Craftsman 113201480 User Manual 50 295 AMP DUAL RANGE ARC WELDER Manuals And Guides L0805139

CRAFTSMAN Welder Manual L0805139 CRAFTSMAN Welder Owner's Manual, CRAFTSMAN Welder installation guides

User Manual: Craftsman 113201480 113201480 CRAFTSMAN CRAFTSMAN 50-295 AMP DUAL RANGE ARC WELDER - Manuals and Guides View the owners manual for your CRAFTSMAN CRAFTSMAN 50-295 AMP DUAL RANGE ARC WELDER #113201480. Home:Tool Parts:Craftsman Parts:Craftsman CRAFTSMAN 50-295 AMP DUAL RANGE ARC WELDER Manual

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MODEL NO.

113.201480

Serial

Number

Model and serial

number may be found

at the rear

of the cabinet.

You should record both

model and serial number

in a safe place for

future use.

CAUTION:

Read

SAFETY

INSTRUCTIONS

carefully

Sold by SEARS,

Part No. 61421

• •i•: i•i::¸:_:::: : ; :• :; :

50-295 AMP

DUAL RANGE

VARIABLE CONTROL

ACARC

eassembly

®operating

®repair parts

ROEBUCK AND CO., Chicago, IL 60684 U.S.A.

Printed ;inU.S.A_

a:. Never permit the electrode or live metal parts

of:the eiectrodeholder t0_t0uch bare sk nor

any: damp:o_ W_eti::covering of the body. The

electrede:cbating slioutd be considered as an

electrical conducltor_ Do n0t insert electrode in

electrode hotde_iWith your bare hand -- wear

pr0pergloVes on both hands.

ELECTRODE AND ELECTRODE HOLDER

WORK CLAMP WORK PIECE METAL TABLE

80 Volts exist between these parts

when welder ison!

Weardry hole_free clothing, gloves and shoes

to protect and insulate the body:

b. Take special care to insulate yourself from

ground using dry insulation (such as dry

wood) of adequate sizewhen welding on metal

floors or gratings, and in:Positions (such as

sitting or lying) where parts or fargo areas of

your body can be in contact with possible

grounds:

c: Turn switch "OFF", and remove plug from

power source before picking up or moving the

welder.

:d. Maintain the electrode: holder, work clamp,

welding cable arid welding machine in good; :i i:

safe Operating i €onditior_ :by :Practii_i_g:!!i: :i:::':

per io d!ic i n S pect ion ::=an d p r e ve n tat ive i!,:_i,:__!.il

e. This Welder':_iis ':not;}:::i_uitable i:iori:_:use

electrically hazardous conditions due to

or persph;atiom Under these c0ndil

automatic control equipment iS required in

accordance: with ANSI Z-49.1:.";SAFETY IN

WELDING AND CUTTING_"

f. Connect the welder on!y to a source of

electrical power meeting the requirements,

including grounding, of the National Electrical

Code (ANSI C1) and local codes,

Improperly wired extension cords can cause a

potentially fatal shock hazard by electrically

energizing the Welder cabinet. Us_ only a

properly wired and adequately sized extension

cord which has agrounded conductor. (See

"Connecting the WeJder to the Power Supply ....

elsewhere in this manual for more

information).

If you receive a shock from the welder cabinet.

immediately disconnect the welder from the

power supply and obtain help from a qualified

electrician.

g. Do not drop or insert objects through the

area or when near a slag chipping operation.

c, Wear oil-free flame resistant protective

garments, such as leather gloves heavy long

sleeved shirt, cuffless trousers and high shoes.

See picture of appropriate dress in "Arc Weld it

YOurself" section of this manual.

d. Protect other nearby persone] with suitable

nOn-flammable screening.

e. Welding can produce fumes and gases which

are dangerous to health. Keep your head out of

the fumes. Use enough ventilation, exhaust at

the arc, or both, to keep fumes and gases from

your breathing zone aod the general area.

Take even greater care when welding on

galvanized or cadmium plated steel and other

metals which produce toxic fumes.

Air-Supplied helmets may be necessary.

f. Protect yourself against a fall should you

recewe an electric shock, particularly when

working above floor level. Keep floor around

your operating position free of clutter. Never

wrap the electrode cable around any part of

your body.

g. Do not weld in locations close to chlorinated

hydrocarbon vapors coming from degreasing.

cleaning, orspraying operations. The heat of

the rays of the arc can react with solvent vapors

to form phosgene, a highlytoxic gas. and other

irritating products.

h. nprotected spectators must keepclear of the

area due to the harmful nature of

et and infra-red arc rays, welding

and weldirig fumes and gases.

a::Remove:flammable and explosive material at

ieast 35 feet from the welding arc to prevent

welding sparks or molten metal from starting a

fire. Keep a type ABC fire extinguisher within

.easy reach.

b. Welding on or near containers which hold or

have held combustibles can cause an

explosion even when they have been cleaned.

Do not weld on such containers until you have

read "Recommended Safe Practices for

Welding and Cutting Containers and Piping

That Have Heid Hazardous Substances" F4.1

available from the American Welding Society.

550 LeJeune Road, Miami. FL 33135.

c. Vent hollow castings or containers before

heating, cutting, or welding. They may explode

from expansion of trapped air or boiling

liquids.

d. When not welding, place the electrode holder

where it is insulated from the work clamp, work

piece, or work table. Accidental grounding can

cause overheating of the cables and welder,

creating a fire hazard.

e. Neverconnecttheworkcableor clamptoany

objectbutthe workpieceor meta_worktable.

Connectingto otherobjectssuchasbuilding

ground can cause stray currents to flow,

resultingin overheatingor fire.

4. PREVENTATIVE MAINTENANCE

a. Never apply power to the welder with any part

of the ,cabinet" removed. Position on-off

switch in "off" position and disconnect welder

from the power supply before doing

maintenance work inside the machine.

Removal of the welder cabinet should be done

onty by a qualified service technician.

b. Before connecting the welder power cord to

the receptacle, check the following:

1. Inspect the power cord and welding cables

for cuts or burns and make sure blades and

ground pin on the plug are straight.

2. Inspect "ON-OFF" switch leverfor cracks or

broken parts.

3, Inspect electrode holder jaw insulators for

cracks or broken parts.

c. Never weld anything on or to the welder

cabinet, as a burn through may cause

transformer failure.

d. If any part of your welder is malfunctioning or

has been damaged or broken, such as switch,

cables, helmet, electrode holder, cease

operation immediately and disconnect welder

from the power source and turn switch "OFF"

until the particular part is properly repaired or

replaced.

5. ADDITIONAL SAFETY INFORMATION

a. For additional safety information, purchase

copies of "Practice for Occupational and

Educational Eye and Face Protection" (ANSI

Z87.1), "Safety in Welding and Cutting" (ANSI

READ AND OBSERVE THE INSTRUCTIONS

APPEARING ON THE WARNING INFORMA-

TION FOUND ON THE CABINET,

ELECTRODE HOLDER AND ON THE INSIDE

OF THE WELDING HELMET.

i

t.,_ WARNING ELECTR,CSHOCKCA.BEFATAL!BeFOa_I

TURNING WELDE R ON, CHECK THE ELECTRODE HOLDER TO 1

BE SURE THAT THERE ARE NO PROTRUDING SCRE W HEADS

_1_ AND THAT ALL INSULATION iS SECURE _ _ :" '_

Z49.1), and "Fire Prevention in Use of Cutting

.... , and ,Welding Processes" (ANSIiNFPA No.

518) from the American National Standards

Institute, 1430 Broadway, New York, New

York, 10018. Purchase copiesof"OSHA Safety

and Health Standard" 29 CFR 1910 from the

U.S. Government Printing Office, Washington,

D.C. 20402.

