WILEY EN GINEERING S E RIES

OXY A CETY LEN E

WE L D I N G M AN U A L

BY

L O R N C A M P B E L L,! R .

Vice-Pr es ide nt and Gej n era l M a nager,

Harr is Ca lo rific Co mpa ny

N EW Y O RK

! O HN WI L E Y S O N S ,I n c .

Le n n o n : C HA PM A N HALL ,LI M IT ED
 5
£ 52 7,

M 1 0!

RA

ITY OF

Co pyrigh ted in Great B ritain

All R igh ts R es er v ed
This bo o k o r an y part thereof mus t no t
be repro duced i n any fo rm witho ut
the writte n permis sio n of the pu lis her b .

PR IN T E D IN U . S . A .

PR E S S O F
B RA U N WO RTH C O IN C
IL D E R S O F
.

B O O KS
'
B U
B R ID G E P O R T . C O N N .
 PR E F A C E

I( )THE -
oxy acetylene method of weldin g and cuttin g
metals has o f late been receivin g considerable atten tion .

I ts tremendous power of crea tin g,repairin g and destroyin g

the work of man has been but recently reco gnized in its
.

broadest sense , and the demand for operators , skilled in

the mani pula tion o f this apparatus ,wh ich always has been
far in excess of the supply ,now kn ows no l im it M any.

au thorities have se t forth the ir views and theories upon

th is subject ,in A merica and also in fore ign countries These
.

have been published from time to time in many of the lead in g

period icals and ma gazin es ,as well as in book form I t seems
.

the purpo se o f most o f these works has been to advance

th e operators who already have a smatterin g k nowled ge of
thi s art ,or to present to the purchaser of apparatus a se t
o f ope ratin g instruct ions
.

( 2 ) I t is s in gular indeed that a s chool manual ,devoted

exclusively to the instruction o f the beginner ,which will
se rve as an aid to th e instructor as well as to the student ,
h as not ye t been put forth . I t cannot be said that there
is not a demand for such . R ecently there seems to have
been a mushroom growth o f weldin g classes Th e majority
.

of the vocational schools ,colleges ,n igh t sch ools ,and auto

mob ile schools have all entered the instruction in oxy
acetylene weld in g o n their rolls and each is attemptin g to
instru ct in an ent irely different m ann er from the o ther .
vi PR EFACE

There can be no question as to the exp ediency o f affordin g

th e educational institut ions a systematic as w e ll as a stand
ardiz e d method of instruct in B ut the books and arti cles
g .

o f the nature mentioned are not su ited to th is purpose

,
and were not designed for it A school book is wanted ;
.
-

somethin g to be used in the classroom ,to be employed as .

a reference in the shop practice ,to be studied fo r what it

contains ,and to indicate further lines of research ,where
such are required .

( 3 ) To meet th is demand , the present M anual has

b ee n wr itte n to serv e the instructor as well as the stud e nt .

I n its pr e parat ion many books , both w e ll known and -

obscure , have be e n e xamined and the methods o f shop

instruct ion have be e n care fully studied by the author .

(4) I t has been found that regardl e ss of how fast the

ground may be covered in the lecture room ,the avera ge
student s power of ass im ilation is lim ited and cons id e rable
’

time h as been spent in determ inin g th is ratio and applying

it between the lecture subjects and shop work .

(5) I t must be remembered that wh ile the chapters c o m

prisin g the theoretical part of this weldin g manual follow
in the order given ,the actual shop practic e ,as pr e viously
mentioned ,is the most important .

(6 ) Kindly aid has been received from many source s .

G ranjon R o s em b erg,K autn ey,M K eith D unham ,S W

. . .

M iller ,H e nry C ave ,C ! N yqu ist ,P F Willis ,B en K

. . . . .

S mith ,and oth e rs have embodied in their wr itin gs many

e xcellent id eas ,wh ich have ass isted th e author in brin gin g

o u t certa in po ints advantage ously Th e following manu

.

fac ture rs are to be given c redit for many o f the illustrations

Th e Oxw e ld A cetyl e ne Co , N ewark ,N I
'

. .

Th e U n ited S tat e s W e ld in g M inn e apoli s ,M inn .

Th e B astian B l e ss in g Co ,C hica go ,I ll
. .
 PRE F A C E Vii

Th e Linde Air Products Co ,New Y ork C ity. .

Th e G eneral W eld in g E qu ipment Co ,B oston ,M ass . .

Th e M esser M anufacturin g Co ,Ph iladelph ia ,Pa

. .

Th e A lexander M ilburn Co , B alt imore ,M aryland

. .

Th e To rch w e ld E qu ipment Co ,C h ica go ,I II

. .

Th e D avis B o um o n v ille Co ,! ersey C ity ,N !

-
. . .

Th e K G W eld in g Co ,N ew Y ork C ity

. . . .

Th e C h ica go E ye S h ield Co ,C h ica go ,I ll

. .

Th e C ommercial Ac e tylen e S upply Co ,N ew Y ork C ity

. .

Th e W eld in g E n gineer ,C h icago ,I ll .

Th e ! ournal of A cetylene W eldi n g ,C h ica g ,

o Ill .

—
NO E Lieut
T . . C ampb e ll o ffe rs h is se rvic e s w ith o ut c h arge to anyo ne
in t e res t e d in th i s m e th o d o f we ldi ng an d m ay b e addre sse d ca re o f J OH N
WI LE Y S ON S ,I NC ,P ub li sh e r s,4 3 2 Fo urt h A ve n ue ,Ne w Y o rk City
.
.
 WI LE Y E N GI N E E R I N G S E R I E S

THE W iley E n gineerin g S eries will embrace books devoted

tos in gl e subjects Th e object of the S eries is
. to place in the
h an ds of the reader all the essential information regarding
the particular subject in which he may be intereste d .

E xtrane ous topics are excluded ,and the contents of each

book are con fined to the field in di cated by its title .

I t has been considered ad v isable to make thes e books

manuals o f practice ,rather than theoretical d iscuss ions of the
subjects treated Th e theory is fully discussed in text books ,
.
-

hence the en gineer who has previously mastered it there ,is,

as a rule ,more interested in the practice Th e Wiley E n
gi n e e rin g S er ies therefore w ill present th e most approved

pract ice ,with only such theoret ical discussion as may be

necessary to elucidate su ch pract ice .
 CO N T E N T S

I NTROD UCTI O N
-AP PARAT US
t

OPE RATI O N
i
t

III S HO P E ! U IP ME NT
.

E APPARATU S R E P AI RS
! PR E II E ATI N G A G ENCIE S
S P AR T ON E — WELD I N G OF CAS T I RON
PART T wo —WE LD I N G OF C A S T I RO N
PART THRE E—WE LDD IG OF C A S T IRO N
P A RT F OU R —WE LDm G OE CAS T IR O N
PART ONE —S TEEL WE LD I NG
PART Two —S TEEL WELD IN G
PART T HRE E—S TE E L WELD I N G
PART FOUR—S TEE L WELD I NG
B RAS S WELDI NG
IX PART ON E —AL UMINU M WELD IN G
.

PART T w o —A L UMI N UM WELD I N G

PART T RE E A L UMI NUM WELD ING
H —
WELD IN G OE MALLEAB LE IRO N
XI OX Y ACE TY LENE C UTT IN G
.
-

CARB O N B URNI N G
G LO S S ARY
LECT URE S
I ND EX
 O x y A c e tyle n e
-
W e ldin g M a n u al

I N T R OD U CT I ON

( 1 ) WHE N choos in g a life vocation ,one generally views

the poss ib ilities it has to o fler and delves deeply into these ,
previous to makin g a decis ion I t is therefore th ou ght
.

advisable at thi s time to present the student with an idea

of what is meant by oxy—acetylene weld in g and cuttin g ; .

how it is appl ied ; the possib ilities and advantages attached

,
to such an art.

( 2 ) A cetylene gas when burned with a proper port ion

o f oxy gen gas ,produces an extremely hot flame ,in fact ,

th e hottest flame kno w n . I ts temperature is over 6 0 0 0

degrees F ahrenheit With th is flame it is poss ible to brin g
.

any of the so called commercial metals ,namely : cast iron ,

-

steel ,copper ,and alum inum ,to a molten state and cause
a fusion of two p ieces of like metals in such a manner that
the po in t of fusion will very closely approach the stren gth
of the metal fused I f more metal of like nature is added ,
.

the un ion is made even stron ger th an the origin al This

.

me thod is called oxy acetylene weldin g and d iffers from

-

what the avera ge layman considers weld ing in the black

sm ith s for ge ,insomuch that there is no blow stru ck to
’

assist fus ion in th is process And wh ile the forge method

.

is lim i ted to wrou ght iron and steel whi ch is detachable

O XY—
ACETYLE N E WELDIN G MANUAL
 I NTR ODU C TION 3 «

an d of restricted s iz e and shape ,the oxy acetylene proces s

.
-

h as ,practically speakin g,no such limi tations .

(3 ) M anufacturers in the metal workin g world were -

v ery slow to grasp the real s ign ificance of th is important

process ,un til the operators began demonstratin g some of

its poss ib ilities .A t the present time ,however , there is
hardly a metal barrel or tank
manufacturer who has not
di scarded the old method of
producin g costly leaky ,riv
eted drum s and conta iners ,
for th is modern fus in g proc
e ss . Th e manufacturers of
fire proof doors and w indows ,
-

cook in g utensils ,seamless p ipe

and tub in g,o fli ce furniture
and what not ,are now v ir
tually dependent upon the
wel di n g torch at every turn .

(4) A s a repairin g agent ,

the weldin g torch has no
rival . Whether it is a cast
in g of iron ,steel ,brass ,o r
aluminum that has broken ; ( C um y f th O w l A tyl
o s o e C )
x e d ce ene o .

F I G —I n En ame l e d P ro duct s fo r th e
a bo iler o r tank that h as . 2 .

Kitch e n th e W e ld is F as t R e placin g
w o rn aw ay m Spots o r an
th e R iv e t ing ,B razi ng,and S o ld e rin g
’

error on the part of e n o f th e L i gh t S h e e t M e t al S e am s .

gin ee r,foundryman or ma
c hin is t,the part c an generally be reclaimed and made
stronger than originally To — . day practically no m an ufac
turin g concern that is dependent upon metalli c machinery
could think of bein g depr ived of its oxy acetylene apparatus ,
-

once havin g learned its wor th In th e not far d istant past ,

.

were a ge ar or some casting to break , it probably meant closin g

4 OX Y -
ACETYLE NE W ELDI N G MANU AL

down the entire plant until a new part could be ob tained ,

which ,whether the source of supply were near o r at a long
,
d istance would mean costly delay With o xy acetylene .
'

equ ipment and an e flic ien t operator On hand ,almost every

emergency is provided for .

5 ) I f an automob ile owner breaks a frame ,he does not

consider replac in g it with a new one ,as the labor alone for

( Courtesy of the Oxweld Acetylene Co )

.

FI G — W e ldi n
g B ro k en F rame o f 5 to n A ut o mo b ile Truck
-
.
3 . .

stripp ing h is machine and settin g it up again ,not to men

tion the cost o f the new frame and the time required for
this operation ,is proh ib itiv e R ather ,b e b as h is car taken
.
'

to the ne arest welder or h is portable apparatus to the car

!

and the jo b is completed within thirty or forty minutes ,

wi th the frame at the poin t o f the br eak made stronger
than ever Locomotive frames are han dl ed in much the
.
 I N TR ODUCTIO N 5

same manner ,only more time is requ ired and perhaps extra
operators ,but the important po int to be brou gh t o ut is
the fact that o n many jobs no d ismantl in g is requ ired and
the repair is permanen tly and qu ickly e xecuted .

(6) An in terestin g example o f the true worth of weld in g

was brought to the attention of th e pu b h c when the U nited

F IG 4
. . S ta ff of In s tructo rs at th e Ordnan ce We lding S ch o o l,U S A
. . .

S tates entered the E uropean W ar , and all the interned

G erman vessels ,which had been greatly dama ged by the
orders of their commandin g o fficers ,were restored to workin g
conditi on with the oxy acetylene and electr ic welding process
-
.

This was cons idered imposs ible by many en gineers not ia

miliar w ith the process ,insomuch as they looked upon o xy
acetylene wel din g as applicable only to small parts and
6 OXY ACE TYLEN E WE LDIN G MAN UAL
-

here some of the sections whi ch had been blown or stru ck

out of the cast cyl inders ,etc ,we ighed many hundreds of
.

pounds I n many instance s the ribs of these same vessels

.

were cut most of their depth ,but th ese were restored to

workin g order in a remarkably short time and th e results
were more convincin g than any words .

(7 ) C uttin g with the oxy acetylene process is just the

-

opposite from that of weldin g Th e latter m ight be con

.

side re d constructive and the former destru c tive In the .

case of weldin g,two parts are brought to a molten condi tion

(

along the line to be joined and both fused together Whereas .

in cuttin g, one piece of metal ,when brou ght to a red

'

heat ,is cut in two by an oxidizing flame C uttin g has n o t .

the wide scope that welding has ,for it can only be applied
successfully at the present day to wrought iron ,rolled and
cast steel Whi le it is limited in its scope ,the Speed of
.

th is process in severin g large masses of metal is very spec

tacular and appeals forcibly to the observer .

(8) Probably the world s first awakenin g to the re al

’

meanin g of o xy acetylene cuttin g came when the U S

-
. .

“ ”
battlesh ip M aine , was being taken from Havana Harbor .

All the heavy armor plate and seemin gly immovable wreck
age was cut into small sections wh ich could be handled

easily This was all accompl ished with the cut tin g torch ,
.

whi ch seems to eat its way throu gh metal with the same
ease that a hot kn ife goes throu gh butter .

“
( )
9 B efore and s in ce the t ime o f th e M aine , the cutting
torch has been accomplishin g wonderful feats In every .

scrap yard ,o ld boilers and the l ike are bein g cut into fur
nace s ize ; speeding up the production in answer to the
world s cry fo r more metal Th e wreckage o n railroads and
’
.

buildin gs usin g steel reinforcements is be in g cleared in

hours ,with the aid o f the cuttin g torch ,where it required
day s by other methods M ost of the fire departments in
.
 IN TR ODUCTION 7

the larger cities now carry the cuttin g torch as part of their
equipment ,and to it has been cred ited th e sav in g of many
lives ,by its timely cuttin g away of steel doors ,bars or barriers
which prevented escape M uch of th e plate in this coun try s
’
.

r y f th Oxw ld A tylen C
( Cou tes o e e ce e o .
)
FI G .
5.
—F irernan Cutt ing a h S t ee l Fire Doo r with Po rtab le Apparatus .

sh ipbu ildin g yards is bein g cut to s ize right on the job ,and
the function of this torch in cutting o ff r isers measur ing
from o n e to thirty six inches in diameter in the foundry
-

seems only to be of secondary importance in comparison with

 OXY ACETYLEN E WELDI N G M AN UAL
-

some of its othe r uses In order to transport som e of the

.

largest inland lake boats whi ch were much to o long to pass

through the locks ,to the se a ,they were cut in parts ,trans
ported ,and later welded to geth e r and placed in s e rvice .

( 1 0 ) I t is not only possible to keep a cutting torch burn

in g under water ,but it can also be made to cut Co n .

tracting companies are cuttin g o ff their pilin g under water

and it has been kn own that in E uropean ports cutting h as

( Co urtesy of the Acetylene !

Publi hi
ou rnal s ng Co )
.

F IG . 6—
. Welder s o f th e Si gnal Co rps ,U S A rmy,in Acti o n
. . .

bee n successfully accomplished at a dep th o f thirty feet .

A Special torch is employed by submarines to cut n e ts under

water .

( I I ) I n reviewing the o xy acetylene welding and cutting

-

process ,we fin d tha t its growth is o n e of the most rem arkable

th e world has ever witnessed About 1 90 7 saw its industrial
.

b irth and s ince that tim e it has advanc e d by l e aps and

bounds , r ivaling the automob ile industry in its progress ,
10 OXY A C E TYLENE WE LDI N G MAN UAL
-

cylinders ,intake and exhaust manifolds and connections ,

spark plug thirn b les and the repair of aluminum crank
cases ,etc .

( )
B A m bi M —
uto o le an ufac ture W eldin g of steel and alu
.

minum bodies ,transm ission and rear axle housings ,crank

shafts ,cylinders ,g ears ,manifolds ,pin ions ,crank cases ,valves ,

F IG 7
. .
-
Welding a 2 fo o t Lengt h o f New S h afting
-
on th e E nd o f a M o to r
Sh aft 2 Inch es in Di ame te r .

rims , muffl ers , frames , fenders , wind sh ield tub in gs , and -

upr ights ,etc .

—
( C ) B oiler S hops W eldin g and buildin g up worn spots
around hand hold plates , repairing cracks and check e d
-

portions of fire boxes ,re tippin g flues ,connections ,etc .

—
( D ) B rass and Copper W eldin g kettl e s , vats , tanks ,
.
 I N TR ODUCTION 1 1

stills , floats , cookin g u tensils , man ifolds , water jackets ,

electrical and chemical wares ,etc .

( E ) Co mm ercial Wel g R eclam ation service on all

din
—

kinds O f metals ,q uick and permanent repairs on all broken

parts o f mach in ery .

—
( F ) E lec tric R ailway W eld in g air receivers on air brake -

systems ,bu ildin g up Shaf ts ,bond ing the rails ,motor hous ings ,

y f th T hw ld Equipm t C )
( Co urte s o e o rc e en o .

F I G 8 — This is a S te e l Tank ,Made o f i nch P lat e ,wh ich M easures 30 Fee t

. .
-

Lo ng an d 8 Fee t in D i ame te r ,Fu se d i n t o On e P i e ce b y th e W e ld ing To rch .

worn box e s ,reclaim ing gears and broken trucks ,steel trolley
wires ,etc .

—
( G) F o rge S ho p W eld in g complicated parts which can
n o t be conveni ently handled in the for ge .

—
( H) F o un dries W eld in g up blowholes ,porous spots ,and
reclai min g castings in general Th e cuttin g o fl o f risers ,
.

gates ,and heads on steel castin gs .

12 OXY A C ETYLE NE WELDIN G MAN UAL
-

—
( I) Lead B urn ing Lead pipe joints , storage b attery
connections an d repairs ,lead linings in vats ,e tc .

( Courtes y f Ben K S mith ,U S

o . . . Welding C0 . )

FI G .
9.
— Lo c omo tive Cylinde r to b e We lded in P lace .

—
M ills B uildin g
(! ) Lumber .up worn shafts ,repairin g
gears ,chains ,and broken parts .

—
( K) M achin e S hops R ectifyin g e rrors o n part of ma
.

”
c hin is ts and en gineers A puttin g o u tool in every respect
.
-
.

—
(L) M an ufacturers Welding spouts and h andles on
.
 IN TR ODU C TION 13

cooking utensil s ,fir e proof doors and window sashes ,o fli c e

-

files and furn iture ,cha ins ,etc .

—
( M ) M in es R epa irin g p ipe l ines ,bo ile rs ,broken shafts ,
.

gears ,and bu ild in g up wo rn parts o n d ippers ,etc Th e .

cutting torch is used fo r c le arin g aw ay wreckage in case of

'

accidents .

( N ) P ipe Wo rk W e ld in g of water ,gas ,and o il,steam

—

y f th Oxweld A tyl ne C )
( Courtes o e ce e o .

FI G . Io .
—
S tee l R o ll To p D esk— all J o i n t s and S eams We lde d An Exc e ll en t
.

Example o f High grade W elded M e tal F urn iture

-
.

and air lines H igh pressure refrigeration systems are cut

.
-

and welded in place .

(0 ) P late Welding Tanks for o il,steam driers ,d igesters ,

—

vats ,chem ical rece ivers ,generators ,etc .

—
( P ) P o w er P lan ts W eld in g o f steam ,
ai r,and water lines , -

of pump castin gs ,cylinders pistons ,worn o r broken parts ,etc

. .

( ! ) R ailro ad Wo rk R eclaimin g bolsters ,coupl in gs ,slot

— .
1 4 OX Y -
ACETYL EN E WELDI N G MAN UAL

tin g forged engin e rods ,bu ildin g metal cars ,repairin g fire
boxes ,patchin g and replacin g S ide Sheets ,flue weld in g,bu ild
in g up frogs and crossin gs ,cuttin g o ff ra ils ,mud r in gs ,weld
in g cracked cy linders , cross heads , s team chests , b uildin g
- -

( Courtes y of the Oxweld Acetylene Co )

.

