Craftsman 113201392 User Manual 295 AMP ARC WELDER Manuals And Guides L0807106

CRAFTSMAN Welder Manual L0807106 CRAFTSMAN Welder Owner's Manual, CRAFTSMAN Welder installation guides

User Manual: Craftsman 113201392 113201392 CRAFTSMAN CRAFTSMAN 295 AMP ARC WELDER - Manuals and Guides View the owners manual for your CRAFTSMAN CRAFTSMAN 295 AMP ARC WELDER #113201392. Home:Tool Parts:Craftsman Parts:Craftsman CRAFTSMAN 295 AMP ARC WELDER Manual

Open the PDF directly: View PDF .
Page Count: 36

Serial

Number ............

ModeJ 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

iNSTRUCTIONS

carefully

CRRFTSMRHo

295 AMP

DUAL RANGE

ARC WELDER

®assembly

®operating

•repair parts

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

Part No. 61341 _ :'_ ' . _ _,

SAFETY iNSTRUCTiONS TO OPERATOR

For your own protection, read and observe all instructions

mcluded nn 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 combnnatlons

Electrode and Electrode Holder

Work Clamp Work Piece Metal Work Table

80 volts exast between these parts

when welder is onq I

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

protect and insulate the body.

bTake special care to insulate yourself from ground

using dry =nsulatuon (such as dry wood} of adequate

s=ze when welding m damp Iocat,ons, on metal floors

or gratings, and in positions (such as s_tting or lying)

where parts or large areas of your body can be in

contact w_th possible grounds.

c. Manntain the electrode holder, work clamp, welding

cable and welding machine in good, safe operating

condition.

d. Do not use welding electrode as a cigarette hghter

e Connect the welder only to a source of electrical

power meeting the requ,rements, including

grounding, of the National Electrical Code (ANSI C1)

and local codes

f. Electrode coating may be eleetncaUy conductnve-

use welding gloves when ehangnng electrodes.

2. EYE AND BODY PROTECTION

a Use helmet, filter, and cover plate complytng with

ANSI Z87 1 to protect your eyes and face from

sparks and the rays of the arc when welding or

obserwng open arc weld=rig

b Always wear safety goggles with side shields

complying with ANSI Z87 1 when Jn awelding area,

or when near slag chipping operation

c. Wear od free protective garments, such as leather

gloves, heavy shirt, cuffless trousers and high shoes

d. Protect other near-by personnel w_th suitable

non flammable screening.

e Provide ddequdte ventilation in the welding area,

particularly when welding on galvanized, lead or

cadmeum plated steel, and other metal whtch produce

toxic fumes

f When worktng above floor level, protect yourself

from a fall should you get a shock. Never wrap the

electrode cable around any part of your body

g Do not weld m Iocat=ons close to chlorinated

hydrocarbon vapors com=ng from degreasmg.

cleaning, or sprawng 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 specators must be kept clear of the

welding area doe to the harmful nature of ultra-wolet

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

fumes and gases

3. FLAMMABLE AND EXPLOSIVE MATERIALS

a. Remove flammable and explosive mater_al at least 35

feet from the welding arc to prevent welding sparks

or molten metal from starting a fire. Keep atype

ABC f_r_ extinguisher within easy reach

b, Welding on or near containers wh,ch hold combustibles

can cause an expiosmn, even when they have been

cleaned For =nforn_atcon purchase "Safe Practtces for

Welding and Cutting Containers that Have Held

Combustrbles" (A6.0-65} from the Amerfcan Welding

Society 2501 Northwest Seventh St, Mnam_ FJorlda

33125

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

is _nsulated from the work clamp, work p=ece, or

work table. Accidental grounding can cause

overheating of the cables and wetder, creating a fire

hazard

dNever connect the work cable or clamp to any object

but the work piece or metal work table. Connectnng

to other objects such as budding ground can create a

fire hazard

4. PREVENTATIVE MAINTENANCE

a, Never apply power to the welder wnth any part of the

"cabinet" removed. Position on-off switch in "Off"

posltnon and disconnect welder from the power

supply before donng maintenance work inside the

machine. Removal of the welder cabinet should be

done only by a qualifned servnce techmcran

b. Before connecting the welder power cord to the

receptacle, check the following

1Inspect the power cord and welding cables for cuts

or burns and make sure blades and ground pm on

the plug are stranght

2 Inspect "On-Off" sw_tch fever for cracks or broken

parts.

3 Inspect electrode holder law insulators for cracks

or broken parts

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

burn through may cause transformer failure

dFor additional safety information, purchase copies of

"Practice for Occupational and Educational Eye and

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

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

Use of Welding and Cutting Processes" (ANSI'NFPA

No 51B) from the Amerncan Natnonal Standards

[nstntute, 1430 Broadway, New York, N Y 10018

READ AND OBSERVE THE INSTRUCTIONS

APPEARING ON THE WARNING LABELS FOUND ON

THE INSIDE OF THE WELDING HELMET, SELECTOR

PLATE, AND CABINET,

_ARNIrJG Pro_e_t _ou,_lf and _ther_ R_d and

un_,stalld thl_ Idbel

_U',IES _rJD GASE_ _arl be _l_r,ge,v_s to _,l_r ne_h_

_pC RA' g _an 1nitre eves _nd bdrr, ,kin _LECTRIC

SHOCK, nr,ll

• _ead _rd understand the m=m_fJ_l_r_, ,n,tr_¢tlons

•n_ y_ur enlp_owr • _fet, praCtl_eS

• Feep y_ur he_d our _t th_ f_,,_es

•U,e en_o@h vent,lab,on eqhust _ tb_ _rc o_ _oth

ro keep fu,_e_ and qase, rr_nl y_r ble_th,ng _one

and th_ _ner_l are_

• Wea_ correct eye eor _ml uauy protect,on

• See Am=r,_n p_uonal Sl_n_rJ Z49 I S_fel_ ,n

¢,eld, l_ _,1_ (urr,,_g m,_h,hall b, the ,_er,c_n

'_eld,nc Society 2501 _ 71h St "1_,_, FL_r,da

_3125 OSH& S,r_t_ a,lo H_lhh _ta_cla,_, ?gCFR

_910 _,l_b_e Tr_rn U _ D_pJrtn,e_l_ _f L_bar

,_asn,_l_n DC 2O210

O0 NOT _E_O. E THIS L_BEL

_AFTSMRn

12_ 0_fy for €_c1_ _ _ Pr_ecb0n

a_,_hr_l _nlU_o_ rays from _C _dhng

_,hPn _m_ lil_S _v_ce _mpacl re

3rid serI_L_SI_ reduce pt01_CllOn--

Inspe_l rr_quenll 7,_nd _mm_al_l_

_NOT REMOVE THiS L_L

LENS @

SHADENO

WARNING -- FOR YOUR SAFETY

REGARD;NG 80 VOLT pO'_ENTIAL

_HOCK AT ELECTRODE

R£GARDING POTENTIAL SHOCK 0_ CABI¢_ET

• , _ u _ _ , _ ,. _ _ _

REGARDI_IG EYE _NJU_y

FIEGARDFNG F_ItE

WARNING" ARC WELDING CAN BE INJURIOUS TO OPERATOR AND PERSONS IN WORK AREA -

READ AND UNDERSTAND OWNERS MANUAL BEFORE OPERATING WELDER

FULL ONE YEAR WARRANTY ON CRAFTSMAN ELECTRIC WELDER

If this Craftsman Electrm Welder fails to perform properly, due to adefect in material or workmanship,

within one year from the date of purchase, Sears wdl repair It, free of charge

Warranty service is available by simply returning the welder to the nearest Sears store or Serwce Center

throughout the United States.

