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Metal Fabrication Technology for Agriculture PDF

569 Pages·2010·32.94 MB·English
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00-D5191-EL1.qxd 12/18/09 9:56 PM Page i Metal Fabrication Technology for Agriculture 00-D5191-EL1.qxd 12/18/09 9:56 PM Page iii Metal Fabrication Technology for Agriculture Larry Jeffus Australia • Brazil • Japan • Korea • Mexico • Singapore • Spain • United Kingdom • United States 00-D5191-EL1.qxd 12/18/09 9:56 PM Page iv Metal Fabrication Technology for Agriculture, © 2011 Delmar, Cengage Learning Second Edition ALL RIGHTS RESERVED. No part of this work covered by the copyright herein may Larry Jeffus be reproduced, transmitted, stored, or used in any form or by any means graphic, Vice President, Editorial: Dave Garza electronic, or mechanical, including but not limited to photocopying, recording, scanning, digitizing, taping, Web distribution, information networks, or information Director of Learning Solutions: Sandy Clark storage and retrieval systems, except as permitted under Section 107 or 108 of the Executive Editor: David Boelio 1976 United States Copyright Act, without the prior written permission of the publisher. Managing Editor: Larry Main Senior Product Manager: Sharon Chambliss For product information and technology assistance, contact us at Editorial Assistant: Jillian Borden Professional & Career Group Customer Support, 1-800-648-7450. Vice President, Marketing: Jennifer Baker For permission to use material from this text or product, Executive Marketing Manger: Deborah S. Yarnell submit all requests online at cengage.com/permissions. Marketing Manager: Jimmy Stephens Further permissions questions can be e-mailed to Marketing Specialist: Mark Pierro [email protected]. Production Director: Wendy Troeger Production Manager: Mark Bernard Library of Congress Control Number: 2009932549 Content Project Manager: Christopher Chien ISBN-13: 9781435498570 Art Director: Benj Gleeksman ISBN-10: 1435498577 Technology Project Manager: Christopher Catalina Production Technology Analyst: Thomas Stover Delmar 5 Maxwell Drive Clifton Park, NY 12065-2919 USA Cengage Learning products are represented in Canada by Nelson Education, Ltd. For your lifelong learning solutions, visit delmar.cengage.com. Visit our corporate website at cengage.com. Notice to the Reader Publisher does not warrant or guarantee any of the products described herein or per- form any independent analysis in connection with any of the product information con- tained herein. Publisher does not assume, and expressly disclaims, any obligation to obtain and include information other than that provided to it by the manufacturer. The reader is expressly warned to consider and adopt all safety precautions that might be indicated by the activities described herein and to avoid all potential hazards. By follow- ing the instructions contained herein, the reader willingly assumes all risks in connec- tion with such instructions. The publisher makes no representations or warranties of any kind, including but not limited to the warranties of fitness for particular purpose or merchantability, nor are any such representations implied with respect to the material set forth herein, and the publisher takes no responsibility with respect to such material. The publisher shall not be liable for any special, consequential, or exemplary damages resulting, in whole or part, from the readers' use of, or reliance upon, this material. Printed in the United States of America 1 2 3 4 5 XX 10 09 08 00-D5191-EL1.qxd 12/18/09 9:56 PM Page v Contents Preface.....................................................................x Fire Protection .......................................................34 Features of the Text........................................xii Equipment Maintenance ........................................36 Acknowledgments............................................xiv Work Area ..............................................................37 About the Author...............................................xv Hand Tools ............................................................37 Index of Experiments and Practices..............................................................xvii Hand Tool Safety ...................................................38 Hammer Safety .......................................................38 Power Tools ...........................................................39 Metal Cutting Machines ........................................41 Chapter 1 Introduction to Agriculture Welding and Fabrication Safe Use of Circular Saws .......................................42 Introduction .............................................................1 Material Handling ..................................................44 Welding Defined ......................................................2 Uses of Welding .......................................................3 Welding Processes ...................................................4 Chapter 3 Oxyfuel Welding and Cutting Occupational Opportunities in Welding .................8 Equipment, Setup, and Operation Training for Welding Occupations ..........................9 Introduction ...........................................................49 Student Organizations ...........................................10 Pressure Regulators ................................................50 Experiments and Practices .....................................10 Design and Service of Welding and Metric Units ...........................................................11 Cutting Torches ................................................55 Welding and Heating Tips .....................................56 Reverse Flow and Flashback Valves ......................58 Hoses and Fittings .................................................60 Chapter 2 Safety in Welding and Fabrication Backfires and Flashbacks .......................................61 Introduction ...........................................................15 Uses of the Oxyacetylene Flame ............................62 Burns ......................................................................16 Characteristics of the Fuel-gas Flame ....................62 Eye and Ear Protection ..........................................18 Fuel Gases ..............................................................63 Respiratory Protection ...........................................21 Acetylene (C H ) ...................................................63 Ventilation .............................................................24 2 2 Liquefied Fuel Gases ..............................................66 Material Specification Data Sheets (MSDS) ...........24 Propane and Natural Gas .......................................68 Waste Material Disposal ........................................24 Leak Detection .......................................................68 Ladder Safety .........................................................25 Types of Flames .....................................................73 