Welding tabie 5-36
5-29 Molten metal transfer with a bare electrode 5-38
5-30 Arc action obtained with a light coated electrode *… 5-39
5-31 Arc action obtained with a shielded arc electrode 5-39
5-32 Electrode drying ovens 5-41
5-33 Correct electrode taper 5-41
5-34 Polarity of welding current 5-42
5-35 Effect of polarity on weld shape 5-43
5-36 AC wave 5-44
5-37 Rectified ac wave 5-44
5-38 Comparison of penetration contours 5-45
5-39 Resistance spot welding machine and accessories 5-47
5-40 Projection welding 5-49
5-41 Thermit welding crucible and mold 5-51
5-42 Portable forge 5-52
5-45 Blacksmith’s anvil 5-53
6-l Chart of welding processes 6-1
6-2 Equipment setup for arc stud welding 6-2
Equipment setup for gas shielded arc stud welding 6-3
6-4 Submerged arc welding process 6-3
6-5 Gas tungsten arc welding 6-4
6-6 Gas metal arc welding 6-5
6-7 Shielded metal arc welding 6-5
6-8 Furnace brazing operation 6-8
Typical induction brazing coils and joints 6-9
6-10 Chemical bath dip brazing 6-9
6-11 Infrared brazing apparatus 6-10
6-12 Steps in making a thermit weld 6-13
6-13 Nomenclature of welds 6-14
Heat affected zones in a multipass weld 6-16
VITC 9-237
vii
6-16 6-15 Welding Basic joint procedure types schedule—various welds 6-17 6—21
6-17 Butt joints in light sections 6-21
6-18 Butt joints in heavy sections 6-21
6-19 Comer joints for sheets and plates 6-22
6-20 Edge joints for light sheets and plates 6-23
6-21 Lap joints 6-23
6-22 Tee joint-single pass fillet weld 6-24
6-23 Edge preparation for tee joints 6-24
6-24 Applications of fillet welds
6-25 Basic groove welds —single and double 6-25 6-25
6-26 Typical weld joints 6-26
6-27 Types of groove welds 6-27
6-28 Surfacing, plug, and slot welds 6-28
6-29 Flash, seam, spot, and upset welds 6-29
6-30 6-31 Welding Welding positions positions—groove welds—plate 6-30
6-32 Welding positions——fillet pipe welds welds—plate 6-30 6-31
6-33 Diagram of tack welded pipe on rollers 6-33
6-34 Diagram of horizontal pipe weld with uphand method 6-33
6-35 Diagram of horizontal pipe weld with downhand method 6-34
6-36 Vertical pipe fixed position weld with backhand nethod 6-35
6-37 Deposition of root, filler, and finish weld beads 6-35
6-38 Work angle—fillet and groove weld 6-36
6-39 Travel angle—fillet and groove weld 6-36
6-40 Forehand welding 6-37
6-41 Backhand welding 6-37
6-42 Results of weld metal shrinkage 6-38
6-43 Methods of counteracting contractions 6-39
6-44 Quench plates Used in the welding of sheet metal 6-40
6-45 Fixture used in the welding of sheet metal 6-41
6-46 Controlling expansion and contraction of cas-Hnga by
preheating 6-41
6-47 Cube of metal showing expansion 6-42
6-48 Longitudinal (L) and transverse (T) shrinkage stresses
in a butt weld 6-43
6-49 Longitudinal (L) and transverse (T) shrinkage stresses
in a fillet wald 6-43
6-50 Distortion in a butt weld 6-44
6-51 Distortion in a fillet weld 6-44
6-52 The order in which to make weld joints 6-46
6-55 6-54 6-53 Ductile Butt Edge welded welded fracture joint jointsurface — —residual residual stress stress pattern pattern 6-53 6-49 6-48
6-56 Brittle fracture surface 6-54
6-57 Fatigue fracture surface 6-56
6-58 Comer joint 6-58
6-59 Tee joint 6-58
6-60 Redesigned comer joint to avoid lamellar tearing 6-59
6-61 Effect of ground location on magnetic arc below 6-61
6-62 Unbalanced magnetic force due to current direction change 6-62
6-63 Unbalanced magnetic force due to unbalanced magnetic path 6-63
6-64 Reduction of magnetic force due to induced fields 6-64
7-1 Tensile strength 7-5TC 9-237
LIST OF ILLUSTRATIONS
F1^6 Title Page
7-2 Shear strength ?_5
“7-3 Compressive strength g_g
7-4 Characteristics of sparks generated by the grinding of metals .. 7-12
7-5 Blast furnace ‘
7-1g
7-6 Conversion of iron ore into cast iron, wrought iron, and
steel 7-ig
7-7 How steel qualities change as carbon is added 7-45
7-8 Weld preparation 7-46
7-9 Heat input nomograph 7-57
7-10 Studding method for cast iron repair 7-65
7-11 Joint design for aluminum plates 7-69
7-12 Aluminum joint designs for gas metal-arc welding processes 7-73
7-13 Joint preparation for arc welding magnesium 7-87
7-14 Position of torch and welding rod 7-89
7-15 Minimizing cracking during welding 7-90
7-16 Baffle arrangements to improve shielding 7-99
7-17 Trailing shield 7-99
7-18 Backing fixtures for butt welding heavy plate and thin sheet … 7-100
7-19 Use of weld backup tape 7-101
8-1 Transfer of metal across the arc of a bare electrode 8-7
8~2 Deposition rates of steel flux-cored electrodes 8-13
8-3 Correct electrode taper 8-15
10-1 Characteristic curve for welding power source 10-3
10”2 Curve for single control welding machine 10-3
10-3 Curve for dual control welding machines 10-4
10-4 Volt ampere slope vs welding operation 10-5
10-5 Volt ampere curve for true constant current machine 10-7
10-6 Pulsed current welding 10-8
10-7 Burn-off rates of wire vs current 10-9
10-8 Static volt amp characteristic curve of CV machine 10-10
10-9 Static volt amp curve with arc range 10-10
10-10 Various slopes of characteristic curves 10-11
10-11 Current density—various electrode signs 10-12
10-12 Electrical circuit 10-13
10-13 Welding electrical circuit 10-14
10-14 Arc characteristic volt amp curve 10-16
10-15 The de tungsten arc 10-17
10-16 Arc length vs voltage and heat 10-18
10-17 The de shielded metal arc 10-19
10-18 The de consumable electrode metal arc 10-20
10-19 Sine wave generation 10-21
10-20 Sequences in multilayer welding 10-23
10-21 Schematic drawing of SMAW equipment 10-24
10-22 Elements of a typical welding circuit for shielded metal arc
welding 10-25
10-23 Three types of free-flight metal transfer in a welding arc 10-25
10-24 Travel speed limits for current levels used for 1/8-inchdiameter E6010 SMAW electrode. Dashed lines show travel speed
limits as determined by amount of undercut and bead shape …. 10-26
vi iiTC 9-237
10-25 Travel speed limits for current levels used for 1/8-inchdiameter EGO11 SMAW electrode. Dashed lines show travel speed
limits as determined by amount of undercut and bead shape …. 10-27
10-26 Travel speed limits for current levels used for 1/8-inchdiameter E6013 SMAW electrode. Dashed lines show travel speed
limits as determined by amount of undercut and bead shape …. 10-27
10-27 Travel speed limits for current levels used for 1/8-inchdiameter E7018 SMAW electrode. Dashed lines show travel speed
limits as determined by amount of undercut and bead shape …. 10-28
10-28 Travel speed limits for current levels used for 1/8-inchdiameter E7024 SMAW electrode. Dashed lines show travel speed
limits as determined by amount of undercut and bead shape 10-28
10-29 Travel speed limits for current levels used for 5/32-inchdiameter E8018 SMAW electrode. Dashed lines show travel speed
limits as determined by amount of undercut and bead shape 10-29
10-30 Travel speed limits for current levels used for 1/8-inchdiameter E11018 SMAW electrode. Dashed lines show travel
speed limits as determined by amount of undercut and bead
shape 10-29
10-31 Shielded metal arc welding 10-32
10-32 Gas tungsten arc (TIG) welding (GTAW) 10-33
10-33 Gas tungsten arc welding equipment arrangement 10-34
10-34 Technique for manual gas tungsten arc (TIG) welding 10-37
10-35 Process diagram – keyhole mode – PAW 10-38
10-36 Cross section of plasma arc torch head 10-39
10-37 Transferred and nontransferred plasma arcs 10-43
10-38 Various joints for plasma arc 10-45
10-39 Circuit diagram – PAW 10-45
10-40 Quality and cannon faults 10-45
10-41 Deposition rates 10-47
10-42 Typical air cooled carbon electrode holders 10-48
10-43 Process diagram – CAW 10-50
10-44 Gas metal arc welding process 10-55
10-45 MIG welding process 10-55
10-46 Typical semiautomatic gas-cooled, curved-neck gas metal arc
welding gun 10-57
10-47 Variation in volumes and transfer rate of drops with welding
current (steel electrode) 10-61
10-48 Voltage versus current for E70S-2 1/16-inch-diameter electrode
and shield gas of argon with 2-percent oxygen addition 10-63
10-49 Voltage versus current for E70S-2 1/16-inch-diameter electrode
and carbon dioxide shield gas 10-63
10-50 Voltage versus current for E70S-3 1/16-inch-diameter electrode
and shield gas of argon with 2-percent oxygen addition 10-84
10-51 Voltage versus current for E70S-3 1/16-inch-diameter electrode
and carbon dioxide shield gas 10-84
10-52 Voltage versus current for E70S-4 1/16-inch diameter electrode
and carbon dioxide shield gas 10-65
10-53 Voltage versus current for E70S-6 1/16-inch-diameter electrode
and carbon dioxide shield gas 10-65
10-54 Voltage versus current for E110S 1/16-inch-diameter electrode
and shield gas of argon with 2-percent oxygen addition 10-66
10-55 Flux-cored arc welding process 10-68
10-56 Equipment for flux-cored arc welding 10-69
10-57 Wire feed assembly 10-70
LxTC 9-237
LIST OF ILLUSTRATIONS
Figure
10-58
10-59
10-60
10-61
10-62
10-63
10-64
10-65
10-66
10-67
10-68
10-69
10-70
10-71
10-72
10-73
10-74
10-75
10-76
10-77
10-78
10-79
10-80
11-1
11-2
11-3
11-4
11-5
11-6
11-7
11-8
11-9
11-10
11-11
11-12
11-13
11-14
11-15
11-16
11-17
11-18
11-19
11-20
12-1
12-2
12-3
12-4
in tr
12-6
12-7
Title Page
Cross-section of a flux-cored wire
Block diagram—SAW *’
Weld Process joint diagram designs —submerged for submerged arc welding arc welding
Deposition rates for single electrodes …..’.
Welds corresponding to table 10-23 ’’’*
Stickout vs deposition rate
Welding on rotating cirmlar parts
Angle of slope of work vs weld ’
Angle of electrode vs weld ”
Two electrode wire svstens .
Strip electrode on surfacing
Welding with iron powder additives
Plasma arc torch terminology
Basic plasma arc cutting circuitry
Dual flow plasma arc cutting
Water injection plasma arc cutting arrangement
Process diagram for air carbon arc cutting ’
Air carbon arc cutting diagram
Resistance spot welding process
Flash welding
Electron beam welding process
The temperature of the flame ’”
Oxyacetylene flames
What MAPP gas flames should look like
Forehand welding
Backhand welding
The fillet used to make the five basic joints
Fillet weld throat dimension
Fillet weld size vs strength
Welding position—fillet and groove welds
Welding a butt joint in the horizontal position
Bead welding without a welding rod ‘.*.W
Bead welding with a welding rod
Position of rod and torch for a butt weld in a flat position ..’