F IG . I I — Office
. Ch air . We lde d at all Jo i n t s .

up worn spots on wheels ,r ims and p ins ,welding spokes

and locomotive frames ,etc .

n g M ills
— F ab ric atin g open hearth water
( )
R R o lli , -

“
jacket doors ,cutting up lost heats , scrap plates and bar
stock b illets G eneral r e pairs of furnace equ ipment , ho t
.

beds ,rolls ,gears ,engines ,plates ,etc .

 I NTR ODUCTION 15

—
M etal M anufacture
( S ) S heet . of tub in g, Oil storage -

barrels ,metallic furn iture ,ran ge boilers ,etc .

—
( ) S py
T h i a rds C uttin g o ff plates and irregular shapes
of steel ,channels , spec ial sections B u ild ing up of worn .

shocks ,bu ild in g and patch in g hulls ,s trin gers and the reclama
tion of propellers ,posts and broken parts of machinery ,etc .

—
( U ) S truc tural S teel C uttin g holes for rivets ,gu ssets and
.

splice plates ,and wrecking W eld in g up m isdrilled holes

.

( Courte sy of the Bri tish Oxygen Co )

.

FIG — Cutti n A rmo r Pl at e b y th e Oxy ac e tylene P ro c ess

. 1 2 .
g -
.

’
and mach in ist s errors C uttin g channels , I beams , and
.

other shapes for cop in g,sp licing and fittin g rails ,welding
reinforc in g rods for concrete work of any des ired length
and structural parts where boltin g and r ive tin g is difficul t
o r imposs ible .

—
(V ) S crap Yards C uttin g up scrap boilers ,tanks and
.

o ther lar ge work to m ill siz e ,wreckin g structural bu ild in gs ,

and reducin g to small size ,rese rv o rrs ,tanks and boilers ,
16 OXY ACETYLEN E WE LDI N G MAN UAL
-

wh ich are housed in bu ildin gs to remove them without

damage to the structures .

(W) Tractor I n dustry C uttin g and welding frames ,

— .

track and wheel guards ,water ,gasoline ,and o il tanks ;

( Courtesy o f the Davis ~ Bou rno noille Co )

.

FI G . I 3 .
— He re is I llu stra te d an Oxy ace tyl ene M ach in e fo r Cuttin g Ho les
-

in th e Web o f Ra il s ,o r in S tructural I ro n ,o f n o t mo re th an In ch in
Thi ckn e s s . I t c an b e ! uickly A tt ach e d and A ccura te ly A dj u s t e d to
P ie rce t h ro ugh th e Iro n In s tan tly ,w ith o ut any P re vio us D rilling,and
it will Cut Smo o th Ro und Ho le s,fro m to 2 Inch es in D iame te r in fro m
30 t o 60 S e co nds I t is Pa rticula rly Adapte d fo r Railro ad Wo rk ,an d
.

En largin g o r Cutting Ho les in B uilding an d B ridge Wo rk .

w eldin g up of blowholes ,porous spots and m isdrilled holes

in castings of all kinds .

( 1 3 ) Th e foregoing,as previously stated ,is but a part ial

lis t o f some of the app lica tions o f the o xy acetyl e ne weld in g -

an d cuttin g process to var ious industr ies Wh at has the .

18 OXY—
ACETYLEN E WELDI N G MAN UAL

in instruction th is kind on a large scale There are many

of .

difle ren ce s to be e xp e cted o n account o f this very fact ,for

there are few who have gone furth e r than the instruction
o f very small classes where ind ividual attention may be

given .

( I 7 ) All h istory O f the process ,gas manufacture and th e

like have been om itted in order to give greater detail to
the actual shop practice and to have th e op e rator become
famil iar with h is apparatus and thereby Op e rate it with all
due resp e ct and intelligenc e
.

( I 8) Oxy ac e tylene weld in g cannot b e learned by watchin g

-

others work ,althou gh observation may at times ass ist the

beginner A ctual torch practic e ,bra in work and a power
.

”
of I will , produce the most efficient O perators F o r those
.

who earnestly apply thems e lves to th e instructions wh ich

follow ,there is every r e ason to believe that success will be
theirs.
 C HA PTE R I

APPA R ATU S

( 9 ) WE LDI N G
1 apparatus in general consists of two regu
lators equipped w ith pressure gau ges ,two lengths of hose ,
and a weldin g torch Th e regul ators are attached to cyl
.

inders of acetylene and oxygen and are used to reduce and

maintain a un iform pressure o f these gases for use at the
torch Th e gases at reduced press ure are conveyed to the
!

torch by the hoses Th e re gulators should each have a

.

h igh pressure gau ge to indicate the contents of the cyl inder ,

-

and also a l ine or workin g pressure gau ge to show the gas

-

pressure o n each hose W hen the gases reach the torch they
.

are there mixed and combust ion takes place at the weldin g
tip , which is fitted to the torch S u ch an apparatus is called
.

portable ,o n accoun t of its movab ili ty There are o ther

.

equipments wherein o n e or both of the gases are generated ,

but these w ill not be d iscussed here .

( )
2 0 F or conven ience o xy acetylene
-
weld in g apparatus
may be divided into three classes ,dependin g upon the prin
c iple s used in secur in g the fuel gas or acetylene for the flame .

Lo w pressure ,med ium pressure and h igh pressure apparatus

- - -

g enera lly u s e about the same pressure of oxy g en and it wi ll

be called a constant Th e acetylene gas is a variable and
.

in the low pressure type only enou gh pressure is required

-

to overcome the friction of the line until it reaches the oxy

gen injector ,located in the torch ,wh ich acts as a syphon ,
drawin g the acetylene gas to the poin t of ign ition I n a.

med ium pressure type about three fourths as much pressure

- -

19
20 OX Y ACETYLE N E WELDI N G M AN U AL
-

is required on the acetylene lin e as on the oxygen This .

type is apt to verge on the injector type ,as it depends to

some extent upon the oxygen under pressure carry in g ac e ty

FI G . I 4.
—A Po rtab le W e lding Uni t
.

lene gas to the point o f ignition In the high pressure type

.
-

equal pressure o n e ach l ine is used To further make this

.

classification clear ,a certa in sized tip usin g,perhaps , 1 2

 A PPARATU S 2 1

pounds of oxygen pressur e can be used as an example In .

a low pressure type perhaps 2 pounds pressur e o r less will

-

be need e d on the acetylene l ine On the med ium pressure .

-

approxim ately 9 pounds will be required , wh ile o n th e

high pressure an equal amount ,o r 1 2 pounds will be needed
-
.

( 2 1 ) Th e m ix in g chambers fo r the gases may be located

in the head ; in the m iddle o f the torch ,or in the handle .

By m ixin g chambers reference is made to that portion O f the

torch where the two gases are brou ght to gether and m ix e d .

AS can be seen with three d ifferent types of weldin g torches

FI G . I5 .
-
L o c ati o n of M ixin g C h amb e rs in W e lding To rch es .

(I ) Sh o ws gase s m x ii ng in th e h a n dl e .
( 2 ) Has th e m iig x n c h am b r i th middl
e n e e of the
tr
o ch . (3 ) Ill tr t
us a es h o w t h e gase s a re k pt p
e se a ra e t til th
un e h ea d of th t rc h i r
e o s e ac h e d .

Ox . r pr
e t
ese n s o x ygen gas ; Ac . ac e ty l
e ne g as ; and rn mixing c h am br
e .

an three d ifferent locations fo r the m ix in g of th e gases ,

d
the manufacturers can fin d a large range for producin g
oxy acetylene apparatus
-
S ome undoub tedly w ill fill cer .

ta in requ irements better than others M uch ,too ,will de .

pe nd upon the ab ility o i the operator in handlin g a torch .

(2 2 ) F lashbacks are caused by the improper m ixture o f

the gases ,whi ch in creas e s the rate o f flame propa gation to
such an extent that the flame will flash back to the m ixin g
chamber A cetylene in a pure state will burn ve ry much
.

slower than when m ixed w ith e q ual parts of oxygen When .

22 OXY ACETYLE N E WELDI N G M AN UAL
-

more oxygen is introduced the flame propagation is much

greater ,so that when an excess of oxygen is used ,there
is bound to be cons iderable trouble from b ac kfl ash in g .When
su ffi cient acetylene is introduced to the m ixing chamber ,
there is absolutely no chance for this lean m ixture to occur .

I f the flam e flashes back to the m ixin g chamber ,both gases

should be closed Ofl immediately ,at the torch ,the oxy ge n
first ,and then the acetylene gas .

(2 3 ) I n some torches the heatin g of th e mix in g chamber

will cause a flashback and with these it is necessary to Shut
o ff the acetylene and leave the oxy gen valv e just cracked

and immerse the torch head in water ,d ippin g it slowly ,

s o as not to cause to o great a stra in . Th e oxygen will bubble
o ut and prevent th e water backin g up in the tip .I f th e
flashback deposits e nou gh soot on the inside o f the tip and
the head to impair th e working quality of th e torch ,the
soot should be removed by usin g a soft wire ,prefe rably o f
copper ,or some oth er material which will n o t mar the tip .

(2 4 ) I t I S Interes tin g to note the action o f a regulator ,

used to reduce th e cyl in der pressur e o n bo th gases Th e .

gas from the cyl inder ,at h igh pr e ssure ,comes d ir e ctly into
th e body o f the re gulator o r chamber (A) ,F ig 1 6 ,throu gh
.

a fin e nozzle (B ) . A seat o f gallili th , c ase n ite , o r fiber

(C) ,attached to an arm (D) ,presses against th is nozzl e .

A rm (D ) ,in turn ,is attached to a very sensitive diaphragm

(E ) and is mov e d every time ther e is a pressure e x e rte d o n
the latt e r Th e move men t o f this diaphragm is controll e d
.

“ ”
by a handle o r a screw ,with a cross bar attached to-

its end as is shown at (F ) . Th is screw bears upon the dia

phragm throu gh th e medium o i the sprin gs (G) A s this .

scr e w is forced in ward the spr in gs force the diaphragm in ,

and thereby move the seat away from th e nozzle o f th e
regulator Th e gas ,e nte rin g und e r high pressure , exerts
.

an e qual forc e on all parts o f th e chamber and th e diaphragm

 APPAR AT U S 23

receives its share N ow the chamber walls are made of

.

a soli d material ,usually a bronze o r brass ,and canno t be

changed ,but th is di aphragm can be moved and as th is
pressure is increased ,th e d iaphragm is forced out and the
nozzle (B ) is automatically closed by havin g the seat (C)
brought in contact with it When gas is drawn o fl throu gh .

the lin e (H) ,the pressure withi n the chamber will naturally

FI G . 1 6 .
—Cro ss -
ctio n o f R egula to r
se .

A ,c ham b r; 8 , l ; C,
e no zz e sea t ; D, t m ; E ,di p h gm ; F , r
sea ar a ra ,o r
c oss -b ar adj u ti
s ng

r
sc e w ; G,d i p h r gm sp ring ; H,g
a a s as o utl t ; I ,
e g i l t
as n e .

drop and as it does so ,the spr in gs will force the diaphra gm

inward , perm ittin g a replacement o f the gas drawn o ff .

Al thou gh not no ticeable ,there is a continual movemen t of

this diaphra gm whenever the gas is bein g used I t can be .

readily seen that the amoun t o f pressure with in the regulator

can be accurately set by the tens ion o f the Spring aga in st
the diaphragm which is controlled by the screw carrying
“ ”
th e cross bar -
.
24 O XY ACETYLE N E WELDI N G M AN UAL
-

(2 5) Ther e are two typ e s of r e gulators manufactured for

the reduction o f gases un d e r h igh pressure ,dependin g upon
the nature of work to be done Th e h igh pressure regulator
.
-

is employed for heavy work wh e r e a gr e at deal of gas is

used and the regulator must pass it without much effort ,
to prevent its freezing Th is type o f re gulator is used o n
.

cuttin g o r o n large we lding work I t d iff e rs from the lo w

.

pressure or ordinary type in four d istin ct features G enerally .

it contains a much heavier d iaphragm wh ich is smaller in

diameter ,makin g it s tifle r in every respect Th e te ns ion
.

sprin gs which act upon th is diaphragm are much heavier .

Th e nozzle wh ich presses a gainst th e seat is much larger ,

to perm it th e passage of a greater amount o f gas Then ,too ,
.

a larger workin g pressure gau ge must b e used ,in order to

read thi s h igh pressure I n the weld in g O f metals ,especially
.

in steel ,the adjustment o f the flame is a very important

matter ,and absolutely dependable regulation must b e b ad .

Th is is not poss ible with a h igh pressure regulator and is

-

not in tended to be so Th e larger th e diaphragm ,the more

.

s e nsitive the regulator ,and th is point should be borne in

.
.

m ind ,and no small wel din g work attempted with the h igh
pr e ssure regulator Th e reve rse form of r e asoning m ay
.

b e applied to lo w — pr e ssure regulators wh ich have been us e d

in cutting . They are very lik e ly to be strained and satis
factory results cann ot be e xp e cted ,for th e y are n o t made
for that purpose A cetylene regulators a re constructe d mlich
.

more sensitively than the oxygen regulators ,to take care

of the lower pressure o f gas and in a s e nse might b e called
weaker ,insomuch that the large r nozzle which passes the
gas is closed or regulat e d by spr in gs whi ch are not nearly
as stron g as in the oxygen regulator F or th is r e ason acetylen e
.

regulators cannot b e interchan ge d with oxygen regulators

for they will not stand th e pressure d e mand e d in th e first
place ,and in the s e cond place ,were a small quanti ty of
2 6 OXY ACETYLEN E WE LDI N G MAN UAL
-

(2 7 ) In acetylene cyl inders an absorbent called acetone

is generally used ,wh ic h gives up the gas as r eq u ired .A
full cylinder can be used for some time without any noticea b le
d ifference in the gau ge readin g,and then ,as it nears the
empty point ,the gau ge readin g will drop very perceptibly .

I t is therefore impossible to depend upon a h igh pressure -

acetylene gau ge as an in dex to the contents of the cylinder .

Th e only method known to correctly check the amoun t of

acetylene gas on hand is to weigh the cylin der There are
.

1 4 5 cub ic feet o f acetylene

gas to the pound ,and when the
-

n e t weight O f the cylinder is given the contents can readily

be figured A tag bearin g th e net weight o r figures which
.

will perm it its computation is generally found attach e d to '

each acetylene cylinder In the case o f oxygen cyl inders ,

.

there bein g no ab sorbent used ,the contents o f the cylinder

is indicated on the h igh pressure gau ge
-
. On the latest
type gau ge th e contents w ill be show n by cub ic feet ,by
pounds pressure and by atmospheric pressure ,to facilitate
the computation Of costs by the operator .

( )
2 8 O ccas ionally a needle valve on a torch w ill begin
to leak and it will be found necessary to gr ind it R ealiz in g
.

that Oil and grease are not to be used where oxygen is in

e vidence ,th e question is often brou ght up as to the proper

lubr icant to be used in do in g this kind of work Glycerine

.

is used by most manufacturers , to gether with powdered

glass or flour emery . In do in g work O f this kind the fin ished
job is thorou ghly washed with ether Occasionally when
.

pipin g oxygen l ines through the shop ,a screwed couplin g

will leak and there is a temptation to calk the same with
whi te lead ,but th is Should never be done ,ra ther use lead
oxide m ixed with the glycerine for th is purpose as it forms
a paste whi ch sets very rap idly and fo rms a hard ,tough
compound .
 C HA PTE R II

O PE RATIO N

2( 9) IN oxy acetylene weldin g there are two gases used,

-

as th e name would ind icate ,nam ely ,oxygen and acetylene .

Th e fir st is used to intens ify the fl ame and can in nowise

be lik ened to the inflammab le nature of the second There
.

is a great deal of oxy gen present in the air we breathe It

.

is an odorless ,tasteless ,and colorless gas ,as most of us are

aware In the commercial world oxygen is manufactured
.

by the decomposition of water into its elements ,oxygen

and hydro gen ,by the electrolyti c process or is tak en from
the air by a reduction process and is stored in steel drawn-

cylinders These cylinders are drawn o ut of o n e p iece o f

.

steel and are of cons iderable thickn ess throu ghout ,havin g
absolutely no seams ,welded or o therwise There is no filler
.

nor absorbent used on the inside of these cylin ders ,as pur e
oxygen un der pressure is not considered dangerous Th e .

standardized s iz ed oxygen cylinder is one wh ich contains

2 0 0 cub ic feet o f gas full y char ed Oxygen is compressed
g
.

in these cy linders at a pressure o f 1 80 0 pounds ,at normal

temperature ,and th is pressure does not vary to any great
extent with ch ange in temperature ( as shown by table o n
page There is attached to the tip of the steel cylinder ,
“
or bottle , as some workers call it,a double seating valve
which has o n e seat operate when the cylin der is closed ,
and the o ther when th e cylinder is wide open A regulator
.

is attach ed to th is valve when workin g.

2 7
28 OXY ACETYLEN E WELDIN G MAN UAL
-

FI G . I 7 —S e cti o nal
. Vi ew o f ( Co m m - P du t C )
V of ”1 6 L in da 4 " ro c s o .

Oxyge n Cylinde r with o ut F I G 1 8 —A S t andard zo o —fo o t Oxygen

. .

Valve .
Cylinde r .
 O PE R ATION 29

(3 0 ) A cetylene is the fuel gas ,and is one o f the greatest

contain e rs O f heat kn own B u rn in g in a free state , its
.

carbon content is so rich that complete combustion is im

T A B LE S H OWI N G THE D IFFER EN T PR E SS UR E S O F OXYGEN

AT VA R I OU S T EM PE R A TUR E S

FIG . 1 9 .

possible ,and strin gy black particles will be noticed floatin g

throu gh the air I n order to fully combust th is gas,oxygen
.

is introduced under pressure and a temperature of over

30 OX Y ACETYLE N E WELDI N G MAN UAL
-

60 0 0 degrees F ahre nheit is Obta ined (A cetylene contains .

about fiv e times as many B T U s ( B ritish Th e rmal Un its)

. . .
’

as hydrogen ) This gas ,unl ike oxygen ,becomes very dan

.

ge ro us when in a free state it is subjected to excessive

FIG . 2 0 .
— A G e ne rat o r fo r P ro ducing Ace tylene unde r P r ssure
e .

pressure Th e sl ightest jar may cause its d is int e gration

.

and a viol e nt explosion follows On account of this .

danger ,acetylene is n o t stored in a free state ; neither is it

subjected to very high pr e ssures I ts cylinders are put .
 O PE R ATION 31

out by various manufacturers to comply wi th the laws and

re gulations of the I nterstate C ommerce C omm ission S ome .

o f these cylinders have been welded ,but the most modern

method is to make them of one p iece of drawn steel They

are then filled with an absorbent of some kind to take up
the gas and prevent any portion of it bein g left in a free state .

A cetone is the popular absorbent ,an d is a l iqu id capable

o f absorb in g twenty fiv e tim es its own volume of acetylene
-

as at normal pressure Th e fill in g mater ial var ies with each

g .

of the m an ufacturers ,but charcoal ,asbestos and m ineral wool

are in very common use A c e tylene is obtained fro m cal cium
.

carb ide brought in contact with Water ,o r v ice versa ,an d

is compressed and th e n stor e d in the cyl inders at a pressure
varyin g from 1 50 to 2 50 pounds When fully char ged . .

th is pressure w ill vary almost d irectly with any change

o f temperature . A cetylene cyl ind e rs for weld in g are avail
able in 1 0 0 ,2 0 0 ,2 2 5,and 3 0 0 cub ic foot s izes .

(3 1 ) In settin g up apparatus for the first time ,th e regu

lator con tainin g the 3 0 0 0 pound gauge is a ttached to the
-

taller o f th e cylinders ,which holds the oxygen gas ,and

the other regulator is fastened to the shorter cyl inder Th e .

hoses ,wh ich Should be cleared o f all powder o r scale on

their in terior , are then added Th e black hose should
.

connect the oxygen r e gulator to the torch valve ,marked

“ ”
OX and the red hose ,the acetylene regulator to the
“
torch valve stamped A C I n attachin g re gulators to
.

”
full cylinders the cross bar -
on the r e gulator should
always be turned out ,that is to the left ,un til it turns freely ,
to insure all pressure bein g released from the d iaphragm ,
before the cylinder pressure is turned on Another pre .