Electrical Safety ......................................................26 Filler Metals ...........................................................74 Electrical Safety Systems ........................................26 Mild Steel ...............................................................76 Voltage Warnings ..................................................28 Extension Cords ....................................................28 Safety Rules for Portable Electric Tools .................30 General Work Clothing .........................................30 Chapter 4 Oxyacetylene Welding Special Protective Clothing ....................................31 Introduction ...........................................................79 Handling and Storing Cylinders ............................32 Mild Steel Welds ....................................................80 v 00-D5191-EL1.qxd 12/18/09 9:56 PM Page vi vi Contents Outside Corner Joint .............................................88 Selecting the Correct Tip and Setting Butt Joint ................................................................88 the Pressure .....................................................153 Lap Joint ................................................................90 The Chemistry of a Cut .......................................154 Tee Joint .................................................................92 The Physics of a Cut ............................................155 Out-of-position Welding .......................................93 Plate Cutting ........................................................158 Vertical Welds ........................................................93 Cutting Table .......................................................158 Butt Joint ................................................................95 Torch Guides .......................................................158 Lap Joint ................................................................96 Distortion .............................................................160 Tee Joint .................................................................96 Cutting Applications ............................................162 Horizontal Welds ...................................................97 Pipe Cutting .........................................................164 Horizontal Stringer Bead ........................................97 Butt Joint ................................................................98 Lap Joint ................................................................98 Chapter 7 Plasma Arc Cutting Tee Joint .................................................................98 Introduction .........................................................169 Overhead Welds .....................................................98 Plasma ..................................................................170 Stringer Bead ..........................................................99 Plasma Torch .......................................................171 Mild Steel Pipe and Tubing .................................100 Cables and Hoses .................................................173 Horizontal Rolled Position 1G .............................100 Power Requirements ............................................173 Horizontal Fixed Position 5G ..............................103 Heat Input ............................................................174 Vertical Fixed Position 2G ...................................104 Distortion .............................................................175 45°Fixed Position 6G ..........................................105 Applications .........................................................175 Thin-wall Tubing .................................................106 Starting Methods ..................................................177 Kerf ......................................................................178 Gases ....................................................................179 Chapter 5 Soldering and Brazing Machine Cutting ..................................................180 Introduction .........................................................109 Safety ....................................................................181 Advantages of Soldering and Brazing ..................110 Manual Cutting ....................................................182 Fluxes ..................................................................112 Straight Cuts ........................................................182 Filler Metals .........................................................115 Beveling of a Plate ................................................184 Joint Design .........................................................120 Cutting Holes .......................................................185 Building Up Surfaces and Filling Holes ...............127 Gouging ...............................................................186 Silver Brazing .......................................................130 Cutting Round Stock ...........................................187 Soldering ..............................................................132 Chapter 8 Shielded Metal Arc Equipment, Chapter 6 Oxyacetylene Cutting Setup, and Operation Introduction .........................................................139 Introduction .........................................................191 Metals Cut by the Oxyfuel Process ......................140 Welding Current ..................................................192 Eye Protection for Flame Cutting ........................140 Types of Welding Power ......................................194 Cutting Torches ...................................................141 Open Circuit Voltage ...........................................195 Cutting Tips .........................................................142 Operating Voltage ................................................195 Oxyfuel Cutting, Setup, and Operation ...............145 Arc Blow ..............................................................195 Hand Cutting .......................................................148 Types of Power Sources .......................................196 Layout ..................................................................152 Generators and Alternators ..................................200 00-D5191-EL1.qxd 12/18/09 9:56 PM Page vii Contents vii Rectifiers ..............................................................201 Wire Melting and Deposition Rates .....................274 Duty Cycle ...........................................................202 Welding Power Supplies ......................................275 Welding Cables ....................................................203 Molten Weld Pool Control ..................................277 Electrode Holders ................................................204 Equipment ...........................................................281 Work Clamps .......................................................205 Spot Welding .......................................................285 Setup ....................................................................205 Chapter 12 Gas Metal Arc Welding Chapter 9 Shielded Metal Arc Welding Introduction .........................................................291 of Plate Setup ....................................................................292 Introduction .........................................................209 Gas Density and Flow Rates ................................298 Effect of Too High or Too Low Current Settings .....212 Amperage and Arc Voltage Characteristics .........298 Electrode Size and Heat .......................................213 Electrode Extension .............................................300 Arc Length ...........................................................214 Welding Gun Angle .............................................302 Electrode Angle ....................................................215 Effect of Shielding Gas on Welding .....................303 Electrode Manipulation .......................................218 Practices ...............................................................304 Positioning of the Welder and the Plate ..............219 Metal Preparation ................................................304 Practice Welds .....................................................220 Flat Position, 1G and 1F Positions ......................305 Stringer Beads ......................................................221 Vertical Up 3G and 3F Positions .........................308 Square Butt Joint ..................................................223 Vertical Down 3G and 3F Positions ....................311 Edge Weld ............................................................227 Horizontal 2G and 2F Positions ..........................312 Outside Corner Joint ...........................................232 Overhead 4G and 4F Positions ............................313 Lap Joint ..............................................................236 Pulsed ArcMetal Transfer, 1G Position ..............316 Tee Joint ...............................................................239 Axial Spray ...........................................................319 Chapter 10 Shielded Metal Arc Welding Chapter 13 Flux Cored Arc Welding Equipment, of Pipe Setup, and Operation Introduction .........................................................245 Introduction .........................................................323 Pipe and Tubing ...................................................247 Principles of Operation ........................................325 Preparation and Assembly ...................................248 Equipment ...........................................................326 Practice Welds .....................................................250 Advantages ...........................................................326 1G Horizontal Rolled Position .............................254 Limitations ...........................................................328 2G Vertical Fixed Position ...................................258 Electrodes ............................................................328 5G Horizontal Fixed Position ..............................260 Flux .....................................................................329 Pipe Tee Joints .....................................................261 Shielding Gas .......................................................333 Laying Out a Saddle Pipe Tee Joint .....................263 Welding Techniques ............................................334 Troubleshooting FCA Welding ...........................339 Chapter 11 Gas Metal Arc Welding Equipment, Setup, and Operation Chapter 14 Flux Cored Arc Welding Introduction .........................................................269 Introduction .........................................................343 Metal Transfer ......................................................270 Practices ...............................................................344 Filler Metal Specifications ...................................274 Flat-position Welds .............................................348 00-D5191-EL1.qxd 12/18/09 9:57 PM Page viii viii Contents Square-groove Welds ...........................................349 Welding Symbols .................................................423 V-Groove and Bevel-groove Welds ......................349 Indicating Types of Welds ...................................423 Fillet Welds ..........................................................353 Weld Location ......................................................423 Vertical Welds ......................................................356 Location Significance of Arrow ............................425 Horizontal Welds .................................................358 Fillet Welds ..........................................................425 Overhead-position Welds ....................................361 Groove Welds ......................................................426 Thin-gauge Sheet Metal Welding ........................364 Backing ................................................................427 Fabrication ...........................................................427 Layout ..................................................................432 Material Shapes ....................................................440 Chapter 15 Filler Metal Selection Introduction .........................................................369 Assembly ..............................................................441 Manufacturers’ Electrode Information .................370 Assembly Tools ....................................................442 Understanding the Electrode Data .......................370 Fitting ..................................................................444 Data Resulting from Mechanical Tests ................370 Tack Welding .......................................................444 Data Resulting from Chemical Analysis ..............370 Welding ...............................................................445 SMAW Operating Information ............................371 Finishing ..............................................................446 Core Wire ............................................................371 Functions of the Flux Covering ...........................372 Filler Metal Selection ...........................................373 Chapter 18 Plastic and Other Nonmetallic AWS Filler Metal Classifications .........................374 Fabrication Techniques Carbon Steel .........................................................376 Introduction .........................................................459 Stainless Steel Electrodes .....................................381 Types of Plastics ...................................................460 Aluminum and Aluminum Alloys .......................384 Acrylonitrile/Butadiene/Styrene (ABS) ................461 Polyethylene (PE) ................................................461 Polyvinyl Chloride (PVC) and Chlorinated Chapter 16 Weldability of