Wo1 i nrr a – » •__ i • j_ •
j_u uiie veircxcax position
Welding a butt joint in the overhead position
Silver braseiner -ioi n-t-^
Starting a cut and cutting with a cutting torch
Procedure for oxyacetylene cutting of cast iron
Coupling distance
Torch angle ******
Arrangements for underwater welding
The wire metallizing process
Electric arc spraying process
Flame spray process
Plasma spray process
Process diagram of oxygen cutting
Manual oxygen cutting torch
10-73
10-83
10-85
10-88
10-90
10-92
10-96
10-97
10-97
10-98
i n nn
1U”77
10-100
10-101
10-102
10-105
10-106
10-107
10-108
10-109
10-113
10-116
10-118
10-120
11-7
11-8
11-11
11-13
11-14
11-15
11-16
11-16
11-18
11-19
11-20
11-20
11-21
11-22
11-23
11-32
11-34
11-35
11-39
11-39
12-3
12-6
12-11
12-13
12-13
12-17
12-19TC 9-237
12-8 Methods of preparing joints 12-19
12-9 Procedure for oxyacetylene cutting of cast iron 12-23
12-10 Operations and time intervals in flame descaling prior to
painting 12-25
12-11 Removal of countersunk rivets .. 12-26
12-12 Removal of buttonhead rivets 12-27
12-13 Method of cutting stainless steel welds 12-34
12-14 Method of removing surface defects frcm stainless steel welds .. 12-35
12-15 Preparation for welding cracks in homogenous armor plate 12-37
12-16 Backing methods for depositing weld beads at the root of a
double V joint 12-38
12-17 Sequence of passes when depositing weld beads on homogenous
armor plate 12-39
12-18 Carmon defects when welding root beads on homogenous armor
plate and the remedial procedures 12-40
12-19 Procedure for welding single V joint on homogenous armor
plate 12-41
12-20 Double V weld on homogenous armor plate 12-42
12-21 Butt strap welds on cracked armor plate 12-43
12-22 Emergency repair of shell penetration through armor 12-44
12-23 Double V plug welding procedure for repairing shell penetration
in homogenous armor plate 12-44
12-24 Correct and incorrect plug weld preparation for repairing shell
penetration in homogenous armor plate 12-45
12-25 Welding homogenous armor without welding butt strap 12-47
12-26 Welding repair of gouges in surface of homogenous armor plate .. 12-47
12-27 Welding joint data for butt welds on face hardened armor 12-49
12-28 Use of butt strap on face hardened armor to repair cracks or
gaps * 12-50
12-29 Butt strap weld on face hardened armor 12-51
12-30 Weld joint data for corner welds on face hardened armor plate .. 12-51
12-31 Procedure for welding face hardened armor over 1/2 in. thick,
using the double V joint method 12-52
12-32 Procedure for welding face hardened armor up to 1/2 in., using
the depressed joint method 12-53
12-33 Seal bead weld 12-54
12-34 Angle iron serving as jig for small diameter pipe 12-55
12-35 Types of backing rings 12-56
12-36 Template pattern, ell joint, first step 12-58
12-37 Template pattern, ell joint, second step 12-58
12-38 Template pattern, ell joint, third step 12-59
12-39 Tee joint 12-59
12-40 Template pattern, tee joint, first step 12-60
12-41 Tenplate pattern, tee joint, second step 12-60
12-42 Diagram of tack welded pipe on rollers 12-62
12-43 Diagram of horizontal pipe weld with uphand method 12-62
12-44 Diagram of horizontal pipe weld with downhand method 12-63
12-45 Vertical pipe fixed position weld with backhand method 12-64
12-46 Deposition of root, filler, and finish weld beads 12-64
12-47 Studding method for cast iron repair 12-67
12-48 Forge welds 12-72
12-49 Muffle jacket 12-78
12-50 Schematic diagram of resistance spot welder 12-81
12-51 Schematic diagram of upset and flash welder 12-82
xiTC 9-237
LIST OF ILLUSTRATIONS
Figure Title Page
13-1 Guided bend test jig 13-9
13-2 Guided bend test specimens 13-9
13-3 Guided bend and tensile strength test specimens 13-10
13-4 Free bend test of welded metal 13-11
13-5 Nick break test 13-12
13-6 Tensile strength test specimen and test method 13-13
13-7 Portable tensile strength and bend testing machine 13-13
13-8 Internal weld defects disclosed by X-ray inspection 13-15
C-l Distortion C-18
C-2 Warping C-18
C-3 Poor appearance C-l9
C-4 Stress cracking C-19
C-5 Poor penetration C-19
C-6 Porous weld c-20
C-7 Poor fusion C-20
LIST OF TABLES
Number Title Page
2-1 Lens Shades for Welding and Cutting 2-3
2-2 Required Exhaust Ventilation 2-10
3-1 Designation of Welding Process by Letters 3-6
3-2 Designation of Cutting Processes by Letters 3-7
4-1 Welds Applicable to the Basic Joint Combinations 4-2
5-1 Low Pressure or Injector Type Torch 5-15
5-2 Balanced Pressure Type Torch 5-16
5-3 Oxyacetylene Cutting Information 5-21
5-4 Coating, Current, and Polarity Types Designated by the Fourth
Digit in the Electrode Classification Number 5-37
6-1 Preheating Temperatures 6-52
7-1 Physical Properties of Metals 7-2
7-2 Mechanical Properties of Metals 7-4
7-3 Hardness Conversion Table 7-8
7-4 Sunroary of Identification Tests of Metals 7-10
7-5 Summary of Spark Test 7-13
7-6 Approximate Hardness of Steel by the File Test 7-15
7-7 Carbon Content of Cast Iron and Steel 7-17
7-8 Standard Steel and Steel Alloy Number Designations 7-38
7-9 AISI-SAE Numerical Designation of Carbon and Alloy Steels 7-40
7-10 Standard Aluminum and Aluminum Alloy Number Designations 7-41
7-11 Letters Used to Identify Alloying Elements in Magnesium
Alloys 7-41
7-12 Composition of Magnesium Alloys 7-42
7-13 Copper and Copper Alloy Designation System 7-43
7-14 Electrode Numbers 7-55
7-15 Electrodes in the Army Supply System 7-55
7-16 Suggested Preheat Temperatures 7-56
7-17 Maximum Heat Inputs for T1 Steel 7-58
7-18 Maximum Heat Inputs for T1 Type A and Type B Steels 7-58
7-19 Welding Processes and Filler Metals for Cast Iron 7-60
xiiTC 9-237
7-20 Designation of Aluminum Alloy Groups 7-67
7-21 Welding Procedure Schedules for Gas Metal-Arc Welding (GMAW)
of Aluminum (MIG Welding) 7-71
7-22 Welding Procedure Schedules for AC-GTAW Welding of Aluminum
(TIG Welding) 7-74
7-23 Welding Procedure Schedules for DC-CTAW Welding of Aluminum
(TIG) Welding 7-75
7-24 Magnesium Weld Data 7-89
7-25 Magnesium Stress Relief Data 7-91
7-26 Welding Procedure Schedule for Gas Tungsten Arc Welding
(GTAW) of Magnesium (TIG Welding) 7-92
7-27 Welding Procedure Schedules for Gas Metal Arc Welding
(Q4AW) of Magnesium (MIG Welding) 7-93
7-28 Welding Procedure Schedule for Metal-Arc Welding (GMAW)
of Titanium (MIG Welding) 7-97
7-29 Welding Procedure Schedules for Gas Tungsten Arc Welding
(GTAW) Nickel Alloys (TIG Welding) 7-107
7-30 Welding Procedure Schedules for Gas Metal Arc Welding
(GMAW) Nickel Alloys (MIG Welding) 7-108
8-1 Mild Steel Electrode Wire Ccmposition for Submerged Arc
Welding 8-9
8-2 A.W.S. Filter Metal Specification and Welding Processes 8-23
10-1 Established Voltage Limits 10-30
10-2 Welding Position Capabilities 10-41
10-3 Base Metals Weldable by the Plasma Arc Process 10-42
10-4 Base Metal Thickness Range 10-42
10-5 Weld Procedure Schedule—Plasma Arc Welding—Manual
Application 10-47
10-6 Method of Applying Carbon Arc Processes 10-49
10-7 Welding Position Capabilities 10-49
10-8 Welding Procedure Schedule—Galvanized Steel—Braze Welding …. 10-52
10-9 Welding Procedure Schedule for Carbon Arc Welding Copper 10-52
10-10 Welding Current for Carbon Electrode Types 10-53
10-11 Welding current for carbon electrode (twin torch) 10-54
10-12 Mechanical Property ReguirAmenta of Carbon Steel Flux-Cored
Electrodes 10-74
10-13 Performance and Usability Characteristics of Carbon Steel Flux
Cored Electrodes 10-75
10-14 Chemical Composition Requirements of Carbon Steel Flux Cored
Electrodes 10-75
10-15 Mechanical Property Requirement of Low Alloy Flux-Cored
Electrodes 10-76
10-16 Impact Requirement for Low Alloy Flux-Cored Electrodes 10-77
10-17 Chemical Composition Requirements for Low Alloy Flux-Cored
Electrodes 10-78
10-18 Weld Metal Chemical Composition Requirements for Stainless
Steel Electrodes 10-80
10-19 Shielding 10-81
10-20 Reccrrmended Cable Sizes for Different Welding Currents and
Cable Lengths 10-82
10-21 Base Metals Weldable by the Submerged Arc Process 10-86
10-22 Base Metal Thickness Range 10-87
10-23 Welding Procedure Schedules for SAW 10-93
10-24 Typical Analysis and Mechanical Properties of Submerged Arc
Flux-Wire Ccmbinations 10-103
xiiiTC 9-237
LIST OF TABLES (cont)
Lumber Title Paae
10-25 Electrode Type—Size and Current Range 10-110
10-26 Air Carbon Arc Gouging Procedure Schedule 10-112
10-27 Base Metals Weldable by the Resistance Welding Process 10-115
11-1 Low Pressure of Injector Type Torch 11-5
11-2 Balanced Pressure Type Torch H-5
11-3 Heating Values of Fuel Gases * n-u
11“4 Oxy-Fuel Ratios Control Flame Condition 11-37
11-5 Approximate Conditions for Gas Welding of Aluminum 11-42
12-1 Recommended Welding Currents ” 12-5
12-2 Mechanical Properities of Sprayed Coatings 12-7
12-3 Minimum Thickness of As-Sprayed Coatings on Shafts 12-10
12-4 Shrinkage of Commonly Applied Sprayed Coatings 12-10
12-5 Welding Procedure Schedule for Oxyfuel Gas Cutting 12-18
12-6 Template Pattern Data ’ 12-57
12-7 Carmon Heat Treating Problems 12-73
12-8 Time Required in Case Hardening 12-79
12-9 Approximate Reheating Temperatures after Carburizing of SAE
Steel 12-80
12-10 Magnesium Spot Weld Data 12-84
12-11 Ccnmercially Pure Titanium Spot Weld Data 12-85
B-l Guide for Welding Automotive Equipment B-l
B-2 Guide for Oxyacetylene Welding B-l9
B-3 Guide for Electric Arc Welding B-23
C-l Troubleshooting c-l
D-1 Common Welding Equipment by Corrmercial and Government Entitv
Code (CAGEC) D-1
D-2 Metallizing Wire 0-4
D-3 Welding Electrodes D-4
D-4 Overlay, Welding and Cutting, Chamfering, and Heating
Electrodes d-8
D-5 Welding Rods d-9
D-6 Brazing Alloys D-12
D-7 Soldering Materials D-13
D-8 Fluxes, Welding, Brazing, and Soldering d-16
D-9 Carbon Blocks, Rods, and Paste D-17
E-l Temperature Ranges for Processing Metals E-l
E-2 Combustion Constants of Fuel Gases E-l
E-3 Melting Points of Metals and Alloys e-2
E-4 Temper Colors and Temperatures E-3
E-5 Heat Colors with Approximate Temperature E-3
E-6 Stub Steel Wire Gauges E-4
E-7 Standard Gauge Abbreviations E-5
E-8 Metal Gauge Comparisons E-6
E-9 Sheet Metal Gauge E-8
E-10 Elements and Related Chenical Symbols E-9
E-ll Decimal Equivalents of Fractions of an Inch E-10
E-12 Inches and Equivalents in Millimeter (1/64 Inch to 100 Inches) . E-ll
xivTC 9-237
WARNINGS
Cyanide and cyanide fumes are dangerous poisons. The cyaniding method of case
hardening requires expert supervision and adequate ventilation.
