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l-£quipment 2
Arc welding is to weld base metals by melting them with arc heat (about 4,500 deg.C)
generated by applying power voltage between the base metals and a welding rod.

1
I-I Arc Welder t I
Arc welder is a device for generating the welding arc, and is 1
classified according to the power source as DC type and AC .
type.
The AC arc welder of simple construction, advantageous in .
I

view of maintenance and cost, and is thus widely used today.

1-2 Welding Accessories

(I) Holder J
A rod holder is not only to hold a welding rod but to deliver a welding current fromi
conductive cable to the rod.

(2) Cable
A cable is to connect the welder with
the holder. It contains numerous fine
conductive wires twisted together
and shielded with rubber.

(3) Face cover Parts of holder Cable

As the arc generates not only high heat but also harmful ultraviolet rays, the welder shaul
not directly expose his eyes and skin to such light beams by using a face coverfc
protection. The harmful light beams can be absorbed by a black glass of the face cover.

Face cover
Left: Hand type .1
Middle: Full face type
Right: Quick shade type
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1-3 Welding Rod (electrode) ~
A welding rod uniformly shielded with flux around its core wire is used in arc welding. J
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autions to be-raken ."

'Welding work should be carried out at a site where mechanical or natural ventilation can
be expected. Flammable materials should be removed from around the welding
workplace.
'Always wear leather gloves, rubber boots, an apron, etc.
.
'Be sure to use a face cover.
'Be careful not to inhale the gas generated during
welding.
.
'Especially in the arc welding of galvanized steel plates,
a large amount of zinc oxide gas is generated, which
causes gas-poisoning if inhaled. Thus pay attention to
good ventilation and use a gas mask, if available.
IHolders and power cables should be those perfectly
insulated and a grounding wire should be secured
properly.
'If a coiled cable is used as shown in fig.1 , the resistance
of the cable increases and generates unstable arc,
which results in an uneven beading. To avoid this, use a
Electro shock protector
welding cable of proper length. When it is inevitable to
use a long cable, lay the cable as shown in fig.2.

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x 0
II

II
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fig.1 fig.2
I
Teweld a steel plate supported by magnets.
In the case of arc welding of a steel plate which is supported by magnets, the arc
becomes unstable, which may result in the generation of blowholes (air bubbles) and
pits (small dents on the surface).
Such magnets shall be removed when tack welding is implemented before starting
regularwelding.
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3-1 Arcing (~
Generate the arc at a point approximately 1 to 2 cm from the point A, and return to starting
point A, and then move the electrode straight along the weld line without oscillating the tip
of the electrode.
While moving the electrode, it is important to keep the arc length and of the electrode
tilting angle in constant.

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Point A (Arc start) End point

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3.

3-2 How to Join Weld Bead

(1) At the end of a bead, quickly raise the electrode backward (left side) to scoop up fused
metal in the molten pool, thus making shallow dimple on the end portion.

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(D Chapter 3
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(2) Generate the arc again at a point 1 to 2 cm from the end of point of the bead, and quickly
move the electrode to the end point of old bead with the electrode raised at right angle,
then keep the electrode as the previous posture.

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I
How to Terminate the Bead
Attheendof bead, rotate the electrode by 2 to 3 turns likely to make a mound.

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Startingpoint End point !I

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End point
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4
3.4 Grooving and Tack Welding
Areas to be welded of the base metal should be free from rust and oil as such impurities 4.11
lead to a defective welding.
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(1) Prior to main welding, preparatory works such as grooving and tack welding are required
The base metal should be properly grooved (beveled) corresponding to their thickness.

t=thickness (mm

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Grooving (or beveling)

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(2) In order to induce arc discharge, the tip of the welding rod should be contact! 4-31
instantaneously with the base metal and pulled quickly. F<:
(3) To prevent the welding rod from adhering to the base metal and to induce the arc, theu
of the welding rod should be swung little by little like striking a match.

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Electrode Holding-Angle
(.1 Flat Welding
Atrightangle to the weldment.
At70to 80 deg. for advancing direction.
(

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(:2 Horizontal Welding

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At 70 to 90 deg. to the weldment.
At 70 to 80 deg. for advancing direction.

----

70. ~90.

\ertical Welding
Forverticalwelding, the same as flat welding.

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5-1 Weaving
For both flat and vertical weldings, the first layer shall be welded by manipulating the
electrode straight or slight weaving. For the 2nd layer, manipulate the electrode a little
faster in the middle, while stop it for a moment at both ends so that the weld bead dose
not become convex.
For the 3rd layer, stop electrode for a moment at the corner of groove to prevent the
undercut.
For weaving, it's better to oscillate not the tip of electrode but the entire electrode.

