Page 5 of 561
UNITOR WELDING HANDBOOK 1.00
4
1 SAFETY IN WELDING . . . . . . . . . . . . . . . . . . . .
9
1.01 Introduction . . . . . . . . . . . . . . . . . . . . . . .
1.02 How to use the handbook . . . . . . . . . . .
1.03 Welding instructions and training . . . .
1.04 Personal protection . . . . . . . . . . . . . . . .
1.04.01 Arc welding face shields . . . . .
1.04.02 Protective goggles . . . . . . . . . .
1.04.03 Welder's protective clothing . .
10 11 12 13 14 18
20
1.05 Work site protection . . . . . . . . . . . . . . . .
1.05.01 Welding curtain . . . . . . . . . . . . .
1.05.02 Welding blanket . . . . . . . . . . . . .
1.05.03 Fire extinguisher . . . . . . . . . . . .
22 22 22
23
1.06 Welding fumes . . . . . . . . . . . . . . . . . . . . .
1.06.01 Welding fumes . . . . . . . . . . . . . .
1.06.02 Fume extraction . . . . . . . . . . . . .
1.07 Safety check list . . . . . . . . . . . . . . . . . . .
1.07.01 Equipment . . . . . . . . . . . . . . . . . .
1.07.02 Work place . . . . . . . . . . . . . . . . .
1.07.03 Hot work procedure . . . . . . . . .
1.07.04 Operator protection . . . . . . . . . .
24 26 27 30 30 31 32
32
2 SOLUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
2.01 Introduction . . . . . . . . . . . . . . . . . . . . . . .
2.01.01 Quick reference for cutting . . .
2.01.02 Quick reference for joining . . .
2.01.03 Quick reference for rebuilding,
hardfacing and coating . . . . . .
2.01.04 Quick reference to
cold repairs . . . . . . . . . . . . . . . . .
2.02 Filler material consumption . . . . . . . . .
2.03 Metal identification . . . . . . . . . . . . . . . .
2.04 Unalloyed / low alloyed steel . . . . . . . .
2.04.01 Introduction . . . . . . . . . . . . . . . .
2.04.02 Unalloyed steel . . . . . . . . . . . . .
2.04.03 Low alloyed steel . . . . . . . . . . . .
2.04.04 Heat resistant steel . . . . . . . . . .
2.04.05 Low temperature steel . . . . . . .
2.04.06 Weathering steel . . . . . . . . . . . .
2.05 Problem steels . . . . . . . . . . . . . . . . . . . . .
2.06 Stainless steels . . . . . . . . . . . . . . . . . . . .
2.06.01 Introduction . . . . . . . . . . . . . . . .
36 37 38 41 43 45 48 53 53 53 53 53 54 54 62 65
65
2.06.02 Austenitic Stainless Steel . . . .
2.06.03 Ferritic Stainless Steel . . . . . . .
2.06.04 Martensitic Stainless Steel . . .
2.06.05 Duplex Stainless Steel . . . . . . .
2.06.06 Clad Steel . . . . . . . . . . . . . . . . . .
2.06.07 Stainless Steel corrosion types
2.06.08 Storing and handling of
Stainless Steel onboard . . . . . .
2.06.09 Grinding/cutting consumables
for Stainless Steel . . . . . . . . . . .
2.06.10 Unitor Safety Grinder . . . . . . . . .
2.07 Cast iron . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.07.01 Introduction . . . . . . . . . . . . . . . .
2.07.02 Grey cast iron . . . . . . . . . . . . . . .
2.07.03 White cast iron . . . . . . . . . . . . . .
2.07.04 Malleable cast iron . . . . . . . . . .
2.07.05 Ductile cast iron . . . . . . . . . . . . .
2.07.06 High alloy cast iron . . . . . . . . . .
2.07.07 Identification of cast iron . . . . .
2.07.08 Preparation of the
work piece . . . . . . . . . . . . . . . . .
2.07.09 Arc welding of cast iron . . . . . .
2.07.10 Braze welding of cast iron . . . .
2.07.11 Cold repair on cast iron . . . . . .
2.08 Copper and copper alloys . . . . . . . . . . .
2.08.01 Introduction . . . . . . . . . . . . . . . .
2.08.02 Brass . . . . . . . . . . . . . . . . . . . . . .
2.08.03 Aluminium brass (Yorcalbro) . .
2.08.04 Bronze . . . . . . . . . . . . . . . . . . . . .
2.08.05 Nickel bronses (Cunifer) . . . . . .
2.09 Aluminium . . . . . . . . . . . . . . . . . . . . . . . .
2.10 Evaluation of welds . . . . . . . . . . . . . . . .
2.10.01 Typical welding faults . . . . . . . .
2.10.02 Inspection of welded joints . . .
2.10.03 Crack detection . . . . . . . . . . . . .
66 68 69 70 71 72
84 87 95 97 104 104 104 105 106 107 112 114 114 118
123
3 CONSUMABLES . . . . . . . . . . . . . . . . . . . . . . . .
125
3.01 Coated Electrodes . . . . . . . . . . . . . . . . . .
3.01.01 Introduction . . . . . . . . . . . . . . . .
3.01.02 Types of electrodes . . . . . . . . . .
3.01.03 Storing and re-drying . . . . . . . .
3.01.04 Classification and approvals . .
3.01.05 Welding positions . . . . . . . . . . .
126 127 128 134 140 148
74 75 77 78 78 79 80 80 81 82 83