Craftsman 113201372 User Manual 230 AMP WELDER Manuals And Guides L0807090

CRAFTSMAN Welder Manual L0807090 CRAFTSMAN Welder Owner's Manual, CRAFTSMAN Welder installation guides

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User Manual: Craftsman 113201372 113201372 CRAFTSMAN CRAFTSMAN 230 AMP WELDER - Manuals and Guides View the owners manual for your CRAFTSMAN CRAFTSMAN 230 AMP WELDER #113201372. Home:Tool Parts:Craftsman Parts:Craftsman CRAFTSMAN 230 AMP WELDER Manual

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MODEL N_ °

113.201372 _

Serial

Number

Model and serial

number may be found

at the rear

of the cabinet.

You should record both

model and serial number

in a safe place for

future use,

CAUTION:

Read

SAFETY

UNSTRUCTIONS

carefully

230 AMP

DUAL RANGE

ARC WELDER

®assembly

e operating

®repair parts

Sold by SEARS, ROEBUCK AND CO., Chicago, IL 60684 U.S.A.

Part No. 61337 Printed in U SA

SAFETY gNSTRUCTIONS TO OPERATOR

For your own protection, read and observe all instructions

included in this manual as well as the following specific

safety precautions:

1, PROTECTION FROM ELECTRICAL SHOCK

a_ Do not let bare skin or wet clothing come between

the following combinations:

Work Clamp

Electrode

Work Piece Metal Work 'Table

80 volts exist between these parts

when welder is onH!

Wear dry hole-free, clothing,_ gloves and shoes to

protect and insulate the body.

b. Take special care to insulate"yourself from ground

using dry insulation (suchas dry wood) of-ad.equate

size when welding] in dam'p locations on metal floors

or grat ngs, and mposlt_ons (such as s=ttmg or lying ! "

where parts-or"large"areas of your body can be ir

contact with phssible ground_. ; ".;_ ro"_

C. Maintain the_.#l_ctr_de h_tder work clamp, w_ldin'g

cable and welding_:rnach_ne'._n_Qd, safe operating._

condition, :_ _; " " ,:' -' • "

Do not use weldm_ electrode as-a claarette hg_ter, . -

e. Connect the welder only to a source of electncal'.-

power meeting the requirements, irrcluding

grounding, of the National Electrical Code (ANSI Cl)

and local codes.

f. Electrode coating may be electrically conductive-

use welding gloves when changing electrodes.

2. EYE AND BODY PROTECTION

a. Use helmet, filter, and cover plate complying with

ANSI Z87 1 to protect your eyes and face from

sparks and the rays of the arc when welding or

observing open arc welding,

b Always wear safety goggles with side shields

complying with ANSI Z871 when in a welding area,

or when near slag chipping operation

c. Wear oil free protective garments, such as leather

gloves, heavy shirt, cuffless trousers and high shoes.

d Protect other near-by personnel with suitable

non-flammable screening_

eWelding can produce fumes and gases which are

dangerous to health, Keep your head out of the

fumes, Use enough ventilation, exhaust at the arc, or

both, to keep fumes and gases from your breathing

zone and the general area, Take even greater care

when welding on galvanized or cadmium plated steel

and other metals which produce toxic fumes

Ab-supplied helmets may be necessary

f When working above floor level, protect yourself

from a fall should you get a shock Never wrap the

electrode cable around arty part of your body

g Do not weld in locations close to chlorinated

hydrocarbon vapors coming from degreasing,

cleaning, or spraying operations The heat of the rays

of the arc can react with solvent vapors to form

phosgene, a highly toxic gas, and other irritating

products

h Unprotected spectators must be kept clear of the

welding area due to the harmful nature of ultra÷violet

and infra-red arc rays, welding sparks, and welding

fumes and gases

3. FLAMMABLE AND EXPLOSIVE MATERIALS

a Remove flammable and explosive material at least 35

feet from the welding arc to prevent welding sparks

or molten metal from starting a fire Keep a type

ABC fire extinguisher within easy reach.

b, Welding on or near containers which hold combustibles

can cause ar_ explosion, even when they have been

cleaned= For information purchase "Safe Practices for

Welding one Cutting Containers that Have Hel d

Combustibles" (A6.0-65_ from the American Welding

:.Society 2501 Northwest Seventh St Miami, Florida

c. When not welding, place the electrode holder where it

"" i_ ihs'61ated from the work clamp, work piece, or'

wc_rk 'table_._ Ac_'idental grounding can cause

,_ overheating of the_ables'and_welder, creating a fire

haz_rd_ _ ::_" _ "

iild Never-c_nnect the_work cablelor clamp to any obJect

b_ _'he'worl<:p e_e o_ me.to _ork tab e Conr]ecting

to other objects such as bu_l_mg ground can create a

fire hazard.

4. PREVENTATIVE MAINTENANCE

a. Never apply power to the welder with any part of the

"cabinet" removed_ Position on-off switch in "Off"

position and disconnect welder from the power

supply before doing maintenance work inside the

machine. Removal of the welder cabinet should be

done only by a qualified service technician,

b.

c.

d_

Before connecting the welder power cord to the

receptacle, check the following:

1 Inspect the power cord and welding cables for cuts

or burns and make sure blades and ground pin on

the plug are straighL

2 Inspect "On-Off" switch lever for cracks or broken

parts.

3Inspect electrode holder jaw insulators for cracks

or broken parts.

Never weld anything on or to the welder cabinet, as a

burn through may cause transformer failure.

For additional safety information, purchase copies of

"Practice for Occupational and Educational Eye and

Face Protection" (ANSI Z87.1), "Safety in Welding

and Cutting" (ANSI Z49.1), and "Fire Protection in

Use of Welding and Cutting Processes" (ANSI/NFPA

No. 518) from the American National Standards

institute, 1430 Sroadway, New York, N.Y 10018_

2

READANDOBSERVETHEINSTRUCTIONSAPPEARINGONTHEWARNINGLABELSFOUNDONTHEINSIDEOF

THEWELDINGHELMET,ANDONTHESELECTORPLATE,CABINETANDELECTRODEHOLDER.

_MERIEAN N,_ 71ON,_L ST,INI,),_RDS hV_TITUTE

PttEC,_UTION_RY I Af]EL

WARNII_G: prolel:I VotJt_ell _t_d {_thefs _e;l(I ;_f_{I

unders14_mt lh_ I_bel

F UJ%_ES AND GASES c;lll he (i,ln{J_ f al_s tn ymJl he_hh

ARC RAYS call inlllle eyel and hum stroll ELECTRIC

SHOCK cml kill

• Be,_d and understand _l_e incm_Hanh_fef _ =nslnJ_io_t_

and yo_Jt amployef's _alely pr acllce_

•Keep your head aut of _1_ h_nles

• U_a enmJ_h Vel_il_iOl_, _xha_Jst al Ihe ;_,c, ot boUI

lo kee I) _ume_ and _ase_ from 7o_f I_re;_lhi_ I z_)m_

and the {Jene[al area

• Wear cot _ecl eye, _ar _nd body ltlo_ectlon

• Do I_O_ _ouch llve elec_ rical I)aFt_

•See American National Si,_nIt,_f(I Z49.1 S_lety in

Wl!h_hlg mid Cliilin=j ¸' i)_JIilillle(I I}7 lhe Ait/eficalt

Wohthlg Sociel¥ 2501 NW71h SI,, _,tbm_ Florida

33125; OSIIA Saf_W _1_{I He_hh SI,_ndatds 29 CFR

1910, availal)_J_ hont U S Dep_tmenl o_ Labor

Washinglon , DC 20210

DO NOT R E_,_OV E THIS LABEL

WARNING ELeCTR,C SHOCK CAN BE FATALt BEFORE

TURNING WELDER ON CHECK THE ELECTRODE HOLDER TO

BE SURE THAT THERE ARE NO PROTRUDING SCREW HEADS

AND THAT ALL INSULATION IS SECURE _ _ll!! 2

CllRI0_

USe _lJ 101 IE,_ _n0 _y_ pi01egi0n

a_ins$ =nj_io_ rays Itom _c _ding

_nd culling US_ propel shade li!I_

plale _P¢_.I {ssi_IO _12 plo[_ction

(Iil_ pble b_ck_up plale• s_p_lale

salely spectacles) shou+d be worn

wheII U_l_ 0this device It_cl fe-

sislanl plal_ ale DOT un_le.lkable

elted ¢_ s_la_h_d _Je_ t_u_ VISI_I

al_{_ 5_liO_$1 le_uc8 pI01eGIJ0r_--

{epia_eintricately

Inspecl {(equ_Ily an_ immedi31_ly

I_p_u_ _om ot d_m_ged p_tls

t,it4_ ir_ t¢=¢.¢_ =f JJ.I.L zr/1

DO NOT REMOVE "fills [/_3,E L

LENS

SHADENO

WARNING -FOR YOUR SAFET'_

R_GAR_ING B0 VOLT POTENTIAL

SHOC;{ AT ELECT}IOD_

REGARDING POTENTIAL SHOCK ON CABINET

COW,FORMING TO 1H_ _ATIONAL _L_CTnlCAL COD_

REGAROING £yE INJURY

REGARDING FIRE

LI_ O_AW _*nC eT_muY't

FULL ONE YEAR WARRANTY ON CRAFTSMAN ELECTRIC WELDER

If this Craftsman Electric Welder fails to perform properly, due to a defect in material or workmanship,

within one year from the date of purchase, Sears will repair it free of charge,

WARRANTY SERVICE IS AVAILABLE BY SIMPLY RETURNING THE WELDER TO THE NEAREST

SEARS STORE OR SERVICE CENTER THROUGHOUT THE UNITED STATES.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to

state,

SEARS, ROEBUCK AND CO. Sears Tower_ BSC 41-3, Chicago, IL 60684

MATERIAL THICKNESS GAUGE.

ON-OFF SWITCH.-.

GETTING TO

KNOW YOUR

ARC WELDER

LOCKING KNOB

'IAMETER GAUGE

DUTLETJACKS

HELMET

AND

ELECTRODE HOLDER

WORK CABLE AND WORK CLAMP

TABLE OF CONTENTS

OPERATING INSTRUCTIONS

Safety I nstructions to Operator .............................. 2

Warranty ............................................ 3

Getting to Know Your Welder ............................. 3

Unpacking and Checking Contents .......................... 3

Assembly ................................... 4

Operating Controls ................................ 6

Operating Instructions ........................... 7

Trouble Shooting ............................... 8

ARC WELD IT YOURSELF MANUAL .............. 1-1

WELDING ROD SPECIFICATIONS ............... 2-1

REPAIR PARTS ..................................... 2-6

Input Volts (AC): ........... 230

Hertz (Cycles): ................ 60

Output Amperage: ........ 30 to 140

40 to 230

Rated Input Amps: ............... 50

Short Circuit Input Amps: ......... 66

SPECIFICATIONS

Fuse or Circuit

Breaker Required: ......... 50 Amps

Arc Voltage: ............... 25

KVA: .................... 108

KW: ........................... 7 1

Max Open Circuit

Output Volts .......... 80

Power Factor ........... 66%

Duty Cycle: ........ 20 to 100%

Electrode Capacity: 1/16" to 3/16"

UNPACKING AND CHECKUNG CONTENTS

SET-UP INSTRUCTIONS

This Craftsman welder is shipped complete in one carton

In order to facilitate packaging, certain items have been

removed at the factory and must be assembled when

received by the purchaser Remove all items from the

carton and identify item as shown in the exploded view

illustration These "Loose Parts" should be accounted for

before discarding any packaging material.

3 4

LOOSE PARTS LIST

Key

No. Part Name O.ty.

i

1WeldingHelmet (Partially assembled) ..........

2Helmet bandassembly (Not Assembled) ........