“
caution that should be obs e rved is the crackin g o f the ”

cylinder valves ,before atta ch in g the regulator ,in ord e r

to blow o u t any dirt or foreign part icles that may be lod ged
there ,o therwise they will be carried in to the regulator seat ,
32 OXY ACET YLE N E WELDI N G MAN U AL
-

or lodged in some small passage ,wh ich will impair the

workin g o f the apparatus Then too ,if no truck or clampin g
.

d e vice has been provided both the oxygen and acetylene

cylinders should be securely clamped o r wired toge th e r ,
a rule which should be insisted upon at all times ,whether in
a job shop ,manufacturin g concern ,o r train in g school ,o r
any place where top heavy oxyge n cylinders are bein g used
-
.

N o particular harm r e sults if these cylind e rs are turned over ,

wh ich is very eas ily done o n account o f their rounded base ,
if no r e gulator is attach e d ,but very frequently r e gulators
are attach e d and the hose connectin g the same to torch
is foun d in the O perator s way
’
Th e slightest pull o r tr ipp in g
.

on th is hose will upset the cyl inder ,usually d e molishing

the regulator and expensive gau ges and at times causin g
much confusion among the workmen ,on account o f the
loud h iss ing noise given o ff by the escap ing gas A lways .

s e cure the drums or th e cylinders in a safe manner .

(3 2 ) I n turnin g on the gas ,the oxygen valve is opened

wid e until seated and the ac e tyl e ne valve is only partially
op e n e d Often the qu e stion is raised as to where the oper
.

ator should stand ,espec ially wh e n d ealin g with h igh — pr e s

sure oxyge n I t is recomm e nd e d that th e op e rator should
.

s tan d at th e s ide and towards the rear when perform in g th is

operation ,for som e t imes an unreli able gau ge may b e a t

tac h e d,wh ich if burst in g,would s e nd th e glass into th e
’
operator s face .

(3 3 ) A s soon as an operator has gas pressure in h is regu «

lators ,he begins wond e r in g h o w much pr e ssur e should be

place d on h is line ,that is ,th e portion between th e r e gulator
and the torch Of course ,th is d ep e nds upon th e size o f
.

the tip ,but the O perator should have some m e ans of approx
’
im a tin g th is pressure without go in g to h is manufactur e r s
chart e very tim e A n e utral flame ,that is ,the oretica lly
.

equal parts o f oxyge n and ac e tyl e n e ,is d e sired fo r we lding .

34 O X Y ACETYLEN E WE LDI N G MAN UAL
-

line ,appearin g likethe end o f an unused p iece of chalk ,

only ,o f course ,much smaller I n F ig 2 5 can be seen an . .

excess or too much pressure of oxygen I t will be noticed .

that the neutral flame assumes a more bluish color ,is a

FI G . 2 3
—M o r e Oxygen
. P ressure Appli ed Flame C o n t ain s S li gh t Exc ess
. of

A ce tylen e ,and i s Kno wn as Carb o n izing

“
.
”

little poin ted ,and a very noticeable h iss in g sound is in

ev idence Th is is what is called an oxi d izin g flame and will
.

be again referred to To o much oxygen is used Operators

. .

who attempt to turn on th e oxygen fir st an d then light it,

FIG 2
— “ Neut ral ” F lame Co rre ct P r o po rt io ns of Oxygen and A ce tylen e
.
4 . .

G ases .

wil l fin d that it d o es not burn ,and their efforts will be useless .

I n p icking up a torch for the fir st time ,an y operator can

turn on o n e valve an d d e tect by the o dor o f the gas ,whether
it is oxygen or the fuel gas ,and can light it in accordance .

FIG . 2 5
.
— “
Oxidiz in g Flame
”
. Too much Oxygen P re sen t .

S ome operators ,however ,attempt to turn on a l ittle o f .

each gas and light Th is is not to be recommended ,for

.

flashbacks may occur Wh en the welder accustoms h imself

.

to turnin g on enou gh pressure to accommodate whate ver

siz ed tip he may have ,he will fin d that there is no great n e ed
for payin g attention to the pressur e gau ges on h is regulators
 O PE RATION 35

except to check up on the full d rums of oxygen ,and to te h

whether he has enough gas left to complete a cer tain piece
of work .

(34) A neutral flame is theoretically composed of e q ual

parts of oxyg en and acetylene ign ited ,but this ratio is very
seldom worked out in practice There is usually an excess
.

of oxygen in evidence A neutral flame is generally spoken

.

o f as be in g over 60 0 0 degrees F ahrenheit ,and th is does not

vary with the d ifferent sized tips as most welders thi nk .

Of course there are d ifferent quan tities of heat between

a very small tip and a lar ge sized one ,but the temperature
of the flame is the s ame .

(3 5) I f too much acetylene gas is used ,a feather flame

such as was seen in F ig 2 3 w ill appear Thi s has a car
. .

b o n izin g efle c t on the weld ,for it in tr oduces carbon and

causes the weld to become very brittle .

(3 6) I f too much oxygen gas is used ,th e effect shownin

F ig 2 5 will take place ,and the weld w ill have oxy gen intro
.

duced ,wh ich is a very detrimental feature ,and is partic u

larly noticeable in workin g on steel ,for it raises a wh ite
foam over the surface of the melted metal ,which sometimes
is worked r ight into the weld itself An experienced welder
.

will always know just what kind of a flame action he is

O btainin g on h is weld ,not because he takes the flame away
every time he wishes to look at it,but he can tell by the
action of h is metal exactly th e nature of h is flame .

(3 7 ) I nfra red ( heat) and ultra violet ( light) rays present

- -

to a small extent in th e neutral flame are injur ious to the

nak ed eye C olored glasses or goggles are used to shield
.

the eyes when workin g with th is fl ame To o dark a glass

.

should not be used ,as it will cause a strain upon the eyes
more injurious than the flame E xposed metal frames Should
.

be avoid ed too ,as they hold the heat and bu rn the operator .

(3 8) To shut o ff the apparatus for several hours or so ,

36 O X Y ACETYLE N E WELDIN G MAN UAL
-

it isbest to rel ieve all pressure from the lines ,such ashose
and s o forth ,and to do thi s close bo th tank valves ; open the

( Co urte s y f the
o Chicago E ye S hi eld Co .
)

FI G . 2 6 .
-
A S pectacl e M ad e fo r We lde r s ,h avi n g a F rame o f F ib e r and A rr ange d
so th a t Le n se s m ay b e R eplac ed .

( Co urtes y f the
o Ch icago E ye S hieldC o. )

FI G . 2 7 .
-
Sh o wing C o ve r G lass which P r o te cts th e C o l o red Lens and th e
Replaceab l e F eatures o f a M ode rn G o ggle .

torch valves ; release the tension on the regulator ,by screw

“ ”
in g the cross bar to the left ,and finally ,close the torch
-
 O PE R ATION 37

valves I t is qu ite necessary that these torch valves closed ,

.

for qu ite frequently ,if a small tip is in the torch and

an excess of oxygen pressure comes throu gh the l ine ,when
bo th torch valves are open ,much of the oxygen may back
up the acetylene lin e and cause a ser ious flashback when
lightin g up
. Th is can be avo ided by keep in g both torch
valves closed when not in use .

(39 ) I f a valve o n an empty acetylene cylinder is left

open the acetylene gas w ill escape ,and m ixin g with the air,
wh ich is a supporter o f combust ion ,a very inflammable
m ixture will be formed I f any fire is presen t ,such as m ight
.

be s moulder in g in a forge ,poss ibly n o t used fo r several

hours or so ,o r a match l ighted ,o r a flame started in any
way ,an explos ion is l ikely to occur W hen an acetylene
.

cyl inder is exhausted ,as far as possible ,in a moderately

high atmospheric temperature , then shut o ff for a wh ile
and the temperature drops ,air w ill be draw n into the vacuum
thus formed when the valve is again opened I n this man
.
~

ner an explosive m ix ture fo rms in an empty acetylene cyl inder

and is certa inly to be avo ided C are should be taken ,
.

expec ially in winter ,to guard against such occurrences ,as

in some outly in g shops a dec ided chan ge in temperature
takes place between closin g time and startin g up time the
followin g morn in g A cetylene tanks should always be se
.

curely c losed when empty , not only for the above reasons
but insomuch that each contains acetone ,wh ich is l ikely
to escape if the tank is thrown around A cetone is very
.

costly and used extensively in the manufacture o f smokeless

powder ,so that at t imes it is hard to replen ish .

(4 0 ) Oxygen has an a ffin ity fo r oils and greases ,and

should not be allowed to come in contact with them ,esp e cially
in con fined places ,as a spontaneous combustion may result .

Oils and greases should never be used around o xy— acetylene

weldin g apparatus and on nearly every apparatus o n the
38 OXY ACETYLE N E WELDI N G MAN UAL
-

market the words U se no o il, will be found D espite this

.

precaut ion ,however ,m any times ignorant operators will

be found squ irtin g o il into the holes around the regulator
cap ,and throu gh the gau ges ,in order ,as they say,to allow
them to work easier Th is use of o il should be discouraged ,
.

an d the sooner the better

.
 C HA PTE R I II

S HO P E ! UI P M E NT

( )
41 IN
equ ipp in g a shop for weld in g ,in add ition to the
weld in g apparatus , the operators are many times unde
c ided whe ther it is advisable to have a planed metal or a
brick top table to use for weldin g purposes ; each has its
advantages ,but were there a cho ice of o n e or the o ther ,
it is su ggested that the bric k top table be used
-
Th e theory
.

of having a planed metal top for lin ing up work does not
prove as satisfactory in actual practice as m ight be expected ,
fo r the s imple reason that the average welder generally
places his metal in d irect contact with th is cold top ,and
much of the heat which is supposed to go into the weld is
conducted away by the table top ,producin g a hard ,brittle
weld I n the case o f cast iron ,these welds are generally
.

porous Then to o ,the operator to a lar ge extent depends

.

upon the table top for lin in g up h is work and does not study
h is contraction and expans ion as thorou ghly as he m ight .

Th e result is that many of h is p ieces warp in coolin g To .

rectify the first objection it is advisable to cover the table

top with asbestos paper as shown in F ig 2 8 In the second
. .

place ,sometim es clamps are used to hold the work in position .

Preheatin g withou t a layer of br ic ks on a metal topped -

table is not to be recomm ended .

(4 2 ) A fire brick table ,made up alon g the lin es shown

-

in F ig 2 9 ,is very eas ily constructed and can be used for all
.

sorts of jobs I t is well to have everyth in g clear around the

.

legs and have no braces to cut the O pe rator on the shins

39
40 OX Y -ACETYLE N E WELDI N G M AN UAL

or to in te rfere in any way with h is work Th e b e st fire .

bricks ob tainable should be u sed A large number of e xtra .

FI G . 2 8 — M e th o d
. of Ho ldi ng He at wh en We ldin g o n M e tal To p Tab le s .

As b t p p r,P ,i l id up th
e s os a e s a on e m t l t p ,M , d th pi
e a o ,A d B ,p l
an d p P
e ec e s an ac e u on

in s u h
c m a r th t t h w l d
anne b a e e c an e m d
a t Ce aTh b t p p r pr t t m u h h t
. e as e s os a e ev en s oo c ea

esc a pi g fr m th b tt m f th w ld
n o e o o o e e .

bricks should always be o n hand for they come in very

handy in most of th e weldin g operations ,and in fact to

F IG 2
—A
Fire b rick Tab le fo r We lding
-
.
9 . .

l ir m uring
Ang e on e as 2 b y b y i h i w ld d t g th r i th m
2 nc es s r e e o e e n e anne sh o wn and c o v e re d
with fi bri k s w hi h m
re- c c eas re 2u ; by 4 } b y 9 i h nc es .

conduct a weldin g shop without fire bricks could almost

be likened to a blacksm ith s shop withou t an anvil B e ’
.

s ides bein g used for table tops ,preheating furnaces of a

42 OXY ACETY LE N E WE LDI N G MAN UAL
-

metal from enter ing the hole A t other times it is meces

.

sary to back up preheated work such as alumin um ,to

prevent its collapsing Ordinary clay or putty cann ot
.

be used for this purpose Th e simple reason bein g that

.

when metal is heated it expands and the clay or putty in

g iv in g o ff i ts mo isture contracts ,showin g two opposite reac
tions R etort cement is a name given furnace cement
.

m ixed with shredded asbestos ,this ,as well as carbon flour ,

has been found to be very satisfactory for fil l in g in holes
and backing up pre heated work R etort cement is purchased
-
.

in a irtight conta iners ,harden in g very qu ickly when brou ght

in contact with the air,so at all times it should be kept in
containers Similar to those in wh ich it is purchased I t .

cannot be reclaimed once it is hardened .

(4 5) A blacksmith forge will be the medium o f saving

much valuable gas and time in a weldin g shop I t will heat .

up parts to be welded in very short order and while in this

condi tion they may be welded and then thr own back into
the forge and allowed to cool very slowly .

(46) S everal pails of water should always be located

where welding is being done to prevent fire from flying .

sparks ; to cool the torch tips and filler rods ,when working
-

on large jobs ; to keep cert ai n parts o f work being welded

cool ,and to harden or temper other parts .

(4 7 ) A simple and efficient manner of handling flux in

the welding shop has puzzled many welders ,o n account
of the flux containers being easily upset ,their in ac c e sib ility
and the action of the air upon large quantities of flux A .

simple method o f overcoming th is is to cut in two ,a two

and o n e half or three inch p ipe coupling and mount it by
- -

wel di ng on a square piece of one eighth inch plate ,as shown in

-

F ig 3 1
. . Th is type of container is very hard to upse t
may be used when working on preheated jobs ; is easy to ge t
at on account of its shallow nature ,and ,as it only hold s a
-
 S HOP E ! UI PME N T 43

small amount of flux ,it can be cleaned out frequently and

a fresh flux will always be available .

(48) A dditional equ ipment benefic ial to the welder will

be a quantity of various s iz e d carbon rods and blocks ; as
b es to s paper ; goggles ; V blocks for linin g up shafts and
-

an assortment of m e chanics tools ,such as wrenches ,ham

’

mers ,Chisels ,hack saws ,and o ther th ings wh ich m ight be

-

used in dissemblin g or assembling var ious k inds of machinery .

(49) Another important item whi ch is generally overlooked

in the average weld in g shop is the q uestion of ventilation
!

A lthough the welding flame itsel f contains no objectionable

FI G .
31 .
—A G oo d F lux C o n tai n e r fo r th e Weldin g Tab le .

gases ,those from fresh charcoal preheating fir e s ,those given

o fl when some of the alloys of the filler rods are melted -

when brass ,copper ,and other metals are being worked o n ,

and from gas engine exhausts are not des irable A t times .

they w ill give the operators violent headaches unless means

are taken to carry them o ff Th e ventilation should be such
.

that it will not directly affect the work D rafts are to .

be avo ided as much as possible ,for many times they will

Warp p ieces being preheated if allowe d to come in d irect
contact with them I t is a good thing to remember that
.

ind irect vent ilation and plenty of it is a prime requ is ite

in a good weld in g shop .
 C HAPTE R I V

APPA R AT U S RE PAIR S

(50 ) OCCA S I ON A LLY in s e tting up a we ld ing apparatus ,a

leak may be n oticed along the l ines ,some time after th e
plant is in operation L e aks o n e ith e r the oxygen or acet
.

ylene lines are to be cons id e red dangerous as w e ll as costly

and ther e fore to be avoided at all times When the cyl inder
.

valves are closed on the drums c ontaining the gases ,and the
hands o n the low pr e ssure gauges of e ach r e gulator are
-

seen to drop or reduce th eir pressure wh e n the torch valves

are shut o ff and allowed to remain so ,th is is an ind ication
that there is a leak between the regulator and the torch .

I t is n o t des irable to use a m atc h or a flam e o f any k ind

t

in test in g for leaks . There are var ious methods employed

by the caut ious we lder ,but about the b e st o f th e s e is a soapy
solut ion o f water ,wh ich is kept in a can at all times and
is applied with a paint brush I f this solution is applie d to
.

any leaky part ,bubbles will form immediat e ly and th e

leak will b e located .

(5 1 ) At times ,when working in isolated places ,wher e

repairs cannot be had , and no means have pr e viously
pr e s e nted themselves fo r testing o u t th e cyl ind e rs or th e
apparatus as a whole ,it may be found that the threads or
g round seat on the cyli nd e r valv e o f th e re gulator wh ich
is connected will be in such a cond ition that a leak is in e v i
denc e Or it may b e that the thr e ads will n o t p e rm it the
.

seat being drawn up su ffi cie ntly to mak e it a irtight I n .

cases O f this ki nd ,th e welder must fin d som e m e ans o f pro

44
 APPAR ATU S RE PAI R S 45

c e e ding with hi s work ,and wh ile it will be im possible for

h im to use wh ite lead o r any o h substance with safety ,
he may stop the leak with li thar ge o r lead ox ide m ixed with
a small quantity of glycer ine A str ing soaked in th is solution
.

may b e wound around the main connection and the swivel

nut screwed up to the seat as far as it w ill go I f allowed .

to harden for a short time ,the lithar ge will set and a very
satisfactory temporary repair will be effected .

(5 )
2 T h e method shown in F ig 3 2 of attach ing con .

n e c tio n s to hoses so that they will not blow o ff when pres

sure is applied is a very s imple and efl e c tiv e means of over ~

com ing this d iffi culty U ndoubtedly it will ass ist some
.

operators in solvin g the trouble th at has bee n occas ioned by

FIG — M e th 0 d o f A tt ach i ng Ho se to C o nne ctio n so it cann o t Pull o r B lo w o ff

.
32 . .

the ord inary hose clamps ,especially when doing cutting or

heavy welding work where the gas pressure is cons iderably
h igher than usual Th e wire used should be lar ge enou gh to
.

prevent cutting the fabr ic in the hose .

( 53 ) A n injured hose which may leak should never be

used after the leak is noticed u nl ess some means are taken
to repair it Th e us e o f tape in trying to repair hose on
.

an o xy acetylene weld ing outfit should never be perm itted

-
.

Th e most e fli c ie n t way of overcom ing an injury of this kind

is to cut the hose at th is part and insert a p iece of p ipe .

Th e ends of the hose are then wired to th is pipe and a union

is thereby e ffected wh ich wi ll generally outlast the l ife of
the hose S pec ial connections for this purpose are put o ut
.

by most weld ing companies ,so that a supply may be on

hand if hose trouble is expe cted .
46 OXY ACETYLE N E WELDIN G MANUAL
-

( 54 ) When transporting weld ing apparatus ,occasionally

the cross —
“
bar on the regulator is lost and many times the
operators do not know what is to be done Th e purpose .

“
of the cross bar , as we have already seen ,is only to apply
-

pressure on the d iaphragm sprin gs ,so that if a s e t screw

o f the same diameter and same thread as those of the cross
bar can be found and screwed into its place with a wrench ,
!

a section o f filler rod can be weld e d across the top o f it and

-

the use of the regulator will not be impaired I f a spec ial .

thread is used by any particular company ,a p iece of brass

or iron can be turned down in a lathe to fit .

( 55) Th e manufacturers of practically all regulators use

the quarter inch tapered pipe thr ead in attach ing the cyl inder
-

connections to the regulator and do not depend upon the

threads being gas t ight ,so they solder them in There are
-
.

various types of cyl inder connections put o ut by difleren t

manufacturers of the gases and occasionally it may be n e c es
sary to use a cylinder of gas whi ch contains a different con
n e c tio n than is suppli ed on the re gulator V arious adapters ,
.

such as Shown in F ig 3 3 ,are supplied to overcome this

.

d iffi culty ,but at times the operator is confronted with the

v e ry embarrassing situation ,o f havin g a cylinder of gas
and h is re gulator o f d ifferent connections ,but no adapter
su itable Th is pred icament is usually foun d when some
.

very impor tant work is to be done and sometimes far from

a supply depot A t times the operator may have an adapter
.

which will fit the cylinder but not the regulator I f this is .

the case ,h is difficulty can be very easily overcome ,for gen

“ ”
e rally all adapters are made of two parts , sweated to
gether ,and have the same quarter inch tapered thread as
-

us e d in th e cylin der connections o n the regulator Th e adapter .

can be separated ,the tank connect ion removed and the

”
correct connection sweated into the regulator .

(56) M ost gauge s used in the o xy acetylene in dustry to

-
 APPAR ATU S RE PAI R S 47

ind icate gaspressure are of the B ourbon type Th e most .

recent types of th e oxygen h igh pressure gau ges are con

-

structed with a h in ged back and a sol id front ,which means

that Should an o il or foreign matter enter the gauge from

( Courtes y of the Bas tian Blessing Co )

- .

