Metal Fabrication Technology for Agriculture

569 Pages·2010·32.94 MB·English

by  Larry Jeffus

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Metal
Fabrication
Technology for
Agriculture
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Metal
Fabrication
Technology for
Agriculture
Larry Jeffus
Australia • Brazil • Japan • Korea • Mexico • Singapore • Spain • United Kingdom • United States
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Metal Fabrication Technology for Agriculture, © 2011 Delmar, Cengage Learning
Second Edition
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Larry Jeffus
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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
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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
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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
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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
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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
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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.