UNITOR WELDING HANDBOOK

1.00 1 SAFETY IN WELDING . . . . . . . . . . . . . . . . . . . . 9 2.06.02 Austenitic Stainless Steel . . . . 66

1.01 Introduction . . . . . . . . . . . . . . . . . . . . . . . 10 2.06.03 Ferritic Stainless Steel . . . . . . . 68
1.02 How to use the handbook . . . . . . . . . . . 11 2.06.04 Martensitic Stainless Steel . . . 69
1.03 Welding instructions and training . . . . 12 2.06.05 Duplex Stainless Steel . . . . . . . 70
1.04 Personal protection . . . . . . . . . . . . . . . . 13 2.06.06 Clad Steel . . . . . . . . . . . . . . . . . . 71
1.04.01 Arc welding face shields . . . . . 14 2.06.07 Stainless Steel corrosion types 72
1.04.02 Protective goggles . . . . . . . . . . 18 2.06.08 Storing and handling of
Stainless Steel onboard . . . . . . 74
1.04.03 Welder's protective clothing . . 20
2.06.09 Grinding/cutting consumables
1.05 Work site protection . . . . . . . . . . . . . . . . 22  for Stainless Steel . . . . . . . . . . . 75
1.05.01 Welding curtain . . . . . . . . . . . . . 22 2.06.10 Unitor Safety Grinder . . . . . . . . . 77
1.05.02 Welding blanket . . . . . . . . . . . . . 22 2.07 Cast iron . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.05.03 Fire extinguisher . . . . . . . . . . . . 23 2.07.01 Introduction . . . . . . . . . . . . . . . . 78
1.06 Welding fumes . . . . . . . . . . . . . . . . . . . . . 24 2.07.02 Grey cast iron . . . . . . . . . . . . . . . 79
1.06.01 Welding fumes . . . . . . . . . . . . . . 26 2.07.03 White cast iron . . . . . . . . . . . . . . 80
1.06.02 Fume extraction . . . . . . . . . . . . . 27 2.07.04 Malleable cast iron . . . . . . . . . . 80
1.07 Safety check list . . . . . . . . . . . . . . . . . . . 30 2.07.05 Ductile cast iron . . . . . . . . . . . . . 81
1.07.01 Equipment . . . . . . . . . . . . . . . . . . 30 2.07.06 High alloy cast iron . . . . . . . . . . 82
1.07.02 Work place . . . . . . . . . . . . . . . . . 31 2.07.07 Identification of cast iron . . . . . 83
1.07.03 Hot work procedure . . . . . . . . . 32 2.07.08 Preparation of the
1.07.04 Operator protection . . . . . . . . . . 32 work piece . . . . . . . . . . . . . . . . . 84
2.07.09 Arc welding of cast iron . . . . . . 87
2 SOLUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 2.07.10 Braze welding of cast iron . . . . 95
2.01 Introduction . . . . . . . . . . . . . . . . . . . . . . . 36 2.07.11 Cold repair on cast iron . . . . . . 97
2.01.01 Quick reference for cutting . . . 37 2.08 Copper and copper alloys . . . . . . . . . . . 104
2.01.02 Quick reference for joining . . . 38 2.08.01 Introduction . . . . . . . . . . . . . . . . 104
2.01.03 Quick reference for rebuilding, 2.08.02 Brass . . . . . . . . . . . . . . . . . . . . . . 104
hardfacing and coating . . . . . . 41 2.08.03 Aluminium brass (Yorcalbro) . . 105
2.01.04 Quick reference to 2.08.04 Bronze . . . . . . . . . . . . . . . . . . . . . 106
cold repairs . . . . . . . . . . . . . . . . . 43 2.08.05 Nickel bronses (Cunifer) . . . . . . 107
2.02 Filler material consumption . . . . . . . . . 45 2.09 Aluminium . . . . . . . . . . . . . . . . . . . . . . . . 112
2.03 Metal identification . . . . . . . . . . . . . . . . 48 2.10 Evaluation of welds . . . . . . . . . . . . . . . . 114
2.04 Unalloyed / low alloyed steel . . . . . . . . 53 2.10.01 Typical welding faults . . . . . . . . 114
2.04.01 Introduction . . . . . . . . . . . . . . . . 53 2.10.02 Inspection of welded joints . . . 118
2.04.02 Unalloyed steel . . . . . . . . . . . . . 53 2.10.03 Crack detection . . . . . . . . . . . . . 123
2.04.03 Low alloyed steel . . . . . . . . . . . . 53
2.04.04 Heat resistant steel . . . . . . . . . . 53 3 CONSUMABLES . . . . . . . . . . . . . . . . . . . . . . . . 125
2.04.05 Low temperature steel . . . . . . . 54 3.01 Coated Electrodes . . . . . . . . . . . . . . . . . . 126
2.04.06 Weathering steel . . . . . . . . . . . . 54 3.01.01 Introduction . . . . . . . . . . . . . . . . 127
2.05 Problem steels . . . . . . . . . . . . . . . . . . . . . 62 3.01.02 Types of electrodes . . . . . . . . . . 128
2.06 Stainless steels . . . . . . . . . . . . . . . . . . . . 65 3.01.03 Storing and re-drying . . . . . . . . 134
2.06.01 Introduction . . . . . . . . . . . . . . . . 65 3.01.04 Classification and approvals . . 140
3.01.05 Welding positions . . . . . . . . . . . 148