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

state. SEARS, ROEBUCK AND CO

BSC 41-3

SEARS TOWER

CHICAGO. IL 60684

MATERIAL

;ELECTOR LOCKING KNOB

LECTRODE DIAMETER GAUGE

GETTING TO

KNOW YOUR

ARC WELDER

DUAL RANGE OUTLET JACKS

:TRODE CABLE AND

ELECTRODE HOLDER

WELDING

WORK CABLE AND

OPERATING INSTRUCTIONS

Safety Instructions to Operator

Warranty

Getting to Know Your Welder

Unpacking and Check m_ Contents

Assembly

TABLE OFCONTENTS

• 3

Operating Controls

Operating Instructions

Trouble Shooting

ARC WELD IT YOURSELF MANUAL

WELDING ROD SPECIFICATIONS

REPAIR PARTS

1-1

2-1

2=5

SPECIFICATIONS

Welding Range .............. 30 - 295 amps Hertz .............................. 60

Primary Volts (AC) ........ 230 Open C=rcult Volts (Max.) ................. 80

Amps Input (Max.) ................... 60 Duty Cycle ..................... 20% to 100%

Fuse Requ=red (Delayed Act=on Type) ......... 60 Etectrode Capacity .......... 1/16" thre 1/4"

Phase ....................... Single Over-all Dimensions .......... 21" x 14'" x 15"

UNPACKING AND CHECKING CONTENTS

SET-UP I NSTR UCTIONS

Th_s Craftsman welder =s sh_pped complete _n one carton

In order to facd=tate packaging, certain =terns have been

removed at the factory and must be assembled when

received by the purchaser Remove all =terns from the

carton and =dent=fy =tern as shown m the exploded view

If'_l

,,,4:,:

WELDER _'_""'_ 4 5

_llustratton These "Loose Parts" should be accounted for

before discarding any packaging matertal

LOOSE PARTS LIST

Key

No. PartName Qty.

Welding Helmet (Partrafly assembled) .....

Helmet bandassembly{Not Assembled) ..

Electrodecableassembly .......

OwnersManual ..............

LoosePartsBag-Containingthefollowmg ttems

ElectrodeHolder .....

1/4" Hex"'L" Wrench .........

Work Clamp .....

Electrtaal OutletBox

Screw.Pan Hd Ty "AB" N'O"10x'1"/2 """

Outlet Box Cover ......

GroundTerminal

Screw, Pan Hd 10-32 x 1/2 ....

Lockwasher,No. 10 ....... :

Nut, Hex 10-32 ....

Connection Label .....

]

ASSEMBLY

TOOLS NEEDED

7/16-inch wrench Screwdriver (medluml

ATTACHING ELECTRODE HOLDER

TO ELECTRODE CABLE

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

handle locking screw near the rind-point of the insulating

handle. Loosen th_s screw approximately two terns, or

until the handle can be shpped off the electrode holder.

DO NOT REMOVE THIS SCREW COMPLETELY

2. Sbde the handle off electrode holder and insert end of

electrode cable assembly through the handle.

The electrode cable =s the one with insulation stopped

from one end

3 Using the socke[he_d wrench Isupphedl back oet the

Hex head set screw, Ioca[ed near the end of electlode

holder untd the end of screw does not protrude into the

wire socket m the end of holder.

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

cable have not been "frayed" Twist together with

fingers _f necessary.

5. Insert end of electrode cable into electrode holder and

tighten the socket-head set screw very hrmly usmg the

1/4" Hex "L'" Wrench furnished

6 Slide the handle back into place on electrode holder and

pos_t_on tt untd the hole m handle _s d_rectly over the

head of handle locking screw TLghten the screw

clockwise _ lust enough to secure the handle on

electrode holder

ATTACHING THE WORK CLAMP

TO THE WORK CABLE

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

work clamp•

2 Do not use e_ther of the holes m handle ends of work

clamp.

3 T_ghten the screw hrmly enough to insure good contact

and prevent the cable terminal from shppmg on the

clamp.

4 Remove octagon shaped electrical box from Loose Parts

Bag

Attach _he box to the rear of the we_det cabinet _th

the two sheet metal screws provided These screws must

be bght

Attach the ground terminal to the wall of the electrical

box as shown using zhe 10-32 nut, screw and Iockwasher

provided This connection must be t_ght • %

CONNECTING WELDER TO POWER SOURCE

CAUTION: 0o not attempt to connect this

welder to a regular household outlet. Make sure

the power-line voltage and frequency agree with

ratings shown on the selector plate attached to

top of cabinet.

Electrical connections between the welder and 230-volt,

single-phase, 60-cycle AC power source should be made by

aqualified electrician, A_| wiring must comply with the

National Electrical Code (ANSI C1) and The Local

Electrical Code,

1. install an individual (separate) line for the we[der with a

fuse block m the hne. For best results, this circuit should

be as short as possible. The size of the leads will depend

upon their length as shown in the table below

Supply Conductor (incl. Extension Cords)

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

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

NOTE: -- These conductor sizes are for use with _wP]der

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

CONNECT rO GROUND BURS

IN POWER £ANEL.

CONNECT TO HOT WIRES OF

A SINGLE PHASE SYSTEM, ONLY,

MAKE CONNECTIONS INSIDE

OUTLET BOX AND INSULATE

pERkY IN ACCORDANCE '/ITH

LOCAL CODE. INSTALL COVER,

cycle in accordance with Article 630 of the Nat_ona{

Electrical Code (ANSi CI) and may not be adequate for

other loads. Consult a quahfled electrician before us=ng for

other loads.

2, install 60 ampere fuses, of the delayed-action type such

as "Fustat'" or "Fusetron", m the fuse block

3. Connect 230-volt power hnes and ground as shown.

iii, ...............

OPERATING CONTROLS

The name "Dual Range" arc welder tsderwed from the fact

that your new arc welder =s equtpped with two separate

welding ranges.

?he be_jinner or less-experienced welder will f_nd the

30-200 amp range easier to use because it provides extra arc

stabdlty when welding with some of the "more d_fhcult to

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

The 40-295 amp range requires less line (input current)

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

maximum amp settings w=th minimal effect on other

electncal appliances, motors, and hghts, on your electrtcal

system.

Either range may be used, depending on operator

preferences when the electrode diameter permits

REGARDING FIRE

KEEP C_tBU_TIBLES _JT OF RA_JGE _F V ELDI_G _FC_K_

USE FOR MINIMUM US_ FOR MAXIMUM

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 operato_ preference

To Insure a good electrical connectFon always twist the

electrode plug slightly whde inserting. To remove the plug

twist in the opposite direction whde removing.

NOTE: If you extend the welding cables beyond those

already supphed, they must be No 3 AWG or larger to

avoid an undue drop in welding current Do not extend

cables over 50 feet %

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

complete the electrical circuit) or to the welding table rtself

provided it rs metalhc or wdl conduct electncl ty r

OPERATING iNSTRUCTiONS

We feel that weldtng wtth your new Craftsman dual range

arc welder is as s_mple 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 d_rectly beneath the bar

chart d_ctates what the proper electrode d_ameter is for

g_ven thicknesses of metals You wgl note that a specific

diameter of electrodes can be used on varying

thicknesses of mater_al, Th_s _s accomphshed by

adlustmg the heat selector for more or less amperage

B Next verdy the electrode diameter, by placing the bare

porbon of the electrode into the electrode d_ameter

gauge on the right s_de of the cabinet

Because electrodes are mass produced, there may be

smag burrs on the bare end of the electrode Make sure

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

accurate sizing

C Finally, determine the type of electrode by the

tdent_ficatlon on the package or by the American

Welding Soctety number stenctlled on the coated portion

of the electrode, bearing in m_nd the type of electrode

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

diameter (as prewously determtned)

Locate that band on the amp scale There are two E6013

bands and two E7014 bands, use the band which

coordinates w_th the amp range you have selected.