SPECiFICATiONS

INPUT

Volts AC.. ............................ ..... 230

Hertz (Cycles) .;..... ...................... 60

Rated Input Amps .......................... 60

Delay Action Type Circuit Breaker or Fuse 60Amp

Short Circuit Amps ....................... 100

Power Cord Length ................ wire direct

OUTPUT

AC Low Range Amps .................. 50-185

AC High Range Amps .................. 65-295

DC Range Amps ............................ *

Arc Voltage ................................ 30

AC Open Circuit Volts (max) ............... 80

DC Open Circuit Volts (Max) ................ *

Kilo-Volt-Amps .......................... 16,8

Kilo-Watts ............................... 11.0

Power Factor %............................ 65

Duty Cycle % .......................... 20-100

GENERAL

Electrode Capacity ................... 1/16-1/4

Low Hydrogen ...................... 1/16-3/16

Stainless Steel ...................... 1/16-3/16

Aluminum .................................. *

Electrode Cable Length ................... 12'

Work Cable Length ....................... 10'

Dimensions .................... 15" x 12" x 21"

" Does not apply to this welder

LENS (_

SHADE NO.

WARNING! ARC WELDING CAN BE iN3URIOUS TO OPERATOi_ AND PERSONS

_N THE WORK AREA -- CONSULT OWNERS MANUAL BEFORE OPERATING

To get the most from your welder we suggest you read the manual carefully--

even if you're an accomplished welder, and keep it available to serve as a

handy reference, or in the event that repair parts would be required.

FULL ONE YEAR WARRANTY ON CRAFTSMAN ELECTRIC WELDER

if this Craftsman Etectric Welder fails to perform properly, due to a defect in materiaJ or workmanship,within oneyear

from thedate of purchase, Sears will repair it free of charge. This warranty applies only whilethis product is inuse inthe

United States.

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

CENTER/DEPARTMENT THROUGHOUT THE UNITED STATES.

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

SEARS, ROEBUCK AND CO., Dept, 698/731Ai Sears Tower, Chicago, IL 60684

OPERATING!I_INSTR_CTI ONS

Warranty _ : ii !:.! :i _.:_i:::.:... :.:;_:.:. _.i _. !., _i 3

Getting tO ::'.. :,:_:i. :. 4

Unpacking and C_cki"gGontents :; : .!;;...... 4

Operating ContrOls ................. 6

0 ........................ 7

T ................. 8

ARC ..... 1-1

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

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

GETTING TO: KNOW YOUR WELDER

HEAT SELECTOR LOCKING KNOB

ON-OFF SWITCH \

\

DUAL RANGE OUTPUT _"

\

MATERIAL THICKNESS GAUGE

_ELECTRODE DIAMETER GAUGE

WELDING HELMET

!

WORK CABLE AND WORK CLAMP

-%

ELECTRODE CABLE AND

ELECTRODE HOLDER

UNPACKING AND CHECKING CONTENTS

SET-UP I NSTRUCTIONS _

This Craftsmanwelder:is shipped complete in one

carton_ 'In order to:facilitate packaging; ce_'tain

items must be assembled when received by the

purchaser. Remove:all items from the carton and

identify item as _shown in the exploded view

illustration. These "Loose Parts" should be

accounted for before discarding any packaging

material.

Key

No. Part Name 'Oty

_:__ _i 1 WeidingHetmet(Partia,lyassembted) ...............

2 Helmet band assembly (Not Assembled) .............

3 Electrode cable assembly ..........................

4 Owners Manual ...................................

5 Loose Parts Bag -- Containing the following items: ,..

--__ ii 1 "_ 2 E,ectrodeHoJder ..............................

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

WorkClamp .:....................................

Screw. Pan Hd: Ty, "AB" No. 10 x1/2 ..............

iOutlet BoxCover. ...... ..: ....................... '

• G_oundTerminal ...... ;.-:...........................

i]Screw PahHdi10-32 x'_t2 .. .... ,................

J Nut, Hex 10:32 ..... ::..:_..: .... ..................

, ConnectionLabel ;... :.. .........

1

1

t

1

1

1

1

I

I

2

t

t

1

1

1

1

ASSEMBLY

TOOLS NEEDED

@

,

,

7/16-inch wrench Screwdriver (small)

ATTACHING ELECTRODE HOLDER

TO ELECTRODE CABLE

Grasp the electrode holder and locate the

slotted head, handle locking screw near the

mid-point of the insulating handle. Loosen this

screw approximately two turns, or until the

handle can be slipped off the electrode holder.

DO NOT REMOVE THIS SCREW COMPLETE-

LY. Slide the handle off electrode holder and

insert end of electrode cable assembly through

the handle.

The electrode cable is the one with insulation

stripped from one end.

1/4" Hex "L" Wrench

(furnished)

3. Using the sockethead wrench (supplied) back

out the hex-head set screw, located near the

end of electrode holder until the end of screw

does not protrude into the wire socket in the end

of holder.

4. Make sure the wire strands on stripped end of

electrode cable have not been "frayed". Twist

together with fingers if necessary.

5. Insert end of electrode cable into electrode

holder and tighten the socket-head set screw

very firmly using the 1/4" Hex "L" wrench

furnished.

6. Slide the handle back into place on electrode

holder and position it until the hole in handle is

directly' over the head of handle Iock__nngscrew.

Tighten the screw clockwise (,"_.) just

enough to secure the handle on e_ectrode

holder.

ATTACHING THE WORK CLAMP

TO THE WORK CABLE

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

work clamp.

2. Do not use either of the holes in handle ends of

work clamp.

3. Tighten the screw firmly enough to insure good

contact and prevent the cable terminal from

slipping on the clamp.

CONNECTING WELDER TO POWER SUPPLY

CAUTION: Do not attempt to connect this welder to

a regular household outlet. Make sure the

power-line voltage and frequency agree with the

ratings shown on the selector plate attached tothe

cabinet_

Electrical connections between the welder and

230-volt, single-phase, 60-cycle AC power source

should be made by a qualified electrician. All wiring

must comply With the National Electrical Code

(ANSI Ct)a'nd theLocal Electrical Code.

1. Install an individual (separate)line for the

welder With;delayed action type circuit breaker

or fuse in the line:: For best results, this circuit

should: boas shortas possible. The size of the

leads:will depend Upon:their length as shown in

the: table belOW_:i:::_

Suppty C0nduCtor (i.c. Exteriston Cords)

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

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

NOTE .-These conductor sizes are for use with

i ............ ,.,, , , ., ,

2_

3.

H

CONNECT TO GROUND BUSS

IN POWER PANEL,

CONNECT TO HOT WIRES OF

A SINGLE PHASE SYSTEM ONLY.

_ _ MAKE CONNECTIONS INSIDE

OUTLET BOX AND INSULATE

PROPERLY IN ACCORDANCE WITH

LOCAL CODE. INSTALL. COVER,

awelder having arated input not more than 60

amps at 20% dutY cycle in accordance with

Article 630 of the National Electrical Code

(ANSI C1) and may not be adequate for other

loads. Consult a qualified electrician before

using for other loads.

Connect 230-vott power lines and ground as

shown.

Install 60 am pete circuit breakers or fuses of the

delay action type such as "Fustron" or "Fustat".

L ,

LOW r_O-18,_

Am_ Rar_ge

M=xLmum

Arc $_I_#_v

effect on other electrical appliances, motors, and

lights, on your electrical system.

Either range may be used, depending on operator

preferences when the electrode diameter permits.

CON NECTING ELECTRODE

AND WORK CABLES

Insert the tapered plug on the end of the electrode

cable into the proper outlet jack depending on

amperage required or operator preference.

To insure a good electrical connection always twist

the electrode plug slightly while inserting. To

remove the Dlug twist in theoppositedirection while

removing.

NOTE: If you extend the welding cables beyond

those already supplied, they must be No. 3 AWG or

larger to avoidan unduedrop in welding current. Do

not extend cables over 50 feet.