3 Electrodecableassembly .........................

4LooseParts Bag- Containing the following items:

Electrode Holder .....................................

t

1

1

I

1

Work Clamp ........................................... 1

Screw, Hex.-Hd., 1/4-20 x 3/4 in............... 1

Nut, Hex., 1/4-20 ........................... 1

Washer,Flat 17/64 in............................... 1

Loci{washer,1/4 in 1

ASSEMBLY

TOOLS NEEDED

,,lOinchwrenchScrewdriver(medium)

ATTACHING ELECTRODE HOLDER ............. ....

TO ELECTRODE CABLE

I. Grasp the electrode holder and locate the slotted head,

handle locking screw near the mid-point of the insulating

handle Loosen this screw approximately two turns, or

until the handle can be slipped off the electrode bolder..

2 Do not remove this screw completely. Slide tile handle

off electrode holder and insert end of electrode cable

assembly through the handle.

The electrode cable is the one with insulation stripped

from one end

3 Using a screwdriver, back out the slotted-head set screw,

located near the end of electrode holder until the end of

screw does not protrude into the wire socket in the end

of holder

4. Make sure the wire strands on stripped end of electrode

cable have not been "frayed" Twist together with

fingers if necessary.

5 Insert stripped end of electrode cable into electrode

holder and tighten the slotted-head set screw very

firmly

4

_i_i ii _' _ i

6 Slide the handle back into place on electrode holder and

position it until the hole in handle is directly over the

head of handle locking screw Tighten the screw

clockwise @ just enough to secure the Inandle on

electrode holder

ATTACHING THE WORK CLAMP

TO THE WORK CABLE

1. Attach the terminal on end of work cable to the work

clamp, at the hole near the nose of the clamp with the

1/4-20 x 3/4-inch screw, 1/4-20 nut, 17/64-inch flat

washer and I/4-inch Iockwasher furnished in the loose

parts bag

2_ Do not use either of the holes in handle ends of work

clamp

SCREW

LOCKWASHNUTE_ HWORKCABLE

3_ Tighten the screw firmly enough to insure good contact

and prevent the cable terminal from slipping on the

clamp

CONNECTING WELDER TO POWER SOURCE

CAUTION: Do not attempt to connect this welder to a

regular household outlet. Make sure the power-line voltage

and frequency agree with the ratings shown on the selector

plate attached to front of eabinet.

Electrical connections between the welder and grounded

230-volt, single-phase, 60-cycle a-c power source should be

made by a qualified electrician. All wiring must comply

with the National Electrical Code (ANSI C1) and local

codes

1. Install an individual (separate) line for the welder with

delayed action type circuit breaker or fuses in the line

For best results, this circuit should be as short as

possible The size of the supply conductors will depend

upon their length as shown in the table below

Supply Conductor (Incl. Extension Cords)

Up to 30 feet ............................ No_ 10 AWG Copper

30 to 50 feet ............................. No 8 AWG Copper

Over 50 feet ................................... No 6 AWG Copper

NOTE - These conductor sizes are for use with a welder

having a rated input not more than 60 amps at 20% duty

cycle in accordance with Article 630 of the National

RECEPTACLE

k GREENWIRE_. Connect to ground bussin

powerponet

Connect to hot wires o[ Q

single phase system only

FUSES OR CIRCUIT BREAKERS

Electrical Code (ANSI C1) and may not be adequate for

other loads Consult a qualified electrician before using for

other loads

2 Install 50 ampere circuit breakers or fuses

3 Connect 230wolt power lines and ground as shown in

figure

4 Use Sears Cat #20691 Power Receptacle available

through most Sears Retail or Catalog outlets or any

certified 50 amp, 250 volt, 2 pole, 3 wire, grounding

type receptacle.

OPERATnNG CONTROLS

The name "dual range" arc welder is derived from the fact

that your new arc welder is equipped with two separate

welding ranges,

The beginner or less-experienced welder will find the

30-140 amp range easier to use because it provides extra arc

stability when welding with some of the "more difficult to

weld with specialty rods" which are prone to pop-outs

The 40-230 amp range requires less line (input current)

draw for any given amp setting and permits the use of the

maximum amp settings with minimum effect on other'

electrical appliances, motors, and lights, on your electrical

system,

Either range may be used, depending on operator

preferences when the electrode diameter permits

_TAL TABLE AT THE SAME TIM

REGARDING POTENTIAL SHOCK ON CABINET

1 CONNECT ONLY TO A GROUNDING POWER SOURCE

CONFORMING TO THE NATIONAL ELECTRICAL CODE

(A N S I C1) AND LOCAL CODES

REGARDING EYE INJURY

1 WEAR WELDING HELMET WITH NO 12 OR DARKER FIL-

TER LENS MEETING REQUIREMENTS OF A NSI. Z87,1.

2 WEAR GOGGLES OR FACE SHIELD WHILE CHIPPING OR

BRUSHING SLAG.

3 KEEP OTHER PERSONS AND PETS OUT OF WORK AREA

REGARDING FIRE

KEEP COMBUSTIBLES OUT OF RANGE OF WELDING SPARKS

uSE FOR MINIMUM UsE FOR MAXIMUM

LINE DRAW ARC STABILITY

AMP AMP Z

RANGE/

CONNECTING ELECTRODE

AND WORK CABLES

insert the tapered plug on the end of the electrode cable

into the proper outlet jack depending on amperage required

or operator preference.

To insure a good electrical connection always twist the

electrode plug slightly while inserting_ To remove the plug

twist in the opposite direction while removing

NOTE: If you extend the welding cables beyond those

already supplied, they must be No= 4 AWG or larger to

avoid an undue drop in welding current Do not extend

cables over 50 feet,

Connect the work clamp to the piece to be welded, (to

complete the electrical circuit) or to the welding table itself

provided it is metallic or will conduct electricity!

OPERATING RNSTRUCTIONS

We feel that welding with your new Craftsman dual range

arc welder is as simple as A B C

A Determine what diameter electrode should be used by

gauging the piece to be welded on the material thickness

gauge The fractional number directly beneath the bar

chart dictates what the proper electrode diameter is for

given thicknesses of metals You will note that a specific

diameter of electrodes can be used on varying

thicknesses of material. This is accomplished by

adjusting the heat selector for more or less amperage•

B Next verify the electrode diameter, by placing the bare

portion of the electrode into the electrode diameter

gauge on the right side of the cabinet

Because electrodes are mass produced, there may be

small burrs on the bare ends of the electrode Make sure

the bare end of the rod is as clean as possible for

accurate sizing,

C, Finally, determine the type of electrode by the

identification on the package or by the American

Welding Society number stencilled on the coated portion

of the electrode, bearing in mind the type of electrode

you have chosen - E6013 or E7014, and also its'

diameter (as previously determined)_

Locate that band on the amp scale There are two E6013

bands and two E7014 bands, use the band which

coordinates with the amp range you have selected•

Now loosen the heat selector knob and move the pointer

until the fractional number matching your electrode

diameter appears in the pointer window

Tighten the heat selector knob

Insert the electrode cable into the proper jack

(depending on the range selected), Connect the work

clamp to the work.

Wear Welding Helmet,

Turn the On-Off switch to the "ON" position and you

are ready to weld

Because metals vary in their make up and the technique

of each operator is different, you may find it necessary

to increase or decrease the amperage output accordingly,

CAUTION: Do not loosen and move heat selector while

welding

The duty cycle ratings bracketing the amperage scales are

provided for your convenience and protection of your new

welder_ Duty cycle is the performance level of the welder

based on a 10 minute time span. For example welding for 6

minutes out of 10 minutes is a 60% duty cycle To avoid

possible overheating of the welding transformer, which

could shorten the life of your welder, Do Not exceed the

duty cycles listed on the nameplate

7

TROUBLE SHOOTING

WARNING: Removal of the welder cabinet top for any reason must be done by

aqualified service technician.

TROUBLE SHOOTING CHART

TROUBLE SUGGESTED REMEDY

Fan and welder do not

operate, or continually

blow fuses.

Welding current low

or weak,

Can't hold an arc.

PROBABLE CAUSE

1. Improperly fused or

protected_

2 Blown fuse, or open

circuit breaker_

3_"On-Off" switch not "On".

1. Low line voltage,

2_ Welding current

setting too Iow_

3, Poor connections.

1Using a D.C. welding

rod.

2. Low hydrogen rod

1. Use 50 ampere fuses of the delayed

action type such as "'Fusetron" or

"Fustat" or 50 ampere 240 volt

circuit breaker.

2 Replace fuse, or reset the circuit

breaker.

3 Turn switch "On".

1_ Have a voltage check performed by

the local power company_

2. Check current recommended for

the electrode being used.

3, Check electrode holder, work and

electrode cable connections

1_Use AC or AC-DC rods

2, Use rod of 1/8-inch maximum

dian'leter, or' smaller on 30-140

amp range.

SERVICE TIPS

FAN MOTOR

No provision has been made for lubricating the fan motor,

as extra large oil reservoirs provide lubrication for the life

of the motor.

SELECTOR PLUGS OR CONTACTS

WARNING: Be positive you have disconnected the power

supply to the welder_

If for any reason the selector plugs or mating contacts

become burned or pitted, tiley should be cleaned-up with a

fine grade of emery cloth or dressed very lightly with a fine

file,

f

A COMPREHENSIVE

GUIDE FOR YOUR

NEW CRAFTSMAN

ARC WELDER AND

WHAT iT W_LL DO

CONTAINS:

INFORMATION ABOUT

o VARIOUS TYPES OF RODS

o USEFUL ACCESSORIES

TIPS ON CUTTING, WELDING

AND BRAZING

,,,J

Form No SP574-4 1-]

IJELD gT Y©U SELF

TABLE OF CONTENTS

Page

Your WelderandWhat It Will Oo ............. 1-3

How the CraftsmanContactRodSimplifiesWelding 1-3

What HappensWhenYou Weld? .............. 1-3

ReadBeforaWelding ....................... 14

LearnBy Doing .......................... 1-5

PositionWelding ......................... 1-11

Cast-IronWelding ........................ 1-14

HardSurfacingWornCuttingEdges .......... 1-15

TheTwin CarbonArc Torch ............... 1-16

CuttingandOther MiscellaneousOperations ..o 1-17

Inert-GasMetal-ArcWelding ................ 1-19

Read this Manual carefully for additional welding information.

SEARS, ROEBUCK AND COMPANY

AND SIMPSONS-SEARS LIMITED

1o2

YOUR WELDER and what it will do =°.