F I G 33 — Vari0 us Type s
. . of A d apt o rs Use d to C o nnect R egulato rs to Cyl
i nde r s h aving D ifle re n t C o nne ctio n
'

any source whatsoever and tend to burst it,the back would

be blown o ff and there would be no glass that co uld po ssibly
fly around Th is is a safety device wh ich has been w e lcomed
.

with much enthusiasm on the par t of the oxy acetylene in -

48 O X Y ACETYLENE WELDI N G MAN UAL
-

dustry . W hen leaks occur in always best to gau ges ,it is

remove the guage from the r e gulator , stoppin g the hole
temporarily w ith a p ipe plu g and return the gauge to the
manufacturers fo r repair These gauges are v e ry del icately
.

constructed and can be rendered useless if handled by the

y f th U 5 G ug C )
( Cou rtes o e . . a e o .

FI G ,34 .
— S h o w i ng S o lid fro n t and Hinged b ack Fea tures o f a
- -
“
S afe ty first
-

Hi gh pr essure Oxygen Gauge

-
.

in e xperienced . many times after the case of the

A gr e at
au
g g e has been jarred or loosened ,the screws connect in g
th is case to th e inside workin g mechan ism are tightened up ,
break in g the soldered conn ection holdin g the sprin g tub e
o n the ins ide of th e gau ge Th is causes a leak wh ich can
.
50 OXY ACETYLEN E WELDIN G M AN U AL
-

gau ge if the re gulator seat is in good workin g order I t is

.

s imply a cas e o f gas bein g trapped between the regulator

and the cylinder valve To reduce this readin g it is only
.

”
necessary to screw in the cross bar , thus open ing the
-

regulator seat Thi s could be avoided if the cylinder valve

.

were closed first and the torch valves opened while the regu
lator cross bar were still screwed in ,then as soon as th e
-

gas had left the line ,the torch valves could be clos e d and
the cross bar
-
on the regulator could be screwed o ut
until free
.
 CHAPTE R V

PRE HE ATI N G A G E N C IE S

(5 )
8 PRE HE ATI N G , as appl ied to oxy acetylene weldin g, -

means the appli ca tion of heat to the article to be welded

( Cou tesy of th e Messe Mfg Co )

r r . .

FI G .
36 .
—A Large ! o b P repared fo r We ldi ng .

in some m anner which is usually diflere n t than by the

weldin g flame itself C harcoal , coke ,kerosene ,crude o il,
.

coal and natural gas are used for this purpose Th e prin .

c ipal reasons for pre heatin g parts to be welded are :

-
To
take care of the e flec ts of contraction and expansion on the
con fined ends ; to save time ,gas ,and material ; and to make
51
52 OXY ACETYLE N E WE LDI N G MAN UAL
-

a better weld by makin g it qu icker and w ith less chance of

burn in g up the metal .

(59) On account o f the ductile qualit ies of steel ,there

is n o t qu ite as much h e at used in pr e heatin g,to take care
O f th e contraction and e xpansion ,as in cast iron On brass .

work a very dull red h e at is consid e red su ffi c ient ,o r other

wise the alloys m ight burn o u t When preheat in g alumin um ,
.

( Courtesy of the M esser Mfg Co )

. .

FI G —S h o wing h o w Large Wo rk can b e Co vered t Asb es to s Pape r

wi h
.
37.

wh en P r eh ea ti ng
.

there will be no chan ge in color as the heat is introduced ,

s o other methods are used to determ ine the correct tem

p e rature T hree methods

. are used for th is purpose by most
welders Half and half
.
-
solderin g wire will usually
-

melt when applied to the surface of alum inum wh ich is

preheated to the proper state ; the puddle s tick when drawn
smartly across the heated surface should scrape o ff the
oxide and leave a cl e a r blue streak if the work is in condition
 PR E HE ATIN G A G E N CIE S 53

to be weld e d ; and if a medium sized tip is brou ght down so

-

that the neutral flame just touches the surface for a second
o r two ,the meta l will sweat ,if at the proper temperature ,

an d small globules whi ch have th e appearance of mercury

will stand out on the surface .

(60 ) Th e beginner must study contraction and expansion

in order that he may know when and where to apply it in
figurin g out hi s work . M any weld in g jobs have turned
out to be failures throu gh lack of knowled ge in this respect .

Take , for example ,a water cooled cyl inder block of the ordi
-

nary gas en gin e ; the water ja cket may be broken when the
water is allowed to freeze in it Th is problem has certa inly
.

con fined ends ,but some welders have attempted to weld such
jobs cold ,that is ,without preheatin g,and possibly have
succeeded in executing what they thou ght was a very fin e
w eld , but upon exam ina tion ,have d iscovered that the cylinder
walls ,which are very accurately machined ,have been warped
to such an extent that the block is rendered useless Th is .

”
is strictly a preheatin g job ,and the cyl inder should be
brou ght to a dull red heat if the best results are to follow .

A s has been stated elsewhere in thi s volume ,the weld

should not be considered successful unless the p iece worked
upon c an be returned to a usable state .

(6 1 ) S everal di fferent fuels have been mentioned ,all

o f wh ich can be used for preheat in g purposes C harcoal .

is cons idered the best agent for general weld ing ,as it gives o ff
a very steady heat wh ich will gradually b e absorbed by the
article worked upon ,br inging it to the heat desired and hold
ing it there throu ghout the weld ing operat ion I t will then
.

permit very gradual cooling,as th is sort o f fire takes a long

—
time in dying a des irable asset in work o f th is kind On .

account of the scarc ity o f charcoal and its h igh pr ice ,other
agenc ies are used and ch ief amon g them are torches us in g

k erosene ,crude o il,or c ity gas ,as a fuel These usually

.
54 OXY ACETYLE N E WELDIN G MAN UAL
-

heat up the work more qu ickly ,but care in their manipula

tion is necessary A preheating torch to be used in con
.

junction with c ity gas can be very eas ily constructed ,if the
details of F ig 3 8 are observed Thi s proves to be a very
. .

effi cient and cheaply constructed apparatus .

FIG .
38 .
—
P reh eating To rch ,C o n s truct e d of B lack I ro n Pipe ,fo r B urning
City Gas .

(62 ) When work is being preheated ,it is best to have

it protected from all drafts ,to prevent warp in g Poss ibly .

th e most extens ively us e d mater ial for bu ild in g up temporary

ovens to hold the heat and protect the work from the air '

currents is fire brick and with it asbestos paper When .

FI G .
39.
—Tempo ra ry P r eh e at ing Oven ,B uilt o f Fire B rick .

setting up an ord inary casting fo r preheatin g,these bricks

are built up in bu ilder s fashion ,about four inches away from
’

the p ie ce itself ,as shown in F ig 3 9,and practically level .

with the top o f th e p iece I f charcoal is to be used ,draft

. .

spaces are left in the first row o f bricks as shown ,and the
charcoal ignited through th e openi ngs with the welding
torch Th e work to be welded Should have the l ine of weld
.

a t the top if poss ible and be set up from the floor ,o r the sur
 PRE HE ATI N G A G E N CIE S 55

face upon which the oven is restin g,on one or two fire bricks ,
in order that the full benefit of the heat will be received .

Asbestos paper is then laid acros s the top ,and the oven will
appear as in F ig 4 0 W hen starting the fire ,a layer of
. .

charcoal ,a matter of two or three inches th ick ,is at first

used ,but as the ch ill is tak en o ff the p iece th e oven can be
filled to the top ,and usually th is is enou gh to complete the
work .

( 63 ) I n order to protect the operator ,when working over

hot fires ,it is recommended that the asbestos cover ing be
left on ,and that only a small section immediately in the

FI G .
40 .
—Tempo rary P reh ea tin g Ove n of F ire B rick s C o ve red with Asb es to s
Pape r .

vicini ty of the weld be removed ,wh ich can be accompl ished

by cutting a U in the paper as shown by the dotted lines
in F ig 4 0 Th is can be turned back ,expos in g the place
. .

which is to be welded ,and at the same time protecting the

operator , to a lar ge extent , from the unnecessary heat .

When the weld is finished ,thi s lap can be turned back and
the p iece allowed to cool On p ieces wh ich requ ire turning
.

and must be welded in several difleren t positions ,the pre

'

heating oven ,as it is called ,should be built cons iderably

larger ,to provide for handl ing the work I t must be remem .

bered that dur in g the entire operation ,the p iece should be

left ins ide the oven and should not be removed to a wel di n g
56 OX Y -
ACETY LEN E WELDI N G M A N UAL

table S ome beginne rs mak e the m istake o f doing this

. .

Wh e n w e ld ing w ith the charcoal in clos e d rooms ,dur ing th e

winter months ,the fum e s will be found to be very d isagree
able and m e ans should be taken to provide indirect vent ila
tion ,otherwise the welders will be troubled with headaches
and smarting eyes .

( 64) When us ing preheating torches ,the ovens are bu ilt

much closer t o the work and do not have the op e nings along
the bottom row of br icks They are mad e as tight as poss ibl e ,
.

and in some cases it will be found adv isable to bu ild up the

walls with two layers of br icks ,with a sb e stos paper b e twe en

FIG — S h o w i ng Ho w Ove n is B uilt wh en P r e h ea tin g To rch is to b e U sed

.
41 . .

To rch is S h o u t} at ( A) .

them ,in ord e r to hold the heat and cause the work to heat
up in a more uniform manne r A hol e is left in o n e e n d O f .

the oven ,throu gh wh ich the flam e o f the pr e h e ating torch

is introduc ed as shown in F ig 4 1 I t is n o t thought b e st
. .

to have the torch flame come in d ir e ct contact with th e work

wh ich is being preh e ated ,and a baffl in g plate o f m e tal or
br ick is placed d ir e ctly in front o f th e flam e ,in orde r to
spread it around the oven ! udgment will have to be used .

in all such work .

s tt in up of the work wh e n pr e h e at in g,is an

( 5)
6 T h e e g ,
m po rtan t po int ove rlook e d by many welders ,esp e c ially so
i n th e case o f alum inum C are should be tak e n to se e that th e
.
 C HA PTE R VI

PAR T O NE — WE LDIN G O F CA S T IR O N

(66) I N order to know how to weld ,it is qu ite imperative

that the operator first know the kind o f metal he is to work
on I t is surpr is ing to fin d how few welders know their
.

metals thorou ghly A n incident m ight be cited where some

.

welders depend ,upon the sparks given o ff by the emery

wheel in deter mi ning the k ind o f metal they are about to
weld They will approach the wheel ; gr ind o ff their work ,
.

noting the sparks ; return to their welding table ; choose their

filler rods and do their weld ing without any delay whatso
-

ever ,much to the consternation o f their fellow workers .

There are four s imple ways in common use to d isti ngu ish
between cast iron ,malleable iron ,and steel ; they are : By
the cross section of a fresh break ,by application of the weld
-

in g torch ,by the sparks given o ff when applied to the e mery

wheel and by the ch isel test .

(6 7 ) E xternally cast iron usually has some sand on its

surface and its cross section shows the grain to be fin e ,even ,
-

and to have a dull grayish color Th e surface o f malleable

.

iron contains no sand and its gra in is very fin e ,such as cast

iron ,but slightly darker in color A very fin e ste e l veneer
.

is o n all surfaces of malleable iron ,which is much lighter

in color . When the welding torch is appli ed to cast iron ,
no sparks are given o ff,but when appl ied to malleable iron a
bright spark is thrown o ff which breaks in falli ng,sho w ing
that the outside material is steel These sparks soon cease
.

and the metal which is molten is covered by a heavy oxide

58
 WE LDI N G OF CA S T I R ON 59

or skin which recedes o r draws away from the flame sl ightly ,

showin g a very porous cast iron interior When brought in -
.

FIG .
42 .
— C h a ract e ri s tic Sparks of D i ffe re n t I ro n s and S te e l s Th ro wn o ff

by Eme ry W h ee l Wh e e l sh o uld b e Clean Cutti ng and R un ab o ut

an .

7 0 0 0 F e e t per M in ut e .

( ) Sh w
1 t ir
o N p rk u l
s cas im puriti
on .pr t o s a s n e ss e s are e se n .

( ) I w r ug h t ir
2 s lm t fr
o fr m rbon a H t d p rti l th r w fr m w h l f ll w
os ee o ca on . ea e a c es o n o ee o o

str igh t li
a Th ne b m br d r d m r lum i
. e se ec o m di t f m th r
e oa u f h te an o e no us so e s a nc e ro ei so rc e o ea .

( 3 ) Illu tr t m ild t l ti
s a es Sm ll m u t f rb pr t u di i i
s ee ac on f rk i g
. a a o n o ca on e se n c a se s a v s on or o n

o f th lum i u tr k
e no s s ea .

( 4 ) Sh w th o ff t f i r
s ing th rb fr m
e e ec t o p t in m ild t l Th
nc e as e ca on o o er ce n s ee . e

ir p rk li dimi i h th f rki g f th lum i u tr k

on s a ne s n s : ur m r fr qu tl y ,b i g
e o n o e no s s ea oc c s o e e en e n

sub d i id d b y
v e pl i fr m m ll r p rti l
re -e x os o ns o s a e a c es .

(5 ) I pi
s a f rb t l t l Th i li
e ce o ca pr ti lly lim i t d w ith th i
on oo s ee . e ro n nes are ac ca e na e e nc rea se

o f th pl i
e ex d bd i i i , u ing di pl y f figur
os o ns an su v s o ns ca s s a o es .

(6 ) G i th p rk f h igh p d t l, t i i g i dditi t 6 5 p
v es e s a o t rb , th r
-s ee s ee con a n n n a on o e r c en ca on o e

ll yi g l m t , hi fly tu g t
a o n e e en s d h r m ium
c e n s e n an c o .

( 7 ) R pr e t m g p rk ( O i lly f u d i
e se n s a an ane se s a ti ) . c c as o na o n n c as ro n .

( 8 ) S h w p rk th r w fr m ld gr d f M u h tt t l “ ”
o s s a o n o o a e o s e s ee .

(9 ) R p e t m g t t l p rk
re se n s a a ne s ee s a .

contact with the emery wheel steel sparks ,wh ic h are very
lum inous and break in fallin g ,are given o fl first in the case of
malleable iron ,but they soon chan ge to the dull re d s park
60 O X Y ACETYLE N E WELDI N G MAN UAL
-

of cas t iron Wh e n a chi sel is appl ied to cast iron ,the iron
.

ch ips o ff; when applie d to malleable iron the ed ge will curl

up ,then ch ip o ff when th e cast iron is reach e d Th e cross .

s e ction of cast ste el shows a br ight ,coars e ,S ilve ry gray

M E TH OD S O F D I S TI NGUI S H I N G M E TA LS
He r e are fiv e me th o d s ,any wh ic h m ay b e u se d
o n e o r a ll o f to l earn th e
na ture o f co mmo n castings wh ich mi gh t c o nfuse th e we lde r .

Te s t . M a ll e a bl e Ir on . C a s t S t e el . C a s t I ro n .

G e n e rally s m o o t h Ro ugh surface Surface f a i r l y

and

free fro m all san d , wit h san d in ev i s m o o t h b ut gen

we i gh s ab o ut same d en ce , we igh s e rally s h o w s

as c as t iro n . m u c h m o r e so me sand .

t h an c as t iro n .

R i ng o f b righ t s t e e l La rge , b righ t , F i n e un ifo rm ,

crys ta l s o ut s ide , lumi n o u s , sil da rk gray ,crys
with da rk e r iro n v er cry s tal s t al s . .

cry s tal s i n side .

F ew t l spa rks and

s ee B gh ri t ,lumi n o u s D ull re d parks
s

t h e n iro n S pa rk s spa rk s that th a t do no t

fro m i n t e ri o r . b r eak in fa lli ng . b reak .

4 C h i se l Te s t S urface will curl an d Will curl b e fo re W ill ch ip o fi .

i n t e rio r b re ak o ff b r eaki n g . .

5 To rch Te s t G ive s w ay b e fo r e G ive s fo rth b ri gh t G iv es pa rk s

no s

fl ame an d de live r s spark s t h a t e xce pt w h e r e

fe w spa rk s M e t al
. b reak in falli n g . th e re are im
b e co m es po r o u s . puriti e s .

F IG .
43 .

gra in . W hen the torch is appl ied a dis t in c tiv e lv steel spark

which is lum inous and br e aks in fall in g is thrown o ff Wh e n .

applie d to th e em e ry whe e l steel sparks are thrown o ff ; w hen

th e e d ge is chipp e d by a ch is e l it will curl up .
 WELDI N G OF C A S T I R ON 61

(68) Th e metal in th e fille r rod should be the same in

-

prac tically all cases as the metal to be welded There are .

few exc e pt ions to th is rule ,but the pr incipal one is that of

mall e able iron Th e cast I ron in the rods is of a very good
.

g rade and generally much better than the p iece to be worked

upon To perm it the ready flow o f the rod and elim inate
.

oxidation ,as much as poss ible ,three per cent of s ilica is gen
e rally used in the cast in g of fille r rods for cast iron weld in g
-
.

Piston r in gs and other scrap iron should not be used for fille r
rods ,as they contain many impur ities such as core sand , -

d irt ,greas e ,etc ,wh ich w ill ru in th e weld I t is d ishearte n

. .

in g to se e some operators attempt to econom ize on the fille r

’
rod I t is not an uncommon sight to see several dollars worth
.

o f gas and the same amount o f the welder s t ime ,to geth e r
’

’
with a few cents worth of filler rods all lost ,and the opera
tor s reputation ru ined Th is , because an attempt is
’
.

made to save the few cents involved in the fille r rods by -

substitutin g a rod of a very poor grade .

(69 ) A flux is not used ,as many suppose ,to cement the '

fille r ro d to the metal

-
I t is use d pure ly as a cl e ansin g
.

agent and may be likened to the ac id used in solder in g .

I t does not act o n the metal until the latter has reached the
m e ltin g point ,but then it starts to break up the oxides and
-

cl e an the surface This action perm its the metal to flow

.

to gether more readily A cast iron flux is always used in

.
-

weldi ng cast iron ,to break up the ox ide ,because the cast
iron itself will melt before the oxide and no matte r how hot
th e metal is it w ill not flow to gether as lon g as this ox id e is
present .

( 7 0 ) To obta in the best results ,reliable flux e s should

always be used Occas ionally an accident w ill happen to
.

th e flux can , when th e operator is o n some isolated j o b and a

substitute flux must be obtained at once E qual parts o f .

b icarbonate o f soda ( cookin g soda) ,and carbonate o f soda

62 OXY ACETYLEN E WELDI N G MAN UAL
-

( ordinary washin g soda) ,may be purchased from any grocery

in the powdered form and m ixed together thorou ghly Th is .

will tide th e welder over unt il he can return to the shop and
replenish his supply .

(7 1 ) Th e flux is generally applied by means of the filler

'

rod On e end is heated and dipped in the flux ; enou gh will

.

adhere to break up part of the oxides ,o n the ordinary sized -

job Th e flux is carried to the work ,wh ich should be at the

.

melt in g poin t and in troduced between the flame and th e metal

-
.

Oxides will break up immed iately and the metal w ill flo w

to gether ,but it must be remembered that the flux has no

FI G .
44 .
—Wh e neve r Po ssib l e ,th e B egi nn e r sho uld V
“ ”
His Wo rk ,an d Co m
ple te His W
e ld fr o m On e S id e o n ly : On h eavy wo rk ,h o we v e r ,it will
b e n e c e ssa ry to V o ut fr o m b o th s id es ,
“
a s is h e r e sh o wn
”
.

action o n cold o r moderately heated metals Th e flux as .

has been expla ined is used to clean the metal and break up
the oxid e s To the oft rep e ated question ,h o w often should
.
-

the flux be appl ied ,answer is made as follows : A s often as

it is necessary to clean up the metal and break up the ox ide s .

All fluxes should be kept in air t ight conta in ers wh e n not in

u se ,to keep the ir chemical contents in the very bes t condi

tion and it i s best to use only a small quanti ty o f flux o n the

welding tab le at o n e time .

( 7 2 ) Oxy acetylene weldin g is purely a fusin g proc e ss

-

and the most important points to remember in ex e cutin g

a weld are ,to elimin ate the entire crack in the fracture and
 WELDI N G OF CA S T I R ON 63

to add the fille r rod without chan gin g the character of th e

-

metal On th in p ieces of metal it is possible to depend upon

.

the force of the flame to entirely penetrate to the depth of the

crack but on work three eighths of an in ch thick or over ,it
- «

is well to V out or remove some of the surface me tal around

the crack in order to ge t down to the bottom B y V ing .
-

we me an to ch ip o r grind o ff each edge at an angle of

approximately 4 5 d e grees ,so that the openin g w ill form an
angle of 90 degrees where the two p ieces come to gether ,
”
with th e crack at the bottom portion of the V T h is should .