Oil or grease in the presence of oxygen will ignite violently, especially in an
enclosed pressurized area.
Do not substitute oxygen for compressed air in pneumatic tools. Do not use oxygen
to blow out pipe lines, test radiators, purge tanks or containers, or to “dust”
clothing.
Welding machine Model 301, AC/DC, Heliarc with inert gas attachment, NSN 3431-00-
235-4728, may cause electrical shock if not properly grounded. If one is being
used, contact Castolin Institute, 4462 York St., Denver, Colorado 80216 ATIN: Mr.
Lent.
The vapors fron sane chlorinated solvents (e.g. carbon tetrachloride,
trichloroethylene, and perchloroethylene) break down under the ultra-violet radia¬
tion of an electric arc and form a toxic gas. Avoid welding where such vapors are
present. These solvents vaporize easily and prolonged inhalation of the vapor can
be hazardous. These organic vapors should be removed fron the work area before
welding is begun.
Do not assume that a container that has held canbustibles is clean and safe until
proven so by proper tests. Do not weld in places where dust or other combustible
particles are suspended in air or where explosive vapors are present. Removal of
flammable material from vessels/containers may be done either by steaming out or
boiling.
The automotive exhaust method of cleaning should be conducted only in well ventilat¬
ed areas to ensure levels of toxic gases are kept below hazardous levels.
Welding polyurethane foam-filled parts can produce toxic gases. Welding should not
be attempted on parts filled with polyurethane foam. If repair of such parts by
welding is necessary, the foam must be removed fron the heat affected area,
including the residue, prior to welding.
Do not stand facing cylinder valve outlets of oxygen, acetylene, or other conpressed gases when opening them.
If it is necessary to blow out the acetylene hose, do it in a well ventilated
place, free of sparks, flame, or other sources of ignition.
aTC 9-237
WARNINGS (cont)
Purge both acetylene and oxygen lines (hoses) prior to igniting torch. Failure to
do thrs can cause serious injury to personnel and damage to the equipment.
Regulators with gas leakage between the regulator seat and the nozzle should be
repaired immediately to avoid damaged to other parts of the regulator or injnry to
personnel. With acetylene regulators, this leakage is particularly dangerous.
Acetylene at high pressure in the hose is an explosion hazard.
Defects.in oxyacetylene welding torches which are sources of gas leaks must be cor¬
rected immediately, as they may result in flashbacks, or backfires, with resultant
injury to the operator and/or damage to the welding apparatn^.
Damaged inlet
.
connection threads may cause fires by ignition of the leaking gas,
resulting in injury to the welding operator and/or damaged to the equipment.
Dry cleaning solvent and mineral spirits paint thinner are highly flammable. Do
not clean parts near an open flame or in a smoking area. Dry cleaning solvent and
mineral spirits paint thinner evaporate quickly and have a defatting effect on the
skin. When used without protective gloves, these chemicals may cause irritation or
cracking of the skin. Cleaning operations should be performed only in well venti¬
lated areas.
The acid solutions used to remove aluminum welding and brazing fluxes after welding
or brazing are toxic and highly corrosive. Goggles, rubber gloves, and rubber
aprons should be worn when handling the acids and solutions. Do not inhale fumes.
When spilled on the body or clothing, wash immediately with large quantities of
cold water.
Never pour water into acid when preparing solutions; instead, pour acid into wa¬
ter. Always mix acid and water slowly. These operations should only be performed
in well ventilated areas.
Precleaning and postcleaning acids used in magnesium welding and brazing are highly
toxic.and corrosive. Goggles, rubber gloves, and rubber aprons should be worn when
handling the acids and solutions. Do not inhale fumes and mists. When spilled on
the body or clothing, wash immediately with large quantities of cold water, and
seek medical attention. Do not pour water into acid when preparing solution; in¬
stead, pour acid into water. Always mix acid and water slowly. Cleaning opera¬
tions should be performed only in well ventilated areas.
If the electrode becomes frozen to the base metal during the process of starting
the arc, all work to free the electrode while the current is on must be done with
the eyes shielded.
bTC 9-237
The nitric acid used to preclean titanium for inert gas shielded arc welding is
highly toxic and corrosive. Goggles, rubber gloves, and rubber aprons should be
worn when handling the acid and the acid solution. Do not inhale gases and mists.
When spilled on the body or clothing, wash immediately with large quantities of
cold water, and seek medical help. Do not pour water into acid when preparing the
solution; instead, pour acid into water. Always mix acid and water slowly. Per¬
form cleaning operations only in well ventilated arpas ,
The caustic chemicals (including sodium hydride) used to preclean titaninn for
inert gas shielded arc welding are highly toxic and corrosive. Goggles, rubber
gloves, and rubber aprons should be worn when handling these chemicals. Do not
inhale gases or mists. When caustics are spilled on the body or clothing, wash
immediately with large quantities of cold water, and seek medical help. Special
care should be taken at all times to prevent any water frcm caning in contact with
the molten bath or any other large amount of sodium hydride, as this will cause the
evolution of highly explosive hydrogen gas.
When using weld backup tape, the weld must be allowed to cool for several minutes
before attempting to remove the tape from the workpiece.
Safety precautions must be exercised in underwater cutting and welding. Electrode
holder and cable must be insulated, current must be shut off when changing elec¬
trodes, and the diver should avoid contact between the electrode and grounded work.
In thermit welding, the mold must be thoroughly dried before the charge in the
crucible is ignited. When the charge has been ignited, the operator should stand a
safe distance away and should wear goggles. Painful burns may occur fron splashing
metal, upsetting of the crucible, breaking of the mold, or allowing the molten
metal to cone in contact with moisture in the mold.
Before welding on equipment painted with CARC paint, remove the paint from an area
larger than that which will be heated during welding.
Do not operate welding machines in an enclosed area unless the exhaust gases are
piped to the outside. Inhalation of exhaust fumes will result in serious illness
or death.
When filling the fuel tank, always provide a metal-to-metal contact between the
container and the fuel tank. This will prevent a spark frcm being generated as
fuel flews over the metallic surfaces.
Do not fill the fuel tanks while the engine is running. Fuel spilled on a hot
engine may explode and cause injury to personnel.
cTC 9-237
WARNINGS (cont)
Do not attempt any maintenance on the welding machine while it is in operation.
The voltage generated by it can cause injury or death.
Ensure that all welding machines are properly grounded. Failure to properly ground
welding machines could result in electrical shock.
Always use ear plugs. Diesel engines exceed a permissible decibel level. Failure
to observe this warning could result in a permanent hparing injury.
Always wear arc proof glasses or a welder’s helmet when welding to prevent serious
eye burns or possible blindness.
Use only approved cleaning solvents to avoid the possibility of fire or poisoning.
Inert gas, metal-arc welding processes produce intense ultra-violet radiation which
can be harmful to the eyes and skin. Therefore, certain precautions must be ob¬
served to protect the operator frcm injury.
Skin must be completely covered. Leather gloves are recommended for hand protec¬
tion. Heavy, dark colored’clothing should be worn to prevent the radiation from
penetrating to the skin or reflecting onto the neck under the helmet. Lightweight
leather clothing is reccmmended because of its durability and resistance to deterio¬
ration from radiation. Cotton clothing will deteriorate rapidly when subjected to
ultra-violet radiation.
Adequate ventilation should be provided to remove fumes which are produced by weld¬
ing processes. American standard Z-49.1 on welding safety covers such ventilation
procedures. Highly toxic gases are formed when the vapors frcm halogenated sol¬
vents are subjected to ultra-violet radiation. Therefore, it is recarmended that
degreasers and other sources of these vapors should be located so that the vapors
cannot reach the welding operation.
Under no circumstances should acetylene cylinders be positioned or stored in other
than an upright position. Storage of the cylinder in a horizontal or reclining
position could create a hazardous condition.
Stand to the side of gas and oxygen cylinders when turning on the pressure release
valves. The cylinders contain extreme pressure. Injury could occur if a defective
flewmeter or pressure regulator valve ruptures when subjected to these pressures.
dTC 9-237
Ensure that all gages are removed from gas and oxygen cylinders before transport¬
ing. Failure to observe this warning could create a hazardous condition.
Wear head and eye protection, rubber gloves, boots, and aprons when handling steam,
hot water, and caustic solutions. When handling dry caustic soda or soda ash, wear
approved respiratory protective equipment, long sleeves, and gloves. Wear fire
resistant hand pads or gloves to handle hot drums.
Brazing filler metals containing cadmium may form poisonous fumes on heating- Do
not breathe fumes. Use only with adequate ventilation, such as fume collectors,
exhaust ventilators, or air-supplied respirators. See American National Standards
Institute Standard Z49.1-1973. If chest pain, cough, or fever develops after use,
call physician irrmediately.
Acetylene, stored in a free state under pressure greater than 15 psi (103.4 kPa),
can break down from heat or shock, and possible explode. Under pressure of 29.4
psi (203 kPa), acetylene becomes self-explosive, and a slight shock can cause it to
explode spontaneously.
Acetylene which may accumulate in a storage roan or in a confined space is a fire
and explosion hazard. All acetylene cylinders should be checked, using a soap
solution, for leakage at the valves and safety fuse plugs.
Do not stand facing cylinder valve outlets of oxygen, acetylene, or other conpressed gases when opening them.
Always have suitable fire extinguishing equipment at hand when doing and welding.
eTC 9-237
GLOSSARY
Section. I. GENERAL
G-l. GENERAL
This glossary of welding terms has been prepared to acquaint welding personnel with
nomenclatures and definitions of cannon terms related to welding and allied process¬
es, methods, techniques, and applications.
G-2. SCOPE
The welding ta-r-ms listed in section II of this chapter are those terms used to
dA^rrihA and define the standard nomenclatures and language used in this manual.
This glossary is a very inportant part of the manual and should be carefully stud¬
ied and regularly referred to for better understanding of cannon welding terms and
definitions. Terms and nomenclatures listed herein are grouped in alphabetical
order.
Section II. WELDING TERMS
G-3. WELDING TERMS
A
ACETONE; A flamnable, volatile liquid used in acetylene cylinders to dissolve and
stabilize acetylene under high pressure.
ACETYLENE: A highly combustible gas composed of carbon and hydrogen. Used as a
fuel gas in the oxyacetylene welding process.
ACTUAL THROAT: See THROAT OF FILLET WELD.
AIR-ACETYLENE: A low temperature flame produced by burning acetylene with air
instead of oxygen.
AIR-ARC CUTTING: An arc cutting process in which metals to be cut are melted by
the heat of the carbon arc.
at.toy? A mixture with metallic properties composed of two or more elements, of
which at least one is a metal.
ALTERNATING CURRENT: An electric current that reverses its direction at regularly
recurring intervals.
AMMETER: An instrument for measuring electrical current in amperes by an indicator
activated by the movement of a coil in a magnetic field or by the longitudinal
expansion of a wire carrying the current.