Your CRAFTSMAN Arc Welderis asturdilyconstructedend thoroughlytestedmachineengineeredto

give many years of efficient trouble-free service. It is listed by Underwriters' Laboratories,

incorporated,which meansthat it passesall requirementsof safety,fire hazardand temperaturerise

limitsasspecifiedin theirStandard for Transfer-TypeArc-WeldingEquipment,

HOW THE CRAFTSMAN ELECTRODE

SIMPLIFIES WELDING

Craftsman Contact Electrode is self-starting-plus automatic

restarting ,The electrodestartson contacL

Craftsman Contact Electrode is serf-cleaning..... Under normal

conditionstheslagremovesitselfasthe weld cools,Spatter is almost

nen-existenL Craftsman Contact Electrode has an exceptionally

good appearance _ With fine ripple, unusually clean, smooth

appearance,andreduced slaginclusions

CraftsmanContact Electrode depositsmore metal faster .Because

the powderediron in the flux goesinto tile weld_

1 Beth edges of the metal

are heated by the arc,

until --

3mere molten metal and

flux is added from the

rod, which-

2they melt and flow to

gether formingone piece,

instantly --

4fills the crater andcovers

the top of the weld with

slag,

5 This process continues the entire length of the weld

Arc Welding is the process of fusing two or more pieces of

metal together to form one piece. It is accomplished by

heating adjacent metal surfaces to the melting point with an

electric arc, then adding a sufficient amount of molten

metal to provide reinforcement and fill any vacant space

between the parts being joined, as shown in the accompany-

ing illustrations

The arc is created when an electric current, regulated by

a welding transformer, flows across an air gap between an

electrode and the work being welded, The intense heat

generated by the arc is ideally suited for welding, as it

can be directed to affect only the part of the metal to be

welded, Uniform heat from the arc, is acquired by keeping

its length the same for a given rod size and current setting,

At the instant an arc is "struck", a portion of the base

metal directly beneath it, is melted, resulting in asmall

pool of molten metal, some of which is forced out by the

blast of the arc and deposited along the weld path, The

depth of the crater thus formed, is the distance the weld

will extend into the base metal and is referred to as the

penetration of the weld

Some of the electrode (which consists of o metal rod sur-

rounded by a flux coating) is melted simultaneously with

the base metal and is carried by the arc to the liquid pool

This added metal combines with the base metal to form

the deposited weld,

During th_s operation a part of the flux coating burns off

and forms a gaseous smoke screen that completely en-

velops the arc, protecting the molten metal from harmful

effects of oxygen and nitrogen in the surrounding atmos-

phere, The remainder of the flux coating that melts is

carried to the molten pool where it mixes with the metal

to combine with various impurities It then floats to the

surfaces to form a coating of slag which covers the de-

posited weld metal, protecting it from the atmosphere and

retarding its cooilng

I-3

READ 5EFORE WELDI NG

When operating a welder, certain precautions must

be taken to prevent minor injuries to yourself and

others, Although injuries may not be serious or per-

manent, knowing how to use the protective equip-

ment to safeguard against them is the first step in

learning to weld_

The effects of heat and light given off by the arc, while

electric welding, may be compared to that of the sun's rays_

Even greater precautions are necessary for electric arc

welding. Before starting a weld, caution anyone in the

immediate vicinity against looking at the arc_ in case of

occidental eye injury, contact a physician immediately.

To protect the face and eyes a heat-resisting, fibreglass

helmet is used. The special tens, which allows the user

to view the arc safely, is inserted into the framed opening

of the helmet The clear glass, which should be replaced

from time to time, protects the expensive special lens

from breakage and weld spatter. The helmet is held firmly

in place on the head with an adjustable head band, thereby

leaving both hands free° A close-flttlng skull cap should

be worn with the helmet° As the helmet is used only when

actually welding, a tilting arrangement permits it to be

swung up clear of the face. When the welding is resumed

aslight nod of the head tips the helmet down over the face.

To protect the eyes further while cleaning the weld, goggles

should be worn by the welder and others working around

him_ Animals are also affected by the rays and should be

kept at a safe distance_

To safeguard the hands against heat and weld spatter,

gauntlet-type leather gloves should be worn. A leather

jacket will give better protection against the shower of

sparks than ordinary clothing. High top shoes (not oxfords)

should be worn. If a great deal of welding is to be done,

foundrymen's shoesare best.

Precautions must also be taken to protect property and

equipment against flre_ A large fire extinguisher should be

within easy reach. The welding area should have a concrete

or cinder floor, kept dry and clear of inflammable rubbish.

Sometimes, it is necessary to weld close to a fuel tank. If

practical, remove the part to be welded. If not, drain the

tank and completely fill it with water.

Few tools, in addition to those supplied with the welding

machine, are needed and most of them can be found in

the average shop Two sawhorses supporting a 1/4-inch

steel plate makes an excellent welding table A permanent

bench, using the same steel plate, can be made of angle

iron or pipe. A chipping hammer is used to clean slag off

a weld and pliers will be useful for handling hot metak A

wire brush is used to clean the work before welding and

remove small pieces of slag after chipping_

Small pieces of mild-steel scrap iron, reasonably free of

rust and paint, should be used for practice welding_ Angle

iron, bar stock or plate steel are good examples. Do not

use scrap cast iron, high carbon or hardened steel as these

metals require special electrodes and welding techniques.

These should be set aside for future practice after com-

pleting elementary practice lessons°

1-4

LEARN BY DOBNG

OIRECTiON

OFWELG

Experience has proven that short periods of practice at

regular intervals are the best way to teach yourself how

to weld. As learning to weld is simply a process of trial

and error, all practice work should be done on scrap metal

that can be discarded. Do not attempt to make repairs on

valuable equipment until you have satisfied yourself that

your practice welds are of good appearance and free of

slag or gas inclusions. Remember, what you fail to learn

while practicing, must be learned through a series of

mistakes and rewelds later am

A comfortable body position is important when learning,

as tensed muscles will result in fatigue and lack of control.

Sit on a low stool and grasp the electrode holder in one

hand with the cable drawn across the lap. Allow enough

slack to move the holder freely and yet keep the weight

and drag of a long length of cable from becoming tiring,

The ground connection is as much a part of the welding

circuit as the cable and electrode holder_ A poor ground

connection can render the best welding equipment ineffi-

cient. When using a table with a steel top, fasten the lug of

the ground cable to it securely with a bolt or C<lamp, so that

any piece of iron placed on the table top will be propedy

grounded. If a steel table is not used, connect the ground

cable d_recfly to the work with a ground clamp or bolt

Select a fairly large piece of steel plate approximately

1/4-inch thick and clamp it to the table top to prevent it

from lifting, should the electrode stick or "freeze" when

I

90

first attempting to weld. insert a small, mild-steel welding

electrode in the electrode holder and connect the welding

cables to produce the heat specified by the CONTROL

panel Connect the ground cable to the work and set the

indicator in the current range recommended for the

diameter of rod used.

Any method of bringing the tip of the rod in contact with

the work, then quickly raising it until there is approximately

a 1/8-inch gap between the rod and the work, will start an

arc_ The easiest way for a beginner to strike an arc is to

scratch the tip of the rod a short distance on the surface of

the work, as you would a match, then lift it (quickly) the re-

quired 1/8-1nch (fig. 1). Another method is to strike the work

a hard blow with the tip of the rod and allow it to bounce

up to form the arc gap. The important thing is to strike

the arc qelckly and not allow the rod to remain in contact

with the work

A common mistake often made by a beginner is to point

the rod toward the work and, after lowering the helmet,

feel slowly about until the tip of the rod touches the work.

This always results in sticking or "freezing" of the rod

which produces a direct short circuiL When this occurs the

rod can be loosened by bending it from side to side while

pulling on the holder (fig 2). If this fails, turn the welder

off_ The electrode must be released in a matter of seconds

to avoid unnecessary heating of the welder or damage to

the flux coating on the rod

,'/,'II'U]I

,,',/

Figure 1

To strike an arc, scratch the

end nf the red ne the plate

and then quickly raise ap-

proximately 1/8-inch,

Figure 2

Should the rod stick or

"freeze" bend it from side

to side while palling upward

on the rod ho_er.

\\

\\/

\/

I

1-5

Figure 3Figure 4

To lay aweld bead only two

movements are used, dowfi-

ward and in the direction the

weld is to he laid.

Watch the weld puddle to

keep the slag from flowing

in front of it, causing inclu-

sions and gas pockets

Figure 5

Fill the crater, when starting

a new rod, by striking the

arc at A then moving to 8

and back to C position

Figure 6

To widen the head, work the

red from side to side slight

ty, with a slow, zigzaggmg

crescent-shaped motion

If difficulty is experienced after repeated attempts to

maintain an arc, check the ground connection for proper

contact with the work If this does not help, increase the

welding current Also check the rod size, as larger rods

require higher current settings.

Practice striking and maintaining an arc for a few seconds,

then snap it out by rapidly pulling the rod away from the

work_ Repeat this operation until the arc can be started

and the gap maintained as uniformly as possible. In a

short time you will find the arc length can be controlled by

the crackling or "frying" sound which may be recognized

by gradually shortening the arc until it sputters irregularly

as though it were going to "choke out'* and stick--then

slowly lengthening the arc by pulling the rod away from

the work until it snaps out_ Somewhere between these two

extremes the steady crackllng sound of a proper arc length

will be heard_

To lay a weld bead, only two movements are used, a

steady downward feeding of the rod to maintain the correct

arc length and a slow travel in the direction in which the

weld is to be lald (fig. 3)_ Watch the weld puddle and

arc length, and move the rod steadily in a straight llne as

the back end of the crater fills up (fig 4). The slight angle

of the rod will keep the flux or slag flowing over the

deposited weld metal to form a protective coating. If the

rod is moved too slowly the slag will flow in front of the

puddle and be trapped in the weld, producing inclusions

and gas pockets.

Lay a bead approximately four inches long. After allowing

it to cool slightly, remove the slag coating, which covers the

top of the weld, by scraping along each edge of the weld

with a cold-chlsel foJowed by wire brushing until it is bright

and clean_ Inspect the surface of the weld carefully before

starting another_ The surface of a good weld is rippled

unlformly, which results from a steady rate of travel and

uniform arc length_

If the scrap plate used is small, it will become very hot after

laying a few beads. This will alter welding conditions

which could be very confusing to a beginner Have several

scrap pieces handy so each may be allowed to cool before

laying a second bead,

When starting with a new rod, chip slag from the crater

and strike the arc at the forward end as shown at "A" in

figure 5, Then move the rod to "B" and back to "Ci" at

about twice the normal rate of travel to give the rod and

base metal time to heat up for proper fusion

After laying anumber of beads, try "working" the rod

from side to side slightly (fig. 6) This movement should

be slow and not wider than the diameter of the rod being

used. Experiment with different current settings, rod sizes

and rates of travel.. Compare results with welds shown in

the diagrams (fig, 9).

Too low a current setting tends to deposit the bead on top

of the plate with very little penetration. The arc sound will

be an intermittent crackle with irregular sputtering Too

high a current setting (for the size of the rod being used)

wiII provide sufficient penetration but the bead will be thin

and undercut in places. The arc makes a hissing sound and

the rod becomes red hot before it is half used.

If travel is too slow it will pile up a wide, heavy bead with

good penetration but with overlap of the weld metal on

sides without fusion_ A large area surrounding the weld is

heated to a high temperature which produces distortion,

even on a simple weld If the rod is moved too fast the

small bead will result w_th little more than melted base

metal. An extremely long arc causes the rod to melt off in

globules, with little or no penetration, and a very irregular

weld surface The arc produces a hissing sound.

A good weld laid with correct current setting, speed and arc

length will produce a surface that is rippled uniformly, with

the same width throughout its length, and well formed

crater. The cross-sectional view shows it to have good pene-

tration and no undercut or overlap.

II

Figure 7

Lay the weld beads about

one inch apart, ffemove the

slag and examine each weld

before starting the next

Figure 8

A pad of weld metal is built

up by running a series of

beads in layers at right

angles to each other,

1.6

CURRENTTOO LOW

Arc is difficult to maintain.

Vurylittle peflctrationHigh

bead,

TRAVELTOO FAST

Small bead undercut in

some places. Rough top

and little penetration

CURRENTTOO HIGH

Wide thin bead, undercut,

Crater pointed and long,

Rod hurns off very fast,

ARC TOO LONG

Surface of weld rough

Rod melts off in globules

Arc makes hissing sound.

TRAVELTOO SLOW

Metal piles up. making a

wide heavy bead, over°

lapped at sides in places

NORMALCONDITIONS

Uniform ripples on surface

of weld, Arc makes steady

crackling sound,

Figure 9

Practice laying beads approximately one inch apart until

a good weld can be produced with all the different rod

sizes the welder will handle (fig, 7). After becoming pro-

ficient in running a bead, build up a pad of weld metal,

Clean each bead before laying the next and make sure

they are fused together (fig. 8) Run the second layer at

right angles to the first and the third at right angles to the

second, etc_, _sntil a pad approximately 1/2-inch thick has

been built up This type of welding is used to build up

round or flat surfaces or reinforce parts that are rusted thin_

To avoid distortion when building up the end of a shaft,

run the beads parallel to the axis and lay each successive

bead on the opposite side as shown by the numbered steps

in figure 10. Cover the entire shaft with weld metal for

the desired length. If the place to be welded is not at the

end of the shaft, weld around it and turn the shaft slowly

to keep the weld puddle in the flat position (fig_ 11). Clean

off the slag after each bead, then machine the shaft to

proper size.