L

AC Amp Output

leArnp se

$MRN Arc Welder

__J

6

Connectthework clamp to the piece to be welded,

(to complete the electrical circuit) or to the welding

table itself provided it is metallic or wilt conduct

electricity!

OPERATING INSTRUCTIONS

We feel that welding with your new Craftsman dual

range arc welder is as simple as A.B.C.

A. Determine what diameter electrode should be

used by gauging the piece to be welded on the

material thickness gauge. The fractional

number directly beneath the bar chart dictates

what the proper electrode diameter is for given

thicknesses of metals. You will note that a

specific diameter of electrodes can be used on

varying thicknesses of material. This is

accomplished by adjusting the heat selector, for

more or less amperage.

B. Next verify the electrode diameter, by placing

the bare portion of the electrode against the

electrode diameter gauge located under the bar

chart.

Because electrodes are mass produced, there

may be small burrs on the bare ends of the

electrode. Make sure the bare end of the rod is

as clean as possible for accurate sizing.

C. Finally, determine the type of electrode by the

identification on the package or by the

American Welding Society number stencilled

on the coated portion of the electrode, bearing

in mind the type of electrode you have chosen

E6013 or E7014, and also its' diameter (as

previously determined).

Locate that band on the amp scale. There are

two E6013 bands and two E7014 bands, use the

band which coordinates with the amp rangeyou

have selected.

7

weld.

Because metals vary {n their make up and the

technique of each operat0r is different, you may

find it necessary to: increase: or decrease the

amperage output accord!ngly.

CAUTION: Donol loosen and move amp se|ector

while welding..

The duty cycle scales bracketing the amperage

sca':les are provided for your convenience and

protection of your new weGder. Duty cycle is the

performance level of the welder based on a 10

minute time span. For example welding for 6

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

avoid possible overheating of the welding

transformer, which could shorten the life of your

welder, Do Not exceed the duty cycles indicated on

the duty cycle scales.

TROUBLE SHOOTING

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

by a q ualified service technician.

TROUBLE SHOOTING CHART

TROUBLE , SUGGESTED REMEDY

Fan and welder do not 1. Improperly fuse_l or 1. Use 60 ampere fuses of the delayed

operate; orcontinually : protected, action type such as "Fusetron" or

blow fuses. ' : "Fustat" or 60 ampere 240 volt

I................ circuit breaker.

i 2, Blown:fuse,; or open 2. Replace fuse, or reset the circuit

Circuitbreaker. breaker.

.3,?"OPi:-0ff":switch not "On". 3. Turn switch _'On".

i; Welding current low: !i:i i':: ':_ilLow ine voi'tage , "t. Have a voltage 'c'heck performed by

or:weak; :!; :/ : :the local powerl Company.

.... : I: Welding current I 2! Check current recommended for

: : : !: setting:too Iowl Ithe electrode being used.

...... :- :: i I3 P0or:c0nnect ons I3: Check eiectrode holder work and

; I : ..... .... : electrode Cable Connections.

Can't hold an arc.

PROBABLE CAUSE

1. Using a D.C. welding rod.

2. Low hydrogen rod.

i 1: Use ACor AC-DC rods.

2. Use rod of 3/16-inch maximum

diameter, or smaller on 50-185

amp range or lower.

3. Get new dry undamaged rod.

3. Damp or damaged

coatings on rod.

SERVICE TIPS

FAN MOTOR

No provision has been made for lubricating the fan

motor, as extra large oil reservoirs provide

lubrication for the life of the motor.

SELECTOR PLUGS OR CONTACTS

WARNING: Be positive you :have disconnected the

power supply to the welder.

If for any reason the selector plugs or mating

contacts become burned or pitted, they should be

cleaned-up with a fine grade of emery cloth or

dressed very lightly with a fine fife.

8

fl

%_

A COMPREH ENSIVE

GUIDE FOR YOUR

NEW CRAFTSMAN

ARC WELDER AND

WHAT iT W=ILL DO

CONTAt NS:

INFORMATION ABOUT

o VARIOUS TYPES OF RODS

o USEFUL ACCESSORIES

e TIPS ON CUTTING, WELDING

AND BRAZING

,,J

Form No. SP574+5 t.1

_i_?/:-: ¸ _:!. ......

_iii_!i.i___

TABLE OF _cONTENTs

Page

Your WelderandWhat it Will Do ............. 1-3

Howthe CraftSmanCOntactRod SimplifiesWelding 1-3

WhatHappensWhenYou Weld? .. .......... 1-3

RoadeefareWeiding .:i._._,.!..:,....i.,.... 1-4

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

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

Cast4ronWelding....; .... ...... . 1-14

.a,dSu ,,=jn.Wor,,C. .gEd,-IIZ 1-15

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

CuttingandOtherMiscellaneousOperations ... 1-17

Read this Manual carefully for additional welding information.

._ ••• H• •••• H•¸

SEARS, ROEBUCK AND COMPANY

AND S|MPSONS-SEARS LIMITED

1.2

YOUR WELDER and what H wil/ do . .

Your CRAFTSMAN Arc Welderisa sturdilyconstructedandthoroughlytestedmachineengineeredto

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

incorporated,which meansthat it passesal! requirementsof safety, fire hazardand temperaturerise

limitsasspecifiedin their Standardfor Transfer-TypeArc-WeldingEquipment.

Sreply rest the electrode :an the iwork, Maintaining consta_nt:arcilength::is _

effortless as the cOne_:depth aOtomatiCaly pt+oydes the correct! spacin[i

between electr#de:a:ndlw0rkfor proper arc length andals0 p{ev _ht_,e ei_trede

freezinj Drag the electrode at the appropriate speed f0r the Weld:desired_:

E

,ec/_'/_# MUSe' WAY /Ji''LoEC_OOe

Special coating containing powdered iron forms ashell around wire

Core, Core burns back from outside coating to keep proper: go:p;

Easiest arc_welding method known.

HOWTHE CRAFTSMAN ELECTRODE

SIMPLIFIES WELDING

Craftsman Contact Electrode is se/f-starting--p{usautomatic

restarting... The electrode startson contact.

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

conditionstheslagremovesitselfastheweldcools.Spatter is almost

non-exiszent. Craftsman Contact Electrode has an exceptionally

good appearance... With fine ripple, unusuafiyclean, smooth

appearance,and reducedslaginclusions.

CraftsmanContact Electrodedepositsmore metal faster... Because

the powderedironin the flux goesintothe weld.

W H AT H A P P NS WHEN YOU WELD?

1Bath edges of the metal

are heated by the arc,

until --

mare molten metal and

flux is added from the

rod, which-

2_hey melt and flow to-

gether forming onepiece,

instantly -

4 fills the crater and covers

the top of the weld with

sing.

5 This process continues the entire length of the weld.

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

metal together to form one piece. It is accomplished by

heating adjacent metal surfaces to the melting point with an

electric arc, then adding a sufficient amount of molten

metat to provide reinforcement and fill any vacant space

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

ing itlustrations.

The arc is created when an electric current, regulated by

a welding transformer, flows across an air gap between an

electrode and the work being welded. The intense heat

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

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

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

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

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

metal directly beneath it, is melted, resulting in a small

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

blast of the arc a_d deposited along the weld path. The

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

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

penetration of the weld.

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

rounded by a flux coating) is melted simuhaneousty with

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

This added mete! combines with the base metal to form

the deposited we}.d.

During this operation a part of the flux coating burns off

and forms a gaseous smoke screen that completely en-

ve!ops the arc, protecting the molten metal from harmful

effects of oxygen and nitrogen in the surrounding atmos-

phere. The remainder of the flux coating that melts is

carried to the molten pool where it mixes with th_ metal

to combine with various impurities. It then floats to the

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

posited weld metc_{, protecting it from the atmosphere and

retarding its coollng.

When operating a welder, certain precautions must be

taken to prevent injuries to yourseff and others. Knowing

ha w to use the protective equipment to safeguard against

them is the first step in learning to weld.