ANNEALING: A comprehensive term used to describe the heating and cooling cycle of
steel in the solid state. The term annealing usually implies relatively slow
cooling. In annealing, the temperature of the operation, the rate of heating and
cooling, and the time the metal is held at heat depend upon the ccmposition,
shape, and size of the steel product being treated, and the purpose of the treat¬
ment. The more important purposes for which steel is annealed are as follows:
to remove stresses; to induce softness; to alter ductility, toughness, electric,
magnetic, or other physical and mechanical properties; to change the crystalline
structure; to remove gases; and to produce a definite microstructure.
ARC BLOW: The deflection of an electric arc from its normal path because of magnet¬
ic forces.
ARC BRAZING: A brazing process wherein the heat is obtained from an electric arcTC 9-237
G-3. WELDING TERMS (cont)
A (cont)
formed between the base metal and an electrode, or between two electrodes.
ARC CUTTING: A group of cutting processes in which the cutting of metals is accom¬
plished by melting with the heat of an arc between the electrode and the base met¬
al. See CARBON-ARC CUTTING, METAL-ARC CUTTING, ARC-OXYGEN CUTTING, AND AIR-ARC
CUTTING•
ARC LENGTH: The distance between the tip of the electrode and the weld puddle..
ARC-OXYGEN CUTTING: An oxygen-cutting process used to sever metals by a chemical
reaction of oxygen with a base metal at elevated temperatures.
ARC VOLTAGE: The voltage across the welding arc.
ARC WELDING: A group of welding processes in which fusion is obtained by heating
with an electric arc or arcs, with or without the use of filler metal.
AS WELDED: The condition of weld metal, welded joints, and weldments after welding
and prior to any subsequent thermal, mechanical, or chemical treatments.
ATOMIC HYDROGEN WELDING: An arc welding process in which fusion is obtained by
Haa-f-ing with an arc maintained between two metal electrodes in an atmosphere of
hyd-mgen. Pressure and/or filler metal may or may not be used.
AUSTENITE: The non-magnetic form of iron characterized by a face-centered cubic,
lattice crystal structure. It is produced by heating steel above the upper criti¬
cal temperature and has a high solid solubility for carbon and alloying elements.
AXIS OF A WET.Dr A line through the length of a weld, perpendicular to a cross
section at its center of gravity.
B
BACK FIRE: The iranentary burning back of a flame into the tip, followed by a snap
or pop, then immediate reappearance or burning out of the flame.
BACK PASS: A pass made to deposit a back weld.
BACK UP: In flash and upset welding, a locator used to transmit all or a portion
of the upsetting force to the workpieces.
BACK WELD: A weld deposited at the back of a single groove weld.
BACKHAND wet,DTNG: A welding technique in which the flame is directed towards the
completed weld.
BACKING STRIP: A piece of material used to retain molten metal at the root of the
weld and/or increase the thermal capacity of the joint so as to prevent excessive
warping of the base metal.
BACKING wetd: A weld bead applied to the root of a single groove joint to assure
complete root penetration.
BACKSTEP: A sequence in which weld bead increments are deposited in a direction
opposite to the direction of progress.
BARE ELECTRODE: An arc welding electrode that has no coating other than that inci¬
dental to the drawing of the wire.
BARE METAL-ARC WELDING: An arc welding process in which fusion is obtained by
h^abing with an unshielded arc between a bare or lightly coated electrode and the
work. Pressure is not used and filler metal is obtained from the electrode.
BASE METAL: The metal to be welded or cut. In alloys, it is the metal present in
the largest proportion.
BEAD WELD: A type of weld composed of one or more string or weave beads deposited
on an unbroken surface.
BEADING: See STRING BEAD WELDING and WEAVE BEAD.
revet, ANGLE: The angle formed between the prepared edge of a member and a plane
perpendicular to the surface of the member.TC 9-237
BLACKSMITH WELDING: See FORGE WELDING.
BLOCK BRAZING: A brazing process in which bonding is produced by the heat obtained
frcm heated blocks applied to the parts to be joined and by a nonferrous filler
metal having a melting point above 800 °F (427 °C), but below that of the base
metal. The filler metal is distributed in the joint by capillary attraction.
BLOCK SEQUENCE: A building up sequence of continuous multipass welds in which sepa¬
rated lengths of the weld are completely or partially built up before intervening
lengths are deposited. See BUILDUP SEQUENCE.
BLOW HOLE: See GAS POCKET.
BOND: The junction of the welding metal and the base metal.
BOXING: The operation of continuing a fillet weld around a comer of a member as
an extension of the principal weld.
BRAZING: A group of welding processes in which a groove, fillet, lap, or flange
joint is bonded by using a nonferrous filler metal having a -melting point above
800 F (427 °C), but below that of the base metals. Filler metal is distributed
in the joint by capillary attraction.
BRAZE WELDING: A method of welding by using a filler metal that liquifies above
450 °C (842 °F) and below the solid state of the base metals. Unlike brazing, in
braze welding, the filler metal is not distributed in the joint by capillary
action.
BRIDGING: A welding defect caused by poor penetration. A void at the root of the
weld is spanned by weld metal.
BUCKLING: Distortion caused by the heat of a welding process.
BUILDUP SEQUENCE: The order in which the weld beads of a multipass weld are depos¬
ited with respect to the cross section of a joint. See BLOCK SEQUENCE.
BUTT JOINT: A joint between two workpieces in such a manner that the weld joining
the parts is between the surface planes of both of the pieces joined.
BUTT WELD: A weld in a butt joint.
BUTTER WELD: A weld composed of one or more string or weave beads laid down on an
unbroken surface to obtain desired properties or dimensions.
C
CAPILLARY ATTRACTION: The phenomenon by which adhesion between the molten filler
metal and the base metals, together with surface tension of the molten filler met¬
al, causes distribution of the filler metal between the properly fitted surfaces
of the joint to be brazed.
CARBIDE PRECIPITATION: A condition occurring in austenitic stainless steel which
contains carbon in a supersaturated solid solution. This condition is unstable.
Agitation of the steel during welding causes the excess carbon in solution to pre¬
cipitate. This effect is also called weld decay.
CARBON—ARC CUTTING: A process of cutting metals with the heat of an arc between a
carbon electrode and the work.
CARBON—ARC WELDING: A welding process in which fusion is produced by an arc be¬
tween a carbon electrode and the work. Pressure and/or filler metal and/or
shielding may or may not be used.
CARBURIZING FLAME: An oxyacetylene flame in which there is an excess of acety¬
lene. Also called excess acetylene or reducing flame.
CASCADE SEQUENCE: Subsequent beads are stopped short of a previous bead, giving a
cascade effect.
CASE HARDENING: A process of surface hardening involving a change in the conposition of the outer layer of an iron base alloy by inward diffusion frcm a gas or
liquid, followed by appropriate thermal treatment. Typical hardening processes
are carburizing, cyaniding, carbonitriding, and nitriding.
CHAIN INTERMITTENT FILLET WELDS: Two lines of intermittent fillet welds in a T orTC 9-237
G-3. WELDING TERMS (cont)
C (cont)
lap joint in which the welds in one line are approximately opposite those in the
other line.
CHAMFERING: The preparation of a welding contour, other than for a square groove
weld, on the edge of a joint member.
COALESCENCE: The uniting or fusing of metals upon heating.
COATED ELECTRODE: An electrode having a flux applied externally by dipping, spraypainting, or other similar methods. Upon burning, the coat produces a gas
which envelopes the arc.
CQMMUTATORY CONTROLLED WELDING: The making of a number of spot or projection welds
in which several electrodes, in simultaneous contact with the work, progressively
function under the control of an electrical ccmnutating device.
COMPOSITE ELECTRODE: A filler metal electrode used in arc welding, of
more than one metal component combined mechanically. It may or may not include
materials that improve the properties of the weld, or stabilize the arc.
COMPOSITE JOINT: A joint in which both a thermal and mechanical process are used
to unite the base metal parts.
CONCAVITY: The maximum perpendicular distance from the face of a concave fillet
weld to a line joining the toes.
CONCURRENT HEATING: Supplemental heat applied to a structure during the course of
welding.
CONE: The conical part of a gas flame next to the orifice of the tip.
CONSUMABLE INSERT: Preplaced filler metal which is completely fused into the root
of the joint and becomes part of the weld.
CONVEXITY: The maximum perpendicular distance from the face of a convex fillet
weld to a line joining the toes.
CORNER JOINT: A joint between two members located approximately at right angles to
each other in the form of an L.
COVER GLASS: A clear glass used in goggles, hand shields, and helmets to protect
the filter glass fran spattering material.
COVERED ELECTRODE: A metal electrode with a covering material which stabilizes the
arc and inproves the properties of the welding metal. The material may be an
external wrapping of paper, asbestos, and other materials or a flux covering.
CRACK: A fracture type discontinuity characterized by a sharp tip and high ratio
of length and width to opening displacement.
CRATER: A depression at the termination of an arc weld.
CRITICAL TEMPERATURE: The transition temperature of a substance from one crystal¬
line form to another.
CURRENT DENSITY: Amperes per square inch of the electrode cross sectional arpa ,
CUTTING TIP: A gas torch tip especially adapted for cutting.
CUTTING TORCH: A device used in gas cutting for controlling the gases used for
preheating and the oxygen used for cutting the metal.
CYLINDER: A portable cylindrical container used for transportation and storage of
a compressed gas.
D
DEI‘ECT: A discontinuity or discontinuities which, by nature or accumulated effect
(for example, total crack length), render a part or product unable to meet mini¬
mum applicable acceptance standards or specifications. This term designates
rejectability.
G-4TC 9-237
DEPOSITED METAL: Filler metal that has been added during a welding operation.
DEPOSITION EFFICIENCY: The ratio of the weight of deposited metal to the net
weight of electrodes consumed, exclusive of stubs.
DEPTH OF FUSION: The distance from the original surface of the base metal to that
point at which fusion ceases in a welding operation.
DIE:
a. Resistance Welding. A member, usually shaped to the work contour, used to
clamp the parts being welded and conduct the welding current.
b. Forge Weld-ing. A device used in forge welding primarily to form the work
while hot and apply the necessary pressure.
DIE WELDING: A forge welding process in which fusion is produced by heating in a
furnace and by applying pressure by means of dies.
DIP BRAZING: A brazing process in which bonding is produced by heating in a molten
chemical or metal bath and by using a nonferrous filler metal having a melting
point above 800 °F (427 °C), but below that of the base metals. The filler metal
is distributed in the joint by capillary attraction. When a metal bath is used,
the bath provides the filler metal.
DIRECT CURRENT ELECTRODE NEGATIVE (DCEN): The arrangement of direct current arc
xvplding leads in which the work is the positive pole and the electrode is the
negative pole of the welding arc.
DIRECT CURRENT ELECTRODE POSITIVE (DCEP): The arrangement of direct current arc
weld i ng leads in which the work is the negative pole and the electrode is the
positive pole of the welding arc.
DISCONTINUITY: An interruption of the typical structure of a weldment, such as
lack of homogeneity in the mechanical, metallurgical, or physical characteristics
of the material or weldment. A discontinuity is not necessarily a defect.
DRAG: The horizontal distance between the point of entrance and the point of exit
of a cutting oxygen stream.
DUCTILITY: The property of a metal which allows it to be permanently deformed, in
tension, before final rupture. Ductility is canmonly evaluated by tensile test¬
ing in which the amount of elongation and the reduction of area of the broken
specimen, as compared to the original test specimen, are measured and calculated.
DUTY CYCLE: The percentage of time during an arbitrary test period, usually 10
minutes, during which a power supply can be operated at its rated output without
overloading.
E
EDGE JOINT: A joint between the edges of two or more parallel or nearly parallel
members.
. . .
EDGE PREPARATION: The contour prepared on the edge of a joint member for welding.
Ehl’ECTIVE LENGTH OF WELD: The length of weld throughout which the correctly propor¬
tioned cross section exits.