F_gure 10

1-7

FLAT WELDING

TACK

•WELOS

Flat welding includes all types of joints in which the weld

is horizontal, and the electrode is fed down as in the practice

welds of previous pages The five types of joints in figure 1

can be welded in the flat position

Butt welds on llght material should be practiced first on

scrap stock_ Use 16-gauge mild steel sheet metal (approxi=

mately 1/16-inch thick) and 5/64-1ech rods with the welder

set at approximately 30 to 50 amperes, Butt edges of metal

together and tack-weld approximately every three inches

(fig. 2)_ (Tack welds are small beads 1/4 to 3/8-1nches in

length_) Place bars of scrap iron under ends of the work to

provide an air space above the table. Simply move the rod

in a straight llne directly above the edges to be joined.

If the weld burns thro.ugh in places, reduce the welding cur-

rent or increase the rate of travel. Some difficulty may be

experienced in starting the arc at these low current settings

However, once the arc is started, there wlll be sufficient

heat to make a sound weld. After laying a bead, turn the

work over and inspect the underside which should also have

asmall uniform bead. To prevent burning through where

the edges are not butted tightly together, move the rod back

and forth with short quick strokes in the direction of the

weld to bridge the gap and give the metal in the crater a

chance to solidify (fig 3).

Butt welds on sheet metal lighter than 18 gauge should

not be attempted by the beginner without the use of a

back-up strip (fig 4). This consists of a bar of copper

clamped tightly against the underside of the seam to absorb

the heat of the arc and prevent the weld from burning

through To assure complete penetration with butt welds

on 8-gauge metal or heavier, a 1/16 to 3/32-1nch gap

should be allowed between them (fig .5) insert a wedge or

screwdriver between the plates when tack-welding to main*

tain the gap, then turn the piece over, so the tack welds are

on the underside_

Use enough current to melt edges of plates to a depth of

at least one-half their thickness Clean off the slag and

inspect it for smoothness, penetration and height of rein-

forcement Agood weld should havea relnforcement slightly

more than flush with the surface (fig 6) Turn the plate

SLIGHT / /

GAP /,St;EEl"

METAL

k___J\ BACK-UP

STKIP

Figure 4

Figure 3

REINFORCEMEHT

Figure 6

Figure 5

Figure 7

over and weld a similar bead on the other side (fig. 7) A

higher weidlng current can be used on this side as there is

no danger of burning through and fusion with the first

bead will be assured

Although butt welds can be made on steel plates up to

3/8-inch thick, with a 295-ampere machine using 1/4-1nch

rod, the same results can be obtained with the 180 and

230-ampere machines if edges of plates are beveled (fig. 8)

Metal of almost any thickness can be welded in this manner

by depositing a number of beads, one on top of the other

until the groove is completely filled= If the plate can be

welded from both sides, always use a double bevel (fig_ 9)_

If only one plate is beveled, the angle should be at 45 de-

grees (fig 10)

1-8

UNDERCUT GASPOCKET

EHT

PENETRATION

Figure II

Figure 12

Figure 13

Run the first pass on beveled plates with a 5/32-1rich rod

and use as high a current as you can handle to obtain a

small bead on the underslde_ If this is not done, insufficient

penetration will result, as shown in figure 11. Be sure to

clean each pass before laying on the next All beads are

la_d by moving the rod in a straight llne with no weaving

or slde-to-side movement_ On the last or reinforcing pass,

a weaving motion must be used to obtain a wide weld that

will completely cover preceding beads. For the beginner,

the slde-to-side movement (with a slight hesitation at each

end) will produce a smooth top without undercut or overlap

Select several practice welds of different thicknesses and

cut them into 1-1/2-inch strips. Clamp each strip in a vise

and bend it at the weld (fig. 12)_ If it breaks through the

weld, study it to find the cause of failure

Corner welds are made on light sheet metal by running

a single bead along the top, after tack-weldlng at three-

inch intervals to prevent warping (fig 13)_ if numerous gaps

are present, a back-up strip may be used, On heavier

metal two passes may be necessary and, if the design

permits, a smaller pass can be lald on the underside.

Beveling may be used to advantage on the thicker metals

FgLLET WELDS

I

IWELD

BREAKING

THEWELD

Figure 4

WELD

Fi9ure 6

Fillet welds are used to join two pieces of metal with sides or

edges at right angles to each other The size of such a

weld is based on the leg length of the largest isoscelesright

triangle that can be inscribed within the cross sectional

area, as shown by the dotted-line triangle (fig 1). The

size of a fillet weld may also be measured with asquare

and ruler, subtracting 1/32-inch from all dimensions under

3/16-inch and 1/16-inch from all over 1/4-inch (fig. 2)

For example, a 1/4-inch fillet weld should measure 5/16-

inch This will offset any inaccuracy due to the slight radius

at the toe of the weld and allow for concavity of the bead.

When a fillet weld is stressed to its maximum capacity,

failure will usually occur through the throat section (fig. 3)

Therefore, the strength is determined by the throat dimen-

sion multiplied by the Fength of the weld Finished welds of

this type should always be at least four times their size in

length; that is, a 1/4-inch fillet weld should never be less

than one inch long, The direction in which the load is applied

to a weld greatly affects its strength, which can be clearly

demonstrated by breaking the weld (fig 4) A joint so

roaded should always be welded on both sides with fillets

equal to the plate thickness (fig 5) If this cannot be done,

bevel the plate to assure complete penetration and position

the work at a 45-degree angle if possible.

For practice, tack-weld three pieces of scrap iron together

to form a cross (flg_ 6) Use a 5/32-inch rod with high current

and hold it as indicated in the front and side views. Move

the rod at a steady even pace along the seam without any

side-to-side movement and deposit one inch of weld for

each inch of rod melted. The surface contour of a good weld

1-9

SIZE

Figure 11

ROD

UNBERCUTf_P

_,,-CENTER

_OF SEAM

Figure 8

Figure 9

Figure 10

I'_ !EXCESS

BLA

Figure 13

LAPWELDS

Figure 16

LAPWELDS

Figure 14 Figure 15

INTEBMII_ENT

WELOS

STAGGERED

INTER-

MITTENT

WELOS

Figure 17

WELDON BOTHSIDES

AT ENDOF JOINT

should be nearly flat with a slight radius at the sides or

toes_ Avoid excessive concave or convex surfaces of the

fillet (fig_ 7) Undercuts and colddaps are caused by not

holding the rod in the center of the seam (flg_ 8)_ if the

desired fillet weld cannot be made with a single pass,

several passes are used to build it up to required size (fig_ 9).

Slag must be cleaned from each pass before depositing

the next. Fillet welds over 1/2-inch in size are rarely used

because joints requiring more strength can be made more

economically by beveling and groove-welding, followed

by a small concave fillet weld to provide a radius in the

corner_

Horizontal fillet welding is used when the side or edge of

one member of the joint is in the vertical position particularly

for small single-pass welds where the work cannot be tilted.

For practice, tack-weld two pieces of scrap together to

form a tee-joint (fig. 10)_ Use a 5/32-inch rod held at

angles indicated, and direct the arc into the corner of the

joint. The arc length should be somewhat shorter than for

flat fillet welding_ To assure penetration at the root, use the

highest welding current that can be handled (fig 11)_

Good penetration is of prime importance and appearance

will come with experience. If the arc is advanced too fast,

or held too close to the vertical plate, undercutting may

result (fig. 12). Too slow travel will cause overlapping and

an extremely dose arc or low current will produce a bead

with a convex surface (fig. 13). To check the penetration and

soundness of the bead, break some of the welds for inspec-

tion, as shown in figure 4_

When making a lap weld, care should be taken not to melt

too much of the upper corner on the top plate (fig. 14)

Some melting will take place, but proper advance of the

rod will cause the weld metal to build up and blend into the

top surface. On sheet metal, hold the 3/32-inch rod almost

perpendicular and move the arc rapidly. Welds of this

type should be wider than they are high, somewhat like a

flat bead (fig_ 15) A slight discoloration on the underside

of the lower sheet indicates good penetration, On heavy

metal, a 3/8-inch fillet weld can be lald in one pass with a

1/4-1nch rod using a 295-ampere machine However, with

smaller machines, the same weld or larger can be made by

building up with a number of passes (flg_ 16)_ When

welding long narrow pieces, stagger the welds in short

intermittent beads, first on one side then on the other side,

to minimize distortion (fig_ 17).

1-10

_i_ _¸ _ __

POSMTION WELDING

BUTT WELD

in order to derive the greatest benefits from your welder,

you should practice until you can make a welded iolnt

in almost any conceivable position. The ability to do this

is especially useful when making repairs on machinery as

the amount of welding in most cases is small and does not

warrant disassembling the parts to weld them in the flat

position Welds of this type have been classified into three

groups according to their location and are referred to as

vertical, horizontal and overhead welds (fig 1) Of the

three positions, vertlca[ welding will be used the most and

should be practiced first. Skill gained in this type of weld

will make horizontal and overhead welding easier

VERTICAL WELDING

The two methods of welding in the vertical position are

commonly known as "vertlcal-down" and "vertlcal-up"

welding (fig_ 2)_ In the former the bead is started at the

top and welded in a straight llne downward In the latter

the bead is started at the bottom and welded up, usually

with a weaving motion

The chief difficulty encountered with any position weld is

keeping the molten metal in the puddle from falling out.

To prevent this the arc must be held as short as possible and

the weld puddle kept fairly small so it will solidify rapidly

Verficabdown welding is the easiest to perform and is used

on material up to 1/8-inch thick Before attempting a vertical

weld, run a few practice beads to get the feel of the

arc_ Tack-weld a piece of scrap iron to an old practice plate

so it is positioned vertlcal]y (fig 3). Use l/B-inch rods for

the first welds and a current of about 75 to 115 amperes

Experiment with various amperage settings until you are

using the highest current you can handle Hold the rod at

right angles to the plate laterally, with the tip pointed up

at the angle shown in figure 3 Start the weld at the top

of the plate and move the rod in a straight line downward

The correct rate of travel can be determined by gradually

reducing the speed unti! molten metal in the puddle can no

longer be kept in place Then, increase the speed slightly

while watching the puddie, arc length and angle of the rod

A short arc provides better control of the molten meta!

Follow the same procedure with 3/32 and 5/32-inch rods

It will be noted that the larger the rod the more difficult it

is to control the puddle For this reason smatler diameter

rods are always used for position welding

Lap or tee-joints are made by simply directing the arc into

the cornel of the joint as in fiat welding and moving the

rod down the seam at a steady pace Butt welds may require

more practice, as there is a tendency to burn through on

light gauge material if this occurs, continue until the seam

is completed and patch the hole by chipping the slag and

wire brushing until clean Then, with slightly lower current,

strike an arc on the weld directly above the hole and quickly

bring the rod down to the lower rim of the hole to deposit

a small amount of metal Raise the rod far an instant to

let the metal solidify and repeat until the hole is welded

Hold a long arc when raising, so there will be no metal

deposited except when the rod is lowered Any hesitation

in the rate of travel will cause a "burn through/' if this

happens repeatedly, lower the welding current

Leave a slight gap between pieces for butt welds on material

over 3/32-1nch thick_ Inspect the back side after welding

for small bead along the seam, indicating complete pene-

tration (fig 4) Butt joints on material around 3/16-1nch

thick should be welded on both sides.