The effects of heat arid:tight given off by the arc, while

electr €I welding, may belcompared 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 injury, contact a physician immediately.

Animals are also affected by the rays and should be kept at

a safe distance.

To protect the face and eyes aheat-resisting, i fiber-glass

he met sused. The special lens,:i which alloWs the User to

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

the helmet. The clear glass, which should be replaced from

time to time, protects the expensive special lens from

breakage and weld spatter. The helmet is held firmly in

place on the head with an adjustable head band, thereby

leaving both hands free. A close-fitting skull cap should be

worn with the helmet. As t.he helmet is used only when

actually welding, a tilting arrangement permits it to be

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

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

To protect the eyes further while cleaning the weld, goggles

should be worn by the welder and others working around

him.

To safeguard the hands against heal and weld spatter,

gauntlet-type leather gloves shou|d be worn. A leather

jacket or apron will give better protection against the

shower of sparks than ordinary clothing. High top shoes

(not oxfords) should be worn. If a great deal of welding is

to be done, foundrymen's shoes are best.

PrecaOtions must also be taken to protect property and

equipment against fire. A large fire extinguisher should be

within easy reach. The welding area should have a concrete

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

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

practical; rem0ve-the part to be welded. If not, drain the

tank and comptetelyfil! it with water,

Few tools, in addition to those supplied with the welding

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

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

steel plate makes an excellent welding table. A permanent

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

iron or pipe: A Chipping hammer is used to clean slag off

a weld and pliers will be useful for handling hot metal. A

wire brush is used to clean the work before welding and

remove small pieces of slag after chipping.

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

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

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

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

metals require special electrodes and welding techniques.

These should be set aside for future practice after com-

pleting elementary practice lessons.

_4

LEARN BY DO|NG

DIRECTIOH

OFWELD

Experience has proven that short periods of practice at

regutar 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 arid free of

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

while practicing, must be ]earned through a series of

mistakes and rewetds later on.

A comfortable body position is important when learning,

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

Sit on a tow 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 work connection is as much a part of the welding

circuit as the cable and electrode holder, A poor work

connection can render the best welding equipment

inefficient. When using a table with a steel top, fasten the

tug of the work cable to it securely with a bolt or C-c_amp,

so that any piece of iron placed on the table top will be

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

work cable directly to the work with a work clamp or belt.

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

/

/

tl

f

/

Figure 1

To strike an arc, scratch the

end of the rnd on the plate

and then quickly raise ap-

proximately 1/8-inch.

I90':

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

electrode in the electrode holder and connect the welding

cables to produce the heat specified by the CONTROL

panel. Connect the ground cable to the work and set the

indicator in the current range recommended for the

diameter of rod used.

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

the work, then quickly raising it until there is approximately

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

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

scratch the tip of the rod ashort distance on the surface of

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

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

ahard blow with the tip of the rod and aIIow it to bounce

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

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

with the work.

A common mis{ake 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 ur

"freeze" bend it frum side

to side while pulling upward

un the rod holder.

\\

\\\

_/?/////////,_

i j HJInn

Ii/

.......s/ /.

i :V /

!!

/

t

9 ¢

_/_ ¢?'///////1,,_

Figure 3..... Figure 4 ;'

TO lay a weld:bead _nly two Watch the weld puddle ta

movements are ,sod. down* keep the slag from flowing

ward andin the eirectiOnthe in front of it. causing ioclu-

weld is to be:laid. i ....: : ....... :sions and gas pockets

:, i _ " _: :

Figure 5 Figure 6

Fill the crater, whenstarting

a new rod, by std.king the

arc at A then moving to B

and back to C pnsitinnl

1"owiden the bead, work the

rod from side tn side sliEht-

ly_ with a slow, zigzagging

crescent-shaped motinn.

If difficulW is experienced after repeated attempts t9

maintain an arc; Check:the work.connection for •proper

contact with the work. If this _does not help, increase the

welding current. AlSocheck the rod size, as [arger rods

require higher current settings.

Practice Striking and maintc_ining an arc for a few seconds,

by gradually shorteninglthe arc until it sputters irregularly

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

slowly {engthening 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 length

will be heard.

To lay aweld bead,! only two movements are used, a

steady downward feeding of the rod to maintain the correct

arc lef_gth and a :slave:travel in the direction in which the

i.ay a bead approximately four inches 10ng. After allowing

it to cool slightly, iemove the slag coating, whichcovers the

top of the weld; foy Scraping ai0ng:each edge of the weld

with o 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 a steady rote of travel and

uniform arc length

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

laying a few beads. This will alter welding conditions

which could be very confusing to a beginner. Have several

scrap pieceshandy so each may be allowed to coo! before

laying a second bead.

When starting with anew rod, chip slag from the crater

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

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

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

base metal time to heat up for proper fusion.

After laying a number of beads, try "working" the rod

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

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

used. Experiment with different current settings, rod sizes

and rates of travel. Compare results with welds shown in

the diagrams (fig. 9).

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

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

be an intermittent crackle with irregular sputtering. Too

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

will provide sufficient penetration but the bead will be thin

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

the rod becomes red hot before it is half used:

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

good penetration but witff overlap of the weld metal on

sides without fusion. A large area surrounding the weld is

heated to a high temperature which produces distortion,

even on a simple we{d. If the rod is moved too fast the

small bead will result with little more than melted base

metal An extremety long arc causes the rod tc melt off in

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

Weld surface. The arc produces ahissing sound.

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

length wifl produce a surface that is rippled uniformly, with

the same width throughout its length, and wet! formed

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

tration; and no undercut or overlap.

i i

Figure 7

Lay the weld beads about

one inch aparL Remove the

stag and examine each weld

before starting the nexL

Figure 8

A pad of weld metal is built

up by running a series of

beads in layers at right

anglesto each other.

CURRENTTOO LOW

Arc is difficult to maintain.

Verylittle penetration.High

bead.

TRAVELTOO FAST

Small bead undercut in

some places. Rough top

and little penetration.

CURRENTTOO HIGH

Wide thin bead, undercut.

Crater pointed and tong.

Rod burns off very fast.

T.........

ARC TOO LONG

Surface of weld rough.

Rod melts off in globules.

Arc makes hissing sound.

TRAVELTOOSLOW

Metal piles up, making a

wide heavy bead, over-

lapped at sides in places.

NORMALCOHOITIONS

Uniform ripples on surface

of wetd. Arc makes steady

crackling sound.

Figure 9

Practice laying beads approximate]y one inch apart until

agood weld can be produced with aft the different rod

sizes the welder wit] handle (fig. 7). After becoming pro-

ficient in running a bead, build up a pad of weld meta!.

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 1i2-1nch thick has

been built up. This type of welding is used to buiid up

round or flat surfaces or reinforce parts that are rusted thin.

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

run the beads parallel to the axis and lay each successive

bead on the opposite side as shown by the numbered steps

in figure 10. Cover the entire shaft with we{d metal for

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

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

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

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

proper size.

,i ii i, ....................

......... i Ll' I!

_-7

Flat welding includes all types of joints in which the weld

ishorizontal; and the electrode is fed d own as inthe practice

Welds Of previous pages_ The five types of ioints in figure 1

can b_ welded in the flat position.

Butt welds on light material should be practiced first on

scrap Stocki Use 16-gauge mild steel sheet meta! (approxi-

mately t/16_inch thick) and 5/64-inch rods with the welder

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

together and tack-weld approximately every three inches

(fig. 2). (Tack welds are small beads I/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 joined.

If theweld burns thrQugh in places, reduce the welding cur-

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

experienced in starting the arcat these low current settings.