N OT be ground down to a kn ife ed ge , for it w ill read ily burn

up I t is preferable to leave about o n e e ighth inch alon g the
.
-

l ine in order that the pieces will fit together and the proper

FI G .
45.
— S tart ing a C ast iro n
-
W eld .

alignment may be obta ined I f two p ie ces of cast iron have

.

been prepared in th is manner the neutral flame of the weld in g

torch is brou ght down in such a manner that the tip of the
cone just lick s the metal Th e h e at is n o t applied directly to
.

the line o f weld to start w ith ,but rather to the surround in g

part Thi s is done in order to ge t the ent ire loca lity in a con
.

d ition which will not w ithdraw too much o f the heat from the
line o f the weld ,once th e fus in g is begun I f it is found that.

the tip will n o t produce enou gh heat to br in g th e metal to a

red heat in a fa irly short t ime ,a larger tip should be used .

(7 3 ) N o se t rule can be given as to the s ized tip to be used

o n var ious k inds of metal I t w ill lar gely d e pend upon the
.

w e lder s ab il ity and jud gment When the metal is brou ght
’
.
64 O XY—
ACETYLE N E WELDI N G M AN U AL

to red heat ,the neutral flame or cone is brou ght into contact
-

with the lowe st portion o f th e V and h e ld th e re unt il ”

it is s ee n that th e m e tal is melted o n both s ides Th e fille r .

ro d ,wh ich has pr e viously been heated at o n e end and d ipped

into the flux so that an amount adheres to the e n d o f the rod ,
then carries th is flux to that portion o f the weld wh ich is
under way E nou gh flux is blown Off the ro d into the weld
.

to clean up the surfac e and perm it the metal flowin g to ge ther .

Th e crack should be melt e d to gether all alon g befor e any

add itional metal is added ,fo r the eli m ination of the crack is
extr emely important I t m ight be not e d that as soon as th e
.

metal begins to flo w freely the neutral flame should be raised

a short d istance from th e work in order to better control the

FIG — Cas t iro n We ld

l

.
4 6. R e in fo rc in g a -
.

molten metal I n order to build up the metal to the or iginal

'

state along the l ine o f we ld o r perhaps re inforce it ,the s id e s

and bottom o f th is V c d o u t part are th e n brou ght to a
-

molten state and held there wh ile the fille r rod wh ich brings -

up more flux is stirred into thi s metal and the end melt e d Off .

I n th is way the flam e does n o t come in direct contact with

the fille r ro d and is u sed only to k e ep the metal in a molten
-

condition A s much of the fille r ro d can b e melt e d o ff as is

.
-

thou ght necessary to br in g th e we ld to the normal condition

o f th e metal o r an add it ional re inforcement can be bu ilt up ,

if it is thou ght advisabl e I f care is taken in th e abov e pro

.

c e dure ,many o f the blow hol e s and hard spots in th e w e ld will

be e h m in ated,fo r any impur itie s that m ight gather will b e
66 OXY ACETYLEN E WELDI N G MAN UAL
-

o ut as Shown at the point C N ow as soon as the heat is .

introduced at C there is bound to be an e xpans ion o f the metal

at that point N aturally if the p ieces were heate d slowly
.

and for a considerabl e d istance ,the cool e nds o f these bars

would be forced outward We will assum e that the heat is
.

introduced v e ry rapidly and the metal is brou ght to a molten

state ; that inste ad Of the contraction forc ing the cool ends
outward ,whatever expans ion there is ,is taken care of ,
at the weld ,for the metal when melted will read ily push to

FI G .
48 . P reh ea tin g P r b lem
-
o . E n ds of B ar s A ’
and B are C o nfin ed .

g ether .I t is also assumed that the bars are heavy enou gh to

overcome what Slight force m ight be in evidenc e from the '

e xpans ion A w e ld is then made and allowed to cool A s

. .

it cools ,there is b ound to be a contract ion along the line o f

the weld and the welded p ie ce will be Slightly shorter than the
work before the we ld ,for it will draw in the piec e s A and B .

A s can be seen ,there is no particular force preventing the

contraction of such a weld for the ends are fr e e to mov e .

Howe ver ,let us turn to F ig 4 8 ,wh ich constitut e s an entirely

.

’ ’
diffe r e nt p roblem I t might s e e m that the ends A and B
.
 WELDI N G OF C A S T I R ON 67

appear the same as A and B in F ig 4 7 ,but such is not the .

case Th e ends farthest from the weld are co nfined ,held in

.

place by a heavy frame wh ich does not permit th eir free

movement When heat is introduced at the point of weld ing
.

’
C ,about the same action takes place as in the prev ious
problem ,but as soon as the weld commences to cool let us
’ ’
se e what happens Th e bar A B must be shortened so there
.

’ ’
is an inward pull on the bars D and E I f th is work were .

cast iron o r alum inum it would certa inly be broken by the

’
strains se t to workin g and would naturally break at C , where
the metal is still hot I f it were steel or one of the ductile
.

m etals ,it m ight tw ist and warp in its endeavor to overcome

these internal strains Th is illustrates in a very s imple
.

”
ma n ner the difference between what is known as a cold
”
and a preheating job I n the first no provision is made
.

for expans ion and contract ion I n the second means are taken
.

to overcome these important factors I n order to provide .

for the successful welding of the second problem ,it is only

necessary to heat up the bars X and Y about the same distance
as the center will be heated , and keep them in that condition
’
while executin g the weld at C , then allo wing the whole to cool

gradually .

PA R T TWO .
— WE LDI N G OF C AS T IR O N

( 7 6) commenc ing to weld ,or even turning o n the

BE F ORE
gas ,it is well to see that all preparat ions have been made and
all mater ials on hand to bring the weld or whatever job it
may be ,to a finished state .

(7 7 ) As a specific example o f a sim ple weld in g operation

le t us cons ider that two cast iron bars ,measurin g one by six
-

inches and twenty four in ches lon g are to be welded end

-

to end To start with it would be necessary to V o fl the

'

ends that were to be joined at an an gle of about 4 5 degrees ,

68 OXY ACETYLENE WELDI N G MAN UAL
-

leavin g about o n e—
eighth inch along the bottom edge to line
the metals up with and to see whether they are in proper
position I f the bar were to measure exactly forty eight
.
-

in ches when fin ished it would be necessary to move these

( Courtes y f Ben K S mith,U

o . . 5 . Welding Co .
)

FI G .
49 .
-
Th is Lo co mo tive Cylin de r was We lded at th e Saddle ,nea r th e
F rame .

bars apart about o n e sixteenth of an inch in order to provide

-

for their contraction I t is assumed that the weight of

.

the bars would be suffi cient to prevent their pushin g apart

when the line of the weld is brou ght to a molten state and that
 WE LDI N G OF CA S T I R ON 69

the expansion will be taken care of with in the weld Th e .

bars after being l ined up are ready fo r weld in g,but there

are such th ings as fille r rods ,flux and goggles that are p eces
-

sary to have o n hand before startin g to work I t is well .

to have a few fire br icks ,a little asbestos paper and a bucket

of water conven ient ,in case these thin gs are needed Th e .

acetylene gas should th en be turn e d on and ignited A suf .

ficien t pressure should be pass in g throu gh the re gulator ,when

using a me di um ,or h igh pressure apparatus ,to cause the
-

flame to leave the torch tip about tw ice the distance of the
d iameter of th e or ifice of th at particula r tip Then turn on
.

the oxygen until a neutral flame is ob tained On some .

torches it is necessary to make a s e cond adjustment by

turn in g on a little more acetylene gas and still more oxygen ,
until a goodly sized neutral flame results A pply th e flame
.

to the pieces ,so th at the neutral flame will just lick the sur
face o f the metal M ove the torch slowly forward and back
.

ward o n each Side of the V until the two ed ges are a dull
red color ,or better still a br ight cherry red ,then hold the torch
stationary until the metal in the V nearest to the Operator
commences to melt Then br in g the filler—rod end in contact
.

with the flame to ge t it heat e d and plun ge it into the flux

whi ch should be near at hand E nou gh flux will adhere
.

to break up the oxides and by placin g the ro d between the

flame and the metal ,enou gh flux will be introduced to allow
fus in g of the metal Proce ed in th is manner unt il the metal
.

in th e bottom of th e V is properly fused throu ghout

its len gth
. D O not add the fille r rod ,up to this po int unl e ss
-

necessary I n hold ing the flame ,see that the preheatin g

.

flame will heat the parts ye t to b e w e lded Th e weld should

.

b e made away from th e operator A fter the metals alon g

.
'

the bottom have un ited and a good foundation has been

obtained ,then start the weld at the beginn in g once mor e ,
workin g the flame across th e p iece ,in the same manner as
70 OX Y -ACETYL E N E WE LDI N G MAN U AL

before ; br in gin g the metal to the molten state and stirrin g

the fille r ro d in it A s th e fille r rod melts ,the amount o f
-
.
-

molten metal naturally increases and the flame is moved

'

along the weld as fast as th e metal is added I t is important .

that the metal is in a molten condition I t is almost im .

possible to ge t to o much heat on th is type of work B uild .

up the weld slightly h igher than the or iginal piece I t may be .

found in fin ish in g up the corners that the velocity of the gases

or the force o f the flame will be suffi cient to blow the melted
metal away Th is may be overcome by d irecting the flame
.

at a d ifferent an gle ,and will cause no diffi culty after a li ttle

practice T rouble ,too ,may be exper ienced on thin cast
.

iron sections by havin g the metal collapse throu gh the force

of the flame ,but this can be remed ied in the same manner .

Wh ile the weld is still in a heated condition ,it is possible to

fin ish it by scraping the surplus metal OH with the sid e of the
fille r rod ,th e ch ill of wh ich h as been taken o ff before it is
-

allowed to come in contact with the molten metal Anoth er .

popular method that will produce even better results is to

use a very heavy rasp fil e to brin g the weld down to th e meas
urem en ts des ired .D urin g all of the previous opera tions th e
flame never leaves the l ine of weld When the weld is com
.

l t d,the torch i shut down by turn in g of

f the oxy gen
p e e s

first ,and then the acetylene ,and the welded bar is covered
up to prevent its coolin g too rap idl y .

P AR T TH RE E —WE LDI N G
. OF CA S T IR O N

(7 8) PR OB LE M S in
expansion and contraction should not
be d ifficult ,if it is remembered that heat causes expansion
an d the w ithdrawal of heat ,o r coolin g causes contract ion .

A s previously stated ,when the ends of the p ieces whi ch are

b e in g welded are free to move ,there is n o t much dan ger o f
havin g contraction strains se t up Where the ends are con
.
 WE LDIN G OF C A S T I R ON 71

fined ,measures must be taken to overcome th is I n weld in g .

large pulley wheels ,for example ,it may be advisable to do

th e job without takin g t ime to preheat B reaks may be
.

in evidence at any part of the wheel and generally th e end s

are con fined ,such as in the case of a spoke I f it is borne in.

m ind that the expans ion w ill take care of itself ,the c o n trac
tion is the only cons ideration ,in a case of th is kind Th e .

welder will see that if he can sprin g the edges apart a su fficient
amoun t to provide for the spoke com in g back to normal when
welded ,he will have no d iffi culty Th e way to proceed in a
.

case o f th is k ind would be to open th e rim by sawin g it and

then in troduce a jack or some sort of a wed ge between the
hub and the rim Th is will open the crack in the spoke th e
.

amount desired A s soon as the weld is executed and while

.

st ill hot ,the jack is removed to perm it the rim bein g drawn
in. L ater the rim can be welded ,by in troducin g jacks b e
tween the spokes and the same procedure followed I t .

always must be remembered that provision mus t be made

for the contraction ,even thou gh it be only one thi rty second -

or on e Sixteenth of an inch Th e distan ce will depend em

-
.

tirely upon the welder ,as some operators u se small tips and
cover a small area ,while others employ larger tips and cover
twice the area I t is therefore impossible to set any specific
.

distance and each welder Should try to figure this out for
h imself
.

(7 9) There are many jobs not of a preheating nature

that at t imes cause perplexity on the part o f the welder A .

g ood example of th is is a cast iron gea r wheel

-
A number of.

its teeth have been broken o u t N ow there are three very

.

co m mon ways of bu ild ing up or repairing such castings .

F irst by aid o f carbon blocks ,cut to form and the teeth cast
in by the use o f the torch ; second ,by blanking in the space
between the teeth and then sawin g out the ind ividual tooth
o r cuttin g it out w ith a m illin g machine or shaper ; third ,by
72 OXY ACETYLEN E WELDI N G M AN UAL
-

bu ilding up each tooth with the weld ing rod and torch ,
and later dressing it down with a file On e very important .

point must be uppermost ,when dental work on gears is being

done ,a good foundation is necessary ,for regardless of how
well the tooth may be shaped ,if it is not firmly s e cured to th e
wheel itself ,it will be of very little value A nother ver y .

( Co urtes y of To rchw eld Equipment Co )

.

FIG —La r C as t iro n G e a r Wh e e ls A lt h o ugh th e Face o n Th e se Gears

50 ge
-
. . .

M easure d 1 0 I nch e s ,N e w Tee t h we re A dde d b y Bla nki ng I n ,as Sh o wn

in th e R igh t h an d Vi e w,
-
a nd L a t e r M a c h i n e d
.

important p o int is in the fin ishin g

of such gears ,to see that
the teeth which have b een added correspond in th e p itch
and mesh exactly as the others do Th e importance o f seeing
.

that things of th is nature are machined correctly should n o t

requ ire mention ,but it has often been found that machin ists
are very careless about finishing th is k ind o f work and if
74 OXY ACETYLE NE WE LDI N G MAN UAL
-

soft as possible ,and great care should be exercised in cooling .

A ny weld that is subjected to machining,allow it to cool

slowly in slack lime ,in ashes ,o r cover it securely with asbestos
paper Occasionally it may be found diffi cult to fin d sections
.

of carbon blocks which will take care of a job o f th is k ind .

M any welders who have had to run around the country ,

and do jobs in isolated places ,have found that the carbon
centers ,from the ord inary dry cell batteries ,wh ich may he
found practically everywhere in a d iscarded condition ,can
be shaped on a n emery wheel and patched to gether in a manner

that will permit their use However ,when such are used ,
.

it is qu ite necessary that they be heated a l ittle with a torch

beforehand ,in order to dr ive out any chem icals or acids
that may be contained in them U nless these chemicals are
.

removed ,the molten metal coming in d irect contact with

them m ight be injured to a considerable extent .

( )
8 0 O ftt imes there are cast in gs upon wh ich parts wear
off in a very short time . There may be very l ittle strain
upon these parts ,yet the constant wear will weaken them in
tim e I t is well to remember the action o f a carboniz ing
.

flame when executing work o f th is kind I ntroduc e an

.

excess of acetylene when finish ing up the work

’
I t will be
.

found that with a strongly c arb o nizin g flam e ,carbon will

be taken up by th e molten me tal and the finished weld will
be considerably harder and will wear longer than if it were
execute d by a neutral flame . A n abrupt cooling will chill
the metal o n the surface and make it wear longer than it
would otherwise .
 WELDIN G OF CA S T I R ON 75

PAR T F O U R .
— WE LDIN G OF C A S T IR O N

(8 1 ) THE true in dex as to the success of a weld will depend

entirely upon the finished job I f it is usable ,i e ,if it can . . .

be put back into service a gain and give satisfaction ,it may be
considered a successful weld I f a p iece were to be warped ,
.

d istorted ,contain hard spots which could not be machined ,

or have internal strains ,which would not make it safe for

( Courtes y f Ben K S mith ,U S

o . . . Welding Co ).

FIG .
52 .
—Vi e w of L o co mo tive Cyli nd e r wit h Th re e Jacke t s 3 In ch es Th ick .

Th i s j ob we igh e d o v e r 1 6 To ns and Requir ed F ifty S ix Ho urs o f W elding

-
.

use ( such as fly wheels) ,it could not then be considered

-

satisfactory and it would be only wasted ener gy Perhaps .

one of the most common jobs in the ordinary commercial

shop ,and one wh ich is the most abused ,is the common cast
iron cylinder block found on the gasoline engine This is .

so constructed that there are two walls o f metal ,very th inly

cast ; the innermost being the cylinder wall ,and the outer
76 OXY ACETYLE NE WELDI N G MAN UAL
-

most a water jacket Th e cyl inder wall is machined very

-
.

accurately to accommodate pistons moving at a very rapid

rate , up and down and yet holding compression Th e .

upper part o f the cylinder is called the head ,and generally

has two or more valve seats wh ich must be in al ignm ent
with the valve gu ides to make an airtight seat for the valves .

N ow this water jacket is usually very thi n ,perhaps three

-

Sixteenths to o n e quarter inch in th ickness ,and when there are

-

two ,thr e e ,four ,or more cylinders cast in one block ,t h ere are
bound to be internal strains set up in casting within the
pie ce itself Th e s e strains are removed to a lar ge extent
.

by baking the rou gh casting before mach ining G enerally.

there are som e strains left in every cyl inder block of this
natur e I f the water in the water jacket freezes or som e
.
-

other force comes in contact with the th in castings wh ich con

s titute a block ,the metal will give way at its weakest po int ,

and the w e lder is usually called upon to repair it A t times

!

these cracks are exceed ingly small and the temptation is to

braze or attempt to weld the small portions However , .

as soon as there is heat introduced into the water jacket and-

not into the cylinder wall ,there are certain to be strains se t

up wh ich ,if sufficient ,will d istort the cylind e r and make it
usel e ss unl ess it is rebored Th e sooner welders real ize that
.

work of this natu re must b e preheated throughout ,to a

point as near melting as they can approach without caus ing
the metal to scale ,before any weld in g is attempted , the
better success will be obtained in these lines I t is quite
.

necessary to line up the work well ,so that it will not sag
when heated I t is b e st to heat very slowly and cool in the
.

same manner to in sure the best r e sults There are many

.

preheating agencies ,such as o il ovens ,preh e atin g torches

-

an d th e l ike ,but about th e best and most rel iable agent

known is charcoal ,wh ich heats up very gradually ,m ak e

a good even fire and d ie s down slowly whi ch is the mann e r
WE LD I N G IR ON 77
'

OF
78 OX Y -ACETYL E NE WE LDI N G MANUAL

desired Occasionally cracks will be found in the c o m b us

.

tion head of the cylinder I t is very difli cult to ge t the

.

torch down inside the cylinder to execute thi s weld unless

the operator has a special torch for th is purpose E ven then .

it is d iffi cu lt to keep the torch lighted when workin g over a

newly made charcoal fire F or th is reason ,other means.

must be used when workin g on a job o f th is kind F irst .

the crack is accurately located ,then a p iece is cut o ut of the

water jacket just over the crack by means of a chi sel ,hack
-

s aw o r drill press N ever attempt to remove a p iece of th is

.

nature with the flame ,for the introduction of heat may dis
“
tort the p iece at th is t ime V o ut the crack in the com
.

b us tio n head and scrape o h as much of the brown ox ide and

d irt formation as poss ible I t is well to clean o ff more than
.

needed and to even V out the crack a greater distance than

is thou ght necessary Thi s w ill insure a good weld bein g
.

made in o n e operation Th e cyl inder is then preheated with

.

the crack uppermost so that weld in g can be executed w ith th e

least possible diffi culty Whi le preheatin g is taking place
.

it is well to tack the small section of the water jacket whi ch -

has been removed ,to the end o f the fille r rod ,and place it -

too ,in the preheating oven ,with the end o f the filler rod -

projecting so that it will be available whenever needed .

When the cylin der is red hot the weld should be executed ;
particular attention bein g given to see that each part of the
metal is actually fused to prevent any leaks occurr in g later .

As a rule the welder can tell when he has made a successful

weld by observing the flo w of h is metal ,and it will not be
necessary for him to te st out this cylinder weld before adding
the water jacket Th e p iece o f the water jacket is then
-
. .
-

replaced ; it can be very easily handled by means o f the

filler rod wh ich has been tacked o n
-
Weld this section securely
.

in place and cover the p iece o f work w ith asbestos paper and
permi t it to cool with the dyin g fire When cold ,all port .
 WE LDIN G OF C A S T I R ON 79

holes in the water jacket should be closed and the cylinder

-

tested for leaks This c an be done by introducing water

.

into the water jacket and apply in g

-

about fifteen pounds of air pressure .