ELECTRODE:
a. Metal-Arc. Filler metal in the form of a wire or rod, whether bare or cov¬
ered, through which current is conducted between the electrode holder and the arc.
b. Carhnn-Art-. A carbon or graphite rod through which current is conducted
between the electrode holder and the arc.
c. Atomic Hydrogen. One of the two tungsten rods between the points of which
the arc is maintained.
d. Electrolytic Oxygen-Hydrogen Generation. The conductors by which current
enters and leaves the water, which is decomposed by the passage of the current.
e. Resistance Welding. The part or parts of a resistance welding machine
through which the welding current and the pressure are applied directly to the work.
G-5TC 9-237
G-3. WELDING TERMS (cont)
E (cont)
ELECTRODE FORCE:
a. Dynamic. In spot, seam, and projection welding, the force (pounds) between
the electrodes during the actual welding cycle.
b. Theoretical. In spot, seam, and projection welding, the force, neglecting
friction and inertia, available at the electrodes of a resistance welding machine
by virtue of the initial force application and the theoretical mechanical advantage
of the system.
c. Static. In spot, seam, and projection welding, the force between the elec¬
trodes under welding conditions, but with no current flowing and no movement in the
welding machine.
ELECTRODE HOLDER: A device used for mechanically holding the electrode and conduct¬
ing current to it.
ELECTRODE SKID: The sliding of an electrode along the surface of the work during
spot, seam, or projection welding.
EMBOSSMENT: A rise or protrusion from the surface of a metal.
ETCHING: A process of preparing metallic specimens and welds for macrographic or
micrographic examination.
F
FACE REINFORCEMENT: Reinforcement of weld at the side of the joint from which
welding was done.
FACE OF WELD: The exposed surface of a weld, made by an arc or gas welding pro¬
cess, on the side frcm which welding was done.
FAYING SURFACE: That surface of a member that is in contact with another member to
which it is joined.
FERRITE: The virtually pure form of iron existing below the lower critical tempera¬
ture and characterized by a body-centered cubic lattice crystal structure. It is
magnetic and has very slight solid solubility for carbon.
FILLER METAL: Metal to be added in making a weld.
FILLET WET.D: A weld of approximately triangular cross section, as used in a lap
joint, joining two surfaces at approximately right angles to each other.
FILTER GLASS: A colored glass used in goggles, helmets, and shields to exclude
harmful light rays.
FLAME CUTTING: See OXYGEN CUTTING.
FLAME GOUGING: See OXYGEN GOUGING.
FLAME HARDENING: A method for hardening a steel surface by heating with a gas
flame followed by a rapid quench.
FLAME SOFTENING: A method for softening steel by heating with a gas flame followed
by slow cooling.
FLASH: Metal and oxide expelled frcm a joint made by a resistance welding process.
FLASH WRIT)TNG: A resistance welding process in which fusion is produced, simultane¬
ously over the entire area of abutting surfaces, by the heat obtainedfrcm resis¬
tance to the flew of current between two surfaces and by the application of pres¬
sure after heating is substantially completed. Flashing is accompanied by expul¬
sion of metal from the joint.
FLASHBACK: The burning of gases within the torch or beyond the torch in the hose,
usually with a shrill, hissing sound.
FLAT POSITION: The position in which welding is performed frcm the upper side of
the joint and the face of the weld is approximately horizontal.
FLOW BRA2ING: A process in which bonding is produced by heating with a molten
G-6TC 9-237
nonferrous filler metal poured over the joint until the brazing temperature is
Attained. The filler metal is distributed in the joint by capillary attraction.
See BRAZING.
FLOW welding; A process in which fusion is produced by heating with molten filler
metal poured over the surfaces to be welded until the welding temperature is at¬
tained and the required filler metal has been added. The filler metal is not dis¬
tributed in the joint by capillary attraction.
FLUX: A cleaning agent used to dissolve oxides, release trapped gases and slag,
and to cleanse metals for welding, soldering, and brazing.
FOREHAND WELDING: A gas welding technique in which the flame is directed against
the base metal ahead of the completed weld.
FORGE WELDING: A group of welding processes in which fusion is produceci by heating
in a forge or furnace and applying pressure or blows.
free BEND TEST: A method of testing weld specimens without the use of a guide.
FTm,FILLET WELD: A fillet weld whose size is equal to the thickness of the thin¬
ner member joined.
FURNACE BRAZING: A process in which bonding is produced by the furnace heat and a
nonferrous filler metal having a melting point above 800 °F (427 C), but below
that of the base metals. The filler metal is distributed in the joint by capil¬
lary attraction.
FUSION: A thorough and complete mixing between the two edges of the base metal to
be joined or between the base metal and the filler metal added during welding.
FUSION ZONE (filler PENETRATION): The area of base metal melted as determined on
the cross section of a weld.
G
GAS CARBON-ARC WELDING; An arc welding process in which fusion is produced by
heating with an electric arc between a carbon electrode and the work. Shielding
is obtained frcm an inert gas such as helium or argon. Pressure and/or filler
metal may or may not be used.
GAS METAL-ARC (MIG) WELDTNG (GMAW): An arc welding process in which fusion is
produced by heating with an electric arc between a metal electrode and the work.
Shielding is obtained frcm an inert gas such as helium or argon. Pressure and/or
filler metal may or may not be used.
GAS POCKET: A weld cavity caused by the trapping of gases released by the metal
when cooling.
GAS TUNGSTEN-ARC (TIG) WELDING (GTAW): An arc welding process in which fusion is
produced by heating with an electric arc between a tungsten electrode and the
work while an inert gas flows around the weld area to prevent oxidation. No flux
is used.
GAS WELDING: A process in which the welding heat is obtained frcm a gas flame.
GLOBULAR TRANSFER (ARC WELDING): A type of metal transfer in which molten filler
metal is transferred across the arc in large droplets.
GOGGLES; A device with colored lenses which protect the eyes frcm harmful radia¬
tion during welding and cutting operations.
GROOVE: The opening provided between two members to be joined by a groove weld.
GROOVE ANGLE: The total included angle of the groove between parts to be joined by
a groove weld.
GROOVE FACE: That surface of a member included in the groove.
GROOVE RADIUS: The radius of a J or U groove.
GROOVE WELD: A weld made by depositing filler metal in a groove between two mem¬
bers to be joined.
GROUND CONNECTION: The connection of the work lead to the work.
G-7TC 9-237
G-3. WELDING TERMS (cont)
G (cont)
GROUND LEAD: See WORK LEAD.
GUIDED BEND TEST: A bending test in which the test specimen is bent to a definite
shane _ bv means of a iic.
– – J — J –
UT\MMT7D TZFfT TATKT<^ • A e?
ru-y.’U’icux\ m»JC*jUL>XLXMi luiyc wextuixy ptut-coo •
HAND SHIELD: A device used in arc welding to protect the face and neck. It is
equipped with a filter glass lens and is designed to be held by hand.
HARD FACING: A particular form of surfacing in which a coating or cladding is
applied to a surface for the main purpose of reducing wear or loss of material by
abrasion, impact, erosion, galling, and cavitation.
TJ1DD • The annlir-ot-irm rx-F a +*rx cniT-’FAr’o
a softer metal.
HARDENING:
a. The heating and quenching of certain iron-base alloys from a temperature
above the critical temperature range for the purpose of producing a hardness superiJ 4-1^4. ^U-U-s 4-U^ -J i e* neninl /^4-—
(JL LU Hide kJlULdXlltXA Wild! L4.ie axiuy Lb HUU ‘4uc.iL.kicu. iillo lcj-ih xo uoua-Lj.^ xcoui.xuu
ed to the formation of martensite.
b. Any process of increasing the hardness of metal by suitable treatment, usual¬
ly involving heating and cooling.
HEAT AFFECTED ZONE: That portion of the base metal whose structure or properties
have been changed by the heat of welding or cutting.
HEAT TIME: The duration of each current inpulse in pulse welding.
HEAT TREATMENT: An operation or combination of operations involving the heating
and cooling of a metal or an alloy in the solid state for the purpose of obtain¬
ing certain desirable conditions or properties. Heating and cooling for the sole
purpose of mechanical working are excluded frem the meaning of the definition.
trr»TX fT’TW’ CTkrnT. 4 -» rl K -iz-rP» r.^-iz-‘h 4-Pz-s r-\ov-4-c» 4-z-x Purx
JTULrtX XINLj <irt.XIL; 1UC Xll CL L-LICXILLLU. HULU lughuuijii mixuii l-luc l-l> wcxuctu
are preheated.
HETMET: A device used in arc welding to protect the face and neck. It is equipped
with a filter glass and is designed to be worn on the head.
HOLD TIME: The time that pressure is maintained at the electrodes after the weld¬
ing current has stopped.
rj/ADTry/ARTmAT TULT ta
– a k.-iLL r.-,^1 -J -J t.t-i XP 4 +- c 1inznnr i T-cxrM-i rArx HrAY“i vnn—
nkjru.6WI XMXl rvr.J il /. M XA^CXUl LUX LJULCU. WdXUXXXILj wj.uk -Luo J-juicuj. uxj-‘-uuj.^h
+-a1 nr i nori i n<=r? ^1- ^r> ;>nnTp hhan 4S decrees to the horizontal, and the Darts
— — —— — — — * Z> — — ‘ – x
welded being vertically or approximately vertically disposed.
HORN: The electrode holding arm of a resistance spot welding machine.
HORN SPACING: In a resistance welding machine, the unobstructed work clearance
between horns or platens at right angles to the throat depth. This distance is
measured with the horns parallel and horizontal at the end of the downstroke.
HOT SHORT: A condition which occurs when a metal is heated to that point, prior to
melting, where all strength is lost but the shape is still maintained.
HYDROGEN BRAZING: A method of furnace brazing in a hydrogen atmosphere.
HYDROMATIC WELDING: See PRESSURE CONTROLLED WELDING.
HYGROSCOPIC: Readily absorbing and retaining moisture.
IMPACT TEST: A test in which one or more blows are suddenly applied to a speci¬
men. The results are usually expressed in terms of energy absorbed or number of
blows of a given intensity required to break the specimen.TC 9-237
IMPREGNATED-TAPE MetAL-ARC WELDING: An arc welding process in which fusion is
produced by heating with an electric arc between a metal electrode and the work.
Shielding is obtained from decomposition of an impregnated tape wrapped around
the electrode as it is fed to the arc. Pressure is not used, and filler metal is
obtained from the electrode.
INDUCTION BRAZING: A process in which bonding is produced by the heat obtai ned
from the resistance of the work to the flow of induced electric current and by
using a nonferrous filler metal having a melting point above 800 °F (427 °C), but
below that of the base metals. The filler metal is distributed in the joint by
capillary attraction.
INDUCTION WELDING: A process in which fusion is produced by heat obtained fran
resistance of the work to the flow of induced electric current, with or without
the application of pressure.
INERT GAS: A gas which does not normally combine chemically with the base metal or
filler metal.
INTeRPASS TEMPERATURE: In a multipass weld, the lowest temperature of the deposit¬
ed weld metal before the next pass is started.
J
JOINT: The portion of a structure in which separate base metal parts are joined.
JOINT PENETRATION: The maximum depth a groove weld extends frcm its face into a
joint, exclusive of reinforcement.
K
KERF: The space from which metal has been removed by a cutting process.
L
LAP JOINT: A joint between two overlapping members.
LAYER: A stratum of weld metal, consisting of one or more weld beads.
LEG OF A FILLET WELD: The distance frcm the root of the joint to the toe of the
fillet weld.
LIQUIDUS: The lowest temperature at which a metal or an alloy is completely liquid.
IOCAL PREHEATING: Preheating a specific portion of a structure.
LOCAL STRESS RELIEVING: Stress relieving heat treatment of a specific portion of a
structure.
M
MANIFOLD: A multiple header for connecting several cylinders to one or more torch
supply lines.