However, once the arc iS :started, there will be sufficient

heat to make a sound 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 tightly together, move the rod back

and forth with short quick strokes inthe direction of the

weld to bridge the gap and glVe the metat inithe:crater a

chance to solidify (fig,:3)i

Butt welds on sheet metal lighter than 18 gauge should

not be attempted by the beginner without the use of a

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

clamped tightly against the underside of the seam to absorb

the heat of the arc and prevent the weld from burning

through. To assure complete penetration with butt welds

an 8-gauge metc_t or heavier, a !/16 to 3/32-inch gap

should be aJlowed between them (fig. 5). Insert awedge or

screwdriver between the plates when tack-welding to main-

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

on the underside.

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

at feast one-haft their thickness. Clean off the slag and

inspect it for smoothness, penetration and height of rein-

forcement. Agood wetd should have a reinforcement slightly

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

STRIP

Figure 4

Figure 3

1/16-INCH

REIKFORCEMENT

Figure 6 p_ Figure 5

F_gure 7

-'Y-/' EOGES::-r_ ure

f:ii!ii: ;?

GAP _i_i:_?-ii?;,

oo

4-PASSBUTTWELO

E V-WEt_O

Figure 9

k45_p " SINGLE-BEVELWELD

Figure 10

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

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

no danger of burning through and fusion with the first

bead will be assured.

Although butt welds can be made on steel plates up to

3!8-inch thick, with a 295_ampere machine using 1/4-inch

rod, the same results can be obtained with smaller welders

if edges of plates are beveled (fig, 8). Metal of almost any

thickness ca_ be welded in this manner by depositing a

number of beads, one on top of the other until the groove

is completely filled. If the plate can be welded from both

sides, always use a double bevel (fig. 9). If only one plate is

beveted, the angle should be at 45 degrees (fig. 10).

To8

!i •¸ • • ••

UNDERCUT GASPOCKET

F_gure !2

Figure 13

TRAPPEDSLAG PENETRATION

Figure T!

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

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

small bead on the underside. If this is not done, insufficient

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

clean each pass before laying on the next. Aft beads are

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

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

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

witl completely cover preceding beads. For the beginner,

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

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

Select severat practice welds of different thicknesses and

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

and bend it at the weld (fig. t2). 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.

FJLLEET WELDS

FRONTFigure 6

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

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

weld is based on the leg length of the largest isosceles right

triangle that can be inscribed within the cross sectional

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

size of a fillet weld may also be measured with 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 a fillet weld is stressed to its maximum capacity,

failure wiff 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 tess

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

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

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

loaded should always be welded on both sides with fillets

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

bevel the plate to assure complete penetration and position

the work at a 45_degree angle if possible.

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

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

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

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

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

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

LAP WELDS LAP WELDS

Figure _14 Figure 15

..... i• • • •11 • i • •

should be nearly flat with aslight radlus at the SidesOr wilL come: with experience, ffthe arc is advanced too fast,

toes. AVoid excessive concave or convex surfaces of the held:t6o: close to the vertical plate, undercutting may

fillet (fig: 7): UnderCuts and Cold-laps are caused by not

holding the rod in the cen_r! 0f the :seam: (fig; 8). ff the

desired fillet weld cannot be ma_e with a Sing!e pass,

several passesare used to build it up to required size (fig_9).:

Slag must be cleaned from each pass before depositing

the next. Fillet welds over 1!2dnch in size a_e rarely used

because ioints requiring more strength can be made more

economically by beveling and groove-welding0 followed

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

corner,

Horizontal fillet welding is used when the side or edge of

one member of the joint is in the vertical position particularly

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

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

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

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

joint. The arc _ength should be somewhat shorter than for

fiat fillet wetding. To assure penetration at the root, use the

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

Good penetration is of prime importance and appearance

result (fig. ]2).::Toostow trove] will cause oVerlapping and

an extremely close arc or low current will produce a bead

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

soundnessof the bead, break some of the Weldi_for inspec-

tion, as shown in figure 4.

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

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

sorine melting wil! take place, but proper advance of the

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

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

perpendicular and move the arc rapidly. Welds of this

type should be wider than they are high, somewhat like

flat bead (fig. 15). A slight discoloration on the underside

of the lower sheet indicates good penetration. On heavy

metal, (: 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).

_-_0

POS}ITtON WELDING

BUTT WELl)

In order to derive the greatest benefits from your we{der,

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. t). Of the

three positions, vertical welding win 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 "'vertical-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, _suaIty

with a weav{ng motion.

The chief difficulty encountered with any position weld is

keeping the molten metal in the puddle from falling out.

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

the weld puddle kept fairly small so it wilt solidify rapidIy.

Verfica{-down welding is the easiest to perform and is used

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

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

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

so it is positioned vertically (fig. 31. 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 angtes to the plate laterafly, with the tip pointed up

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

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

The correct rate of travel can be determined by gradually

reducing the speed unti{ molten metal in the puddle con no

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

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

A short arc provides better controf of the mohen metal.

Fol{ow the same procedure with 3/32 and 5i32_inch rods.

ft will be noted that the larger the rod the more difficuh i_

is to control the puddle. For this reason smaller diameter

rods are a{ways used for position welding.

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

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

rod down the seam at a steady pace. _utt welds may require

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

light gauge material Jfthis occurs, continue until the seam

is comp{eted and patch the hole by chipping the slag and

wire brushing until dean. Then, with slightly lower current,

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

bring the rod down to the fower 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.

Hotd 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 wl]i cause a "'burn through." if this

happens repeatedly, lower the welding current.

Leave a siight 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 ioints on material around 3!16-inch

thick shou{d be welded on both sides.

vertical-down welds may be made on heavier material by

laying in a number of passes (fig. 51, however, this practice

is not recommended as it takes longer than a heavier single-

pass weld made by the verfica{-up method.

%

VERTICAL-DOWN

WELDING

F_gure 2Figure 3

.... !"!' ' I ' IIIIIIII1,11[,llllll IIII, III

A SMALL_EAgON

BACKST{IFINDICATES

COMPleTE P_IfETRATION

Figure 4

•re5

iiiiiii II IIII I I'11111'

WELOING

Figure 6

F.;gure 8

r ,

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

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

until a small amount of metaf is deposited, th,en quickty

raise the rod upward with a wrist movement to increase the

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

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

rod Clown and deposit more metal. Keep repeating this

whipping motion_ while gradually moving the rod upward

and toward the plate asthe electrode burns off. The [ength

Figure 9

Figure I0

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

additional metal is deposited intermittently as the welding

progresses. There shouJd be a slight pause in the weaving

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

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

eled on one or both sides, depending upon the joint.

Practice making a wide bead using a side-to_side weaving

motion with a very slight whipping action at each end to

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

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

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

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

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

fairly light. Multiple vertical welds may be made c_s shown

in the series of diagrams, figure 11.

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 welcl; using the

whipping motion. Leave a gap between the plates and use

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

experimenting. The whipping motion wilt melt the corne_s of

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

metal (fig. 8).

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

back side. After completing the weld, inspect" the back

side for the smo_Jbead, which indicates ]O0-percent pene-

tration. Butt welds on heavier materlaFs should be welded

on both sides.

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

on smafJsingle-pass filtet welds for lap and tee-joints. Larger

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

with astighf side-to-side weave added and combined with

the up and down movement to make a triangular shaped

[ ,

,p,JlL

Figure 17

HORIZONTAL WELDING

Horizontat welding refers to one type of butt weld between

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

as for vertical welding and run straight beads across from

]eft to right (fig. t..'2). Use the same current settings as for

verffcal-down welding and hold the rod as indicated with

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

alight bead. The rate of travel will c_epend upon the current

used. Too slow a travel wiff cause the bead to sag (fig. t3).

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

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

strip, allowing a sffght gap between edges of 1i8qnch

thick meta! and weld from both sides (fig. 15). All metal

3/16-inch tt_ick and over should be beveled and welded

with a number oF £asses (f_g. 16). Tharough}y dean each

bead before laying the next and use higher current than

for single-pass welding.

The appearance of c_ multiple-pass horizontal weld can be

improved by vertical down beads laid ctosety together.