Wet spots will appear if there a re

any leaks I f the cylinder is found
.

tight it should be polished ,then

o iled ,and the outs ide given a coat
o f filler o r pa in ted to make it pre

sen tab le W ork is generally very

.

much d iscolored when com in g o u t

o f th e fire A s imple device for
.

polishin g th e cyl inder bore may be

mad e by turn ing o ut a hardwood
block abou t three inches lon g and F I G 54 —S ugge t e d M e th o d o f . . s

a l ittle less ih d iameter than the P oli sh i n g Cyli nd e r Wall s o f

.

s ize of the p iston Th is should be C as t ir o n Cyli nd e r B l o ck -

a ft e r it h as b e e n P r e h ea t e d
.

spl it as shown in F ig 54 , and .

F I G 55
. .
— C as t
iro n Cylin de r
-
FI G .
56 .
—Sh o wing how B ro k en Pa rt
B lo ck with Part B ro ken on Cas t iro n B lo ck sh o ul d b e L i n e d
-

03 . up b e fo re We ldin g P o siti o n G rea t

.

ly E xagge ra t ed .
80 OX Y ACETYLE N E WELDI N G MAN U AL
-

wrapped with very fin e emery cloth ,then put into the cyl
inder and a wed ge placed between the two halves S pread
.

them apart so they will come in contact with the cyl inder
wall o n all sides A screwdriver may be used for th is purpose
.

if necessary . B y screwin g th is into the cylinder its full

depth ,w ith the aid o f a l ittle o il, a very h ighly polish e d
surfac e may be obtain ed .

(82 ) Another cyl in der block job that generally causes

more confusion than is necessary is brou ght about when
weld in g o n small lu gs ,such as shown in F ig 55 When
. .

weld in g these lu gs o n from the outside only ,they generally

warp upwards in cool in g and it is e ither necessary to bu ild
up the bottom side of th is lug or to mach ine o ff the entir e
fac e in ord e r to have the end square Th is can easily be
.

ov e rcome by perm ittin g the lug to s ag befor e weldin g and

then dress o ff the small portion that con tinues to sag,after it
is welded , rather than face o ff th e whole surface S ee F ig 56
. . .
82 OXY ACETYLEN E WELDIN G MAN UAL
-

duc e d into the weld and its str e ngth will be mat e rially afie c te d
'

Th e s ize Of th is flame must be such that too great an area

will not be covered ,yet enou gh must be covered to keep the
metal along the line o f th e weld in a molten condition I f .

a carbonizing flame is us e d ,one which has an excess of ac e ty

len e ,such as was shown in F ig 2 3 ,much carbon will be taken
.

up by the metal ,produc ing a br ittle weld I f the flam e is

.

ox id izing,that is ,contains an excess o f oxy gen wh ich is noticed

by the shortening o f th e flame and an accompanying h issing
sound ,F ig 2 5,th e metal will burn and a wh ite foam will
.

appear o n the we ld like a m ilky wh ite glue This tends to.

weaken the weld Th is same e ffect will be in evidence if

.

too lar ge a tip is used On the other hand if the tip is too
.

small n o t enou gh heat is obtained and the oxides and other

impur it ies wh ich may be pres e nt will not be allowed to float
to the surface but will be trapped in the weld .

(86) Th e fille r rod used on steel should be as near the

-

same grade ,if n o t b e tt e r than the metal to be weld e d and

should be very low in its carbon content A pur e grade of
.

soft iron wire o r m ild ste e l will mak e a very good fille r rod -

fo r ord inary purposes Th e s ize of th is filler rod is very

.
-

important ,fo r it should fuse at the same time as th e metal

being work e d upon ,and u nl ess it does this th e we ld will n o t
be satisfactory I f th e fille r—
. rod is too lar ge it w ill not be
at th e fus ion point when the work is ,and will not fus e with
it
. I f the rod is brought to a melting po int the work w ill
-

have too much heat and will burn On the other hand ,
.

if the fille r rod is too small ,it will burn up before the work
-

is at the fus ion point ,o r in other words ,the work will still
be too cold when the rod is melted .

( 7)
8 T here are many di fferent methods of execut ing a
ste el weld ,and it has been not e d that very few exp e rienced
welders handle th eir steel in the same manner M ost o f th e s e
.

methods are very diffi cult to learn and can be p e rfected only
 S TE EL WELDI N G 83

after years of practice However ,a s im ple method which will

.

produce results is thou ght the most advisable for the begin ner .

A careful exam ination and study o f this po int has brou ght
out the follo w ing method ,wh ich is very eas ily p icked up and
which d ispenses with most of the torch movements that are
generally advocated by the old time welders .

(88) When welding two pieces o f steel bars ,the cross

section of which will measure one half inch by three inches , -

they are beveled o ff and prepared in the manner illustrated

in F ig 5 7 ,e ither by means o f a chisel ,file ,o r by the use o f a
.

gr ind in g wheel A bout an

. e ighth of an i nch of the or i i
g nal

F IG —P repa ring an d Hea ti n g S t e e l b e fo re We lding

.
57 . .

stock is left o n the bottom S ide and the angle formed from
th e se two places when brou ght together ,should be 90 degrees .

When the p ieces have been prepared and placed in the pos i
tion shown in the illustration , the neutral flame is then
brou ght down at r ight angles to the plane o f the metal ,so that
the end o f the cone will just l ick the surface I t is moved .

up and down upon each s ide o f the part to be welded until

each p iece is brou ght to a red heat ,for a distance o f at least
one inch back Th e pos ition Of the torch during th is opera
.

tion can be seen in F ig 57 F rom th is tim e on ,the O perator

. .

should work as rap idly as poss ible ,for the qu icker the fus ion
84 OXY ACETYL E NE WELDI N G MAN UAL
-

of the metal is brou ght about ,the less oxide or scale wil l
appear and a better weld will result Th e descr iptio n o f .

th is process may take some len gth but th e actual fus ion not
nearly S O long .

(89) When the red hot stage is reach ed ,the neutral flame
-

”
is brou ght down to the very lowest part of the V at the
s ide nearest the operator and held there until the metal has
melted and is about to collaps e Th e flam e is then qu ickly .

twisted away fo r just a s e cond to le t the metal set Perhaps .

F — In W ldi ng S te el ,th e B e gi nne r Sh o uld Fu e His P i c t ge th e r

IG .
58 . e s e es o

l ng th B tto m with th e To rch F lam ,Addi ng n o Ne w M ta l Th e

a o e o e e .

M e t al o n B th S ide o f th e To rch F l ame is M e lt e d t o ge th e r u n til a S m all

o s

Po l f M lt n M e t l Appe ar ,th e n th e To rch is Twi s ted Smartly away ,

o o o e a s

as S h o wn b y th e A rro w ,an d th e M e tal Allo we d to

“
S et fo r an In s tan t
b e fo re P r o ce e di ng al o n g th e L i ne o f W e ld .

this op e ration will fus e about one half inch or less along the -

”
bottom o f the V Th is same op e ration is repeated along
.

th e l ine of w e ld until th e whole p iece is fused along the bot

to m I t will be noted that no fille r ro d has as yet been used
.
-
.

A fter the last portion has been fused ,the flame is brought
back to the starting point and played not only on the bottom ,
-

wh ich has already been fused ,but on the s ides of the V ”

as well ,bringing an area of about o n e inch in d iameter to a

molten cond ition Th e tip o f the welding torch is held in a
.

vertical position all th is t im e to introduce as much heat into

 S TEEL WELDI N G 85

th e weld as poss ible D ur ing th is operation the fille r rod ,

.
-

whi ch should measure three s ixte e nths o r one quarter inch

- -

in di ameter , is p icked up by the operator s free hand and its

’

end brou ght near the heat o f the flame so that it may be
warmed and will not chill the metal when introduced into the
weld W hen the melted metal is runni ng freely ,the tip of
.

the weldin g torch is slowly inclined in the direction of th e part

to be welded and is advanced alon g the V ed out portion -

at thi s angle as rapidly as the metal can be made to melt .

position is show n in F ig 59 I t will be noted that . .

FI G .
59
— M e th o d
. of A dding “
F ill e r—
ro d in W e ldi ng S t e e l . No te th a t th e
R o d is W o rk e d b e h i n d th e F lam e .

as the flame advance s along the line of the weld the molten
metal will mount up beh ind it o f its own accord ,provid ing
th e metal is in a molten cond ition , when the flame passes over
it. D ur ing this pe r iod the fille r rod is stirred into the molten
-

metal in a circular movement wh ich should be in back o f

the torch as much as poss ibl e Th is means that the torch.

comes in contact with the fille r ro d but very li ttle and the rod
-

is melted ,not by the flame ,but by the molten metal of the

piece being welded I t will be noticed at times ,when to o
'

much metal has been welded and the torch is not advanc in g
rapidly e nou gh ,that some of the molten metal will run ahead
86 OX Y ACETY LE N E WELDI N G M AN U AL
-

of the flame ,into that part of the V ye t to be fused ,and

to the unwary stud e nt th is will be looked upon as a safe place
to add h is filler rod However ,when the p iece is broken
-
.

and the cross section Of the weld examined ,it will be found
-

that in this part of the weld ,the metal has only been laid on
and not fused Th e beginner should watch this operation
.

and see to it that this molten metal is not permitted to run

ahead of h is torch ,an act wh ich he can overcome by the proper
manipulation o f h is fille r—ro d,which really governs all the
melted metal behind the flame I f n o t e nou gh m e tal has.

been added to fill in the V to the proper thickness ,thi s

FI G 60 — Th i s M e th o d A dding th e F ill e r ro d wh en We lding

“ ”
. . of -
is no t

R e co mm ende d fo r th e B egin n e r
.

operation can be repeated until e nough metal has been added .

B y practicing thi s method the student can be tau ght to

execute a very successful weld and reinforce it all in o n e
operation without any chanc e o f burning his fille r rod o r -

lapp ing h is metal M ore practice is requ ired to successfully

.

weld steel than most other metals and the beginner should
not be discouraged if it takes him some time to conquer this
metal I t Should be forcibly impressed on the student
.

that the metal must be in a molten condition before the filler

rod is added ,or else it will stick and prevent h is working
readily and in addition will produce a very faulty weld .
 S TEEL WELDI N G 87

F usion is the thi ng to bear in mind for without it success can

no t be expected .

(90 ) Wh ile outs ide appearances should not be considered

as a prime requ isite ,when be gin ning it is always well to add
more metal than is really necessary in order to re inforce the
weld as much as possible I t cannot be expected ,however ,
.

that a steel w ith the same cross section as the or iginal will
-

possess the same prope rties and be as strong,for a weld is

only a casting unless treated otherwise and the steel or wrou ght
iron used in the specimens is o f rolled stock I f too much
.

metal has been added and dress ing down is necessary ,the
student will fin d that by using a slightly oxidizing flame the
surplus metal can be burnt away very rap idly and a very
good look ing job can be executed much more rap idly than if
-

a neutral flame were used I t is well to remember ,however ,

.

that this is used only in dress ing o ff p ieces and in places

where the stren gth of the weld is not to be jeopard ized .

(9 1 ) When advancing in steel work ,it will be noticed that

the same provis ion for contraction and expans ion is not con
side re d in as r at proport ions as on cast iron ,and the reason
g e

is qu ite e vident. I n cast iron we fin d the metal is very

br ittle and will not give without breaking,whereas o n steel
it is more duct ile and will twist and bend befor e break ing .

Th is does n o t mean ,however ,that the important po ints of

expans ion and contraction are to be ne glected in steel work ,
for they are very im portant ,as we shall see later on .

PA R T TWO .
—S TEE L W E LDI N G

(9 2 ) I T is still supposed that the beginner knows very little

about the various k inds of metals ,o r methods of d istin gu ish
ing between them . Th is is of great importance and should
at once be overcome ,as he w ill not at all times have someone
over him to diagnose hi s cas e and tell him the proper procedure .
88 O X Y ACETYLEN E WELDIN G MAN UAL
-

F or instance ,were he to be given a piece o f cast steel to weld ,

think ing that it was cast iron ,he would use a cast iron -

rod in executing h is weld Th e results o f such a weld

fil le r
-
.

would not be very favorable ,and the sam e would hold true
if a steel fille r rod were used o n cast iron
-
A n occasional
.

glance at the table in para graph 6 7 will acqua int him with the
var ious tests to make when d e cid ing upon th e nature of
the piece to be worked upon Th e tests should be applied
.

in every doubtful instance Wh e n working on cast steel ,

.

a student may th ink that he must have a cast steel filler rod ,
- -

but this is an exception to the general rule and he can use

the same style hller ro d as he would employ o n ord inary
-

steel work I t m ight b e mentioned here that when work ing

.

o n alloyed and h igh carbon st e els ,the fille r ro d generally

- -

contains som e o f the alloy o r carbon which will tend to

replace that destroyed by the action of th e flame in the origi
nal metal .

(93) I n welding cast steel the same procedure takes plac e

as previously described fo r steel ,and it should pr e sent no
real d ifficulties after that process is und e rstood There may .

be more sand ,oxide and other impurities pr e sent o n account

of the nature O f the metal ,but these can all b e worked o ut
if plenty of heat is appl ie d A t times ,when working in steel ,
.

it will be found that there may be a small hole develop in

the center o f the we ld and as the torch is worked into this
hole it is found that it goes down a short distance and s e em
ingly r e fuses to be worked o ut Th is is what most welde rs
.

“
call a crater , and is caused by the metal at th e bottom
”

not being hot enou gh for th e surround ing melted metal to

fuse it When found they should be r e moved b efor e adding
.

any more metal B y playing th e torch flame around and

.

around it ,so that the heat may be transmitt e d to the bottom

of th e crater and it brou ght to the melting point l ik e
” -

the Surroundi ng metal and suddenly jerking th e torch away ,

90 OXY A C ETYLENE WELDI N G MAN UAL
-

the metals to gether) ,at var ious po ints before starting the
weld ,or th e parts ahead of the torch can be separated as is
shown in F ig 6 2 and held th is way by using a wedge This
. .

is moved along as the weld advances and permits the ed ges

to close together A nother method used by manufacturers
.

who make a specialty of th is work is to construct a jig which

FI G . 6 1 — Th e
. E n ds on lo ng S tee l W e lds will Ove rlap as th e W elding
P ro gresses if Impro pe rly S tart ed
.

FI G . 62 . Sh o w ing h o w Ope n E nds o f S t eel piec es are Sprea d S ligh tly

-
to Ove r
c o me Lapping o f E n ds in Ma ki ng W e ld .

clamps the ends r igidly and they are welded wh ile in this
pos ition This ph e nom e non in steel welding will appear
.

rather strange to the welder who has had some exper ience o n
th in cast iron work ,such as oven doors and the like I n
-
.

these he found that as h is w e ld advanced ,the welded portion

befor e him would separate ,and when he had welded about
 S TEEL WELDI N G 91

four inches or so it would be necessary for h im to jump h is

flame back to the beginning of h is w e ld and heat up that
po rtion ,in order to close up the cracks before h im previous
to h is continu ing the work This is illustrated in F ig 63
. . .

Th is may be expla ined by the fact that steel is a very

ductile metal and when it is fused ,the expansion is taken
care of internally by the two edges comb ining Then ,in .

cooling,the metal contracts ,an action much more rap id in

steel than in cast iron ,and draws the ed ges of the steel plates
past each other so that they overlap I n cast iron ,whi ch is
.

63 — Th i s
. I llus trati o n S h o ws h o w th e Ope n En ds o f Thin Cas t iro n
-

P i e ces S prea d apart as th e W e ld P ro gresse s To Clo se th e Edges to

.

ge t h e r ,J ump th e To rch F lam e fro m B to A ; as A h e a t s up ,B C o o l s

an d th e L e v e r lik e A cti o n Cl o se s th e Ope n i n g
-
.

r igid ,the ed ges are expanded by the fus ion of the metal and
this space is then filled up with new metal ,holding the ed ges
apart A s the weld pro gresses the metal ahead of the torch
.

is pushing o ut ,and that behind is cooling o ff,which acts as

a lever on each side to open up the unwelded ends .

(96) To weld a broken automob ile frame successfully

the body of the car should be raised if necessary ,to keep it
from burni ng and all p ipes ,wires and gasol ine leads pro
te c ted w ith a covering of asbestos paper Plenty of room .

should be allowed ,so that the welde r may have easy access
to the break ,and the frame should be jacked up on both S ides
92 O X Y ACETYLENE WE LDI N G M AN UAL
-

of the break until th e frame is in proper al ignm e nt Th e n .

weld th e crack from the outside ,working across the top ,

then down the Side and across the bottom ,r e inforcing a
l ittl e if necessary o n all sid e s but the bottom Then r epeat .

this operation on the insid e ,reinforcing at all po ints Then .

take a strip o f steel about o n e eighth o r o n e quarte r inch

- -

thick and six or eight inches long and as wide as the bottom

FI G . 64 — A. G o o d M e th o d R e i n fo rcing a W eld o n an Auto mo b ile F ram e

of

is He r e S h o wn Th e Pa tch as P ictur e d He re is o n ly
.
“
Tacke d On . It
”

S h o uld b e W e lde d S e cure ly to th e B o tto m o f th e F rame o n all Fo ur o f

its E dges .

of the frame Thi s p iec e should b e we lded secur e ly to the

.
.

bottom of the frame with the former break in the middl e o f

the strip A cut repr e s e nting this job is shown in F ig 64
. . .

B y th is method the frame can be mad e stronger than or igi

nally .

P AR T TH R E E — S TE EL WE LDIN G

(9 7 ) A S I DE from th e diffi cultie s already m e ntioned in steel

welding,there are many others A few o f these will be tak e n
.

up in order to let the beginner kno w how to approach th e

var ious problems which may confront hi m B u t in no wis e .

is this to be cons idered to b e a treat ise o n advanced work Oft .

94 OX Y -A CE T YL E NE WEL D I N G M A NU AL

case ,O fttimes the shaft will break in th e ch ee k o f th e o ff

”
s e t , and poss ibly no part o f the shaft is thrown o u t of al i n
g
ment When such is the case ,welding is usually recommended
.

and the shaft may be brou ght back to a useful state in very
quick order Howeve r ,in th e form e r case ,the shaft is apt
.

to be sprung,and wh ile it could be welded ,the mach ine

work necessary to restore it to normal requ ires much time ,
and it has been known ,where afte r spending a matter o f
days in trying to ge t proper alignm e nts ,work was scrapp e d as
useless S o it is entirely up to the welder in work o f this
.

FI G . 65.
— B uildin g Up W o rn Sh afts .

kind to determine whether the j o b is worth while or n o t .

Th e re are certain parts o f a crank shaft upon wh ich w e lding

-

work can be done with a marked de gree o f success ,such

as bu ilding up worn bear ings and the like I n doing work .

o f th is k ind it is recommended th at the welder fuse h is metal

in a line parallel to the center l ine o f th e bearing,see ing to

it that he has a perfect fus ion between the surface of the b e ar
in g and the metal he is fus in g and addin g plenty of m e tal ,
to insur e e nou gh being used ,so that no low spots will show
 S TEEL WE LDI N G 95

up when it is mach ined I t is considered that by add ing the

.

metal as su ggested the welder will hold h is heat much better

!
than if he attempted revolving the shaft continually F ig . .

6 5 will Show the method here outlined in a very clear way .

(99 ) When working on shafts the welder will encounter

such articles as automob ile propeller shafts and rear axles ,
wh ich generally break adjo ining th e s quare ends He will .

no doubt wonder whether it is advisable to weld th is square

end back on ,or whether to try and bu ild up the shaft the
des ired length U ndoubtedly the point of fracture is the
.

F IG . 66 .
—S ha ft B ro ken at E nd o f S quare Sh ank ,its W e akest Po in t .

FIG . 67 .
—
B ro k e n Part S h aft R emo ve d an d N e w P i e ce A dde d ,th e reb y
of

M o vin g th e W e ld a w ay fro m th e Weak P art .

weakest portion of the entire shaft ,else it would not break

there Th e execution of a weld at this po int where no
.

additional metal can be added or any means of re inforc ing

used is not to be recomm ended F ig 66 will show the problem
’

. .

which confronts the welder ,and F ig 6 7 the su ggested means .

of overcom ing the difli culty B y removing about four inches .

from the broken end of the shaft and add ing a new p iece ,
about ten inches long,of the same d iameter ,the weld will
be removed from the weak po int ; a heavier weld can be
made ,and the end can be mach ined o ff to the desired s ize .

Th is procedure is recommended on all jobs of like nature .