MARTENSITE: Martensite is a microconstituent or structure in quenched steel charac¬
terized by an acicular or needle-like pattern on the surface of polish.. It has
the maximum hardness of any of the struckires resulting frcm the decomposition
products of austenite.
MASH SEAM WELDING: A seam weld made in a lap joint in which the thickness at the
lap is reduced to approximately the thickness of one of the lapped joints by
applying pressure while the metal is in a plastic state.
MELTING POINT: The temperature at which a metal begins to liquefy.
MELTING RANGE: The temperature range between solidus and liquidus.
G-9TC 9-237
G-3. WELDING TEEMS (cont)
M (cont)
MELTING RATE: The weight or length of electrode melted in a unit of time.
METAL-ARC CUTTING: The process of cutting metals by melting with the heat of the
metal arc.
METAL-ARC wet,nTNG: An arc welding process in which a metal electrode is held so
that the heat of the arc fuses both the electrode and the work to form a weld.
METALLIZING: A method of overlay or metal bonding to repair worn parts.
MIXING CHAMBER: That part of a welding or cutting torch in which the gases are
mixed for combustion.
MULTI-IMPULSE WET,nTNG: The making of spot, projection, and upset welds by more
than one impulse of current. When alternating current is used each impulse may
consist of a fraction of a cycle or a number of cycles.
N
NeutkAL FLAME: A gas flame in which the oxygen and acetylene volumes are balanced
and both gases are completely burned.
NICK BREAK TEST: A method for testing the soundness of welds by nicking each end
of the weld, then giving the test specimen a sharp hammer blow to break the weld
from nick to nick. Visual inspection will show any weld defects.
NONFERROUS: Metals which contain no iron. Aluminum, brass, bronze, copper, lead,
nickel, and titanium are nonferrous.
NORMALIZING: Heating iron-base alloys to approximately 100 °F (38 °C) above the
critical temperature range followed by cooling to belcw that range in still air
at ordinary temperature.
NUGGET: The fused metal zone of a resistance weld.
O
OPEN CIRCUIT VOLTAGE: The voltage between the terminals of the welding source when
no current is flowing in the welding circuit.
OVERHEAD POSITION: The position in which welding is performed from the underside
of a joint and the face of the weld is approximately horizontal.
OVERLAP: The protrusion of weld metal beyond the bond at the toe of the weld.
OXIDIZING FLAME: An oxyacetylene flame in which there is an excess of oxygen. The
unburned excess tends to oxidize the weld metal.
OXYACETYLENE CUTTING: An oxygen cutting process in which the necessary cutting
temperature is maintained by flames obtained frcm the combustion of acetylene
with oxygen.
OXYACETYLENE WELDING: A welding process in which the required temperature is at¬
tained by flames obtained from the combustion of acetylene with oxygen.
OXY-ARC CUTTING: An oxygen cutting process in which the necessary cutting tempera¬
ture is mai ntai ned by means of an arc between an electrode and the base metal.
OXY-CITY GAS CUTTING: An oxygen cutting process in which the necessary cutting
temperature is maintained by flames obtained from the canbustion of city gas with
oxygen.
OXYGEN CUTTING: A process of cutting ferrous metals by means of the chemical ac¬
tion of oxygen on elements in the base metal at elevated temperatures.
OXYGEN GOUGING: An application of oxygen cutting in which a chamfer or groove is
formed.
OXY—hydrogen CUTTING: An oxygen cutting process in which the necessary cutting
temperature is maintained by flames obtained by the combustion of hydrogen with
oxygen.
G-10TC 9-237
OXY-HYDROGEN WELDING: A gas welding process in which the required waTHing tempera¬
ture is attained by flames obtained from the combustion of hydrogen with oxygen.
OXY-NATURAL GAS CUTTING: An oxygen cutting process in which the necessary mbHng
temperature is maintained by flames obtained from the canbustion of natural gas
with oxygen.
OXY-PROPANE CUTTING: An oxygen cutting process in which the necessary cutting
temperature is maintained by flames obtained from the canbustion of propane with
oxygen.
P
PASS: The weld metal deposited in one general progression along the axis of the
weld.
PEENING: The mechanical working of metals by means of hammer blows. Peening tends
to stretch the surface of the cold metal, thereby relieving contraction stresses.
PENETRANT INSPECTION:
a. Fluorescent. A water washable penetrant with high fluorescence and low sur¬
face tension. It is drawn into small surface openings by capillary action. When
exposed to black light, the dye will fluoresce.
b. Dye. A process which involves the use of three noncorrosive liquids. First,
the surface cleaner solution is used. Then the penetrant is applied and allowed to
stand at least 5 minutes. After standing, the penetrant is removed with the leaner
solution and the developer is applied. The dye penetrant, which has rpmainAd in
the surface discontinuity, will be drawn to the surface by the developer resulting
in bright red indications.
PERCUSSIVE WELDING: A resistance welding process in which a dischargA of electri¬
cal energy and the application of high pressure occurs simultaneously, or with
the electrical discharge occurring slightly before the application of pressure.
PERLITE: Perlite is the lamellar aggregate of ferrite and iron carbide resulting
from the direct transformation of austenite at the lower critical point.
PITCH: Center to center spacing of welds.
PLUG WELD: A weld is made in a hole in one member of a lap joint, joining that
member to that portion of the surface of the other member which is exposed
through the hole. The walls of the hole may or may not be parallel, and the hole
may be partially or completely filled with the weld metal.
POKE WELDING: A spot welding process in which pressure is applied manually to one
electrode. The other electrode is clamped to any part of the metal much in the
same manner that arc welding is grounded.
POROSITY: The presence of gas pockets or inclusions in welding.
POSITIONS OF WELDING: All welding is accomplished in one of four positions: flat,
horizontal, overhead, and vertical. The limiting angles of the various positions
depend sonewhat as to whether the weld is a fillet or groove weld.
POSTHEATING: The application of heat to an assembly after a welding, brazing,
soldering, thermal spraying, or cutting operation.
POSiwelD INtEkVAL: In resistance welding, the heat time between the end of weld
time, or weld interval, and the start of hold time. During this interval, the
weld is subjected to mechanical and heat treatment.
PReHeaTING: The application of heat to a base metal prior to a welding or cutting
operation.
PRESSURE OOtZTROTJED WELDING: The making of a number of spot or projection welds in
which several electrodes function progressively under the control of a pressure
sequencing device.
PRESSURE WELDING: Any welding process or method in which pressure is used to conplete the weld.
G-llTC 9-237
G-3. WELDING TERMS (cont)
P (cont)
PREWEID INTERVAL: In spot, projection, and upset welding, the time between the end
of squeeze time and the start of weld time or weld interval during which the
material is preheated. In flash welding, it is the time during which the materi¬
al is preheated.
PROCEDURE QUAIdTICATTON: The demonstration that welds made by a specific procedure
can meet prescribed standards.
PROJECTION wrtdtng? A resistance welding process between two or more surfaces or
between the ends of one member and the surface of another. The welds are local¬
ized at predetermined points or projections.
PULSATION WELDING: A spot, projection, or seam welding process in which the weld¬
ing current is interrupted one or more times without the release of pressure or
change of location of electrodes.
PUSH WELDING: The making of a spot or projection weld in which the force is ap¬
ing current is interrupted one or more times without the release of pressure or
change of location of electrodes.
PUSH WELDING: The making of a spot or projection weld in which the force is ap¬
plied manually to one electrode and the work or a backing bar takes the place of
the other electrode.
Q
QUENCHING: The sudden cooling of heated metal with oil, water, or ccnpressed air.
R
REACTION STRESS: The residual stress which could not otherwise exist if the mem¬
bers or parts being welded were isolated as free bodies without connection to
other parts of the structure.
REDUCING ELAME: See CARBURIZING FLAME.
REGULATOR: A device used to reduce cylinder pressure to a suitable torch working
pressure.
REINFORCED WELD: The weld metal built up above the surface of the two abutting
sheets or plates in excess of that required for the size of the weld specified.
RESIDUAL STRESS: Stress remaining in a structure or member as a result of thermal
and/or mechanical treatment.
RESISTANCE BRAZING: A brazing process in which bonding is produced by the heat
nhtai ned fran resistance to the flow of electric current in a circuit of which
the workpiece is a part, and by using a nonferrous filler metal having a melting
point above 800 °F (427 °C), but belew that of the base metals. The filler metal
is distributed in the joint by capillary attraction.
RESISTANCE BUTT WELDING: A group of resistance welding processes in which the weld
occurs simultaneously over the entire contact area of the parts being joined.
RESISTANCE WET.DTNG: A group of welding processes in which fusion is produced by
heat obtained frem resistance to the flow of electric current in a circuit of
which the workpiece is a part and by the application of pressure.
REVERSE POLARITY: The arrangement of direct current arc welding leads in which the
work is the negative pole and the electrode is the positive pole of the welding
arc.
ROCKWETT. HARDNESS TEST: In this test a machine measures hardness by determining
the depth of penetration of a penetrator into the specimen under certain arbiG-12TC 9-237
trary fixed conditions of test. The penetrator may be either a steel ball or a
diamond spherocone.
ROOT: See ROOT OF JOINT and ROOT OF WELD.
ROOT CRACK: A crack in the weld or base metal which occurs at the root of a weld.
ROOT EDGE: The edge of a part to be welded which is adjacent to the root.
ROOT FACE: The portion of the prepared edge of a member to be joined by a groove
weld which is not beveled or grooved.
ROOT OF JOINT: That portion of a joint to be welded where the members approach
closest to each other. In cross section, the root of a joint may be a point, a
line, or an area.
ROOT OF WELD: The points, as shewn in cross section, at which the bottom of the
weld intersects the base metal surfaces.
ROOT OPENING: The separation between the members to be joined at the root of the
joint.
ROOT PENETRATION: The depth a groove weld extends into the root of a joint meas¬
ured on the centerline of the root cross section.
S
SCARF: The chamfered surface of a joint.
SCARFING: A process for removing defects and checks which develop in the rolling
of steel billets by the use of a low velocity oxygen deseaming torch.
SEAL WELD: A weld used primarily to obtain tightness and to prevent leakage.
SEAM WEEDING: Welding a lengthwise seam in sheet metal either by abutting or over¬
lapping joints.
SELECTIVE BLOCK SEQUENCE: A block sequence in which successive blocks are complet¬
ed in a certain order selected to create a predetermined stress pattern.
SERieS WELDING: A resistance welding process in which two or more welds are made
simultaneously by a single welding transformer with the total current passing
through each weld.
SHEET SEPARATION: In spot, seam, and projection welding, the gap surrounding the
weld between faying surfaces, after the joint has been welded.
SHIELDED WELDING: An arc welding process in which protection from the atmosphere
is obtained through use of a flux, decomposition of the electrode covering, or an
inert gas.
SHOULDER: See ROOT FACE.
SHRINKAGE STRESS: See RESIDUAL STRESS.
SINGLE IMPULSE WELDING: The making of spot, projection, and upset welds by a sin¬
gle inpulse of current. When alternating current is used, an impulse may consist
of a fraction of a cycle or a number of cycles.
SIZE OF WEED:
a. Groove weld. The joint penetration (depth of chamfering plus the root pene¬
tration when specified).
b. Equal leg fillet welds. The leg length of the largest isosceles right trian¬
gle which can be inscribed within the fillet weld cross section.
c. Unequal leg fillet welds. The leg length of the largest right triangle which
can be inscribed within the fillet weld cross section.
d. Flange weld. The weld metal thickness measured at the root of the weld.
SKIP SEQUENCE: See WANDERING SEQUENCE.
SLAG INCLUSION: Non-metallic solid material entrapped in the weld metal or between
the weld metal and the base metal.