Metals Polyvinyl Chloride (CPVC) ............................461 Introduction .........................................................389 Polypropylene (PP) ..............................................461 Steel Classification and Identification .................390 Polybutylene (PB) ................................................462 Carbon and Alloy Steels .......................................392 Plastic Identification ............................................462 Stainless Steels .....................................................393 The Welding of Plastic .........................................464 Cast Iron ..............................................................395 Heat Welding .......................................................465 Preweld and Postweld Heating of Cast Iron ........396 High-speed Welding ............................................466 Practice Welding Cast Iron ..................................397 Filler Material ......................................................466 Welding without Preheating or Postheating .......398 Hot-gas Plastic Welding .......................................467 Aluminum Weldability ........................................400 Setup, Shutdown, and Servicing ..........................467 Repair Welding ....................................................401 Airless Plastic Welding ........................................469 Hardfacing ...........................................................403 Welding Temperatures ........................................469 Plastic Welding ....................................................470 Hot-gas and Airless Welding Techniques ............470 Double V-Groove Welds ......................................474 Chapter 17 Welding Joint Design, Welding Symbols, and Fabrication Tack Welding .......................................................475 Introduction .........................................................409 Pipe Welding .......................................................476 Weld Joint Design ................................................410 Solvent Welding ...................................................480 Mechanical Drawings ...........................................414 00-D5191-EL1.qxd 12/18/09 9:57 PM Page ix Contents ix Appendices...................................................485 V. Metric Conversion Approximations.............491 I. Student Welding Report...............................486 VI. Pressure Conversion.....................................491 II. Conversion of Decimal Inches to Millimeters VII. Welding Associations and Organizations.....492 and of Fractional Inches to Decimal Inches VIII. Careers..........................................................493 and Millimeters.............................................487 III. Conversion Factors: U.S. Customary Bilingual Glossary.......................................495 (Standard)Units and Metric Units (S.I.)......488 Index................................................................534 IV. Abbreviations and Symbols..........................490 00-D5191-EL1.qxd 12/18/09 9:57 PM Page x x Preface Preface Introduction In much of our society, many items are considered to be disposable. On the farm or ranch, however, that is not true. In addition to the replacement cost, it is not always possible to simply run into town and pick up a new shovel because the blade on the one you have has split. Replacement time, more than money, is often the controlling factor for the farmer or rancher. The farmers and ranchers of today need to be profi- cient in welding and fabrication for a number of reasons: ■ Time—The time it takes to go into town and pick up a replacement part during a busy time can be more costly than the replacement part. ■ Availability—Often the parts needed are not stocked and have to be ordered. ■ Cost—The replacement part will always cost more than the welding materials needed to make the repair. ■ Convenience—Often the broken part on a tractor or trailer can be repaired in place, so removal and replacement time and effort are not needed. ■ Size—Sometimes the part needing repair or fabrication is too large to be trans- ported to and from the farm or ranch. Studying Metal Fabrication Technology for Agriculture in the classroom or shop set- ting will help students prepare for the challenges facing today’s farmers and ranchers. The comprehensive technical content combines the basics of agricultural fabrication with the must-know welding and fabrication techniques. The extensive descriptions of equipment and supplies and the in-depth explanations focused squarely on their agri- cultural applications will make the student familiar with their uses. The book’s complete instructions for setup in preparation for welding make it easier for students to be successful. These comprehensive instructions can later be used as a reference book by graduates as they work on the farm or ranch. Up-close shots of actual welding included throughout the book provide a realistic look at each of the processes. Students can see exactly what their welding should look like, which will enable them to make better welds. Extensive coverage of brazing and specialized nonmetallic fabrication is designed to lead readers step by step in developing the skills necessary for welding all types of agricultural machinery. This book is an effective learning aid; it is a how-to and refer- ence manual as well as a key resource for today’s farmers, ranchers, and students par- ticipating in agriculture education. Organization Each chapter begins with a list of learning objectives that tell the student and instructor what is to be learned as they study the chapter. A survey of the objectives will show that the student will have the opportunity to develop a full range of welding skills, depending on the topics selected for the program. Each major process is pre- sented in such a way that the instructor can eliminate processes having little economic value in the market served by the program. However, the student will still learn all essential information needed for a thorough understanding of all processes studied. In each chapter, Key Terms are highlighted in color and defined. In addition, the new terms are listed at the beginning of the chapter to enable students to recognize the terms when they appear. Terms and definitions used throughout the text are based on the American Welding Society’s standards. Industry jargon has also been included where appropriate. The Bilingual Glossaryincludes a Spanish equivalent for each term, and many definitions feature additional drawings to assist all learners in gaining a complete understanding of the new term.

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METAL FABRICATION TECHNOLOGY FOR AGRICULTURE, 2E provides students with an easy-to-understand, safety-conscious introduction to agricultural welding processes and techniques. Each section of this full-color book begins by introducing students to equipment and materials used in agricultural welding a
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