Vertical-down welds may be made on heavier material by

laying in a number of passes (fig 5), however, this practice

is not recammended as it takes longer than a heavier single*

pass weld made by the vertical-up method

VEBTtCAL-

OOWNWELO

DlflECTIOH

BKVEL

VEffTICAL.DOWN

WELDING

Figure 3

ASMALLBEAD OH

BACKSiDE [HBICATES

COMPLETEPEHETRATIOH

Figure 4

/3EB PASS

-2HO PASS

-IST FkSS

Figure $

I-I1

VERTICAL*UP 90°

WELOIHG

Figure 6

Figure 9

4", J

Figure TO

Use 1/8 and 5/32-1nch rods for all vertical-up welds and

start by running practice beads from bottom to top of a

3/16 or 1/4-inch plate, tack-welded in a vertlca_ position

Hold the rod as shown in figure 6, noting that the angle

of the rod is not as steep as for vertical-down welding, but

tilted just slightly (approximately five degrees) so the tip

of the electrode points upward. Strike and hold o short arc

until a small amount of metal is deposited, then quickly

raise the rod upward with a wrist movement to increase the

length of the arc at the top of the stroke (fig. 7). As soon

as the metal deposited in the crater has solidified, bring the

rod down and deposit more metah Keep repeating this

whipping motion, while gradually moving the rod upward

and toward the plate as the electrode burns off. The length

of the stroke will depend upon the amount of metal de_

posited and the welding current esed_ Keep the rod in

constant motion once it has left the crater. The purpose

of a long arc is to prevent any metal from being deposited

except when the rod is held at the crater. If globules of

molten metal drop from the tip of the rod when the arc is

lengthened, either the current is too high or the rod has

remained away from the crater too long. Care should be

token not to break the arc at the top of the stroke. Do not

deposit too much metal at one time as this will cause the

weld to sag and result in a high narrow bead undercut

along the sides. Better penetration can be had by the

vertical-up method_ This can be demonstrated by ioinlng

two pieces of 3/16-inch metal with a butt weld, using the

whipping motion.. Leave a gap between the plates and use

a 5/32-inch rod with a fairly high current, determined by

experimenting. The whipping motion will melt the corners of

the plate and form a pocket in which to deposit the weld

metal (fig_ 8)°

Burn the rod in deep so the crater extends through to the

back side. After completing the weld, inspect the back

side for the small bead, which indicates 100-percent pene-

tration. Butt welds on heavier materials should be welded

on both sides.

On materials up to 1/4-inch thick, use the whipping motion

on small single-pass fillet welds for lap and tee-joints Larger

single-pass fillet welds can be made by the whipping motion

with a slight side-to-slde weave added and combined with

the up and down movement to make a triangular shaped

weave (fig 9). This will produce a "shelf" upon which

additional metal is deposited _ntermlttenfly as the welding

progresses. There should be a slight pause in the weaving

motion at the toes of the weld to avoid making a bead that

is too convex. Materials 1/4-inch and thicker must be bev-

eled on one or both sides, depending upon the joint

Practice making a wide bead using a side-to-side weaving

motion with a very slight whipping action at each end to

give the metal at each end a chance to solidify and avoid

undercutting along the sides of the weld (fig 10). This type

of bead is used on welds that require more than one pass

and is called the finish bead or "wash" pass. Hold a short

arc, making the bead approximately 3/4-inch wide and

fairly light, Multiple vertical welds may be made as shown

in the series of diagrams, figure 11_

Figure 11

1-12

Figure 12

_/_ UHRERCUTFigure 14

OVER-LAPPED I]ACI(-Up STRIP

Figure 13 Figure 15

DEPOSITMETAL

OH GOWHSTROKE

HORIZONTAL WELDING

Horlzontal welding refers to one type of butt weld between

two plates in a vertlcal plane. For practice, set up a plate

as for vertical welding and run straight beads across from

left to right (fig 12)_ Use the same current settings as for

vertlcal-down welding and hold the rod as indicated with

a short arc. Move the rod in a straight line and deposit

a light bead. The rate of travel will depend upon the current

used Too slow a travel will cause the bead to sag (fig 13).

Practice with 3/32, 1/8 and 5/32-inch rods untll a wel!

formed bead can be made with each size rod (fig 14).

Sheet metal up to 1/16-inch thick can be butt welded from

one side_ if the seam has numerous gaps, use a back-up

strip, albwlng a slight gap between edges of 1/8-inch

thick metal and weld from both sides (fig 15), All metal

3/16-1nch thick and over should be beveled and welded

with a number of passes (fig_ 16) Thoroughly clean each

bead before laying the next and use higher current than

for single-pass welding

The appearance of a multlple-pass horizontal weld can be

improved by vertical down beads laid closely together.

Use a swift circular motion to the right; slowly downward

while welding (fig 17)

OVERHEAD WELDING

Although overhead welding is generally considered diffl-

celt, do not become discouraged, as it is being done every

day by people who have taught themselves_ Once theeart

of maintaining a short arc has been mastered, the rest

will be easy

Since there will be a shower of sparks, wear a leather

jacket and keep the practice plate slightly higher than the

top of your head when standing To keep sparks out of your

glove, grasp the electrode holder as indicated in figure 18

and hold the rod in a nearly vertlcal position with a slight

tilt to the right_ Drape the cable over your shoulder so its

weight will not interfere with the use of the electrode_ Use

1/8-1nch rods and a current setting the same as for vertical

welding, and move the rod in a straight llne without any

weaving or whipping motions A reasonably fast rate of

travel must be used to prevent the bead from sagging and

undercutting along the edges. Vary the rate of travel and

notice its effect on the size and appearance of the weld.

When you feel you can run a satisfactory bead, try the

slde_to-side weaving motion and deposit a thin weld ap-

proximately 3/4-inch wlde_ The movement must be somewhat

faster than for other positions to keep the bead from

sagging (This method of weaving is used only for the

last pass on heavy welds where improved appearance is

necessary)

The whipping motion is used where a gap exists between

the plates as it provides better penetration with higher

we]dlng current, For practice work, set up two plates ap-

proximately 1/8-inch thick, allowing a gap between them

Burn in deep for good penetration with 1/8 and 5/32-inch

rods, varying the plate size and gap distances.

Figure 19

Fillet welds for lap or tee-joints are most common in the

overhead position. Tacbweld two pieces of scrap iron

together to form a tee-jolnt, and clamp in the overhead

position so one plate is held vertically (fig. 19)_ Hold the

rod at angles indicated and deposit a light bead from left

to right without weaving or whipping movements. A slightly

higher current than used for overhead butt welds will be

necessary to get good penetration at the root of the weld

t-13

Figure 21

Figure 20

METAL BENDS

WHEN COOLED

Figure 22 DISTORTION TRENOS

WHEN COOLING

Egff W[LO

[RtH Y_LO

FFigure 23

To simulate actua! conditions tack-weld a piece with an

irregular edge to another piece leaving numerous gaps

along the joint_ Use the whipping motion and deposit a

fairly heavy bead, slowing down the rate of travel where

the gaps are widest to build up a weld of uniform size

throughout its length. If the gaps are rather wide, fill them

first, clean off the slag and lay in a fillet weld the entire

length of the joint (fig. 20)

When you can lay single-pass butts and fillet welds you will

be able to make an overhead weld of any size, as it is

simply a matter of fusing a number of straight beads to-

gether, one on top the other (fig 21)

Weld appearance can be improved by grinding with a

properly guarded abrasive wheel mounted on the end of

a flexible shaft

EXPANSION AND CONTRACTION

Metals expand when heated; contract when cooled. In arc

welding, the deposited metal and edges being joined are

molten and the metal surrounding the weld is heated suf-

ficiently to cause expansion_ When the deposited metal

solidifies, it becomes a part of the plates; but, being unre-

stricte_ in its expansion in the molten state, it tends to

contract more than the heated surrounding metal If the

Figure 24

surrounding metal is free to move (not clamped or tacked)

it cannot resist these forces and bends (flg_ 22)

The weld also contracts in width, as well as in length,

tending to pull the plates together, resulting in locked-up

stresses (fig_ 23) This is not too serious when welding mild

steel up to 1/2-inch thick, as the ductility and elongation of

the metal will pelmit it to deform slightly to compensate

for these forces, and prevent cracking. On sheet metal and

light structural members, long continuous welds may cause

considerable bending and resuJt in a badly distorted weld-

ment Fortunately most of this can be avoided by studying

the effects of expansion and contraction, as related to the

job before welding and working out a procedure to follow.

For example: first assemble the job with tack welds, and

install temporary braces tack-welded to support parts that

might bend. The braces can be removed after the job is

cornpleted_ Lay the beads so the stresses will counteract

or nbutralize one another, by running a short pass first on

one side then on the other, etc. Often the neutralizing weld

is at the other end of the job Do not concentrate too many

welds in one place but space them to distribute the heat

and stresses throughout the entire structure Use intermittent

welds whenever possible_ If continuous welds are necessary

to make a water-tight compartment, use the back-step

method as shown in figure 24, fusing each bead together

at the end

CAST IRON WR=LD|NG

Previous experience in handling the arc, plus good judg-

ment regarding expansion and contraction, will enable

you to weld gray cast iron successfully in a short time.

Two types of electrodes are used, namely: non-machinable

for use in cases where the weld does not have to be

machined, and machinable which deposits a file-soft weld

that can be drilled or machined to close tolerances Non-

machinable rods are used for most repair jobs such as

cracked motor blocks, water jackets, pump and gear hous-

ings, etc. If the weld must be made across a machined

surface that need not be refinished to a close tolerance,

the face of the weld may be ground flush with an abrasive

wheel.

As cast iron is very brittle, care must be taken to control

expansion and contraction, and thus avoid cracking of the

weld or the casting_ Because of low tensile strength and

lock of ductility it cannot bend, stretch or distort itseff to

conform to the contraction of the weld metal In some cases

it may be necessary to pre-heat the entire casting before

welding_ However, as most cast iron welding jobs can be

done without pre-heatlng, this method will be considered

first.

The part must be free of rust, grease, paint or dirt; cleaned

by wire brushing, grinding or washing with solvent. The

crack should be beveled for penetration. If the parts are

broken apart completely,they may be ground on an abrasive

wheel to asingle or double bevel, depending upon the

thickness of parts and whether or not the ioint can be

welded from both sides. Do not bevel to asharp edge along

the entire crack Instead, allow approximately 1/16-inch

1-14

of the fractured surface to line up the two pieces Tack-weld

or clamp parts in position If the crack has not separated

the casting, a vee-groove can be chipped out with a dla-

mond-polnt chisel Chip an inch or so beyond the visible

ends of the crack as it may extend under the surface. On

cracked water jackets, where only a sea! is required, the

depth of the groove need only be one-half the thickness

of the casting.