Now loosen the heat selector knob and move [he

pointer untd the fractional number matching your

electrode diameter appears m the pointer window.

Tighten the heat seEector knob

Insert the electrode cable mto the proper tack

(dependmg on the range selected) Connect the work

clamp to the work

Wear Welding Helmet.

Turn the On-Off swttch to the "ON" positron and you

are ready to weld.

Because metals vary m their make up and the techntque

of each operator [s different, you may find _t necessary

to increase or decrease the amperage output accordingly

CAUTION. Do not loosen and move heat selector whde

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 m4nutehrnespan Fo_ example wetdlng for 6

minutes out of 10 minutes _s a 60% dut,, c,,,ele Tc a,c !

possible overheatlr_g of _he _e_dlng tTal,s{o_q_',_ ' _ h _'

could shorten the hfe of your ,velde_, Dc [.Jo7 v<.-._,J tr

duty c,/c_es t_ied ON "h_ r-213 _D'3_ _"

TROUBLE SHOOTING

WARNING:REMOVAL OF THE WELDER CABINET TOP FOR ANY

REASON MUST BE DONE BY A QUALIFIED SERVICE

TECHNICIAN.

TROUBLE PROBABLE CAUSE SUGGESTED REMEDY

Fan and welder do not

operate, or continually

blow fuses.

Welding current low

or weak.

Can't hold an arc.

1. Improperly fused or

protected.

2. Blown fuse, or opeR

circuit breaker.

3. "ON-OFF" sw=tch not "ON".

1. Low line voltage.

2. Welding current

setting too low.

3. Poor connections.

1. Using a D,C, welding

rod

2. Low hydrogen rod.

Use 60 ampere fuses of the delayed

action type such as "'Fusetron" or

"'Fustat" or 60 ampere 240 volt

mrcutt breaker.

Replace fuse, or reset the ctrcu_t

breaker

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 ACor AC-DC rods

2. Use rod of 3!16-inch maximum

d=ameter, or smaller on 30-200

amp range or lower

SERVICE TIPS

FAN MOTOR:

No provision has been made for lubricating the fan

motor, as extra large otl reservoirs provide lubrication

for the hfe of the motor.

SELECTOR PLUGS OR CONTACTS:

WARNING: BE POSITIVE YOU HAVE DISCONNECTED

THE POWER SUPPLY TO THE WELDER.

DO NOT REMOVE CABINET TOP OR

SELECTOR PLATE.

If for any reason the selector plugs or mating contacts

become burned or pitted, they should be cleaned with a

fine grade of emerycloth or dressed very bghtly w=th a

fine file.

t:RRFTSMRNo

A COMPREHENSIVE

GUIDE FOR YOUR

NEW CRAFTSMAN

ARC WELDER AND

WHAT iT WiLL DO

CONTAINS:

INFORMATION ABOUT

• VARIOUS TYPESOF RODS

•USEFUL ACCESSORIES

•TIPS ON CUTTING° WELDING

AND BRAZING

Form No. SP574-4 _'_

r.._o_.;__ _,_ __ ,_j_ ___,_ ,L_ .

TABLE OF CONTENTS

Page

Your Welder and What It Will no ............. 1-3

How the Craftsmen Contact Rod Simplifies Welding 1-3

Wkat Happens When You Weld? .............. 1-3

Read Before Welding ...................... 14

Learn By Doing .......................... 1-5

Position Welding ......................... t-t 1

Cest-lron Welding ........................ 1.14

Hsrd Surfacing Worn Cutting Edges .......... 1-15

The Twin Carbon Arc Torch .............. 1-16

Cutting and Other Milcellaneo=JsOperations , .. !-17

Inert-Gas Metal*Arc Welding ................ 1-19

Read this Manual carefully for additional welding information.

SEARS, ROEBUCK AND COMPANY

AND SIMPSONS-SEARS LIMITED

1-2

YOUR WELDER and what it will do..,

Your CRAFTSMAN Arc Welderisa sturdilyconstructedandthoroughlytestedmachineengineeredto

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

incorporated,which meansthat it passesall requirementsof safety, fire hazardandtemperaturerise

limitsasspecifiedintheir Standardfor Transfer-TypeArc-WeldingEquipment.

HOWTHE CRAFTSMAN ELECTRODE

SIMPLIFIES WELDING

Craftsman Contact Electrode is self-starting--plusautomatic

restarting... The electrodestartson contact.

Craftsman Contact Electrode is self-cleaning ... Under nnrmai

conditionsthe slagremovesitselfastheweld cools.Spatteris almost

non-existent. Craftsman Contact Electrode has an exceptionally

good appearance .., With fine ripple, unusually clean, smooth

appearance,and reducedslaginclusions.

CraftsmanContact Electrodedepositsmoremetalfaster.., Because

the powderedironin theflux goesinto the weld.

W H AT H A P P m=N S VHEN YOU WELD?

1Beth edges of the metal

are heated by the arc,

until --

3more molten metal and

flux is added from the

rod, which --

2 they melt and flow te-

EetherforminE one piece,

instantly--

4[ fills the crater and covers

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 c=ccompiished by

heating adjacent metal surfaces to the melting point with an

electric arc, then adding o 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 etectrlc 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, c=sit

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", aportion 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 weFd.

Some of the electrode (which consists of ometal 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 metat to form

the deposited weld.

During this operation a part of the flux coating burns off

and forms a gaseous smoke screen that completely en-

velops the arc, protecting the molten meta_ 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 cooling.

READ BEFORE /VELD|NG

_AiUSTABLE SPECIAL

_HEA, DLENS

BAND GASKET

CET_R

HEb_ET

LEATHER GLOVES

SPECTACLE TYPE

GOGGLES

SHOES

W1RE BRUSH

1/4-INCH

STEEL

SAW

HORSE

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.

HELMET SWINGS

UP TO

CLEAR THE FACE

C-CLAMP

GROUND

CABLE

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

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

accidental eye iniury, contact a physician immediately

To protect the face and eyes aheat-resisting, hbreglass

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

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

of the helmet The dear glass, which should be replaced

from t_me to t_me, protects the expensive special lens

from breakage and weld spatter. The _elmet is held firmly

_nplace on the head with an adjustable head band, thereby

leaving both hands free. A close-fittlng skuff cap should

be worn w_th the helmet. As the he)met _sused only when

actually welding, a t_ltmg arrangement permits _t to be

swung up clear of the face. When the welding _sresumed

as|ight nad of the head tips the helmet down over the Face.

To protect the eyes further wh_le 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 s_ould be worn. Aleather

jacket will give beiCer protection against the shower of

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

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

foundrymen's shoes are best.

Precautions must also be taken to protect property and

equipment against fire. A large fire extinguisher shouTdbe

within easy reach. The we_dingarea should have a concrete

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

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

practical, remove the part to be welded If not, dram the

tank and completely fill it w_th water.

Few tools, in addition to those supplied w_th 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 Apermanent

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

iron or p_pe. A ch_pping hammer is used to clean slag off

aweld and phers will be useful for handling hot metak A

w_re brush _sused to dean the work before welding and

remove small pieces of slag after chipping.