Use a swift circular motion to the right; slowly downward

while welding (fig. 17)-

OVERHEAD WELDING

Although overhead welding _sgenerally considered diffi-

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

day by people wl_o have taught themselves. Once the art

of maintaining a short arc has been mastered, the rest

will be easy.

Since there wilt be a shower of sparks, wear a leather jacket,

tight fitting cap and ear plugs and keep the practice plate

slightly higher than the top of your head when stanoqng. To

keep sparks out of your glove, grasp the electrode holder as

indicated in figure 18 and hold the rod in a nearly 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 7/8.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 side-to-side weaving motion and

deposit a thin weld approximately 3/4-inch wide, The

movement must be somewhat faster than for other

positions to keep the bead from sagging. (This method of

weaving is used only for the last pass on heavy welds where

improved appearance is necessary.)

The whipping motion is used where a gap exists between

the plates as it provides better penetration with higher

welding current. For practice work, set up two plates ap-

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

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

rods, varying the plate size and gap distances.

F;gu_'e 18

Figure 19

plrll I I

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

overhead poshiom Tc_ck-wetd two pieces of scrap iron

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

position so one plate ts t_eld vertically (fig. 19). Hofd the

rod at angles indicated and deposit a light bead from left

to right without weaving o,r whipping movements. A slightly

higher current than used fo:r overhead butt welds wifl be

necessary to get goad :penetration at the root of the weld.

To simulate actual conditions tack-weld a piece with on

irregular edge to another piece leaving numerous gaps

along the ioint. Use the whipping motion and deposit a

fairly heavy bead, slowing down the rate of travel where

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

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

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

length of the ioint (fig: 20),

Whei_ y0u can:10y single-pass butts and fillet welds you will

be6bleto, make anioverhead 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_heOted; cOntraCt:when coo_ed. In;arc

:anti: edggs being oined: are

molten and: the metal ::sUrroundirfg: ithe weld is }_eaie(JlsufL

flc entt_/ to cause eX :ansion _Whe:_ ::the :de 0sted meta

:...... p.... :.......... .... P....

solidifies; it becomes €¢parf all the: plates; but, :beingUnr_

stricted in its eXpansi0n in:the molten::state, itI tends: t0

c0ntract_m0re thanlthel heated SurroOn_Jing_metal_ lf 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 in length,

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

stresses (fig. 23). This is not too serious when welding mitd

steet up to 1!2-inch thick, as the ductility and elongation of

the metal will permit it to deform slightly to compensate

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

light structural members, lor_g continuous welds may cause

considerable bending and result in o badly distorted weld-

ment. Fortunately most of this can be avoided by studying

the effects of expansion and contraction, as related to the

job before welding and working out a procedure to follow.

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

install temporary braces tack-welded to supporl parts that

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

completed. Lay the beads so the stresses witl counteract

or n_utralize one another, by running a short pass first o_

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

is at the other end of the iob. Do not concentrate too many

welds in one place but space them to distribute the heat

and stresses throughout the entire structure. Use intermittent

Welds whenever, possible, if continuous welds are necessary

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

method as shown in figure 24, fusing each bead together

at the: end.

CAST: iRON WIELDING

Previous experience in handling the arc, plus good judg-

ment regarding expansion and contraction, will enable

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

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

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

machined, and machinable which deposits a file-soft weld

that can be drilled or machined to close tolerances. Non-

machinable rods are used for most repair jobs such as

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

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

surface that need not be refinished to a close tolerance,

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

wheel.

As cast iron is very brittte, care must be taken to controt

expansion and contraction, and thus c_void cracking of the

weld or the casting. Because of low tensile strength and

Jack of ductility it canno_ bend, stretch or distort itself to

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

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

welding. However, as most cast iron welding jobs can be

done without pre-heating, this method wilt be considered

first.

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

by wire brushing, grinding or washing with solvent. The

crack shouid be beveIed for penetration. Jf 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 joint can be

welded from both sides. Do not bevel to a sharp edge along

the entire crack. Instead, allow approximately 1i16_inch

!-14

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

or cramp parts in position. If the crack has not separated

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

mond_point chisel. Chip an inch or so beyond the visible

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

cracked water jackets, where only a seal is required, the

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

of the casting.

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

compiete a weld in cast iron as rapidly as in the same Length

in mild steel. Use a smaWer rod and a slightly higher current

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

an inch tong, 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. I).

Allow enough lime 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 tacked-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 fil! the groove with short weld beads as before, working

rapidly when depositing and peening the bead. Albw plenty

of time for co01ing. Examine the casting for cracks that may

develop during cooling periods. If any of the beads crack,

chip them out and re-wetd, tf c_acking persists, preheat

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

lene torch or blow-torch. When the preheated method is

used, the welding can be continuous. After completing the

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

so it will coof 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 HEAO SECBH_ READ

FACING WORN CUTTING EDGES

HARD FACING

OR UHOERSI_E

Figure t

Excavating equipment, earth-cutting farm machinery or

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

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

cavating buckets, or any surface subject to abrasive action

will last much longer and require less sharpening when

their cutting edges are hard faced with hard surfaclng

electrodes. The arc welding process consists of depositing

a fayer of abrasion resisting weld metal on the worn cuffing

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 deposffed in the flat position. If the material is 1!4-inch

thick or less, use a Ii8-inch rod and as low a current as

possible that will still permit the metal to flow out smooth

and fairly thin (t/t6 to 1/8-inch thick). Weave the rod

from side-to-side in acrescent-shaped movement and de_

posit a bead about 3/4 to 1-inch wide. Severat passes

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

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

___ ........................ i _, iiiiiiiii

GRIND OFF WEAVEBEADS

,1"'_ 1-1/2 IHCH "_

_MAt.L BEAt]..,.J

F_gure 2 F_gure 3

HARD FACING HARO FACIH_

-- /- F;gure 4__EEL

SOFTBASE METAL .,L!D-S'tEEL PATC,

WEARSAWAYFASTER WELDS

THAH HARDFACIN_ Figure 5

_111,,i,,, i 1,1! ii

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

Make beads heaviest where the wear will be greatest, but

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

machined, if shaping is required, heat the wetd metal and

forge it. Smoothing and sharpening can be accomplished

by grinding.

For plow and tister shares, cultivator shovels and similar

cutting points, deposit the weld metat on one side only

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

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

leave a knife-like edge of hard facing materlai. Parts that

must wear uniformly on both sides shoutd be hard faced

on both sides. The condition of the worn part must afso be

taken into conslde_ation. If the part requires a number of

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

welding rods first; then cover with deposited metal from

hard surfacing rods. tf the edge is entirely worn away, a

steel patch (cot to fit) may be welded in place with mild_steef

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

when hard facing smatl parts, peen the deposited wetd

metat before it cools,

TH TIWIN iCAR B O N I:A R C TO R C H

-[ CAH_ON ELECTRODES

CONNECTTO

SCREY+VS 6ROUHt] AND ©

F+IJF+CTRODE

CABLESOF

EI.ECTROOETIPS A. C+WEILOER

Figure I

Work ordinarily done with a gas welding torch is possible

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

The carbon-arc flame is similar to the flame of a gas we]d_

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

by direct arc between work and electrode. This flame heat

greatly widens the scope of work possible with the arc

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

and localized heating for bending, forging and hardening.

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

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

justable to permit striking and breaking an arc at the carbon

tips, A thumb knob on the handle performs the adjustment

and Operates a shut-off switch built into the handle. There

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

ground and electrode cables of the welding machine.

Grounding of the work is not necessary as the operation of

the arc flame is entirely independent. With the thumb knob

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

bon electrodes in the holders and damp in pIace at approxi-

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

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

Overheating of the carbons. When tightening the clamping

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

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

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

of the carbons do not line up with each other, an adiustment

may be made by turning the longest of the electrode holders

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

sary to disassemble the torch to again tighten it properly.

Do not make any turning adjustments with the sliding holder

as this would spoil the contact tension in the switch.