Keep the casting as cool as possible and do not expect to

complete a weld in cast iron as rapidly as in the same length

in mild steel Use a smaller rod and a slightly higher current

than for the same thickness of steel. Lay a short bead, about

an inch long, at one end of the crack and peen it immediately

with a cross-peen hammer or blunt chisel to spread the

weld metal and relieve locked-up stresses, Do not strike the

edges of the casting. Place the second bead at the opposite

end of the crack and the next in the center, etc (fig 1)r

AllOW enough time between welding to permit your bare

hand to be held on it Never use water or a blast of air

to cool the casting Although cracks may not show up

immediately, the locked-up stresses due to uneven cooling

will cause the casting to fail after it is back in service_ Wire

brush each bead before depositing the next Then continue

to fill the groove with short weld beads as before, working

rapidly when depositing and peening the bead Allow plenty

of time for cooling. Examine the casting for cracks that may

develop during cooling periods if any of the beads crack,

chip them out and re-weld If cracking persists, preheat

the entire casting slowly to a dull red heat with an oxyacety-

lene torch or blow-torch When the preheated method is

used, the welding can be continuous After completing the

weld, cover the casting with warm dry sand or slaked lime

so it will cool slowly

Malleable iron is ordinary gray cast iron that has been heat

treated to give it a tough ductile outer skin The method of

welding is the same as for cast iron

HARD FACING WORN CUTTltNG EDGES

PLOW

CULTIVATOR

SHOVEL

SPIKE /

HARROW

TOOTH .'ULTIVATOR

SWEEP

Figure I

Excavating equipment, earth_cutting farm machinery or

others such as plow shares, lister shares, cultivator shovels,

sweeps, subsoilers, spike harrow teeth, tractor treads, ex-

cavating buckets, or any surface subject to abrasive action

wil! last much longer and require less sharpening when

their cutting edges are hard faced with hard surfacing

electrodes The arc welding process consists of depositing

a layer of abrasion resisting weld metal on the worn cutting

edges as indicated in red on the parts shown in figure 1

Prepare the part for welding by cleaning the surface to be

welded by grinding it approximately 1-1/2 inches back

from the edge (fig. 2) Position the part so weld metal can

be deposited in the flat position If the material is 1/4_inch

thick or less, use a I/8-inch rod and as low a current as

possible that will still permit the metal to flow out smooth

and fairly thin (1/16 to 1/8-1nch thick) Weave the rod

from side-to-side in a crescent-shaped movement and de-

posit a bead about 3/4 to 1-1nch wide Several passes

(lald side-by-slde) may be necessary where the worn sur-

faces are quite wide In some cases a small straight bead

DRtHO OFF WEAVEDEARS

Figure 2RARD EACIRR

SMALLBEAR-

Figure 3HA_DEACIHR

SOFTBASEMETAL

WEARSAWAYEASTER MILD,STEEL PATCD

TRAHRAflDFACIDG WELDS Fieure 5

must be deposited along the edge to build it up (fig. 3)

Make beads heaviest where the wear will be greatest, but

avoid excessive build-up as the metal cannot be filed or

machined If shaping is required, heat the weld metal and

forge it. Smoothing and sharpening can be accomplished

by grinding.

For plow and lister shares, cultivator shovels and similar

cutting points, deposit the weld metal on one side only

which will result in a self-sharpenlng edge (fig 4) The

softer base metal on the other side will wear away first and

leave a knlfe-like edge of hard facing material Parts that

must wear uniformly on both sides should be hard faced

on both sides The condition of the worn part must also be

taken into consideration If the part requires a number of

passes to bring it up to the desired thickness, use mild-steel

welding rods first; then cover with deposited metal from

hard surfacing rods If the edge is entirely worn away, a

steel patch (cut to fit) may be welded in place with mild-steel

electrodes, then hard faced (fig 5) To prevent distortion

when hard facing small parts, peen the deposited weld

metal before it cools

1-15

TRUMB KHOB

CARBORELECTRODES

CORRECTTO

GROUNDAND:

SCREWS ELECTRODE

CABLESOF

ELECTRODETiPS A C WELDER

Figure 1

Work ordinarily done with a gas weldlng torch is possible

with the twln-carbon arc torch connected to an A.C welder,

The carbon-arc flame is similar to the flame of a gas weld-

ing torch in that it provides heat by radiation, rather than

by direct arc between work and electrode, This flame heat

greatly widens the scope of work possible with the arc

welder for brazing, soldering, welding of non.ferrous metals

and localized heaffng for bending, forging and hardening,

The arc torch (fig. 1) consists of an insulated handle wlth

two projecting carbon electrode holders, one of which is ad-

justable to permit striking and breaking an arc at the carbon

tips. Athumb knob on the handle performs the adjustment

and operates ashut-off switch built into the handle There

are no valves or gouges that require fine adjustment as

with an oxyacetylene torch. The same protective equipment

used for ordinary arc welding is used when operating the

carbon-arc torch.

A wide selection of flame heats may be had by varying

the current and size of the carbon electrodes, Although the

actual temperature of the arc remains the same for any

current setting, the volume of transferable heat increases

with an increase in amperage° However, amperages in

excess of those given below will only cause short carbon life.

1/4-ira carbons ............ 30 to 40 amperes

5/16-im carbons .............. 40 to 65 amperes

3/8-im carbons ............... 65 to 90 amperes

To prepare the torch for use, connect its two cables to the

ground and electrode cables of the welding machine.

Grounding of the work is not necessary as the operation of

the arc flame is entirely independenL With the thumb knob

on the handle in the "off" position, insert two 3/8-inch car-

bon electrodes in the holders and clamp in place at approxi-

mately one-half their length (fig, 2) Do not clamp them

on or near the ends opposite from the arc as this will cause

overheating of the carbons When tightening the clamping

screws, be careful not to apply too much pressure on the

carbons, as they are very brittle and break easily Use only

enough pressure to hold them firmly in place. If the tips

of the carbons do not llne up with each other, an adjustment

may be made by turning the longest of the electrode holders

slightly; too much turning will loosen it, and make it neces-

sary to disassemble the torch to again tighten it properly,

Do not make any turning adlustments wl h the s,id ng holder

as this would spoil the contact tension in the switch.

To strike the arc, turn on the welding machine and set it for

approximately 70 amperes Lower the welding helmet and

hold the torch up to silhouette it against the light of a win-

dow Slowly move the thumb knob forward until contact

is made between the tips of the carbons. This will start the

arc Then immediately move the knob back to increase the

gap between the carbons The actual distance can be deter-

minecl with a little practice When the carbons are too close

the arc flame will have a sharp crackling noise As the

distance between the carbons is increased, the crackling

will change to o soft purring sound which indicates the best

arc flame There are two heat zones and the small inner

zone is by far the hottest, having an estimated temperature

of 9000 degrees Fahrenheit (fig, 3)

The shape of the flame gleatly influences the way in which

it must be used For example: on beveled work the torch

should be held parallel to the groove so the flame will reach

the bottom (fig 4), If held at right angles to the groove, the

flame straddles the groove and the heat will not reach the

bottom (fig 5). Filler rods, as for gas welding, must be used

on joints of this type.

The soft, bushy flame is pressureless and has no tendency

to blow the mohen metal This is a distinct advantage when

welding thin sheet metal Joints on light material should be

Figure 2Figure 3

CORRECT FLAME POSITION

Figure 4

INCORRECT FLAME POSITION

Figure 5

,r.,,,,,

1-16

bent and edges fused together by melting down the excess

metal to form a bead (fig 6) No filler rods are required

The carbon-arc torch is ideally suited for brazing and

soldering small tubing+

Cast and malleable iron can be brazed with excellent

results A bronze filler red and common brazing flux are

used Rust, paint or grease must be cleaned from the area

to be brazed If it is a butt joint, such as a crack in a casting,

grind or chip out a beveled groove as for arc welding

Apply the heat from the arc flame gradually by passing

it over the metal surrounding the joint+ When the casting

has become warm, concentrate the arc flame at the joint

The important thing to remember when brazing cost iron

is never to heat the edges of the joint to the melting point

The temperature of the work should not exceed the melting

paint of the filler rod The carbons are held as close to the

work as possible without causlr_g the metal to bubble Hold

the filler rod in the left hand and heat the end of it slightly

by passing it through the arc flame Then dip the heated

end in brazing flux Raise the torch slightly and deposit

some of the flux at the part of the joint being heated. When

the surface of the heated metal takes on ashiny or wet

appearance, the filler rod can be applied

Do not put the rod directly in the flame, but hold it on the

work and let the heat of the edge of the flame and the work

melt the rod Deposit only enough metal to fill the part of +

the joint that has been coated with flux As the metal is

being deposited, move the !orch along the joint slowly,

applying flux to the rod and joint as required

Copper and copper-base alloys such as bronze and brass

may also be brazed, but as their melting temperatures are

so close to the melting point of the filler rod, the process

in many cases becomes one of welding rather than brazing

A bronze filler rod and common brazing flux are used.

Most non-ferrous metals can be welded by manipulating

the torch and filler rod in the same manner as for brazing,

with the exception that the edges of the joint are heated to

the melting point before depositing the filler metar. If the

work is a copper alloy, use common brazing flux If it is an

Figure 6

B

aluminum alloy, use aJumlnum flux The filler rod should

be of the same analysis as the work if regular welding

rod is not available, strips of the parent metal may be used

A back-up strip should be used when welding thin material

Small diameter carbons and low amperage setting are

used for soldering. The torch is held so the work is just within

the visible edge of the flame. Apply the soldering flux and

play the flame over the work until it is just hot enough to

melt the solder. If the joint is to be sweat-soldered, tin the

surfaces to be iolned, then press them together and reheat,

adding mare solder at the edges of the joint

One of the most practical uses of the arc torch is heating

metal for bending, forging, etc, Set the torch for a wide,

enveloping-type flame and apply the heat to the bottom of

the work (fig 7) Since a red heat is not visible through the

dark weldlng glass, the helmet must be raised periodically

so the work can be inspected to avoid overheating To pro-

tect the eyes from the rays of the arc, hold the torch to

one side and above your head The carbon-arc torch is

not recommended for welding mild-steeL However, it may

be used for brazing mild-steel if the metal is too thin for

regular metallic-arc welding

CUTTgNG

and other miscellaneous operations

CUTTING WITH THE ELECTRIC ARC

Arc cutting is simply the continuation of a "burn through"

such as you probably experienced when practicing with

light sheet-metal welding When this action is accelerated

by using extremely high currents, it becomes an efficient

method of cutting metals Although the edges of the cut

surfaces are not as smooth as when cut with a saw or

oxyacetylene torch, there are many cases where such pre-

cision is not required. Ordinary mild-steel welding rods

may be used The current will vary with the type and thick-

ness of the material. In general, high currents increase the

speed of cutting but also increase the rod burn-off rate and

width of the cut

\\ \\

ST_T

CUT

ffEI1E

F_gure 1

d,..-MOLT]_HMETAL

STEEL

COHTA_HER

117

MOVERODUPANO--_.

DOWNVERTICALLY_:..., _ _'_

,_ --' _" START

CUT

HERE

Figure 2

To make a trlal cut, place a bar of steel approximately

1/4-inch thick on the table so that one end projects over

the edge. Use a 3/32-1nch rod and a current setting of

around 140 amperes HoJd the rod as shown in figure 1 and

strike an arc on the tap corner at the edge of the bar where

the cut is to be made, Feed the rod into the molten puddle

and keep the crater burning through as the rod is moved

across the bar. To catch the molten metal, place a metal

container on the floor directly under the cut

When cutting metal heavler than 1/4-1nch, the arc is started

at the bottom corner and worked up and down vertically

as shown in figure 2, advancing the bottom of the cut

slightly ahead of the top of the cut to permit molten metal

to run out more easily_ if a smooth edge is desired, the

pieces can be ground on an abrasive wheel. Electrodes

designed especially for cutting may also be used_

REMOVING SEAMS

In addition to cutting, the electric welding arc can be used

for beveling the edges of material to be welded, gouging

out cracked welds for rewelding or removing tack-welds.

The surface of the metal being worked upon should be ap-

proximately in the vertical position, or tipped slightly toward

the arc (flg_ 3)_Start at the bottom of the seam to be gouged

out and work upward. The rate of speed will depend upon

the depth of the groove and the amount of metal removed.