SLOT WELD: A weld made in an elongated hole in one member of a lap or tee joint
joining that member to that portion of the surface of the other member which is
exposed through the hole. The hole may be open at one end and may be partially
G-13TC 9-237
G-3. WELDING TERMS(cont)
S (cont)
or completely filled with weld metal. (A fillet welded slot should not be con¬
strued as conforming to this definition.)
SLUGGING: Adding a separate piece or pieces of material in a joint before or dur¬
ing welding with a resultant welded joint that does not comply with design draw¬
ing or specification requirements.
sotperTNG: A group of welding processes which produce coalescence of materials by
heating them to suitable temperature and by using a filler metal having a
liquidus not exceeding 450 °C (842 °F) and below the solidus of the base materi¬
als. The filler metal is distributed between the closely fitted surfaces of the
joint by capillary action.
SOLIDUS: The highest temperature at which a metal or alley is completely solid.
SPACER STRIP: A metal strip or bar inserted in the root of a joint prepared for a
groove weld to senzp as a backing and to maintain the root opening during welding.
SPALL: Small chips or fragments which are sanetimes given off by electrodes during
the welding operation. This problem is especially cannon with heavy coated elec¬
trodes.
SPATTER: The metal particles expelled during arc and gas welding which do not form
a part of the weld.
SPOT WELDING: A resistance welding process in which fusion is produced by the heat
obtai ned from the resistance to the flow of electric current through the work¬
pieces held together under pressure by electrodes. The size and shape of the
individually formed welds are limited by the size and contour of the electrodes.
SPRAY TRANSFER: A type of metal transfer in which molten filler metal is propelled
axially across the arc in small droplets.
STAGGERED INTERMITTENT FILLET WETD: Two lines of intermittent welding on a joint,
such as a tee joint, wherein the fillet increments in one line are staggered with
respect to those in the other line.
STORED ENERGY WELDING: The making of a weld with electrical energy accumulated
electrostatically, electronagnetically, or electrochemically at a relatively low
rate and made available at the required welding rate.
STRAIGHT POLARITY: The arrangement of dirent current arc welding leads in which
the work is the positive pole and the electrode is the negative pole of the weld¬
ing arc.
STRESS RELIEVING: A process of reducing internal residual stresses in a metal
object by heating to a suitable temperature and holding for a proper time at that
temperature. This treatment may be applied to relieve stresses induced by cast¬
ing, quenching, normalizing, machining, cold working, or welding.
STRING BEAD WETDING: A method of metal arc welding on pieces 3/4 in. (19 rrm) thick
or heavier in which the weld metal is deposited in layers composed of strings of
beads applied directly to the face of the bevel.
STUD WELDING: An arc welding process in which fusion is produced by heating wzith
an electric arc drawn between a metal stud, or similar part, and the other work¬
piece, until the surfaces to be joined are properly heated. They are brought
together under pressure.
SUBMERGED ARC WELDING: An arc welding process in which fusion is produced by heat¬
ing wzith an electric arc or arcs between a bare metal electrode or electrodes and
the work. The welding is shielded by a blanket of granular, fusible material on
the work. Pressure is not used. Filler metal is obtained fron the electrode,
and sometimes from a supplementary welding rod.
SURFACING: The deposition of filler metal on a metal surface to obtain desired
properties or dimensions.
G-14TC 9-237
T
TACK WETD? a weld made to hold parts of a weldment in proper alignment until the
final welds are made.
TEE JOINT: A joint between two members located approximately at right angles to
each other in the form of a T.
TEMPER COLORS: The colors which appear on the surface of steel heated at low tem¬
perature in an oxidizing atmosphere.
TEMPER TIME: In resistance welding, that part of the postweld interval during
which a current suitable for tempering or heat treatment flows. The current can
be single or multiple impulse, with varying heat and cool intervals.
TEMPERING: Reheating hardened steel to sane temperature below the lower critical
temperature, follcwed by a desired rate of cooling. The object of tempering a
steel that has been hardened by quenching is to release stresses set up, to re¬
store sone of its ductility, and to develop toughness through the regulation or
readjustment of the embrittled structural constituents of the metal. The timetemperature conditions for tempering may be selected for a given composition of
steel to obtain almost any desired combination of properties.
TENSILE STRENGTH: The maximum load per unit of original cross-sectional area sus¬
tained by a material during the tension test.
TENSION TEST: A test in which a specimen is broken by applying an increasing load
to the two ends. During the test, the elastic properties and the ultimate ten¬
sile strength of the material are determined. After rupture, the broken specimen
may be measured for elongation and reduction of area.
THERMIT CRUCIBLE: The vessel in which the thermit reaction takes place.
THERMIT MIXTURE: A mixture of metal oxide and finely divided aluminum with the
addition of alloying metals as required.
THERMIT MOLD: A mold formed around the parts to be welded to receive the molten
metal.
THERMIT REACTION: The chemical reaction between metal oxide and aluminum which
produces superheated molten metal and aluminum oxide slag.
THERMIT WELDING: A group of welding processes in which fusion is produced by heat¬
ing with superheated liquid metal and slag resulting fron a chemical reaction be¬
tween a metal oxide and aluminum, with or without the application of pressure.
Filler metal, when used, is obtained from the liquid metal.
THROAT DEPTH: In a resistance welding machine, the distance from the centerline of
the electrodes or platens to the nearest point of interference for flatwork or
sheets. In a seam welding machine with a universal head, the throat depth is
measured with the machine arranged for transverse welding.
THROAT OF FILLET WELD:
a. Theoretical. The distance fron the beginning of the root of the joint perpen¬
dicular to the hypotenuse of the largest right triangle that can be inscribed with¬
in the fillet-weld cross section.
b. Actual. The distance fron the root of the fillet weld to the center of its
face.
TOE CRACK: A crack in the base metal occurring at the toe of the weld.
TOE OF THE WELD: The junction between the face of the weld and the base metal.
TORCH: See CUTTING TORCH or WELDING TORCH.
TORCH BRAZING: A brazing process in which bonding is produced by heating with a
gas flame and by using a nonferrous filler metal having a melting point above
800 °F (427 °C), but below that of the base metal. The filler metal is distribut¬
ed in the joint of capillary attraction.
TRANSVERSE SEAM WELDING: The making of a seam weld in a direction essentially at
right angles to the throat depth of a seam welding machine.
G—15TC 9-237
G-3. WELDING TERMS(cont)
T (cont)
TUNGSTEN ELECTRODE: A non-filler metal electrode used in arc welding or cutting,
made principally of tungsten.
U
UNDERBEAD CRACK: A crack in the heat affected zone not extending to the surface of
the base metal.
UNDERCUT: A groove melted into the base metal adjacent to the toe or root of a
weld and left unfilled by weld metal.
UNDERCUTTING: An undesirable crater at the edge of the weld caused by poor weaving
technique or excessive welding speed.
UPSET: A Inca!i?:pd increase in volume in the region of a weld, resulting frcm the
application of pressure.
UPSET WELDING: A resistance welding process in which fusion is produced simultane¬
ously over the entire area of abutting surfaces, or progressively along a joint,
by the heat obtained frcm resistance to the flow of electric current through the
area of contact of those surfaces. Pressure is applied before heating is started
and is maintained throughout the heating period.
UPSETTING FORCE: The force exerted at the weldinc surfaces in flash or upset weld¬
ing.
V
VERTICAL POSITION: The position of welding in which the axis of the weld is approx¬
imately vertical. In pipe welding, the pipe is in a vertical position and the
welding is done in a horizontal position.
W
WANDERING BLOCK SEQUENCE: A block welding sequence in which successive weld blocks
ara completed at random after several starting blocks have been completed.
WANDERING SEQUENCE: A longitudinal sequence in which the weld bead increments are
deposited at randan.
WAX PATTERN: Wax molded around the parts to be welded by a thermit welding process
to the form desired for the completed weld.
WEAVE BEAD: A type of weld bead made with transverse oscillation.
WEAVING: A technique of depositing weld metal in which the electrode is oscillat¬
ed. It is usual1y accomplished by a semicircular motion of the arc to the right
and left of the direction of welding. Weaving serves to increase the width of
the deposit, decreases overlap, and assists in slag formation.
WELD: A localized fusion of metals produced by heating to suitable temperatures.
Pressure and/or filler metal may or may not be used. The filler metal has a melt¬
ing point approximately the same or below that of the base metals, but always
above 800 °F (427 °C).
WELD BEAD: A weld deposit resulting frcm a pass.
WELD GAUGE: A device designed for checking the shape and size of welds.
wetd METAL: That portion of a weld that has been melted during welding.
WELD SYMBOL: A picture used to indicate the desired type of weld.
WELDABILITY: The capacity of a material to form a strong bond of adherence under
pressure or when solidifying from a liquid.
WELDER CERTIFICATION: Certification in writing that a welder has produced welds
G-16TC 9-237
meeting prescribed standards.
WELDER PERFORMANCE QUALIFICATION: The demonstration of a welder’s ability to pro¬
duce welds meeting prescribed standards.
WELDING LEADS:
a. Electrode lead. The electrical conductor between the source of the arc weldincr current and the electrode holder.
b. Work lead. The electrical conductor between the source of the arc welding
current and the workpiece.
WELDING PRESSURE: The pressure exerted during the welding operation on the parts
being welded.
WELDING PROCEDURE: The detailed methods and practices including all joint welding
procedures invo!vaH jn the production of a we1ament x
WELDING ROD: Filler metal in wire or rod form, used in gas welding and brazing
processes and in those arc welding processes in which the electrode does not pro¬
vide the filler metal.
WELDING SYMBOL: The assembled symbol consists of the following eight elements, or
m —I -W—» T. 1 4
uicoc ao gu-c . LCLeieiiUC clluj# — -r L. Udi5XC: — ~ WtiXU 1 J syiriLXJXSz — —I— — 1 — ci i —
sion and other data, crmnl pmpnt^rv ovmKnl a. F-inicb qwbplc +-p>i 1 p-ir’ai-ipn
, J —J*— , — ,
process, or other references.
WELDING TECHNIQUE: The details of a manual, machine, or semiautomatic welding
operation which, within the limitations of the prescribed joint welding proce¬
dure, are controlled by the welder or welding operator.
WELDING TIP: The tip of a gas torch especially adapted to welding.
WELDING TORCH: A device used in gas welding and torch brazing for mixing and con¬
trolling the flow of gases.
WELDING TRANSFORMER: A device for providing current of the desired voltage.
WELDMENT: An assembly whose component parts are formed by welding.
WIRE FEED SPEED: The rate of speed in mm/sec or in./min at which a filler metal is
consumed in arc welding or thermal spraying.
WORK T.rad• The electric conductor (cable) between the conroe of arc w»1ai ng mr—
rent and the workpiece.
X
X-RAY: A radiographic test method used to detect internal defects in a weld.
Y
YIELD POINT: The yield point is the load per unit area value at which a marked
increase in deformation of the specimen occurs with little or no increase of
load; m other words, the yield point is the stress at which a marked increase in
strain occurs with 1ittla or no increase in stress.