96 O XY ACETYLEN E WE LDI N G MAN UAL
-

( ) 1 00 Occas ionally
cas e hardened ring ge ars are brou ght
-

to the we lder to have teeth bu ilt up o r n ew ones added ,and

although the welder must realize that the hardenin g is de
stroy e d by the action of the flame ,yet he does not under
stand why it is necessary to reharden the gear A l ittle .

thou ght on thi s subject will make h im appreciate the fact that
if he destroys certain properties in metal wh ich have been
introduced fo r a reason ,these must be replaced if he would
br ing the jo b back to normal I t would be like heating up a
.

tempered lathe tool ,o r cold ch is e l fo r that matter ,and try

ing to us e it b e fore it had been retempered Therefore if .

FIG . 68 .
— Wh en W ldin g
e a Small S ecti o n to a La rge r One ,th e F lame of th e
To rch is D ir ect e d to wa rd th e He avi e r o f th e Tw o
.

hardening o r temper is d e stroyed by the flame it must be

r e stor e d .

e ak ,it would be necessary fo r

( )
1 0 1 I f a weld were to br
the welder to r e move all m e tal added in the first weld befor e
att e mpting to rewe ld This is true o f h is o w n work as well
.

as that o f others wh ich he may be call e d upon to do F o r .

no ma t ter how good the surface may appear ,without a sol id

foundation no weld is o f any value ,and unl e ss he clears o ut
all o f the old metal he cannot b e sur e o f the work This will .

apply n o t only to steel work ,but to all metals ,and it is a point

wh ich should b e borne in m ind .

t t mes th r re jobs come up in wh ich o n e p iece

( )
1 0 2 A i e e a
98 O XY ACETYLEN E WELDIN G MAN UAL
-

iron fille r rods together ,to ge t the desired angle as Shown in

-

F ig 6 9 ,but th is is n o t as common as the steel method ,

.

probably because cast iron will not bend and it requires some
time to weld the rods together in this manner .

( 1 0 5) I n some parts of the country boiler flues are

acted upon and eaten away by the impure water used ,and
when h igh prices prevail ,re tippin g is generally resorted to A .

Simple method in which they can be satisfactor ily and cheaply

FI G 69 —K in k s fo r Han dl ing F ill e r —

ro d Large Wo rk to Remo ve W e lde r s ’
. . on

way fro m Heat o f F l ame

Han d a .

( a ) S h o w s h o w th e t l Fill r d i h t d b y th t r h fl m b ut 6 i h
s ee
“
e -ro ”
s ea e e o c a e a o nc es r
f o m th e
e nd and b tten o th e an gl d ir d
e es e .

( b ) illu t t
s ra e s how t Fill r d
c as
“
e h dl d
-
ro Si th y will t b d ,th y
s
”
are an e . nc e e no en e are we ld d
e

in th T h p
e s a e sh o w n . Fir t s id i u d i fu i g, d th th th r
o ne s e s se n s n an en e o e .

done is as follows : C ut o ff the poor end until solid metal

is reached ,with a pipe cutter ,which will tend to V the
work as it cuts and at the same time will squeeze the ed ge of
the pipe in After cutting,this end o f the flue is placed o n
.

the horn of an anvil and the burr on the inside ,which has been
made by the cutter ,is flattened out I t is very important that .

th e flue be o f the same s ize throu ghout in order to perm it

“
its being cleaned I t is then placed in V . blocks or a
 S TEEL WE LD I N G 99

trou gh ,made of angle iron ,such as shown in F ig 7 0 ,and the .

new end which has been prepared in much the same way
is placed in the pos ition shown in A in the same figure .

T h e p iece is tack ed on at two o r more spots and then la id

as ide until the whole set o f fin es has been prepared in th is
manner Then they are replaced in the trou gh and welded ,
.

one after another ,being turned at one end by a helper ,thus

allowing the welder to do cont inuous work C are must .

be taken at all times that perfect fusion takes place between

the flue proper and the piece being added ,yet at no time
should the metal be allowed to run on the inside of the p ipe .

M ore metal can be added than is really necessary and c an

— Sh o wing a S imple Way to Line up “ 7 , F lues wh en R e tippin g

F IG .
70 .
-
.

B Re prese n t s th e o ld F lue ,and A th e N ew P i ece to be Adde d .

later be dressed down o n a gr ind ing wheel to th e desired s ize ,

which must be such that replacement of the flue can be made .

V arious s ize d p ipes can be welded in much the same way

-

where no reducers are obtainable , the only change being

that there must be a step made in the trou gh which will
permi t the var ious sized p ipes bein g lined up correctly
-
.

i
! gs for the speedi n g up o f manufactured ar ticles wh ich are
to be welded are always being brou ght out by the in genious
workman and are to be encouraged whenever po ssible .

( 1 0 6) I n the repair of boilers many a feasible job h as

1 00 OX Y -ACE T YLE N E WE L D I N G M A NU A L

been given up a s imposs ible by the unth ink in g welder .

C racks have b e e n found in fire b o x she ets around the s tay

-

bolts which ,as soon as they are touched with the flame ,
seem to run and k eep runni ng They really d iscourage those
.

w h o are not fam il iar w ith th is class o f work M any such .

welds have been executed and are apparently all r ight until
tested ,when they give way and make the job worse than it

( Courtesy of the Oxweld Acetylene Co )

.

FI G .
71
—Welded C racks b e tween
. S tayb o lts .

was previously Th e trouble is in these instances that the

.

welder has made no provision fo r contraction and while

the job might app e ar to be successful ,yet the internal strains
exerted will not show themselves at the te st M any boiler .
1 02 OXY A C ETYLE N E WELDI N G MAN UAL
-

but seein g to it that a pe rfect fusion is made between the

patch and the sheet all the way through As soon as the .

weld is complete the torch is played upo n th e high part of th e '

patch ,wh ich is protruding,and as the weld cools o ff,sharp

qu ick blows can be appl ied to the center of the patch ,wh ich
should be kept in a heated condition until it is nearly flat .

Th is will take care of any contraction that might se t up and

is a very good way of handl ing patches which do not exceed
six or e ight inches in diameter .

( 1 0 8) A corru gated patch has been brou ght out more

”
recently than the d ished patch ,and as its name woul d

”I l l ! 1 7 1 1 0 1 1 1 1 0 fi ll ! 1

FI G .
74 .
—
A C o rrugat e d Pat ch
“
.

indicate ,it has corrugations around at least three of its s ides .

”
Wh ile a d ished patch is limited in its scope and cannot
be appl ied to square holes u nless the square holes be cut
“
round ,the corrugated patch knows absolutely no l im its
”

as to s ize or shape Wh ile its preparation is probably more

.

diffi cult ,yet its purpose is th e same ,that is ,to take care o f
the contraction wh ich takes place in sheets of metal where
”
heat has been introduced To prepare a . corru gated
patch ,a piece of metal which is somewhat lar ger than the
hole is taken and the corru gation is made by placing two rods
on one s ide and somewhat separate d and between th e m o n the
o ther s ide another rod With thi s section of the patch
.

heated to a red heat ,a drop hammer is played upon it and

 S TEEL WELDI N G 1 03

a corru gation effected Or an easier method is b y the use o f

.

spe cially prepared d ies ,wh ich will turn out a patch in qu ick
order I t must be rememb e re d that wh ile the patch shown in
.

F ig 7 4 is only for a very s imple j o b ,wh ich is rectangular

.

”
in shape ,yet L shap e d patches can be pr e pared and
'

handled in the same manner When the corru gation h as been

.

introduced into the patch ,th e latter is cut so that it w ill

fit the hole ,and it is tacked in pos ition w ith the bell ied
sides out Th e method used in applying a patch of this k ind
.

is to weld the uncorru gated s ide ,then start up the corru gated
sid e and weld for tw o o r three inches ,then play the torch
'

upon the corru gation ,adjo ining the part welded ,and sl ightly
hammer to assist in the expans ion of the same ; then return
to the weld ,continu ing it until the corru gation can a gain be
played upon B y d oing th is ,wh e n finished the patch will
.

be flat and no s igns of the corru gations will be shown Wh ile

.

many patches of th is nature are in use giving the very best

ser v ice ,the welder who looks upon the finished job cannot
tell how it has been accomplished .

( 1 0 9) Wh ile the methods here given seem only to apply

to boiler work ,they are not so r e stricted and can be appl ied
to tanks and various vessels with succ e ss However ,when
.

weld ing o n tanks wh ich have contained infl ammable gases o r

g asol ine the welder is caut ioned to take every measure to
safe guard h imself ,and wh ile it is known that much work is
being done o n such jobs ,it is not recommended and in fact
qu ite the contrary I t is true that there are such methods as
.

fillin g the conta iners with water ; cleans ing with l ive steam ,
and so forth ,but the cautious man will refra in from work ing
on these vessels even thou gh such measures have been
taken G asoline has a faculty of penetrating the pores
.

of metallic surfaces ,and althou gh these vessels have been

emptied and have remained so a matter o f a year ,the gaso
line is still present to some extent ,as is evidenced by th e
1 04 O X Y ACETYLEN E WELDIN G MAN UAL
-

fact that as soon as he at is applied and the molecules o f the

metal are expanded ,the gas is r e leased in suffi c ient quantities
to cause an e xplos ion Th is is n o t in o n e instance only ,
.

but in many ,so it has been thou ght best to discourage any
welding work o n vessels which have contained gasoline at
any time .

( 1 1 0 ) Wh ile it is possible to weld cast iron on the vertical ,

by the use o f carbon blocks and so forth ,the same k ind o f
work can be accompl ish e d o n steel with much ease ,w ithout
th e use o f any blocks ,or mater ials other than the fille r rod -

F IG
— W o rkin g a Ve rtica l Weld o n S tee l ,fro m th e To p D o wn
.
75 . .

and the wel di ng torch Ther e are two methods of handl ing
.

vertical welds ; welding from the top down ,or starting from
the bottom and working up Th e former seems to be con .

de m n e d by those who have never tr ied it ,o n accoun t o f the

carelessness wh ich is apt to be used on work of this kind How .

ever ,for the beginner ,it is thought advisable to teach th is

method ,as there are many plac e s where it can be used ad
v an tage o usly Th e metal at the top o f the seam ,such as a
.

broken automob ile frame ,or the like ,is brought to a molten
state and held there ,not only by the velocity of the flame ,
but also by the filler rod ,as is Shown in F ig 7 5 With the
- . .
 C HA PTE R V III

B RA S S WE LDI N G

(1 1 2 ) I T is d iffi cult for the beginner to accustom h im

self to brass weldin g,especially on large work Wh ile he
.

has been tau ght to believe that brass has a much lowe r
melting po int than iron or steel ,yet when he comes face to
-

face with the actual problem of melti ng it ,he will fin d that

it is necessary to hold h is flame in contact with h is piece much
longer ,on brass work than on either of the other tw o ,before
the meltin g po int is reached Th is can be accounted for by
.

the great conductivity of brass On cast iron and steel

.

the heat was rather local ,but on brass work it is transm itted
to all parts of the p iece as rapidly as it is introduced ,and th is
absorb ing process continues until practically the entire piece
is near the meltin g po rn t.

( 1 1 3 ) B rass has for its base ,copper to wh ich an alloy

of zinc has been added N ow the most difli cult part o f fus ing
.

brass work ,is to add more metal from the fille r rod to the -

parts which are to be fused ,without burnin g up any more

O f the alloy ,than is absolutely necessary S ee ing that the
.

copper and zinc have d ifferent melting points ,it is a very

diffi cult feat and re q u ires considerable practice M uch of
.

th is trouble can be el im inated by the use o f a fille r ro d which

-

has the correct propor tion o f alloy added ,so that it m ay take
care of and replace any that has been d e stroyed by the flame .

( 1 1 4 ) B rass work is V e d out when weld ing is to be

-

done ,in pract ically the same way as cast iron Only under
.

no circumstances should th e ends o f the parts be burned

1 06
 B R A SS WELDI N G 1 07

o ff, when V
-
in g , as the heavy ox ide wh ich is depos ited
o n th e rema inin g metal is very hard to combat w ith the weld

in g flame . Th e ends of the work are brou ght to a red heat

with the flame that is slightly carboniz ing Th is is held .

d irectly in contact with the work during the preheating

stages ,in much the same manner as on cast iron ,and a small
layer of carbon may be seen to accumulat e around the weld .

N ow ,in theory ,this would seem the worst th ing poss ible to
have present ,but in practice a small quantity of th is soot
acts as an aid in making the weld ,besides making the flame
less intense ,which S aves much of the alloy ,from be in g
burned when the fusion occurs When the ends have become
.

red hot ,the same procedure is used as in work in g steel ,

except that the torch is given a slightly greater angle and a

brass flux is used .

( )
1 1 5 C ontrary to most author ities we fin d that an
abundance of good flux is des irable on brass work and that
it is almost imposs ible to use too much I t is des irable
.

to use only the best weld ing fluxes ,for the best welds are
to be insured only under ideal conditions I f a welder were
.

to run Short of flux ,however ,he might use powdered borax

of the 2 0 M ule Team var iety ,to tide h im over until he could
ge t a new supply . Th e flux is added in the same way as the
cast iron flux ,that is ,by d ipp ing the heated end o f the fille r
-

rod into the flux container E nou gh will adhere ,and when
.

added will clear up the metal in the v i c inity o f the weld I t.

should be add e d as often as a welder notices h is metal needs

cleanin g and th is will vary depend ing upon whether there is a
slow o r rap id worker beh ind the torch A man must use
.

h is o w n jud gment in cases of this k ind R emember that

.

the flux is a cleanin g agent and if the surface is clean ,no

add itional flux is necessary ,but if the contrary is true ,that
is ,if the surface is full Of ox ide and the filler refuses to flow
easily ,flux is necessary and should be added .
1 08 OXY ACETYLEN E WELDI N G MAN U AL
-

( 1 1 6) D ur ing the weld ing,dens e white fumes will come

from the fusin g brass Th is is the burning out of the alloy ,
.

that is ,the zinc These fumes are injurious to the welder and
.

should be avo ided ,if po ss ible ,by proper ventilation Th e

.

use Of a proper fille r rod and rap id work will lar gely tend to
-

overcome the presence of these fumes ,but if the operator

is very slow ,they will appear ,and are followed by a porous
and br ittle weld ,whi ch if broken afterwards will Show a
lar ge number of blow holes Th e most d iffi cult part o f brass
.

weld ing as a whole is to add the fille r rod ,being certain of a

-

fus ion ,without burn in g o ut the zinc When brass is in a

.

heated cond ition ,it is very fragile and will crack read ily
if d isturbed
. A ll precautions should be taken to see that no
sudden jarring is given the p iece until the weld h as completely
se t
. W hen th is work is done many welders plunge their work
in water ,in an e ffort to make it more ductile and eas ier to
machine Wh ile th is ,o f course ,is condemned by theor ists
.

and righ tly so ,in practice th ere seems to b e no injury results

.
OXY A CE TYLEN E WE LDIN G M AN UAL
-
 ALUMI N UM WELDI N G 1 1 1

the cond ition mentioned ,fast work is necessary or the metal

will collapse ,for it loses most o f its strength when heated to
th is cond ition Th e end o f the fille r rod bearing the flux
.
-

is brou ght down o n the metal and immed iately the surfaces
will clear up and run to gether ,l ike so much mercury Th e .

torch is instantly jerked away and applied farther along the

weld Th e theory of th is reaction is that the heavy alum i
.

num oxide is the only th ing wh ich prevents the metal flow in g
to gether when heated ,and as soon as the flux is introduced
th is oxide will be destroyed along the line of weld and a fusion
o f the metal e f fected
. Th is actually takes place ,provid ing
enou gh heat has been introduced to permit th is reaction to
penetrate the depth of the weld Th e flux contains the
.

chem icals necessary to cause th is reaction if the metal is

in the r ight cond ition There are many welders who do not
.

use suffi c ient heat and blame the faulty results upon th e

flux On the other hand ,there are many fluxes which are
.

absolutely useless in performing a function o f th is kind .

Th e chem icals necessary in compound ing a good flux for

th is class o f work are expens ive and therefore th is flux cannot
be procured at a low pr ice W hen the weld is finished and
.

cooled the surface should be scrubb e d with soap and water

to remove all traces o f the flux ,otherwise a corrosion may
occur a month or so afterwards ,and wh ile it may not a ffect
the weld in any degree ,the owner of the p iece may not be
pleased at the s ight I t is therefore advisable to remove all
.

traces of flux used o n alum inum work .

( 1 2 0 ) Th e puddle system d iffers from that o f the flux .

insomuch that when the metal has been brou ght to the
same heat ,where the flux has been appl ied it will be foun d
that the metal is really in a pasty cond ition I t can be
.

stirred together and the break entirely el im inated by the use

o f a puddle st ick ,e ither o f a po inted or a flat spoon shape
-

des ign ,as Shown in F ig 7 7 D ur ing th is puddling stage ,

. .
1 12 OXY AC E TYLEN E WELDI N G MAN UAL
-

th e torch is usually held in the left hand with the flame some
d istance away from the work ,only introducing enough heat
to keep the puddle pasty Th e puddle stick is handled .

by the right hand and when extra metal is needed the puddle
stick is la id aside and the alum inum filler rod is picked up -

an d worked into the weld When su fficient metal has been

.

added the puddle st ick a ga in comes into play and can be

u sed in stirr in g the metal to gether and finishi n g it o ff in the

des ired manner R e inforc in g the weld will apply to alum inum
.

t h e sam e as every other metal ,and a very neat jo b can be

made after a l ittle practice with the puddle stick At .

FI G .
77 . Puddl e sticks
-
fo r W e ldi ng A lumi num .

som e of the alum inum may adhere to the stick ,wh ich is made
from a quarter inch p iece of steel fille r ro d ,but th is can be
- -

rem oved by scrapin g it upon the fire br icks which should be

in th e vic in ity of the weld .

( 1 2 1 ) There are two k inds o f fille r rods used in alu m inum -

w e l d in g
. B oth are alum inum ,but one is cast and the other
is a drawn rod Th is same d ifference will also be noticed in
.

bro nze fille r rods ,and there has been much d iscussion as to
-

Wt h is the des irable o ne to use N either of them is sup

.

posed to be 1 0 0 per cent pure aluminum ,as such a fille r rod -

does n o t give the desired r e sults under the action o f th e

1 14 OXY A C ETYLENE WELDI N G MAN UAL
-

applied Th e metal may be molten on each S ide o f an

.

ox id ized crack and at times will cause the l ine of fracture to

even float ,but if the oxide is not destroye d the metal will
not fuse A s has been noted previously ,two methods are
.

used to destroy th is oxide ,namely ,the flux method and the

puddle system On account of this exceedingly rapid oxida
.

’
tion ,it will be found to the operator s advantage to complete
h is aluminum welds as qu ickly as poss ible in order that he
will have less of this oxide to combat I t will be found in
.

using the puddle system that greater haste can be made by

us ing the torch in the left hand ,leaving the r ight free to do
the puddl ing and to add whatever metal is necessary I n .

this method most of the success depends upon the operator s ’

skill in handling his puddle stick and puddling in additional

metal G enerally the r ight hand can do th is more rapidly
.

than the left .

( 1 2 4) I t is well to learn how to make a successful weld

from o n e side o f the metal o nl y ,and while this will apply
to all metals , it is especially advanta geous in workin g
alum inum W here a small layer of metal has been added
.

to o n e side o f an aluminum job ,such as a crank case ,and it

does not penetrate the entire thickness of the metal ,when the
other s id e is turne d ,and the flame appl ied to it ,a d ifference
in t e mperatur e and the loss of stren gth in th is metal when
h e ated will cause th e first side welded to crack unl ess the
operator is extr e mely cautious Therefore it is always well
.

to l e arn how to penetrate the entire thickness o f the metal

from o n e s ide and make a satisfactory weld in th is manner .

( 1 2 5) A s previously stated , alum inum when melted

loses most o f its strength ,and if not supported by some
means o r other the metal will collapse On account o f th is
.

it is advisable to back up alum inum work ,when poss ible ,

wh e ther th e j o b is to b e done cold o r in pr e heate d cond ition.

Th e most successful manner o f backi ng up is shown in F ig .

 ALUMI N UM WELDI N G 1 15

7 8 ,where in A represents a thin sheet of copper wh ich has

been fitted to the work ,and daubs o f asbestos cement shown
at B wi ll aid to some extent in hold in g the plate in pos it ion ,
but this alone should not be depended upon A prop or .

fire brick ,upon the top of which has bee n placed a cush ion
of cement ,will serve as a good backing,but where th is cannot
be accompl ished fille r rods may be bent in the manner shown
-

in F ig 7 8 These fille r rods are not o f the spr in gy type ,

. .
-

but are of sof t Wire and the loop as shown is not for a spr ing

Ih c .
78.
—On e M e t h o d U se d to B ack Up A lumi num W o rk ,wh e n W e ldin g
“
.