BOLT AND RIVET CUTTING

Removing rusty bolts or rivets is an easy job with an electric

arc welder The arc is struck on the head or nut of the bolt

and worked around in a slight circular movement until the

head is completely melted off (fig. 4). A punch is then

used to drive out the remaining part. The bolt or rivet con

be removed by heating the head almost to the melting point,

then quickly shearing it off with a cold chisel Care must be

taken not to cause the bolt to become welded to the metal

HOLE PIERCING

Another usefu] application of the welding arc is piercing

holes in metal Coated metallic electrodes ore best far

this purpose because of their small size and insulation

afforded by the coatlng_ The process is extremely fast and

a surprisingly clean circular hole can be made For practice,

place a piece of scrap iron 1/4-inch thick (or less) on the

table and allow it to project over the edge as for arc

cutting Use a 3/32-1nch rod and the same current as for

cutting_ At the place where the hole is to be pierced, strike

an arc and hold it until a molten puddle is formed_ Then

push the electrode down against the molten puddle and

force it through the plate_ It is possible to hold the electrode

against the melted plate because the metal core meffs off

faster than the coating_ The coating (not the rod) touches

the molten metal (fig 5) 1"he gap maintained by the pro-

truding coating prevents the metal core of the electrode

from sticking or freezing to the plate

if a larger diameter hole is desired, first pierce a hole as

described. Then, holding o fairly long arc, melt the edges

of the hole away by moving the rod around it (flg_ 6). Holes

of almost any diameter can be mode_ To pierce a hole

through material thicker than 1/4_inch, work from the

underside

HEATING

The carbon arc provides a convenient method for localized

heating of aJI metals. S_mply strike an arc on the part to be

heated and "play" it across the surface until the required

temperat_ure is reached

GQUGIRG

Figure 3 Figure 4 Figure 6

!-18

mNERT-GAS METAL-ARC WELDING (Nonconsumabne)

ALLCABLES

SHOULDBE

KEPTSHORT

ASPOSSIBLE

(Donotex-

ceed12-f/2

feet[nlength)

GROUNDEDWORKPIECE

ORWORKTABLE

TOELECTRODE /

HOLDER /

/GROURBCLAMP

K.F.ATT WELDER

_/\ GROUNDCABLE IGROUND

CABLE

_,,o g 230VOLT

_=========E_6OCYCLE

SINGLEPHASE

HiGHFREQUENCY

ATTACHMENT

WELDINGCABLETO WELDER

Figure I

ANYCRAFTSMAHWELDER

MAYBEUSEDWiTHHF,

ATTACHMENT

[] D

O_

ooWELDER

CABINET

MUSTBE

GROUNDER

ACORDOWELDER

Figure 2

HIGH FREQUENCY ATTACHMENT

The Craftsman, High-Frequency Attachment may be used

with any Craftsman welder or other single-phase, trans-

former_type welder of high quality construction having an

AC, or AC/DC power output Tungsten inert gas (T.LG.)

welding has many useful and advantageous applications

as described in the following paragraphs_ In order to use

the T.LG. process with an AC welder, a high-frequency

attachment must be provided_ Figure 1 shows a typical

hookup using this high-frequency attachment with a Crafts-

man welder_ When not using the TJ.G, welding process, the

high-frequency attachment also permits easy "arc" start.

ing and greatly improved results with many hard-to-weld

rods (low hydrogen rods) as well as making the welding

operation much easier to perform.

The use of a hlgh-frequency attachment makes possible the

establishment of an arc without touching the electrode to

the work., Once the arc has been established, it isstabilized

by the hlgh-frequency output_ This is essential in the T.I.G.

process in order to avoid contaminating the tungsten elec-

trode or the work..

PRINCIPLES OF OPERATION

The necessary heat for inert-gas welding (nonconsumable)

is produced by an electric arc maintained between the non-

consumable electrode and the work-piece. The electrode

used for carrying the current is usually a tungsten or tungsten

alloy rod_ The heated weld zone, the molten metal and the

nonconsumable electrode are shielded from the oxidizing

effects of the atmosphere by a blanket of inert gas fed

through the TJ_G. torch and the weld is made by applying

the arc heat until the abutting edges of the work-places are

melted, adding filler rod if necessary_ The resultant pool

of molten metal, upon solidifying, joins the edges of the

members togethen The process may also be used for adding

metal to surfaces, Iocally-meltlng and spot-joinlng parts.

Athorough cleaning of the surface to be welded isrequired_

Alloil, grease, paint, rust, dirt or other contaminants must

be removed either by mechanical means or by the use of

vapor or liquid cleaners, Files, chisels and stainless wire

brushes may be used Grinding is not recommended, Liquid

cleaners such as naphtha, mineral spirits, alcohol, acetone

and methyl-ethyl-ketone can be used All surfaces must be

wiped dry with a clean cloth, Cleaners should not be used

after a joint is assembled prior to welding,

Striking the arc may be accomplished as follows:

1_ Touching the electrode to the work momentarily and

quickly withdrawing it a short dlstance_ (DC power source)

2 Use of an apparatus which will cause a spark to jump

without touching the electrode to the work. (AC power

source with high-frequency unit attachment)

The high-frequency arc stabilizer provides for this latter

method of starting the arc. Such devices are not required

with DC, consequently it is usually necessary to touch the

electrode to the work to start the arc.

For manual welding, once the arc is started, the electrode

holder is held with the electrode positioned at an angle of

about 75 degrees to the surface of the weld puddle as

shown in figure 2To start the welding, the holder is usually

moved in a small circle until a pool of molten metal of suit-

able size is obtained. Once adequate fusion is achieved at

any one point, a weld is made by gradually moving the

electrode along the parts to be welded to melt the adjoin-

ing edges progressively, adding filler rod as required.

Solidification of the melted metal follows progression of

the arc along the joint and completes the welding cycle_

Material thickness, joint design and weld characteristics

desired will determine whether or not filler metal should

be added to the joints_ When filler metal is added during

manual welding, it is applied by hand feeding the filler rod

(from the side) into the pool of molten metal in the region

of the arc. Filler rod is added in essentially the same manner

when welding by the oxyacetylene method.

1-19

(1) DEV_.LOP

THEPUDDLE

DIRECTION

OFWELD"._

_///I/I///f////////////J

f

WOREPIECE

Figure 3

(2)MOVE

TORCH

(4) REMOVEROD/7

_////////////_;///////////_/_

The filler rod is usually held at an angle of approximately

15 degrees to the work and slowly fed into the weld puddle.

One of the most commonly used techniques for feeding filler

rod is shown in figure 3. Another method, used most often

in multlple-pass welding of vee joints, is to press the filler

rod into the vee groove in line with the weld and melt it

along with joint edges_ Still another method, used fre-

quently in making large welds, is to feed filler metal con-

tinuously into the weld puddle by oscillating the filler rod

and arc from one side of the weld to the other° The filler

rod moves in one direction while the arc moves in the

opposite direction, but the filler rod is at all times in close

proximity to the arc and feeding into the weld puddle.

Joints may be welded by the T.I.G process include all

standard types, such as square abutting edge, vee butt, tee

and lap connections, It is seldom necessary to bevel edges

of material 1/8-1nch or less, although heavier materials are

usually beveled. Whenever joints are beveled, filler ma-

terial must always be added_

The accompanying tame provides a guide to the type of

current recommended for welding some typical materlals.

Electrodes used for the T.I.G. (nonconsumable) process may

be pure tungsten or tungsten aBoy. Pure tungsten electrodes

were formerly used exdusively_ At this time, however, many

(3)ADD '_

TILLERMETAL

_,/,//////////,',/,/,,'/,,////,,/_/27_

(5)MOVETORCH

TOLEADINGEDGE_

OTPOD L

ADDITIONOF

FILLERMETAL

(VERTCAL -_s°'_ I

POSITIO_

electrodes are alloyed with small percentages of thorium

or zirconium. Such electrodes have the advantage of greater

current-carrying capacity for a given diameter, a more

stable arc at low current values, and longer life with less

deposit of tungsten in the welds.

TYPES OF GAS TO USE

Either argon, helium, or a mixture of the two can be used with

the T.I.G process. Argon is used most frequently because:

1. It provides general suitability with a wide variety of

metals

2. It maintains a stabilizing influence on the welding arc.

3_ It costs less (due to the lower flow rates required).

Helium is generally used when welding heavy metal sections

because it provides greater weld penetration. Mixtures of

argon and helium are useful when a balance of these char-

acteristics is desired_

Argon is generally supplied in K-cyllnders, having a capacity

of approximately 238 cubic feet at a pressure of 2200 psi,

or in T-cylinders, having a capacity of approximately 330

cubic feet at a pressure of 2640 psi. Purity of commercial

argon ranges between 99,95% and 99_99%

CurrentSelectionfor Inert-gas

(nonconsumable)welding

Matetla]

Magnesiumup to _i_-imthick

Magnesiumabove_'iG.in thick

Magnesiumcastings

AIuminumup to _32.in thick

Aluminumover_-in thick

Aluminumcastings

Stainlesssteel

Brass alloys

iliconcopper

;liver

Higb-chlomium,nickelbase,high.

temperaturealloys

Silver cladding

Hardfacing

Castiron

Lowcarbonsteel, O015 to 0 030 int

Lowcarbonsteel,0.030 to 0.125 in.

High.carbonsteel, 0015 to O,O30in

High.carbonsteel, 0030 in andup

DeoxidizedcopperP

*Where aIternating current _s recommended as a second choice, use about 25% higher current than that

recommended fat DCSP,

tCo no use _lte nang cu rent on tigEhlly jigged p_rts.

Use brazing flux or sl con-bronze _x o_ /4, nch and h ck_

1-20

WELDgNG RGD $PEC FmCATmONS

AWS E-6Gll MILD STEEL AC-DC

GENERAL APPLICATIONS: Farm Equipment o Sheet Metal o Car and Truck •

Body and Fender = Pipe o Tanks oMaintenance o Jigs and Fixtures o Cabinets

o General Repairs oStructuralSteel

Diameter ....

Flat

Vertical

Overhead

SIZES AND HEATS (AMPS)

1/16" 3/32" 1/8"

20"55 20-80 75"130

20"55 20"65 75"115

20-55 20"B5 75"115

5132"

100-175

100-t50

100-150

3/16" 7132""

t50-225 175-250

150-200

t/4'*

200-375

MEETS

THESE

REQUIREMENTS _'

SPECl FICATIONS

AmericanWeldingSociety ..................... Class:E-6011

Military ....................................... MIL-E-15599C

American Bureauof Shipping .............. Class:E-5011

Physical Properties of Deposited Metal: As Welded

Tensile Strength .......................................... 70,000 to 75,000 psi

Yield Point .......................................... 60,000 to 65,000 psi

% Elongation in 2-inches ....................................23% to 25%

Reduction in Area ..................................... 50% to 55%

Stress Relieved

65,000 to 70,000 psi

55,000 to 60,000 psi

30% to 35%

65%to 75%

DESCRIPTION

The AWS E-6011 is an AC-DC (reverse polarity) electrode with a special coating that provides strong

fluxing action for high quality welds, even in dirty, rust covered, galvanized or plated steels, An extremely

stable, spray type penetrating arc, is produced that is easy to start and restart after interruption. It is a

versatile electrode, producing welds far beyond the requirements of its A.WS. classification It adapts to a

wide variety of jobs due to the wide range of amperage settings at which top quality results are obtained

Features: Deeper Penetration - Fast-Freeze Puddle - Greater Arc Stability.

WELDING PROCEDURE: Weld with AC or DC (reverse polarity) Strike the arc by brushing rod tip lightly

at the point where weld is to be made. After the arc is established and weld material is deposited,

concentrate on holding a short arc that is just long enough to keep the electrode from touching the molten

metal, In the flat position, usea slight oscillating motion as you advance, In vertical position, on sheet steel

start at the top of the seam and weld down, This provides a more rapid speed of travel, lower penetration,

and minimum warpage When welding overhead use a straight stringer bead or a circular motion Keep the

molten pool as small as possible_ Use small electrodes overhead, none larger than 5/32 diameter_

2_1

AWS E-6013 MBLD STEEL AC-DC

multi-purpose all position

GENERAL APPLICATIONS: Farm Equipment oCar and Truck oSheet Metal o

Pipe oTanks e Boilers = Structural Steel o Maintenance Repairs o General Repair

Work

SIZES AND HEATS (AMPS)

Diameter ......