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

rust and paint, should be used for prachce welding. Angle

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

_ssescrap cast iron, high carbon or hardened steel as these

rneta|s require special electrodes and welding techniques.

These should be set aside for future practice after com-

pleting elementary practice lessons

LEARN BY DOING

OiRECTIOH

OF WELO

Expe_ience 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 on.

A comfortable body position is important when learning,

as tensed muscles will result in fatigue and lack of contro].

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 asteel top, fasten the lug of

the ground cable to it securely with a bolt or C-damp, 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 dlrecfly to the work wlth 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

Figure 1

To strike an arc, scratch the

end of the rnd on the plate

and then quickly raise ap-

proximately 1/8-inch.

first attempting to weld. Insert a small, mgd-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 (qulckly) the re-

quired 1/8-inch (fig. 1). Another method isto 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 quickly and not al]ow 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 circuit. 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.

Figure 2

Should the rod stick or

"freeze" bend it from side

to side while puHingupward

on the rod holder.

\\\\

I I t_ *_ _._ _

// //

X.,'///J//I///'/f////_

F_ger_3"

To laya weld beadonlytwo

movementsare used,down-

wardandinthe directionthe

weldis th be laid.

Figure 4

Watch the Weld puddle to

keep the slag from flowing

in front of it, causing inclu-

sions and gas pockets.

Figure 5 Figure 6

Fill the crater, when starting

a new rod by striking the

arc at A thee movng to B

and back to C position•

Te widen the bead. work the

rod from si[le to side slight-

ly, with a slow. zigzagging

crescent-shaped motion.

If difficulty is experienced offer 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 stlck--then

slowly lengthening the arc by pulling the rod away from

the work until it snaps out. Somewhere between these two

extremes the steady crackling sound of a proper arc tength

will be heard.

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

steeay 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). _/atch the weld puddle and

arc length, and move the rod steadily in astraight llne as

the back end of the crater fills up (fig. 4), The slight c=ngle

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 incheslong. After allowing

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

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

with a cold-chisel to]owed 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

uniformly, which results from o steady rate of travel and

uniforrr 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 mc_ybe allowed to cool before

laying a second bead.

When starting with anew rod, chip slag from the crater

and strike 'i-he arc at the forward end as shown at "A'" in

figure 5. Then move the rod to Band back to C, a

about twi_e _ fi0t_ai raf_ of travel to give the rod a_d

base _et_l tim_ t0:_f up T0r proper fusion.

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

from side to side slight y (fig. 6). This movement should

be slow and not wider thcsnthe 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 wi[[

be an intermittent crackle with irregular sputtering. Too

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

will provide sufficient penetration but the bead will be thin

ana 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 awide, 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 stmple weld. If the rod is moved too fast the

small bead will result with little more thor melted base

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

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

weld surface. The arc produces a hissing sound.

Agood 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-sectlonal view shows it to have good pene-

tratlon and no undercut or overlap.

Figure 7

Lay the weld beads about

one inch apart, gemove the

slag and examine each wed

before starting the nexL

Figure 8

A pad of welfl metal is built

up by running a series of

beads in layers at right

angtes to each other.

CURRENTTOOLOW

Arcis difficult to maintain.

Verylittle penetration.High

bead.

T_AVELTOO FAST

Sman bead undercut in

some p_aces. Rough top

and little penetration.

CUREEHTTOO HIGH

Wide thin head, undercut.

Crater pointed and long,

Rod burns elf very fast.

ARC TOO LONG

Surface ef weld rough.

Rod melts off in globules.

Are makes hissing sound.

TRAm/ELTOOgLOW

Metal piles up, making a

wide heavy bead, over-

tapped at sides in places.

NORMAL CONDtTIONS

Uniform ripples on su_ane

of weld. Arc makes steady

crackling sound.

Figure 9

Practice laying beads approximately one inch apart until

agood we_d can be produced with all the different rod

sizes the welder wilt handle (fig. 7). After becoming pro_

ficlent in running abead, 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.,.until a pad approximately 1/2-inch thick has

been built up. This type of welding _s 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 paralle! to the axis and lay each successive

bead on the opposite slde 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 we|d puddle tn the flat position _fig. 11). Clean

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

proper size.

Figure 10

FLAT WELDING

nff 'lffiff.g_

vrt19

Figurel i

i ]lr

fp,.JLETWIELD

LAPWELD

TACK

WELOS

Fiat welding includes all types of joints in which the weld

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

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

can be welded in the flat position.

Butt welds on light material should be practiced first on

scrap stock. Use 16-gauge mild steel sheet metal (approxi-

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

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

together and tack-weld approximate]y every three inches

(fig. 2). (Tack welds are small beads 1/4 to 3/8-inches 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 line directly above the edges to be (greed

If the weld burns through in places, reduce the welding cur-

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

experier_ced in starting the arc at these low current settings.

However, once the arc Js started, there will be sufficient

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

work over and inspect the underside which should also have

a small uniform bead. To prevent burning through where

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

and forth with short quick strokes in the dlrechon of the

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

chance to solidify (fig. 3).

Butt welds on sheet metal hghter 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 burmng

through. To assure complete penetrahon with butt welds

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

should be altowed between them (fig 5) Insert awedge or

screwdriver between the plates when tack-welding to mare-

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

on the underside

Use enough current to melt edges of ploFes to o depth of

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

respect it for smoothness, penetration and height of rem-

forcernent A good weld should have a reinforcement shghtly

more than flush with the surface (f_g 6)- Turn the plate

SLIGHT

GAP SHEET

METAL

L____I\

RACK-UP

STRIP

Frgure 4

Figure 3

Fcgure 5

Figure 7

t-.t-- GAP

FIRSTPASS

T_IRDPASS_SECONDPA_S

REIHFORCING_(WEAVE)

_PAS$BlrffWELD

Figure 8

E V-WELD

Figure 9

E-BEVELW£LO

Figure 10

over and weld a slm_iar bead on the other side (fig 71 A

hEgher welding current can be used on this s_de as there ws

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-inch

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

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

Metal of almost any thickness can be welded m th_smanner

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

until the groove _s completely filled. If the plate can be

welded from both sides, always use a double bevet (fig. 9)

]f only one plate _s beveled, the angle should be at 45 de-

grees fflg. 10).

1-8

UNDERCUT GAS POCKET

ENT

PENETRATION

Figure 11

Figure 12

Figure 13

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

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

small bead on the underside. 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

laid by mowng the rod in a straight line with no weaving

or side-to-slde movement. On the last or reinforcing pass,

aweaving motion must be used to obtain a wide weld that

will completely cover oreceding beads. For the beginner,

the side-to-side movement .with a slight hesitation at each

end) will produce a smooth too without undercut or overlap.

Select several practice welds of different thicknesses and

cut them into 1-1/2-1nch 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-welding 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 laid on the underside.

Beveling may be used to advantage on the thicker metals.

FILLET WELDS

WELD

BREAKING

THE WELD

Figure 4

Figure 6

Fillet welds are used to join two pieces of metal with sidesor

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-llne triangle (fig. 1). The

size of a fillet weld may also be measured with a square

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 csfillet weld ]s 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 length 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 aweld greatly affects its strength, which can be dearly

demonstrated by breaking the weJd (fig. 4). A ioint so

loaded should always be welded on both sides with fillets

equat 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 pleces of scrap iron together

to form a cross (fig. 6). Use a 5/32-inch rod with high curren_

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

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

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

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

lr?