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

approximately 70 amperes. Lower the welding helmet and

hold the torch up to silhouette it against the light of a win_

claw. Slowly move the thumb knob forward until contact

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

arc. Then immediately move the knob back to increase the

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

mined with a little practice. When the carbons are too close

the arc flame will have a sharp crackling noise. As the

distance between the carbons is increased, the crackling

will change to a soft purring sound which indicates the best

:: are na valves or: gauges that:require fine adjustment as arc flame. There are two heat zones and the small inner

i_::: i ::withan oxyacetylene:torch_ The sam epr0tectlve equipment z.one Lsby far thehottest, hav!ng an estimated temperature

at yuuu cfegrees ranrenne_r Lng .3)

::: i na:rya:rC welding::is:usedWhehoperatingthe ' "

:::: i:i: : :::;i::i=i: ::i iii: i The shape Of the flame greatly influences theWay in which

::I:A:wide Selection:lot flame heats may be:iha:d: ,t, mus _:ibel. USed?i °nvbeveled f_a_: twhi; ;:ar_hh

the_Current and size of the Carbon : Sn°U_a: bene!aPara!!e! t° ! e gr: o e so:the . :

acfuai temperature of the bottom (!Ig, r'cghtLahg_est twOiltlheo?r:eOV_ _h_

current seffing; the Volume 0f transferable heat:ir_creaSes : flame straddles th e groo e a

_with an increase in :arn'perage. However; amperages in : bottom (fig: 5). Filler rod s, as for gas welding, must be used

:e_CesS0f thoseglven belbw will Onty cause Short Carb0_ life. On joints at this: type.:.

1/4-ira carbons:_;.:;:.., i, .!L30 to40 amperes The soft, bushy flame is pressureless and has no tendency

:5/16-in. carbons.:_:!.'; !_. _!40 to65 amperes to blow the molten metal This is a distinct advantage when

3/8-in. carbons. 65 to 90 amperes welding thin sheet metal. Joints on light material should be

i ii iii iiii II iiii III !ll iii

Figu_'e 2i

H

i I I III i[ I

/

Figure 3

L

Cg_RECT FLAME POSITION

F_gure 4

iu ........ L_ , i IHI

INCORRECT FLAME POSITION

Figure 5

,11_ ..

1_16

bent and edges fused together by melting down the excess

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

The carbon-arc torch is ideally suited for brazing and

soldering small tubing.

Cast and malleable iron can be brazed with excellent

results. A bronze filler rod and common brazing flux are

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

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

grind or chip out a beveled groove as for arc welding.

Apply the heat from the arc tame 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 of the ioint to the mehing 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 sfghfly

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 ;n the flame, but hold it on the

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

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

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

being deposited, move the torch along the joint slowly,

applying flux to the rod and ioint as required.

Copper and copper-base alloys such as bronze and brass

may also be brazed, but as their melting temperatures are

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

in many cases becomes one of welding rather than brazing.

A bronze filler rod and common brazing flux are used.

Most non.ferrous metals can be welded by manipulating

the torch and fiHer 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 filer metal. ,:If the

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

aiumlnum alloy, use aluminum flux. The filler rod should

be of the same analysis as the work. If regular welding

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

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

Small diameter carbons and }ow 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 untt it is just hot enough to

melt the solder. If the ioint 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 practicaJ 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 overhec_ting. To pro-

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

one side a:nd 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 metat is too thin for

regular metallic-arc welding,

CUTTING

and olher miscellaneous operations

CUTTING WITH THE ELECTRIC ARC

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

such as you probab]y 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. Affhough the edges of the cut

surfaces are not as smooth as when cut with osaw 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.

i 11 i1,,111

START

C_T

HERE

Figure I __

_MOLTEN METAL.

'STEEL

RTAIHER

i,11 ii ii i !1 iii ,I

t-17

START

CUT

HERE

Figure 2

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

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

the edge._ Usea 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 isto be made. Feed the rod into the molten puddle

and: keep the Crater burning through as the rod is moved

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

container onthe 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 vertica!ly

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 asmooth edge is desired, the

pieces can be ground on an abrasive wheel. Electrodes

designed especially for cutting may also be used.

out and work Upward-The rate of speed wit1 depend upon

thedepth o_ the groove and the amount of metal removed'

GOUGING

Figure 3

BOLT

RIVE

MOLTE#

Figure 4

BOLT AND RIVET CUTTING

Removing rusty botts Or rivets is an easy i0b with an electric

arc welder. _The arc is struCk on the head or nut of the bait

and w0rkedaround in a slight circular movement untll the

head s complete]y meffed 0ff(fig. 4)° A punch is then

L_sedto drive out the remaining part. The bolt or rivet can

be removed byheating the head almost to the melting point,

then qu!ckly shearing it off With a coJd chisel. Care must be

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

HOLE PIERCING

Another useful application 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

asurprisingly clean circular hole can be made. For practice,

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

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

cutting. Use a 3/32-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 unti{ a molten puddle is formed, Then

push the electrode down against the molten puddle and

force it through the plate. It is possible to hold the electrode

against the melted plate because the metal core melts off

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

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

truding coating prevents the metal core of the electrode

from sticking or freezing to the plate.

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

described. Then, holding a fairfy 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 :materia i_ithic.ker than 1/4-inch, I work from the

!HEATING i _i:i,

_The method for localized

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

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

temperature is reached.

Figure 5 Figure 6

NOTES

NOTES

• ,,__,;,i_:_i,i,i:i

1-20

WELDING ROD SPECJF|CATiONS

AWS E-6011 MiLD STEEL AC-DC

GENERAL APPLICATIONS: Farm Equipment • Sheet Meta/ • Car and Truck •

Body and Fender ®Pipe • Tanks eMaintenance _ Jigs and Fixtures • Cabinets

e General Repairs eStructural Steel

SIZES AND HEATS lAMPS)

Diameter .... l 1/16" ._ 3/32"

Flat _ 20-55 20-80

Vertical I 20+55 ! 20.6,5

Overhead I 20-55 20-65

75-130 100+175 I 150+225 i 175-250 200-375

7,-,,5 _ 1oo.,5o i ,50.2o0 i

75.,15 l 100+150

J

J

SPECIFICATIONS

Phys!cal Pro_rties of Deposited Metal: As Welded

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

YieldPoint ..................................... 60,000 to 65,000 psi

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

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

Stress Relieved

65,000 to 70,000 psi

55,000 to 60,000 psi

30% to 35%

65% to 75%

DESCRIPTION

The AWS E-6011 is an AC-LC (reverse polarity) electrode with a specia_ 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. |t adapts to a wide variety of jobs due to the wide range of amperage settings at which top quality

resuJts are obtained.

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

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

at the point where weld is to be made. After the arc is established and weld mater;at 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 a slight oscillating motion as you advance, in vert+ca; 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 we_ding overhead use a straight stringer bead or acircular motion. Keep the

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

2-1

II I

AWS E-6013 MILD STEEL AC'DC

multi-purpose all position

GENERAL APPLICATIONS: Farm Equipment eCar and Truck eSheet Metal e

Pipe •Tanks • Boilers o Structural Steel = Maintenance Repairs oGeneral Repair

Work

SIZES AND HEATS (AMPS)

Diameter ._-..o,,_, 5164" ,3132" , 1/8" 5/32" 3t16"" 1/4"

Flat 20-55 20-75 75-1":3'0 100-t75 150-225 200-375

_Vertical 20-55 20-65 75-115 100-150 150-200

:: Overhead 20-55 20-65 75-115 100-150

SPECI FICATIONS

Physical Pro_erties of Deposited Metal: AsWelded

Tensile Strength _. ................................... 75,000 to 80,000 psi

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

% EI0ngation in 2-inc_es ............................ 20% to 29%

Reduction inArea ................................ 40% to 55%

Stress Relieved

65,000 to 70,000 psi

50,000 to 60°000 psi

27% to 35%

60% to 70%

The AWS; E:6013 is a generaLpurpoSe mild steel:elec:trode for use with AC or DC. tt produces a very stable,

easily handled arc throughout a wide amperage range,: The moderately penetrating and easily directed arc

provides eXCellent-results i_: allposi_ions_(flat_:vertical or ioverhead) and is ideal for single pass horizontal

fillet welds, s_atter loss is 10w, asthe weld metal Solidifies quickly producing a c!ose]v rippled deposit with

good appearance.