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Flat welding Vertical welding

(I) Various weaving methods

There are many other methods of weaving. The point is to make sure to the electrode at
the corner of groove to prevent undercut at the toe of weld.
To obtain a weld bead of constant width, manipulate the electrode while observing the
state of melting penetration.

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For Multi-layer welding, weld while adjusting
the thickness
corner of groove
of deposited

before final weld bead is laid.

remains
metal so that the
by 0.5 to 1 mm
~ . 0.5~0.1 mm

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I (2) Howto Judge the Propriety of the Manipulation of Electrode

r: Cause of unfavorable arc welding.

'The width of bead is not constant.

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little
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lose Arc length is not kept constant. Electrode
manipulating speed is not constant.

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'The weld bead is scaly or swollen on the side or center.

~~~ Too strong welding current or too large pitch.

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'The weld bead is narrow with sharp ripple on it.

he
at
«««< Welding current is too strong. Arc is too long
due the electrode being tilted too much.

.Bead is scaly.
'Bead is melted down. .The sides of bead are roundish.

Too small current Too large pitch Too small current

Too large pitch
Too large weaving width

Undercut:The weldment is dug along the toe of weld without being filled with deposited
metal, thus and resulted by making a groove-like gap. il

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5-2 Boxing if Fillet Weld Joint (2)

Basically, boxing is employed for fillet weld joint, where arc is not cut off at the each end 01
weldment.

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continously

To prevent a strain arised you can use a prop or change its welding sequence.

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(4)E
5-3 Improper Weld Joint (

(1) Propriety of weld joint from the moment point of view

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(2) Weldjoint to avoid the concentration of weld lines

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(3) Weld joint to avoid stress concentration II

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) Butt welding for the plates of

different thickness

I Defective
repair welding which must be avoided
Too large groove Metal stuffing Misalignment of plates

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5-4 Repair Fillet Welding 5-5
(1) When the root gap is 1.5 mm or less, weld as it is to specified leg length. (1 )

1.5 mm or less

1 1 : specified leg length

(2) When the root gap is 1.5 to 4.5 mm, the joint may be welded as it is, but leg length musl (2)
be increased for the increase in root gap.

1.5 mm~4.5 mm 1+G

1
4
(3)
I
(3) When root gap is 45 mm or more, insert a liner or cut out the defective plate by 300 mm
or more and replace with proper one.

,0(

300 mm

Liner

8 Chapter 3
 A'

5.5Checking and Repairing of the Groove

~1)When groove is 6 mm or less, execute build-up welding on either side (or both sides) until
the groove become as specified.

~LJD ~ Build-up welding

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6 mm or less 1.5+0.5 mm

(2) When root gap is 6 to 16 mm, use a backing strip of approximately 6 mm thickness.

1'1
.After having welded, gouge out Iii
the backing strip, or weld all
around the strip.

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6~16 mm
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(3) When root gap is 16 mm or more, replace the all or part of the plate.

Chapter3 8
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5-6 How to Repair Breakage on a Steel Pipe (3)

(I) When the water flow cannot be stopped (1 )

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Strapped joint I
I (>LCfC Strapped joint
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(1) Prepare a same size or one-size-Iarger pipe, from which a semicircular is cut out to be (6)

used as the strapped joint which covers the breakage at its center. (7)

(2) The pipe length shall be approximately twice the diameter of the broken pipe.
(3) Cut out a semicircular pipe, and chamfer the corners.

(4) Make a drain hole on it,avoiding the section on which strapped joint mounting band isto

be applied. (4)

(5) Mount a small valve or a pair of bolt and nut on the drain hole to prevent water from (1 )

dropping on weldment.
(6) With a thin flat rubber, packing or sealant on the processed strapped joint, tighten the
band.
(7) After tack welding the strapped joint, start regular welding from beneath the leaking poin! (2)

(the point on which water drops). 1

(3) J
8..'Mclok-..

.It's better, to prepare a larger strapped joint, taking it into consideration that the base

metal around the leakage may be thinned.

(2) Breakage at a corner of T -shaped pipe

Chamfer the corner

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/ Chamfer the cornel

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Prepare two symmetric ones
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(1) For the upper part, splitaT-shaped pipe into two pieces. ~
(2) For the lower half, prepare a split pipe.
(3) Make a drain hole on the lower half, and mount a small plug or valve on the hole.
(4) The pipe length shall be 50 to 100 mm according to the size of the pipe.

e Chapter 3