Figure 11

Figure 8

Figure 9

Figure tO _UTTING

Figure 12

_ _ EXCESSWELD_

Figure 13

LAPWELDS LAPWELDS

Figure 14 Figure 15

Figure+ 16

INTERMITTENT

WELOS

STAGGEREO

iNTER+

WELDS

Figure 17

WELD_'\OHBOTHSIRES

ATENDOF 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 cold-laps are caused by not

holding the rod in the center of the seam (fig. 8). If the

desired fillet weld cannot be made with a single pass,

several passesare usedto build it upto 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 ioints 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 inthe vertical positionparticularly

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

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

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

angles indicated, and direct the arc into the corner ot 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 ca_ 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 close arc or low current will produce a bead

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

soundnessof 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 mett

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 almosl

perpendicular and move the arc rapidly. Welds of this

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

flat beacJ (fig. 15). A sfight discoloration on the underside

of the lower sheet indicates good penetration. On heavy

metal, a 3/8+inch fillet weld can be laid in one pass with a

1/4-inch 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 (fig. 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).

t-)O

POSUTION WELDING

WELD

In order to derive the greatest benefits from your welder,

you should practice until you can make a welded joint

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, vertical 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 "'vertical-up"

welding (fig. 2). In the former the bead is started at the

top and welded in a straight line 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 mustbe held as short as possible and

the weld puddle kept fairly small so it will solidify rapidly.

Vertical-down welding isthe easiest to perform and is used

on material upto l/B-inch thick. Before attempting avertical

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 vertically (fig. 3). Use 1/8-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 until molten metal in the puddle can no

longer be kept in place. Then, increase the speed slightly

while watching the puddle, arc length and angle of the rod.

Ashort arc provides better control of the molten metal.

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 smaller diameter

rods are always used for position welding.

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

the corner of the joint as in flat welding and moving the

rod down the seam at asteady 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 for 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-inch 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-inch

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 recommended as ittakes longer than a heavier single-

pass weld made by the vertical-up method.

DOWNWELD

IRSD£_

VERTICAL-DOWN9_

_ure 3

/3RO PASS

-2gB PSi;

ASM,ALLS_ OP4

g_K SiDE|IIOBAWN

COIIPLET_P£WET_Tt0g

Figure 4

Figure 5

iii

VERTICAI..UP

WELDING 90°

Figure 6

Figure 7

Figure 8

F;gure TO

Use 1/8 and 5/32-inch rods for all verticabup welds and

sta_" by running practice beads from bottom to top of a

3/16 or 1i4-1nch plate, tack-welded in a vertical position

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

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

tdted just slightly (approximately five degrees) so the tip

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

until a small amount of metal _s deposited, then quickly

raise the rod upward w_th a wrist movement to increase the

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

os the metal deposited in the crater hessolidified, bring the

rod down and deposit more metal. 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 used. 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 lang. Care should be

taken not to break the arc Qt 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 joining

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

whrpping motion. Leave a gap between the plates and use

a5/32-inch rod with a fairly high current, determined by

experimenting. The whipping motion wifl melt the corners of

the plate and form a pocket in wh]ch 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 smalt bead, whLch indicates 100-percent pene-

tration Buff welds on heawer materials should be welded

on both sides.

On materials up to 1/4-1nch thick, usethe whipping motion

on small single-passfillet welds for lap and tee-joints. Larger

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

with a slight slde-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 intermLttentlyas the welding

progresses•There should be aslight pause in the weaving

mot_an at the toes of the weld to avoid making abead 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 awide bead using aside-to.side weaving

motion with a very shght whipping action at each end to

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

undercutting along the sidesof the weld (fig. 10). This type

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

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

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

fairly hght, Multiple verticoLwelds may be made as shown

in the series of diagrams, figure 11.

TOP _ I$!

Frgure I 1

r pASS

Figure 12 i il

Figure 14

) +

OVER-LAPPED BACK-UP STRIP

Figure 13 Figure 15

HOLD ALOHSARC

UP SIROKE

Figure 16 Figure 17

HORIZONTAL WELD|NG

Horizontal welding refers to one type of butt weld between

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

as for vertical welding and run straight beads across from

left to right (fig. 12). Use tFe same current settings as for

vertical-down welding and hold the rod as indicated with

a short arc. Move the rod in a straight llne 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 until a well

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

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

one side. If the seam has numerous gaps, use a back-up

strip, allowing 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. t6). Thoroughly clean each

bead before laying the next and use higher current than

for single-pass welding.

The appearance of a multiple-pass horizontal weld can be

improved by vertical down beads lald closely together.

Use a swift circular motion to the right; slowly downward

while welding (fig. 17).

OVERHEAD WELDING

Although overhead welding is generally considered diffi-

eu]t, do not become discouraged, as it is being done every

day by people who have taught themselves. Once the art

of maintaining a short arc has been mastered, the rest

will be easy.

Since there will be a shower of sparks, wear aleather

jacket and keep the practice plate slightly higher than the

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

gJove, grasp the electrode ho]der as indicated in figure 18

and ho]d the rod in anearly vertical 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-inch rods and a current setting the same as for vertical

welding, and move the rod in a straight line 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 wide. Themovement must be somewhat

faster than for other positions to keep the bead from

sagging. (This method of weaving is used on]y 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

welding 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 5/32-1nch

rods, varying the plate size and gap distances.

F;gure 18

Figure 19

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

overhead position. Tack+weld two pieces of scrap iron

together to form a tee+iolnt, 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 we_ds will be

necessary to get good penetration at the root of the weld.

_-_3

DISTORTION TRENDS

WHEN COOLING

BUTTW£L_

Figure 23

_T IST mLBH_ T_ yRt9 _. ET_

Figure 20

Figure 24

Figure 21

To simulate actual conditions tack-weld a piece with an

irregular edge to another piece leaving numerous gaps

along the iolnt. Use the _vhlpp[ng motion and deposit a

fairly heavy bead, slowing down the rate of travel where

the gaps are widest to budd up a weld of umform size

throughout Its length. If the gaps are rather wide, fil_ them

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

length of the joint (fig 20)

When you can lay slngle.pass butts and hllet 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 heatedi contract when cooled In arc

welding, the deposited metal and edges being joined are

molten and the metal surrounding the weld is heated suf-

fiaently to cause expansion. When the deposited metal

so|id_fies, it becomes a part of the plates; but, being unre-

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

contract more than the heated surrounding metal If the

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

It cannot resist these forces and bends (fig 22)

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

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

stresses(fig. 23). This is not too serious when weldlng mild

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

the metal will permit it to deform shghtly to compensate

for these forces, and prevent cracking On sheet metal and

light structural members, long continuous welds may cause

conslderabb bending and result in a badly distorted weld-

ment. Fortunately mostof this can be avoided by studying

the effects of expansion and contrachon, as related to the

job before welding and working out a procedure to follow

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

_nstall temporary braces tack-welded to support parts that

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

completed. Lay the beads GO the stresseswill counteract

or nbutralize one another, by running ashort 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 m one place but space them to distribute the heat

and stresses throughout the enhre structure Use intermittent

welds whenever pass.hie, ff continuous welds are necessary

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

method as shown in figure 24, fusing each bead together

at the end.

CAST iRON WELDING

Previous experience in handhng the arc, plus good ludg-

rnent regarding expansion and contraction, wdl enable

you to weld grc_y cast Iron successfully m a short t_me.

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

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

machined, and machinable which deposits a file-soft weld

that can be drilled or machined to close tolerances Non-

rnachJnabJe rods are used for most repair iobs such as

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

ings, etc. I{ 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 wtth an abrasive

wheel.