Fiat

Vertical

Overhead

5/64'"

20-55

20-55

20-55

3/32" 118" 5/32" 3/16"

20-75 75-130 100-175 150-225

20-65 75-115 100.150 150-200

20_65 75-115 100-150

1/4"

200"375

MEETS

THESE

REQUIREMENTS

SPECl FICATIONS

_) mericanWeldingSociety .................... Class:E-6013

Military ................................................ MIL-E-15509C

&MI L-E-S043A

American Bureauof Shipping ................... Class:E-0013

Physical Properties of Deposited Metal: As Welded

TensileStrength ...................................................... 75,000 to 00,000 psi

Yield Point ................................................ 62,000 to 07,000 psi

%Elongation in 2-inches ...................................... 20%to 29%

Redaction in Area ................................................. 40%to 55%

Stress Relieved

05,000 to 70,000 psi

50,000 to 00,00g psi

27% to 35%

00%to 70%

DESCRIPTION

The AWS, E-6013 is a general purpose mild steel electrode for use with AC or DC It produces avery stable,

easily handled arc throughout a wide amperage range_ The moderately penetrating and easily directed arc

provides excellent results in all positions (fiat, vertical or overhead) and is ideal for single pass horizontal

fillet welds_ Spatter loss is low, as the weld metal solidifies quickly producing a closely rippled deposit with

good appearance.

Even though it is designed for production welding in mild steel fabrication, this rod is excellent for

multi-purpose use where sound durable welds are required,

The arc is easily started, even at low amperage settings for light gauge steel, yet is stable at the high

amperages needed for higher welding speeds, and for heavier sections.

Use with AC or DC (see recommended amperages) Hold a short arc, just long enough to keep the electrode

from touching the molten metal. In flat position single pass fillets or butt welds may be made with or

without weaving. Weld from bottom up on vertical welding of heavy sections Welding down on light

material or fillets produces excellent results Use 5/32-inch or smaller electrodes for overhead work, making

either stringer or weaving beads.

2-2

WELDWNG ROD SPECIJFICATiONS

HARD SURFACING AC-DC

medium chrome-carbon electrode

GENERAL APPLICATIONS: Tractor Grousers and Rollers o Scraper Blades o Agri-

cultural Implements oPlow Shares oHitches • Power Shovel o Dipper Teeth and

Drive Sprockets = Coal Cutters eConveyor Rolls • Mining Buckets • Rock Crushers

oetc,

SIZES AND HEATS (AMPS)

Diameter .... 3/32" 1/8" _ 5/32" 3/10" 7/32" 1/4"

Amperes 55-85 100-130 1 130-150 175-200 175-250 225-275

SPECl FICATIONS

MEETS

THESE Military ................................. MIL-E-19141C

REQUIREMENTS

Physical Properties of De_positedMetal

As Welded Condition (Rockwell "C" 46-50) .................................................... 450-500 Brinell Hardness

After Cold Working (Rockwell "C" 50-54) ............................................. 500-550 Brineli Hardness

DESCRIPTION

The Medium Chrome-Carbon rod is ahard-surfacing alloy steel electrode with acoating of powdered metals

and flux. When welding, this special coating combines in the arc with the steel core wire to give an

extremely hard weld-meta! deposit Deposited weld metal requires no heat treatment for maximum

strength, ductility, and wear resistance, Annealing or heat treating will not soften the metal deposit, which

is not machinable, but may be hot forged to any desired shape, Deposited metal has a very fine grain and is

free of slag and porosity The metal is tough and highly resistant to wear and impact

The rod is designed for use with either AC or DC (either polarity) Hold a medium short arc and deposit the

metal with aweaving motion Excellent welding results are obtained in either the vertical or flat position,

WELDING PROCEDURE: Gdnd the surface to clean and remove shallow cracks, rust, or other foreign

material Cracks too deep to be removed by grinding should be gouged out w_th acutting torch or cutting

rod Use the "drag" technique to deposit weld metal, to thin edges when desirable or weave a wider bead,

or use a "free" arc,

2-3

WELDmNG ROD SPECmF CATmONS

AWS E-7014 CONTACT AC-DC

for welding of mild steel

GENERAL APPLICATIONS: Sheet Metal Fabrication and Repairs e Machinery

Fabrication • Construction Equipment Repairs = Storage Tanks e Shipbuilding

Fabricating Structural Shapes and Heavy Equipment = Equipment and Heavy Pipe

Welding

Diameter .... 1/18" 3/16" 1/4"

Length 12" 18'" 18"

Amperes 70-90 200-250 250-350

SIZES AND HEATS lAMPS)

3/32" 1/8" 5/32"

14" 14" 14"

90-110 130-105 190-210

SPECl FICATIONS

MEETS _k

THESE _) AmericanWelding Society ..................... Class:E-7014

REQUIREMENTS JV American Bureauof Shipping ................ C/ass:E-7014

Physical Properties of Deposited Metal: AsWelded

TensileStrength ................................................................................... 72,000 psito 78,000 psi

Yield Point ..................................................................................... 60,000 psito 69,000 psi

%Elongation in 2.inches .......................................................................................... 17%to 28%

DESCRIPTION

The AWS E-7014 is an excellent electrode for the inexperienced or experienced welder_ Starts on contact

with smooth surge-free arc, also restrikes instantly. This Craftsman electrode has powdered iron in the

coating which makes welding easier and faster_ The slag is easy to remove in most casesself-peeling as the

weld cools_

Ideal for fixture welding where weld appearance and lack of spatter is important. The amount of slag

permits use in all welding positions

WELDING PROCEDURES: Weld materials should be clean. Best results are obtained when fit-up is good.

Either AC or DC current may be used. When arc is established, deposit metal holding a short arc or place

electrode in contact with work,.

2-4

Jm=LDBNG ROD SPECNF CAT ONS

MACHINABLE CAST RON AC-DC

machineable welds on all cast irons

GENERAL APPLICATIONS: Cylinder Blocks o Crankcases o Valve Seats e Defective

Castings o Gears o Sprockets e Casting Repairs in General o Garages o Farms o Shops

Diameter

Amperes

SIZES AND HEATS (AMPS)

3/32" 1/8" 5/32"

48-85 75-130 100-150

3/18"

130-175

DESCRIPTION

This electrode uses a nickel core wire, and produces a fully machinable weld without

pre-he._ting the casting, Cast irons can be joined to steel, nickel alloys and copper,

This electrode operates with AC or DC (reverse polarityL It has very stable arc

characteristics

It is recommended for automotive repairs, such as cylinder blocks, crank cases, valve seats

and other cast iron parts In maintenance and repairs it is used on gears, sprockets, and

many farm machinery parts

WELDING PROCEDURE: Remove all dirt and grease from work piece before starting to

weld, A cutting electrode may be used to burn a groove along the break where the weld is

to be made This cutting electrode removes the grease and scale, and then seals in any oil

soaked into the cast iron

Use the lowest amperage that gives good fusion During cooling, peen hammer the weld to

relieve strain and stress

CUTTIING ROD AC-DC

quick, inexpensive, easy cuts through all metals

GENERAL APPLICATIONS: Cutting ePiercing _ Gouging =Scarfing o Beveling = etc

SIZES AND HEATS (AMPS)

Diameter ...... 3/32" 1/8" 3/16"

Amperes- AC 80150 75-130 130-175

Amperes- DC 150-250 - 5/32"

100o150

DESCRIPTION

For piercing, gouging, cutting, and scarfing

Excellent for removing old welds in preparation to rewelding_ Also used for beveling

cracks in castings or removing sharp edges prior to welding Needs no oxygen or special

equipment to cut carbon steels, stainless steel, manganese steel, cast iron, etc

Recommended for the owners of all arc welders_ AC or DC

WELDING PROCEDURE: Place etectrode in holders so that it's positioned like a lance in

the direction of travel The angle between the electrode and work metal should not

exceed 15° Strike arc at starting point, Push electrode along the line of cut, forcing the

molten metal ahead and away If deeper gouge is required, repeat procedure untg the

desired depth has been reached

2_5

REPAIR PARTS

PARTS LIST FOR CRAFTSMAN 230 AMP WELDER MODEL 113o201372

35

42

41 27

\

\ 44

\

43 27 45 45

34

15

11 10

23 24

19

/

12

32

29

\\\

28

27 13

=Transformer not replaceable°

2-6

PARTS LIST FOR CRAFTSMAN 230 AMP WELDER MODEL 113.201372

Always Order by Part Number - not by Key Number

Key Part

No. No., Description

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

61331

61276

61277

STD 511110

61278

61279

!60325

61280

STD 611005

STD 541025

STD 551225

STD 551025

STD 541006

30307

61143

61332

61335

STD 601103

61333

61334

61384

o

61314

61302

STD 501102

61315

STD 551108

Plate, Selector

Spacer

Pointer

*Screw, Pan Hd 10-32 x 7/8

Knob Assembly

Bushing

Washer, 3/8 x 1-3/8 x 3/64

Cabinet, ]'op

*Screw, Type AB Pan Hd No 10 x 1/2

*Nut, Hex 1/4-20

*Lockwasher, 1/4 int..

*Washer, 17/64 x 47/64 x 1/16

*Nut, Hex 6-32

Connector, Cable

Cord

Slide, Shunt

Bracket, Guide

*Screw, Ty T Pan Hd 10-32 x 3/8

Guide, Shunt

Spring

Core Assembly, Moving

Transformer Assembly

Motor

Bracket, Fan

*Screw, Socket Set 10-32 x 1/4

Blade Assembly, Fan

Lockwasher, #8

I(ey J Part

No.. iNo_

r

28 130284

29 51439

30 _STD 522507

31 61234

32 6TD 601105

33 60314

34 STD 510607

35 61295

36 30332

37 61171

36 61086

39 61329

40 STD 510692

41 STD 600805

42 30254

43 STD 551008

44 STD 551010

45 STD 541008

46 60309

47 61115

48 61116

49 61117

50 6TD 541110

51 STD 551110

52 61186

-61298

- 61337

Description

+Holder, Electrode

+Clamp, Work

*Screw, Hex Hd, 1/4-20 x 3/4

Cable Assembly, Work

*Screw, Ty T Pan Hd 10-32 x 1/2

*Screw, Truss Hd.. I/4-20 x 5/8

*Screw, Pan Hd 6-32 x 3/4

Cable Assembly, Electrode

insulator, Plug

Plug, Selector

Relief, Strain

Cabinet, Bottom

*Screw, Pan Hd. 6-32 x 3/16

*Screw, Pan Hd. 8-32 x 1/2

Switch

*Washer, 3/16 x 3/8 x 1/32

*Washer, 13/64 x 5/8 x 1/32

*Nut, Hex 8-32

Washer, 1-1/64 x 1-1/2 x 1/64

Block, Contact Mounting

Contact, Selector Plug

B_ock, Contact Mounting

*Nut, Hex 10-32

*Lockwasher, No 10

+Helmet

Bag Assembly, Loose Parts

Owners Manual (not illustrated)

*Standard Hardware Item - May be Purchased Locally,

+Stock Item - May be secured through the hardware department of most

Sears Retail Stores or Catalog Order Houses,

OTransformer not replaceable,

_7

ISears I

SERVICE

MODEL NO.

113.20137 2

HOW TO ORDER

REPAIR PARTS

230 AMP DUAL RANGE

ARC WELDER

Now that you have purchased your 230 amp arc welder, should

a need ever' exist for' repair parts or service, simply contact any

Sears Service Center and most Sears, Roebuck and Co. stores.

Be sure to provide all pertinent facts when you call or visit

The model number' of your 230 amp arc welder will be found

on a plate attached to your' welder, at the rear' of the cabinet.

WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE

FOLLOWING INFORMATION:

PART NUMBER PART DESCRIPTION

MODEL NUMBER

113,201372

NAME OF ITEM

230 AMP ARC WELDER

All parts listed may be ordered from any Sears Service Center

and most Sears stores. If the parts you need are not stocked

locally, your order will be electronically transmitted to a Sears

Repair Parts Distribution Center for handling.

Sold by SEARS, ROEBUCK AND CO., Chicago, IL 60684 U.S.A.

Part No 61337 Form No SP4271-4 Printed in USA 6/81