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

muiti-pu[pose usewhere sound durabie Welds are required.

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

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

Use with AC or DC (see recommencted amperages). Hold a short arc, just long enough [o keep the electrode

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

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

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

either stringer or weaving beads.

2-2

i :: :i¸ : L :¸ :: . 'i _ • _: //:: i•: I ::/•: ::•::•::i: •i¸'¸ ':_'?_ :_ _i :_•:': _:::•••:,?• _! •i•/:i•::••::: ¸'¸ :::

WELD,NG ROD SP;=CUF,CATIONS

, , ..... __ __.'---____! ......

HARD SURFACmNG AC-DC

medium chrome-carbon electrode

GENERAL APPLICATIONS: Tractor Grousers and Rollers eScraper Blades eAgri-

cultural Implements o Plow Shares o Hitches •Power Shovel • Dipper Teeth and

Drive Sprockets eCoal Cutters o Conveyor Rolls •Mining Buckets • Rock Crushers

•etc.

IDiameter

[Amperes

.... 3/32"

=55-85

SIZES AND HEATS (AMPS)

,/8" 5/32" I_ l3/l'l ',_ I} 7/32" ] 1/4'' I_

100-130 130-150_ 175-200 175-250 225-275

SPECI FICATIONS

Physical Properties of Deposited Metal ....

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

After Cold Working (R0ckwelt "'C" 50-54) ......................................... 500-550 Brinetl Hardness

DESCRIPTION

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

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

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

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

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

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

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

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

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

materiatl Cracks too deep to 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 wider bead,

or use a "free" arc.

2-3

CIFICATION$

AWS E,70141CONTACT AC-DC

f0r welding of mild steel

GENERAL. APPLICATIONS: Sheet Metal Fabrication and Repairs =Machinery

Fabrication oConstruction Equipment Repairs eStorage Tanks e Shipbuilding

Fabricating Structural Shapes and Heavy Equipment e Equipment and Heavy Pipe

Welding.

SIZES AND HEATS {AMPS)

Diameter .... 1/16"

Lengtl_ ,.... 12-:

:Amperes : 70-90

3/32" 1/8"

, .... |4 i:' 14"

: 90-110 i30"165

5/32"

14"

190-210

i3/1s"

18""

200-250

I

t/4"

18"

250-350

SPEC! FICATIONS

Physical P,roperties of Deposited Metal: As Welded

TensileStrength ................................................................ 72,000 psito 76,000 psi

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

%Elongationin 2-inches .................................................................. 17%to 28%

DESCRIPTION

The AWS E-7014: iS an excellent electrode:for:the inexperienced or experienced welder. Starts on contact

With Sm00th: Surge:free arc; als() restrikes instantly; Thls Craftsman electrode has powdered iron in the

coating wi_ich:makes welding easier and faster, :The •slag is easy to remove in most casesself-peeling as the

_td cools:.

Ideal for fixture Welding Where weld appearance and lack of spatter is important. The amount of slag

permits use in all welding positions.

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

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

electrode in contact with work:

2.4

MACHINABLE CAST iRON AC-DC

rnachineable welds on all cast irons

GENERAL APPLICATIONS: Cylinder Blocks •Crankcases = Valve Seats eDefective

Castings eGears eSprockets •Casting Repairs in General eGarages eFarms eShops

SIZES AND HEATS (AMPS)

Oiameter

Amperes

I

/

t3/32" I/8"

48-85 75-130 t|

5/32" J. 3/I 6;'

I00d50 | t30-775

DESCRIPTION

This electrode uses anickel 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.

tt 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, anc_

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 oif

soaked into the cast iron.

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

relieve strain and stress.

......... =........... _ .... ;.--.. _.... _........ ='_.-" ,___ ......

CUTT|NG ROD AC-DC

quick, inexpensive, easy cuts through all metals

GENERAL APPLICATIONS: Cutting o Piercing • Gouging o Scarfing •Beveling o etc.

SIZES AND HEATS lAMPS)

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

-A-c 80. 5o 75- 3o

i

Amperes- DC t 150-250 I -

5132"

100-t50

3t16"

t30-175

DESCRIPTION

For p;ercing, 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 atl arc welders. AC or DC.

WE LDING 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

e×ceed 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.

2-5

I_ 56

• _ i,,,_:_ ,_

145 :47

1

49

42

34

28 _

/•

_32

19 19 18 17

23

24 25

/

/

2_

,i!

!:i

•!

PARTS LIST FOR CRAFTSMAN 50-295 AMP

DUAL RANGE ARC WELDER MODEL 113.201480

Always order by Part Number -- not by Key Number

Key Pa rt

No, No. Description

1

2

3

4

5

6

7

8

10

11

12

13

14

15

16

17

!8

19

20

21

22

23

24

25

26

27

28

29

61416

61276

61419

60359

61350

61279

60325

STD611005

61332

61335

STD601103

6! 356

61334

61391

61420

61418

STD541 ! 10

STD551010

14201

STD551110

61417

61314

61302

STD501102

61315

!STD541006

STD 5512O8

61264

STD541025

Cabinet, Top

Spacer

Pointer

Screw, Pan Rec. Type AB 10x

1-1/4

Knob Assembly

Bushing

Washer, 3/6 x 1-3/8 x 3/64

*Screw, Pan Rec. Type AB 10x

1/2

Slide Assembly

Bracket, Guide

*Screw, Pan Rec. Type "T"

10-32 x 3/8

Guide Assembly, Shunt

Spring

Pin, Guide

Shunt Assembly

Clip, Spring

*Nut, Hex 10-32

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

Clamp

*Lockwasher, No. 10

Cabinet, Bottom

Motor

Bracket, Fan

*Screw, Set Hex Cup 10-32 x

1/4

Blade Assembly, Fan

*Nut, Hex 6-32

*Lockwasher, External No. 8

+Holder, Electrode

*Nut, Hex 1/4-20

Key Part

No. No. Description

i,i

31 STD551025

51439

33

34 61342

35 60444

36 9415852

37 61310

38 30332

39 61171

40 STD510607

41 STD512507

42 61086

43 STD510805

44 61269

45 61422

46 STD551108

47 STD541008

48 61115

49 61116

50 61117

51 STD511105

52 30298

53 37526

54 37525

55

56 37952

57 37435

-- 61421

*Washer, 17/64 x 5/8 x 1/16

+Clamp, Ground

Cabie Assembly, Work

Washer, Spring

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

Cable Assembly, Electrode

Insulator, Plug

Plug

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

*Screw, Pan Rec. Type "T"

1/4-20 x 1/2

Relief, Strain

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

Switch

Lead, Primary

*Lockwasher, No. 8

*Nut, Hex 8-32

Block, Contact Mounting

Contact, Selecting Plug

Block, Contact Mounting

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

Terminal, Ground

Cover, Outlet Box

Ring, Outlet Box

oTransformer Assembly

+Helmet

Wrench, Hex "L'? 1/4

Owners Manuat (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,

o Transformer not replaceable.

2-7

Sears

SERVICE

MODEL NO.

113o201480

HOW TO ORDER

REPAIR PARTS

50=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 afl pertinent facts when

you call or visit.

The model number of your 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

113.201480

NAME OF ITEM

50-295 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 etectronicaIfy

transmitted to a Sears Repair Parts Distribution Center for

handling,

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

Part No. 61421 Form No. SP4654-2 Printed in U.S.A. 7/84