As cast iron is ve,"y brittle, care must be taken to control

expansion and contraction, and thus avoid cracking of the

weld or the casting Because of tow tensde strength and

lack of ductility it cannot bend, stretch or d_stort itseJfta

conform to the contraction of the weld metal. In same cases

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

weJd_ng. However, as most cast _ran welding lobs can be

clone without pre-heatmg, this method will be considered

first

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

by w_re 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 a single or double bevel, depending upon the

thickness of parts and whether or not the ioint can be

we_ded from bath sides. Do not bevel to a sharp edge along

the entire crack. Instead, allow approximately 1/16-,nch

t-14

of the fractured surface to llne up the two pieces. Tack-weld

or clamp parts in position. !f the crack has not separated

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

mond-point chisel. Chlp 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 seal is required, the

depth of the groove need on!y 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_.

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, worklng

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 llme

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.

FIRST BEAD THIRD HEAD SECOND H£AD

i_ '_.4

HARD FACmNG WORN CUTTING EDGES

SPIKE

HARROW

TOOTH

Figure

INOICATES

HARO FACING

HARD FACE ONUNOERSID[

Ig SIDES

_PS

SWREP

Excavating equipment, earth-cuffing 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

will 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 Jess,use a 1/8-1nch rod and as low a current as

possible that will still permit the metal to flow out smooth

and falrly thin (1/16 to 1/8-inch thick). Weave the rod

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

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

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

faces are quite wide. In some cases a small straight bead

GR_D OFF WEJ_VEBEAHS

Figure 2F;gure 3

HARDFACIfH HARDFACING

SOFTBASE METAL MILO-STE£L PA_/CH

W_ARSAWAY EASTEr WELDS

THAN HARD HAS]fiG Figure 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, cuffivator shovels and similar

cutting points, deposit the weld metal on one side only

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

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

leave a knifedike 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. ]f the part requires a number of

passesto bring it up to the desired thickness, use mild-stee_

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 weid

metal before it cools.

THE TWIN-CARE]ON ARC TORCH

Figure I

Work ordinarily done with a gas welding torch _spossible

with the twin-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 radlahon, 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 heating for bending, forging and hardening.

The arc torch (fig. t) consists of an insulated handle with

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

justable to permff striking and breaking an arc at the carbon

tips. Athumb knob on the handle performs the adjustment

and operates csshut-off swltch built into the handle. There

are no valves or gauges that require fine adjustment as

with an oxyacetylene torch The same protective equipment

used for ordinary arc weldmg is used when operating the

carbon-arc torch.

A wide selection of flame heats may be hod by varying

the current and size of the carbon electrodes. Ahhough 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

excessof those given below will only cause short carbon life.

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

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

3/8-1n. carbons ....... 65 to 90 amperes

F_gure 2

iELE Tn0_E

,k_e

F;gure 3

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

ground and electrode cables of the welding machine.

Grounding of the work _snot necessary as the operation of

the arc flame is enhrely independent With the thumb knob

on the handle in the "off" pos_tlon,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

overheahng of the carbons. When tightening the clamping

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

carbons, as they are very bnttle and break easily. Use only

enough pressure to hold them firmly m place, if the hps

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

may be made by turning the Iorlgest of the electrode holders

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

sary to disassemble the torch to agaln tighten it properly.

Do not make any turning adlustments wdh the shding holder

as this would spo_l the contact tensRonin the sw_tch

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

approximately 70 amperes Lower the welding helmet and

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

dow. Slowly move the thumb knob forward untd contact

Lsmade between the hps of the carbons. Th_swLH start the

arc Then Jmmed_ate[y move the knob back to mcrease the

gap between the carbons. The actual d_stance can be deter-

mme_ with a httle prachce When the carbons are too close

the arc flame will have a sharp crackhng noise As the

distance between the carbons is increased, the crackhng

w_rfchange to a soft purring sound which md_cates the best

arc flame. There are two heat zones and the small tuner

zone _sby far the hottest, having an eshmated temperature

of 9000 degrees Fahrenheit (fig 3)

The shape of the flame greatly influences the way m which

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

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

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

flame straddles the groove and the heat w_ll not reach the

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

on Iomts of tb_s type

The soft, bushy flc_me _s pressureless and has no tendency

to blow the mohen metal This _sa d_shnct advantc_ge when

welding thin sheet metal Jo_r_tsan hght mater_al should be

CORRECT FLAME POSITION

Frgure 4

INcoi_RECT FLAME POSITION

F_gure 5

!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 sinai] tubing.

Cast and malleable iron can be brazed with excellent

results. A bronze filler rod and common brazing flux are

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

to be brazed. If it is a buff 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 cast iron

is never to heat the edges ef the joint to the melting point.

The temperature of the work should not exceed the melting

point of the filler rod. The carbons are held as close to the

work as possible without causing 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 a shiny 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 fin the part of"

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

being deposited, move the torch along the ioint 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 meItlng point of the filler rod, the process

in many cases becomes one of welding rather than brazing.

A bronze fil]er 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 metal, tf the

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

aluminum alloy, use aluminum 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 iust hot enough to

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

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

adding more 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 welding 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 meta] is too thin for

regular metallic-arc welding.

CUTTING

and other miscellaneous operations

CUTTING WITH THE ELECTRIC ARC

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

such as you probabty 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.

START

CUT

HERE

Figure 1

,a,,_.MOLTEHMETAL

STEEL

,_ CONTAINER

MOVI[ ROe Lip AND -_, ._

_. START

CUT

HERE

F_gure 2

To make atrial cut, place a bar of steel approximately

1/4-1nch thick on the table so that ene end projects over

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

around 140 amperes. Hold the rod as shown in figure 1 and

strike an arc on the top 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

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

container an the floor directly under the cut.

When cutting metal heavier than 1/4-inch, 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 cllsobe 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 (fig. 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 struckon 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 boff or rivet can

be removed by heating the head almostto the melting point,

then quickly shearing it off with a cold chisel Care mustbe

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

HOLE PIERCING

Another useful appllcahon of the welding arc is piercing

holes in metal. Coated metallic electrodes are best for

this purpose because of their small size and insulation

afforded by the coating. The process is extremely fast and

a surprisinglycleon circular hole can be made. Far practice,

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

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

cutting. Use a3/32-inch 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 itthrough the plate. It ispossible to hold the e4ectrode

against the melted plate because the metal core melts off

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

the molten metal (fig. 5). The gap malntamed by the pro-

truding coahng 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 afairly long arc, melt the edges

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

of almost any diameter can be made. To pierce a hole

through material thicker than 1/4-inch, work from the

underside.

HEATING

The carbon arc prowdes a convenient method for localized

heating of all metals. Simply strike an arc on the part to be

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

temperat_ureis reached

GOUGINe

Figure 3

MOL1TN

Figure 4FJgure 5Figure 6

1-1E

INERT-GAS METAL-ARC WELDING (Nonconsumabme)

ALLCABLES

SHOULDBE

NEPTSHORT

ASPOSSIBLE

(Donot ex-

ceed12-U2

feetin length)

GROUNDEDWORNPIECE ANYCRAFTSMANWELDER

ORWORNTABLE MAYBEUSEOWITHHF

TOELECTRODE /ATTACHMENT

HEATE WELDER

GROONDCABLEJ GROUND

_ - I CABLE o o

230 VOLT

_HOCYCLE SINGLEPHASE

HIGHFREQUENCY

ATTACHMENT

WELDINGCABLETO WELDER AC OR DC WELOER

WELDER

CABINET

MOST BE

GROUNDED

F_ure I

(

/'; \

Figure 2

HmGH FREQUENCY ATTACHMENT

The Craftsman, High-Frequency Attachment may be used

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

farmer-type welder of high quality construction having an

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

welding has many useful and advantageous applications

as described in the following paragraphs. In order to use

the T.LG. process w_th an AC welder, ahtgh-frequency

attachment must be provided Figure 1 shows a typica_

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 high-frequency attachment makes possible the

establishment of an arc without touching the electrode to

the work. Once the arc has been estabhshed, it is stabihzed

by the high-frequency output. This is essential in the T.I.G.

process in order to avoid contaminating the tungsten elec-

trade 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

usedfor 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 T.I.G torch and the weld is made by applying

the arc heat untll the abutting edges of the work.pieces are

melted, adding filler rod If necessary. The resultant pool

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

members together. The process may also be used for adding

metal to surfaces, locally-melting and spot-jolnlng parts

A thorough cleaning of the surface to be welded is required.