G-17(G-18 blank)TC 9-237
ALPHABETICAL INDEX
A
Page
Accessory Tips 12-15
Acetylene Cylinders 2-16,
5-5
Acetylene Generator 5-4
Acid Etch Test 13-8
Acoustic Emission Testing 13-18
AC Welding 10-21
Air Carbon Arc Cutting (AAC) 10-108
Air Carbon Arc Cutting and Welding 2-25
Alloys Used for Hard Surfacing 12-29
Alternating Current Arc Welding Machines 5-25
Aluminum Brazing 11-44
Aluminum Soldering 11-47
Aluminum Welding 7-66,
11-41
Annealing 12-75
Application 12-72
Arc Blow 6-60
Arc Spot and Arc Seam Welds 3-20
Arc Welding 6-2
Automotive Exhaust Method of Cleaning 2-33
B
Back Bend Test 13-11
Backhand Welding 6-37,
11-14
Back or Backing Welds 3-26
Index-1TC 9-237
B (cont)
Basic Weld Symbols 3-5
Brass and Bronze Welding 7-80,
11-50
Brazing 6-7,
11-26
Brazing Alloys 8-18
Brazing Gray Cast Iron 11-31
Brazing Mailable Iron 11-32
Bronze Surfacing 11-58
Butt Joint 6-21
C
Carbon Arc Welding (CAW) 10-48
Cast Iron 7-59,
12-22
Cast Iron, Cast Steel, Carbon Steel, and Forgings 12-65
Categories of Metals ”7-9
Chronium and Stainless Steel 12-22
Construction Lines 3-2
Construction of Symbols 3-12
Controlling Contraction and Expansion in Castings 6-41
Controlling Contraction in Sheet Metal 6-39
Copper Brazing 11-49
Copper Welding 7-81,
11-48
Corner Joint 6-22
Covered Electrodes 8-1
Cutting Armor Plate 12-33
Cutting Technique 12-5
Cutting Torch and Other Cutting Equipment 5-19
Index-2TC 9-237
D
DC Reverse Polarity Welding (See DC Straight and Reverse Polarity Welding)
DC Straight and Reverse Polarity Welding ; 10-13
Description 1-1
Definition of Arc Welding I. 10-1
Determining the Weldable Parts t 9-2
Dimensioning of Intermittent Fillet Welding ; 3-17
Direct Current Arc Welding Machines ; 5-23
Drawing and Quenching After Carburizing ; 12-79
E
Eddy Current (Electromagnetic) Testing 13-17
Edge Joint 6-23
Electric Circuits 2-22
Electrodes, Covered (See Covered Electrodes)
Electrodes and Their Use ‘ 5-37
Electrodes, Flux-Cored or Tubular (See Flux-Cored or Tubular Electrodes)
Electrodes, Nonconsumable (See Nonconsumable Electrodes)
Electron Beam Welding (EBW) 10-120
Elements of a Welding Symbol 3-5
Explosion Hazards 2-28
Extent of Fillet Welding 3-16
Extent of Welding Denoted by Symbols 3-12
F
Ferrite Testing 13-18
Field Inspection of Welds and Equipment Repaired by Welding 13-1
Fillet Welding 11-15
Filling Treatment 2-37
Fire Hazards
Index-3TC 9-237
F (cont)
Flame Adjustment and Flame Types 11-6
Flame Descaling 12-25
Flame Hardening 12-24
Flame Machining (Oxygen Machining) 12-26
Flame Softening 12-24
Flame Straightening 12-24
Flame Strengthening 12-25
Flange Welds 3-28
Flash or Upset Welds 3-36
Flash Welding (FW) 10-116
Flash Welding Titanium 12-86
Flat Position Welding 6-31,
11-19
Fluorescent Penetrant Test 13-15
Flux-Cored Arc Welding (FCAW) 10-68
Flux-Cored or Tubular Electrodes 8-10
Forehand Welding 6-36,
11-13
Forges 5-51
Forging Tools 5-53
Free Bend Test 13-10
Friction Welding (FRW) 10-117
Fuel Gas Cylinders 2-20
G
Gamma Ray Test 13-15
Gas Metal-Arc Welding (GMAW) Equipment 5-28
Gas Metal-Arc Welding (GMAW or MIG Welding) 10-54
Gas Metal-Arc Welding (GMAW) with Flux-Cored Wire 13-6
Index-4TC 9-237
Gas Metal-Arc Welding (GWAW) with Solid-Core Wire 13-4
Gas Tungsten-Arc Welding (GTAW) Equipment (TIG) , 5-26,
10-33
I
Gas Tungsten-Arc (TIG) Welding (GTAW) 10-33
Gas Welding 6-6,
13-4
General Gas Welding Procedures 11-1
Glossary G-l
Groove Welds 3-22
Guided Bend Test 13-8
H
Hard Surfacing 12-28
Hard Surfacing Procedure 12-30
Hardening 12-76
Hardness Tests 13-16
Hazards of Welding Polyurethane Foam Filled Assemblies 2-38
Health Protection and Ventilation 2-7
Heat Source 12-80
i
High Carbon Steels 7-49,
12-22
High Hardness Alloy Steels 7-52
High Yield Strength, Low Alloy Structural Steels 7-54
Horizontal Position Welding 6-32,
11-17
Hose 5-13
Hoses 2-21
Hot Chemical Solution Method of Cleaning 2-35
Hydrostatic Test 13-14
Index-5TC 9-237
I
Identification of Armor Plate 12-33
identifying the Metal 9-2
Inch, Degree, and Pound Marks, Use of (See Use of Inch, Degree,
and Pound Marks)
Incomplete Penetration 13-2
Index
In-Service Cracking 6-53
J
Joint Types
L
Lack of Fusion 13-2
Lap Joint 6-23
Laser Beam Welding (LBW) 10-124
Lead Welding 11-56
Length of Fillet Welds 3-15
Location of the Weld With Respect to Joint 3-10
Location of Weld Symbols 3-12
Location Significance of Arrow 3-8
Low Carbon Steels 7-45
M
Magnaflux Test 13-17
Magnesium Brazing 11-53
Magnesium Soldering 11-55
Magnesium Welding 7-84,
11-51
Magnetic Particle Test 13-14
Making Template Patterns 12-57
Malfunctions and Corrective Actions 12-16
Index-6TC 9-237
MAPP Gas Cylinders 2-19
Marking of Safe Containers 1 2-37
Materials 12-15
Materials Used for Brazing, Welding, Soldering, Cutting, and Metallizing …. D-l
Medium Carbon Steels 7-48
Melt-Thru Welds 3-27
Metal Cutting with Electric Arc 12-28
Metallizing and Welding Torch 12-14
Metals 1-2
Metals that Can be Hard Surfaced 12-29
Methods of Precleaning Containers Which Have Held Flanmable Liquids 2-33
Miscellaneous Data E-l
I
Muffle Jacket 12-80
Multilayer Welding 10-22
Multipass Welds 6-16
N
Nick Break Test 13-12
Nickel Soldering 11-56
Nickel Welding 11-55
Nonconsumable Electrodes 8-14
0
I
Operating the MIG Torch 5-32
Operation 12-15
Operation of Cutting Equipment 5-22
Other Welding Equipment 5-34
Other Welding Problems J 6-68
Overhead Position Welding 6-32,
11-22
Index-7TC 9-237
0 (cont)
Oxyacetylene Rivet Cutting 12-26
Oxyacetylene Welding Torch 5-11
Oxyfuel Cutting 11-33
Oxyfuel Welding Fluxes 11-12
Oxyfuel Welding Rods 11-12
Oxygen and Acetylene Regulators 5-8
Oxygen and its Production 5-7
O 1Q
5-8
P
Parts of a Drawing 3-1
Personal Protective Equipment 2-1
Pipe Welding Procedures 12-61
Pipe Welding Processes 12-60
Plasma Arc Cutting (PAC) 10-102
Plasma Arc Cutting and Welding 2-24
Plasma Arc Welding (PAW) 10-38
Plug and Slot Welding Symbols 3-19
Porosity 13-3
Portable Welding Equipment 5-4
Positions for Pipe Welding 6-32
Potential Hazards 2-27
Preliminary Precautions 9-3
Preparation for Welding 12-54,
B-l
Preparing the Clean Container for Welding or Cutting —
Inert Gas Treatment 2-37
Index-8TC 9-237
Preparing the Container for Cleaning 2-32
Procedure Guides for Welding B-l
Procedures 12-66
Projection Welds 3-34
Properties of Armor Plate 12-32
Properties of Metals 7-1
Protective Measures 2-27
Protective Screens 2-24
Q
Quenching After Carburizing 12-79
R
References A-l
References and General Notes 3-11
i
Regulator Malfunctions and Corrections 5-16
Resistance Seam Welds 3-31
Resistance Spot Welds 3-30
Resistance Welding (EW) 5-46,
6-12,
10-113,
12-80
S
Scope 1-1
Sections of a Weld 6-15
Selecting the Proper Welding Procedures 9-2
Setting Up Welding Equipment 5-14
Setup 12-15
Shielded Metal-Arc Welding (SMAW) 10-23
Shutting Down Welding Apparatus 5-16
Silver Brazing (Soldering) t 11-32
Index-9TC 9-237
S (cont)
Size of Fillet Welds 3-15
Sizing up the Job ^-1
Slag Inclusions 13-3
Soldering 8-16,
11-46
Solid Electrode Wires
Spot and Seam Welding Titanium 12-85
Spot Welding Magnesium 12-83
Standard Designation System for Aluminum and Aluminum Alloys 7-40
standard Designation System for Copper and Copper Alloys 7-42
Standard Designation System for Magnesium and Magnesium Alloys 7-41
Standard Designation System for Titanium 7-45
Standard Designation System for Steel 7-37
Stationary Welding Equipment 5-1
Steam Method of Cleaning 2-54
Strengthening Riveted Joints in Armor Plate 12-54
Stresses and Cracking 6-47
Submerged Arc Flux Additives 8-16
Submerged Arc Welding (SAW) 10-83
Surface Contour of Fillet Welds 3-18
Surface Hardening 12-76
Surfacing Welds 3-28
Symbols, Construction of (See Construction of Symbols)
T
Tee Joint 6-24
Tempering 12-76
Tensile Strength Test 13-12
Termination of Intermittent Fillet Welding 3-18
Index-10TC 9-237
Testing of Military Material 13 1
Thermit Welding 5-50,
6-12
Titanium Welding 7-9$
Tool Steels 7-50
Tools and Equipment 12-14
Torch Malfunctions and Corrections 5-17
Troubleshooting Procedures C-1
Types of Armor Plate i 12-33
Types of Welds 6-25
U
Undercutting 13-3
Underwater Cutting Technique r 12-1
Underwater Welding Technique 12-2
Use of Carbonizing Canpound Paste, NSN 6580-00-695-9268, ajjid Isolating
Paste, NSN 6850-00-664-0355, for Surface Hardening .
— 12-77
Use of Inch, Degree, and Pound Marks 3-12
Using the Explosimeter 2-29
V
Vertical Position Welding I. 6-32,
11-22
W
Warnings a
Water Method of Cleaning 2-35
Waster Plate Alloy Steel 12-22
Weld Accessibility 4-4
Weld-All-Around and Field Weld Symbols 3-11
Weld Failure Analysis 6-66
Weld Joint Design and Preparation 4-2
Index-11TC 9-237
W (cont)
Weld Joints 4-2
Welding Arcs 10-15
Welding Denoted by Symbols, Extent of (See Extent of Welding Denoted by Symbols)
Welding Distortion and Warpage 6-42
Welding Equipment, Portable (See Portable Welding Equipment)
Welding Equipment, Setting Up (See Setting Up Welding Equipment)
Welding Equipment, Stationary (See Stationary Welding Equipment)
Welding Face Hardened Armor Plate 12-48
Welding Homogeneous Armor Plate 12-36
Welding in Confined Spaces 2-13
Welding Machines 2-22
Welding Machines, Alternating Current Arc (See Alternating
Current Arc Welding Machines)
Welding Machines, Direct Current Arc (See Direct
Current Arc Welding Machines)
Welding Symbols, Plug and Slot (See Plug and Slot Welding Symbols)
Welding Tips and Mixers 5-13
Welding with Constant Current 10-2
Welding with Constant Voltage 10-8
Welds, Arc Spot and Arc Seam (See Arc Spot and Arc Seam Welds)
Weld Symbols, Location of (See Location of Weld Symbols)
White Metal Welding 11-57
Working Pressures for Welding Operations 11-5
X
X-Ray Test 13-14
Y
Y Fittings 12-15
Index-12
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