All off, grease, paint, rust, dirt or other contaminants must

be removed either by mechamcal means or by the use of

vapor or hquid cleaners. Files, chisels and stainless wire

brushesmay be used Grinding Jsnot 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 jo_ntis assembled prior to welding

Striking the arc may be accomphshed as follows

1. Touching the electrode to the work momentardy and

quickly withdrawing itashortdistance. (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 stabiffzer provides for this latter

method of starting the arc. Such devices are not required

with DC, consequently it is usuafly necessary to touch the

electrode to the work to start the arc.

For manua_ 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 2. To 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 ts achieved at

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

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

Fng edges progressively, adding filler rod as required

Solidification of the melted metal follows progression of

the arc along the iomt and completes the welding cycle

Material thickness, joint design and weld characterLshcs

desired will determine whether or not filler metal should

be added to the joints. When fll)er metal is added during

manual welding, it is apphed 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 essentlally the sQmemanner

when welding by the oxyacetylene method

(11DEVELOP

THEP.OOL

DIRECTION

WORKPIECE

Figure 3

(2) MOVE

TO C.

f_///I///77///////////3

(4)REMOVEROE}

"[he 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 techniquesfor feeding filler

rod is shown in figure 3. Another method, used mostoften

in multiple-pass welding of vee pints, is to press the filter

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 oscdloting the filler rod

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

red 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 TJ.G. process include all

standard types, suchas square abutting edge, vee buff, tee

and lap connections. It is seldom necessary"to bevel edges

of materlal ll8-inch or less, although heavier materials are

usually beveled. Whenever joints are beveted, filler ma-

teria( must always be added.

The accompanying table provides a guide to the type of

current recommended for welding some typical materials.

ElectTodesused for the T.hG. (nonconsumable) process may

be pure tungsten or tungsten alloy. Pure tungsten electrodes

were formerly used exclusively. At this time, however, many

(31Ann _

FILLERMETAL

(5) MOVETORCH

TO LEADINGEI)GE_

o,PUODL

_////S////////////////_;'//////_///////A

_Lf .OO\

ADDITIONOF

FILLERMETAL

(VERTICAL _"s°"i

POSITION)

electrodes are alloyed with small percentages of thorium

or zirconium. Suchelectrodes have the advantage of greater

current-carrying capacity For a given diameter, a more

stable arc at low current values, and longer llfe 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 mamtalns a stabilizing influence on the welding arc

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

Helium isgenerany 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 isgenerally supplied in K-cylinders, having a capac.ty

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

or in T-cylinders, having acapacity of approximately 330

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

argon ranges between 99.95% and 99.99%.

Current Selectionfor Inert.gas

(nonconsumable)welding

Material

APernse_ Current* Direct Currellt

St_lllz_d St_ght IP_t_ity Reverse POlaritY

I i =

Magnesium up to _z-m th=ck v" \/

Magnesium above %s-m thick _/ \'

MaEneslumcastings %/ _,,

Alummumupto _2-in thick _/ _/

Aluminum over _3a-,n th,ck x/ v

Alurnm_m castmgs \/ V'

Stamless steel V\/

Brass alloys v' x/

_lllCOn copper _ _/

S11ver %/ _,/

Higb-chromium, nickel-base, high

temperature alloys _/ V

Silver cladding _/ x/

Harb facing _/ _,'

Cast iron _/ V'

Low-carbonsteel, 0015 to 0 030 in t %/

Lowcarbon steel 0 030 to O 125 in "/ _/

High-carbonsteel, O O15 to 0030 in %/ x/

High-carbonsteel, 0.030 in and up "_/ \/

Deoxidized copper_ %/ \1

%,t

• Where alternating currs_t is recommended as a second choif;_J_,US_ about 25% hlsher current than that

reco_lmended for OCSP

DO riot Use elternatln_ current On tightly jigged parts

; Use braZlCg flux Or slllCO_ b_ont_ flu:_ for 1/4 inch anr_thicker

1-20

WELDING ROD SPECJFICATmONS

AWS E-6011 MBLD STEEL AC-DC

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

Body and Fender ePipe • Tanks • Maintenance • Jigs and Fixtures eCabinets

•General Repairs oStructuralSteel

Diameter ....

Fiat

Vertical

Overhead

SIZES AND HEATS (AMPS)

1/16" 3/32"

20-55 20-80

20-55 20-65

1/8"

75-130

75-115

75-115 5/32'" I3/16" i 7/32"

100-175 150-225 175-25(:

100-150 150-200

100-t50

1/4"

200-375

MEETS _,

THESE

REQUIREMENTS V

SPECl FICATIONS

American WeldingSociety ............... (:lass: E-6011

Military ............................ MIL-E-t5599C

AmericanBureauof Shipping ............ Class:E-6011

Physical Properties of Deposited Metal: As Welded

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

Yield Point ..................................... 00,000 to 05,000 psi

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

Redaction in Area ................................ 50% to 55%

St rest;Relieved

65,000 to 70,000 psi

55,000 to 60,060 psi

30% to 35%

65% to 75%

DESCRIPTION

The AWS E-6Oll is an AC-DC (reverse polarity) electrode with aspecial 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.W.S. 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, use aslight 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 astraight stringer bead or a circular motion. Keep the

molten pool as small as possible. Use small electrodes overhead, none larger than 5/32 diameter.

WELDmNG ROE) SPECIFiCATiONS

AWS E-6013 MILD STEEL AC-DC

multi-purpose all position

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

P_pe •Tanks = Boilers •Strucl_ural Steel t Maintenance Repairs • General Repair

Work

D la i,tl_ret

Flat

Vertical

Overhead

SIZES ANO HEATS (AMPS)

5164"

20-55

3132" 11/8"

20-75 75-130

20-65 75-115

5t32"

100-175

100-150

3/16" 1/4"

150-225 200-375

150-200

MEETS

THESE

REQUIREMENTS

SPECI FICATIONS

AmericanWeldm9 Socaety............ Class E-0013

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

&MIL-E-G843A

AmericanBureauof Shipping ...... Class E-6013

Phyr_cal Properties of Deposited Metal AsWelded

Tensde Strength ........................ 75,000 to 80,000 psi

Yield Point ....................... 62,000 to 67,000 psi

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

Reduction m Area .................... 40% to 55%

Stre_ Relieved

65,000 to 70,000 psi

50,000 to 60,000 ps_

27% to 35%

60% to 70%

DESCRIPTION

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

easily handled arc xhroughout aw_de amperage range. The moderately penetrating and easdy d_rected arc

provides excellent results in all positions (flat, vertical or overhead) and is =deal for single pass hor_,,ontal

fillet welds. Spatter loss is low, as the weld metal solid=hes qu=cklv producing a closely r_ppled deposit with

good appearance.

Even though it is designed for production welding in mild steel fabrication, th_s rod =s excellent for

multi-purpose use where sound durable welds are requ=rod.

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

amperages needed for higher welding speeds, and for heavrer sections

Use w_th AC or DC (see recommended amperages) Hold ashort are, lust tong enough to keep "_heelectrode

from touch=rig the molter metal. ]re flat posit=on single pass fdlets or butt welds may be made w_th or

w_thout 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, mal<lng

e_ther stringer or weawng beads.

2-2

WELDING ROD SPECmFICATaONS

HARD SURFACING AC-DC

medium chrome-carbon electrode

GENERAL APPLICATIONS Tractor Grousers and Rollers eScraper Blades eAgri-

cultural Implements ePlow Shares eHitches •Power Shovel o D=pper Teeth and

Drive Sprockets o Coal Cutters •Conveyor Roils oMmmgBuckets e Rock Crushers

• etc

SIZES AND HEATS (AMPS)

Otameter 3/32" 1/8" 5/32" 3/15" 7/32" 1/4" I

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

MEETS

THESE _Md=tary

REQUIREMENTS V

SPECl FICATIONS

..... MIL-E-19141C

Physfcal Properties of Deposited Meta_

AsWelded Condttmn (Rockwell "C" 46-50) .......

After Cold Working (Rockwell "C" 50-54) .............

450-500 Brmel_Hardness

500-550 Brmell Hardness

DESCRIPTION

The Medium Chrome-Carbon rod is a hard-surfacing alloy steel electrode with a coating of powdered me_als

and flux When welding, th=s special coating combines _n the arc with the steel core wire to give an

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

strength, duetdlty, and wear resistance Anneahng or heat treating wdl not soften the metal deposit, which

is not machinable, but may be hot forged to any desired shape. Oepos=ted metal has a very fine gram and is

free of slag and porosity The metal _stough and h_ghly resistant to wear and ,mpact

The rod =s designed for use wJth eltber AC or DC (rather DOlarlty). Hold a medium short are and deposit the

metal w_th aweaving motion Excellent welding results are obtained =n eJther the vertical or flat positron

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

material Cracks too deep lco be removed by grinding should be gouged out with a cutting torch or cutting

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

or use a"free" arc

WELDING ROD SPECIFnCAT|ONS

AWS E-7014 CONTACT AC-DC

for welding of mild steel

GENERAL APPLICATIONS: Sheet Metal Fabrication and Repairs a Machinery

Fabrication e Construction Equipment Repairs eStorage Tanks e Shipbuddmg

Fabricating Structural Shapes and Heavy Equipment e Equtpment and Heavy Pipe

Welding.

SIZES AND HEATS (AMPS)

Diameter .... 1116" _3/32"

Length 12" 14"

Amperes 70-90 90-110

1/8"

14"

130-165

5/32"' I3/16" 1/4"

14" I 18'" 18"190-210 200-250 250-350

SPECIFICATIONS

MEETS _,

THESE WAmedcanWeldingSocmty.............. ClassE-7014

REQUIREMENTS VAmericanBureauof Shipping ........... Class E-7014

Physical Properties of Deposited Meta! As Welded

TensileStrength ........................................................ 72,000 ps!to 76,000 psi

Yield Point ............................................................. 60,000 ps_to 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 restrlkes instantly. This Craftsman electrode has powdered iron in the

coating which makes welding easier and faster. The slag is easy to remove in most cases self-peehng 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 ht-up is good

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

electrode in contact w_th work.

WELDING ROD SPECiFmCATnONS

MACHINABLE CAST iRON AC-DC

machineable welds on all cast irons

GENERAL APPLICATIONS: Cylinder Blocks eCrankcases eValveSeats eDefective

Castings e Gears eSprockets e Casting Repairs in General eGarages • Farms ® Shops

SIZES AND HEATS (AMPS)

0iameter I3/32" i

Amperes 48-85

1/8"

75-130

5/32"

100-150

3/16"

130-175

DESCRIPTION

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

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

This electrode operates with AC or DC (reverse polarity). 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. Acutting 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.

CUTTaNG ROD AC-DC

quick, inexpensive, easy cuts through all metals

GENERAL APPLICATIONS: Cutting • Piercing •Gouging •Scarfing eBeveling •etc.

SIZES AND HEATS (AMPS)

IDiameter...... I 3/32" 1/8" 5/32"

Amperes- AC 80-150 75-130 100-t50

Amperes- DC 150-250

3/16"

130-175

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 electrode 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 until the

desired depth has been reached.

REPAIR PARTS

PARTS LIST FOR CRAFTSMAN 295 AMP ARC WELDER MODEL 113.201392

53 54

\\\

28 29 30 31

-,.®24+

32 33 32 16

2-6

PARTS LIST FOR CRAFTSMAN 295 AMP ARC WELDER MODEL 113.201392

Always Order by Part Number -- not by Key Number

Key

No.

Pert

No.

STD 541110

STD 551210

STD 611005

61339

61276

STD 551008

STD 511110

61300

61278

161279

60325

61280

STD 541025

STD 551225

STD 551025

STD 541006

STD 511105

37525

37526

30298

61335

STD 601103

61332

61333

61334

61385

61314

61302

Description

*Nut, Hex 10-32

*Lockwasher, No. 10 Internal

;*Screw, Type A8 Pan Hd. No. 10 x 1/2

Plate, Selector

Spacer

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

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

Pointer

Knob

Bushing, 3/8 x 1

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

Cabinet, Top

*Nut, Hex 1/4-20

*Lockwasher, 1/4 Internal

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

*Nut, Hex 6-32

*Screw, Pan Hd. 10_32 x 1/2

Ring, Outlet Box External

Cover, Outlet Box

Terminal, Ground

Bracket, Guide

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

Slide, Shunt

Guide, Shunt

Spring

Core Assembly, Moving

Transformer Assembly

Motor

Bracket, Fan

Key Part

No. No. Description

STD 501102

61315

STD 551208

STD 541008

61264

61190

STD 561025

ISTD 522507

61342

iSTD 510805

STD 512507

STD 510607

61310

30332

61171

61086

61338

61269

STD 551010

61311

61115

61116

61117

61265

37435

61307

61341

*Screw, Socket Set 10_32 x 1/4

Blade Assembly, Fan

*Lockwasher, No. 8 Ext. Tooth

*Nut, Hex 8-32

+Holder, Electrode

+Clamp, Work

(Includes Key No. 36 & 37)

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

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

Cable Assembly, Work

*Screw, Pan Hd. 8-32 x 9/16

*Screw, SL Tr. Hd. 1/4-20 x 5/8

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

Cable Assembly, Electrode

Insulator, Plug

Plug, Selector

Relief, Strain

Cabinet, Bottom

Switch

*Washer, 13/64 x 3/4 x 1/32

Lead, Primary

Block No. 2, Contact Mounting

Contact, Selector Plug

Block No. 1, Contact Mounting

+Helmet

Wrench, Hex 1/4

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.

eTransformer not replaceable.

$ERVmCE

HOW TO ORDER

REPAIR PARTS

295 AMP DUAL RANGE

ARC WELDER

Now that you have purchased your 295 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 295 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

113.201392

NAME OF ITEM

295 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 aSears

Repair Parts Distribution Center for handling.

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

Part No, 61 341 Form No. SP4272-2 Printed in U.S.A. ! 2/80

Craftsman 113201392 User Manual 295 AMP ARC WELDER Manuals And Guides L0807106

CRAFTSMAN Welder Manual L0807106 CRAFTSMAN Welder Owner's Manual, CRAFTSMAN Welder installation guides

Navigation menu

Versions of this User Manual:

Views

Navigation