A R epresen ts a S h ee t o f C o ppe r ; B ,A sb e st o s C eme n t

.

effect ,but merely to take care of the contraction and exp an

s ion of the wire C oppe r I S gi ven a preference over most o f
.

the o ther Sheet metals ,because it can be peened wi th a hammer

to any shape des ired ,and many odd shaped add itions can
be formed by its use .

( 1 2 6) Th e use of clamps ,when workin g on alum inum ,is

not recommended on account of the great conductivity o f
heat and the weakening o f the metal as it approaches the
melting point Pressure of any kind is not desired and the
-
.
1 16 OXY ACETYLE N E WELDI N G MAN UAL
-

operators who attempt to use clamps will regret it sooner or

later .

( 1 2 7 ) I n alum inum work contraction and expansion take

place the same as in other metals ,only to a much greater
extent ,and greater allowances must be made However , .

the same rul e s can be applied when determining whether

work should be preheated or not ,for if the ends are free to
move ,the work can usually be accompl ished without pre
heating, whereas if confined ,it will be necessar y When .

preheating is n ecessarv the whole piece must be treated in the

same way ,regardless o f the s ize I f only part of the work
.

were preheated and the balance left exposed ,it would be alrn o s t
imposs ible to avo id warpage and shr ink age strains ,which
would render the work useless A lways preh e at the entire
.

p ie ce if any portion requ ires it .

( 1 2 8) G reat care must be exercised when setting up alumi

num work fo r preheating I ts weight Should be d istributed
.

equally o n whatever support is used ,so that there will b e no

danger of any one part sagging,thereby throwing the whol e
p iece o ut o f alignment A good way of accomplishing th is
.

is to lay fir e br icks on their flat S ide ,in such a manner that the
weight o f the work will be fairly well distributed Th e n put .

a daub o f clay or asbestos cement o n each br ick and press the

aluminum piece down o n this cushi on Thi s will overcome
.

th e use of shims and other methods used for jacking up th e.

work ,wh ich are unreliable .

( 1 2 9) I f charcoal is to be used as a preheating fu e l ,an

oven of fir e br ick should be built up with draft holes in th e
bottom layer o f brick ,as described in the chapter o n Pre
heating A layer o r two of charcoal is then ign ited Th e
. .

oven is then covered w ith asbestos paper or a piece of Sheet

metal A sbestos paper is preferable as the metal becomes
.

very hot and is apt to burn the operator A fter the fire .

h as rec e ived a good start , additional charcoal is added

1 18 OX Y -ACETYLE N E WELDI N G M AN UAL

P AR T TH R E E — ALUM I N U M WE LDI NG

( 1 3 1 ) M A N Y times alum inum crank cases wh ich have lar ge

hol e s punched in them and parts m issing are brou ght to a
we ld e r fo r repairs A question ar ises as to whethe r it is b est
.

to back up thes e hol e s and fill in the miss ing parts w ith a
fille r rod as the weld in g pro gresses ,or whether these parts
-

should be cast s e parately o r cut out o f another crank case .

I t w ill generally depend upon the size o f the hole , as to the

desirable procedure in a case o f this kind I t must be re
.

me mbered that if the casting and welding are to be done at

o ne and the same time each add itional layer o f metal
must be fused to the last layer and that in real ity a great deal
o f weld in g is necessary . I n add ition this added metal must
be fused to the crank case On small holes ,perhaps two or
.

three inches in d iam e te r ,th is method is recomm e nded ,but

if the hol e is much lar ger ,it is best to cast a p iece and then
weld it in ,for I n this instance there is onl y o ne l ine of weld
to look after .

( 1 3 2 ) On alum inum work it is proper to weld from the

closed end of a crack toward the open ,whether the piece has
or h as not been preh e ated This is true also o f all other
.

metals ,fo r if the weld were to be started at the open end and
worked backwards th e r e would certainly be internal strains
se t up , wh ich would be undes irable I f it is not clear whi ch
.

end is the open o n e ,the operator should stop a moment and

figure it out .

( 33)
1 W ere a suspens ion arm of the U typ e o n an
aluminum crank case to break about three or four inches from
the body o f the case ,it could be welded in place without dis
mantling the motor ,if h an dle d pro perly F ree access must
t
.

be had to the l ine o f break ,so that the operator can m anipu .

late h is flame at whatever angl e he thinks best D ue to the.

contraction and expansion ,wh ich may throw the p iece being
 ALUMIN UM WELDI N G 1 19

welded o ut of al ignment sl ightly ,it is best to blan k the

bolt hole at the end of this suspens ion arm and face it o ff,
before the p iece is welded in position L ater a new hole can
.

be drilled whi ch will l ine up accurately with the frame ,and

the welder will not then have to worry o r attempt to return
it exactly to its former pos it ion I n order to keep the case
.

itself as cool as poss ible , wet asbestos should be pa c ked

around it,near the brok en arm ,so that too much heat will
not be absorbe d by it Th e broken end is then tacked in
.

pos ition at two or three places and the weld started On .

such a problem the puddle system will be found best ,for both
hor izontal and vertical welding are to be done ,as well as some
overhead As flux causes the metal to flow ,it is ra ther
.

d ifficult for the beginner to apply it to vertical and over

head work Th e puddle stick should work throu gh the metal
.

its full thi ckness and el im inate every poss ible trace of the
break ,digging out the old metal where dirt is found ,and adding
new metal for reinforcing When one s ide has been welded
.

and rein forced it should not be allowed to cool while the other
s ide is be ing worked Th e torch should be played upon it
.

every now and then ,in order that the whole line of weld wi ll
be at approximately the same temperature ; otherwise ,the
weld may break in cool ing Th e ease wi th which alum inum
.

is puddled to gether ,which many welders have l ikened to the

children s method o f mak ing mud p ies ,seems s o s imple to the
’

be ginner that he cannot see where the strength comes from

when cooled On account o f th is ,he invar iably works h is
.

aluminum to o long A fter wel ding a few test b ars o f th is

.

metal and breaking them in the line of weld ,many old welders
will gain co nfidence upon seeing the results of their o w n
efforts
.
 C HA PTE R X

W E LDIN G OF MALLEABLE IR O N

( 1 34) THE weld ing of malleable iron ,so far as the actual
fusion of the metal is concerned ,is not practiced except in
very few instances ,where the parts are very thin and have
been completely annealed Th is is o n account of its being
.

what m ight b e termed a heat tr e ated metal To begin with ,

-
.

malleable iron is cast iron ,and becomes malleable only after

FI G — Illu s tra tin Malleab l e I ro n

79 g Cro ss se cti o n of
-
. . .

it has been h e ated to the proper cond ition in the presence of

mater ial which will absorb much of its carbon content ,and
kept in this state until a su itable depth of its exter ior has
been annealed I t has been changed from a brittle casting
.

to one wh ich will bend to some extent without breaking,and

its surface ,by the withdrawal o f the carbon ,has been con
ve rted into steel Th e interior remains cast iron Th e
. .

depth of pen e tration will depend entirely upon the number

1 20
12 2 OXY ACETYL EN E WELDIN G MAN UAL
-

are very seldom us e d as a wearing surface ,and are generally

employed where there is strain ,to r e place steel castings and
for gings ,wh ich are much more expensive I f it has been .

determined that the metal is malleable iron ,half th e battl e

has been won .

( 1 3 7 ) I n prepar ing malleable iron ,a clean surface is

nec e ssary in the vicini ty o f the weld N o V in g out is
.
-

nece ssary unless the p iece is greater than one —quarter inch
in t hickness ,and th e n the surface o f the V sh ould be as
rou gh as possibl e Th e ends are placed as close to gether as
.

poss ible ,th e same as in brazing,and a we ld ing tip wh ich is

o n e s ize smaller than would be used o n the sam e th ickness

o f cast iron is then us e d ,with a sl ightly carbon iz in g flam e .

S ee F ig 2 3
. . Th e work is heated ,the same as in cast iron
an d steel . Th is flame is playe d d irectly o n the work in a
ve rt ical position ,Similar to that used in preheating the we ld
in cast iron and steel , until h e ated to a cherry re d,back about
o n e—half inch o n each s ide O f the weld A s soon as th is heat
.

is O btained ,th e bronze fille r ro d carries a quant ity of bronz e

-

flux to the weld and th is further tends to clean the surface .

With the end o f the fille r ro d d irectly in contact with the

-

work nearest the operator ,the neutral flame melts the end
o f the rod , wh ich immediately should run ove r the adjoining
surfac e and throu gh the crack W hen th is occurs the flame
.

is abruptly twist e d away from that portion o f the weld to

avoid burning the bronze This is rep e ated along the line
.

o f the we ld until the entire surface is cover e d with a th in

coating o f bronz e With th is as a foundation more bronze

.

is add e d ,but dur in g thi s process the torch is turn e d s o that

th e neutral flame will not bear down d irectly on the bronz e ,
wh ich has already been add e d I t should rather strike it at
.

an angle and rad iate enou gh heat from the Side of the neutral
flame to permit a fus ion between th e filler ro d and the bronz e
-

already added M uch more surface should be cove r e d and

.
 WELDI N G OF MALLEA B LE I R ON 23

more o f a reinforcement made than in e ither cast iron or

steel ,in order to warrant enou gh strength for th is class o f
work .

( 1 3 8) A good bronze for w e ldin g purposes should work

easily under the influence o f the o xy acetylene flame and
-

have s uffi cient alloys present to take care o f those destroyed

by the action of the flame I t is not thou ght advisable to
.

work ove r welds o f bronze ,for fear o f making them porous ,

unless more fille r rod is add e d whenever the flame is brou ght
-

in contact with the weld .

( 1 39) W elds of malleable iron can be made which will

b e even stron ger than the surrounding metal ,and at times
they can be reinforced by add in g small str ips o f steel These .

can be ent irely covered ,to make them inconspicuous C on .

t rary to custom it is recommended that plenty O f flux be us e d ,

for best results have been found when a surplus rather than
a spar ing amount has been e mployed .

( 4 )
1 0 T h e matter o f heat in malleable iron is of con

s ide rab le importance. I f not enou gh heat is used there will

be no fus ion between the bronze and the iron ,whereas on
th e other hand ,if too much heat is used ,the bronze will not
adhere ,but will seem to boil o n the surface and form in small
globul e s rather than spread over the whole metal I n add i
.

t ion th e character of the piece being worked on will be changed

when heated to o much Th is matter of heat should be given
.

gr e at attention and the begin ner should learn and have em

ph asiz e d the fact that the proper heat is one wh ich will per
m it the bronze to run l ike water over the surface ,and th is
will form a good foundation to work upon .

( 1 4 1 ) I n general ,malleable iron work is seldom preheated ,

fo r thi s is not necessary if th e p ieces hav e been fitted to gether
as closely as poss ible before the weld is started Once the
.

stud e nt has l e arned the flow of metal and how to reinforce

his weld ,he will be in a pos it ion to handle most any kind o f
1 24 OX Y -
A CE TYLE NE WE LDIN G MAN UAL

malleable iron prop e rly I t is well to remember ,however ,

.

that malleable iron is allowed to cool slowly and is not

immersed in water ,as has been su ggested when working on
brass ,for here we have one metal in the p ie ce itself and
another in the weld ,and too great a strain would set up if
they were cooled abruptly .
126 OXY AC E TYLEN E WE LDIN G MAN UAL
-

drum ,one side of whic h w ill do fo r welding and the other ,

be ing h igh pressure type ,will produce a constant flow o f
-

h igh —pressure gas ,suitable for the cutting jet Then when .

cuttin g is done a three hose torch should b e employed One

-
.

of its oxyge n connections which governs the ne utral flame

can be connected to the low pressure regulator ,whi le the
-

FIG . 80 — Th e
. Cutting Way th ro ugh S tee l o f any S ize with
To rc h E at s its
Remarka b le E ase ,Leaving a Clea n cut E dge Th i s Vie w Sh o ws a Cuttin g
-
.

To rch in Ope ra tio n at th e Ordnan ce W e ldin g S ch o o l ,U S A rmy

. . .

oxygen jet should be controlled by the h igh pressure regulator ,

-

the th ird connection will furnish the acetylene gas for the
pr e heating flame However ,in place of this three—
. hos e
arrangement ,most cutting is accomplished by means o f a
tw o hose apparatus ,where in only o ne hose is used to convey
-

the oxygen from a single regulator to the torch On such .

 OXY A C ETYLE N E C UTTIN G
- 27

a pparatus much trouble is usually expe rienced in cutting

o ld metals where a great deal of scale is present or in a close

place where the torch is apt to ge t hot .

( 1 4 5) M any times part of th e scale or metal will pop

up a gainst the tip and cause the oxygen jet to fli cker This .

sl ight var iation may cause an excess ive pressure of oxygen

to be introduced into the preheating flame momentar ily ,
by backing up the oxygen in the cutting jet Th is lean .

m ixture o f gas will generally flash back instantaneously and

will deposit a layer of carbon on the ins ide of the tip ,which
causes much a n noyance to the operator Th is condition is
.

to b e found where there is but one oxygen line I n the two

.

hose arr an g m e nt thi s is entirely overcome ,due to the

e

in d e pend e nce of th e pressure on each line .

( 1 4 6) Th e hi gh pressure re gulator d iffers from the low

-

pressure regulator in these respects : Th e di aphragm ,see

F ig 1 6 ,is much smaller in d iameter ,whi ch makes it less
.

sensitive , and of course much stronger Th e d iaphragm

.

spr ings are usually much heavier ; the nozzle contains a

lar ger opening for pass ing gas freely without freezing ; and
to take care of the increased pressure on the line ,usually a
higher pressure workin g gau ge is added to the regulator .

S uch a regulator is capable of pass ing much more gas than

the low pressure type ,but as far as being as sensitive and
-

mainta ining a constant ,absolute flow of gas ,its design will

not perm it it to do so I n cutting,these re q u is ites are not
.

necessary I n welding,however ,the delicate adjustm ent of

.

th e flame demands a very sens itive regulator and usually

the lar ger the d iameter of the diaphragm th e more sensi
t ive the adjustment .

( 1 4 7 ) Th e cutt ing torch d iffers from th e weld ing torch

in many respects . Th e tip itself ,when looking at its end ,
may resemble any one of the views shown in F ig 8 1 .In .

the weld ing torch ,but one hole is to be found in the tip ;
128 OXY ACETY LE NE WE LDI N G MAN UAL
-

in the cutting tips ,two or more holes are to b e found I n .

all cases the center hole passes pure oxygen ,whereas in the
surrounding holes ,both oxygen and acetylene m ix and when
lighted give a neutral flame This w ill hereafter be called
.

the preh e ating flame Th e gases issuing from these openings

.

are controlled by three valves ,one of which may have a

trigger or lever arrangement for qu ick action ,and it will
control the cen ter jet of oxygen which really does the cutting .

Th is is under much h igher pressur e than the preheat ing

flame Th e other two valves will control the oxygen and
.

FI G . 8 1 — E nd
. Vi ews o f Cutting Tips ,S h o w m g Po ssib le A rrangeme nts o f
P reh eating F lames in R egard to Oxyge n ! e t Th e B lack Circles R e pre
.

se n t th e P r eh ea t in g F l ames ,wh ich Va ry in Numb e r and A rrangeme n t

A cco rding to th e Nature o f th e Wo rk ,th e Po ssib le L im it b e in g a Co n
tin uo us C ircl e ,as S h o wn
. Th e Wh ite Circles Illu stra tes th e Oxyge n

! e t ,wh ich ,too ,Va ri es in S ize Acco rdin g to th e Work

.

acetylene gases used for the preheating flame I n light ing .

such a torch ,the acetylene is turned o n in the same manner

as has been tau ght when welding,until it just leaves the end of
the tip Then the oxygen valve is opened ,which controls
.

the preheatin g flame ,and enou gh is perm itted to pass to

produce a neutral flame A s soon as th is has been ac co m
.

p lis h e d,the th ird valve should be qu ickly ope ned and held

s o a moment ,to see if the neutral flame has been changed .

G enerally th is operat ion will deprive the neutral flame of

some o f its oxygen ,and a feather flame ,showi ng to o much
1 30 OXY A C ETYLE N E WELDI N G MAN UAL
-

hundred pounds should be used ,depending upon the th ick

ness o f the metal and the conditions wh ich must be met .

I n extreme cases where very heavy cuts are to be mad e ,a

much hi gher pressure than h as b e en mentioned should be
used ,but the lim itations given will cover a wide range of
work To start a cut it is necessary to bring the preheating
.

flame in contact with one edge of the metal to be cut and play
it there unt il the metal is red hot A s soon as this condition
.

is reached the torch is h e ld steady — the ne u tral flame

just touch ing the metal ; then the th ird valve controlling
the cutting jet of oxygen is opened Thi s oxygen ,under high
.

F I G 83 — P o siti o n to Ho ld To rch in
. . wh en Cutting M e tal .

pressure ,qu ickly acts upon the hot metal and severs it instan
tan eo usly,m e lting and oxidizing the metal so that it will not
flow together ,m o m and the same operation AS soon as .

th is occurs the torch should be advanced as rapidly as possible

in the d irection the metal is to be cut Th e more rapid the
.

advancement and the steadier the torch is held the cleaner

the cut will be ; and incidentally ,less gas consumed in the
execution of the job I n cutting,as in weldin g,it is always
.

well to give the torch a chance ,an d when the ope rator sees
much molten metal splash ing d irectly back o n the torch ,he
should change the angle sl ightly to avoid h is apparatus
becoming ove rheat e d I t has been found that if th e cutting
.
 OXY ACETYLE N E CUTTI N G
-
1 31

torch is held at the angle shown in F ig 83 ,the most satisfac .

tory res ults can be expected .

( 1 49) A t the present time only such metals as steel and

wrought iron can be successfully cut When it comes to .

cast iron no method has ye t been d iscovered to cut it with

any degree of success by the o xy acetylene flame ,on account
-

of the high melting po int of the oxide and var ious other mat
-

ters Th e day is looked forward to ,however ,when after

.

sufli c ie n t time and study h as bee n devoted to this subject ,

FIG . 84 — M e th o d
. Cuttin g with Tw o We ldi ng To rch es To rch A is A dj u s ted
of .

so th a t a Ne utra l F l am e will do th e P r e h ea tin g ,wh ile a Fo rk in th e Oxyge n

L in e S upplies Oxyge n o n ly to To rch B ,and it do es th e Cuttin g .

that cast iron can be as successfully cut as any other metal ,

by introducing another gas or agent to destroy some o f
the reactions which retard its application at the present
t ime .

( 1 50 ) Th e use of the cutting torch in prepar ing steel

work ,for welding of lar ge s iz e ,plays an important part ,in
”
quickly and effic iently V in g out and getting it ready for
-

us e C are should be ta ken ,after its use , to see that the

.

heavy oxide wh ich it leaves is lar gely destroyed ,before any

more metal is added .
 1 32 OXY ACETYLENE WELDI N G MAN UAL
-

( 1 5 1 ) F requently the welder has a call for a cutting

torch ,where none is available ,yet an extra wel ding torch
o r two may be on hand I f this is the case ,two welding
.

“
torches may be fastened to gether in such a manner that a
temporary job of cutting may b e handled Th e arrange .

ment shown in F ig 84 illustrates this po int I f no extra

. .

weld ing torch is available ,a carbon burning torch or any piece

o f copper tub ing wh ich has a valve in one end ,su itable for

tak ing a hose connection ,and the other end free to have a
welding tip brazed on ,can be used in the same manner Th e .

weld ing torch will give the neutral flame and the extra l ine
of oxygen will do the cutting I t is well to remember that.

FIG . 85 —
. Wh e n no E dge isAva ilab l e to S ta rt th e Cut o n La rge Wo rk ,M uch
T ime m a y b e S ave d b y M aki ng a Curl w it h a C o ld C h i se l ,as S h o w n .

oxyge n ,no matter under what pressur e ,cannot be expected

to act upon cold metal A red heat is absolutely ne ce ssary
. .

There are var ious short cuts ,it is true ,in obta ining thi s heat ,
and where a lar ge Shaft is to be cut ,th e operator would not
th ink o f playing h is torch upon such a p iece of metal until
it was red hot in the locality in wh ich he wished to start
his cut Th is would consume too much time and gas
. G en .

e rally a hammer and cold ch isel are brou ght into play and a

slight curl o n the metal is obtained as shown in F ig 8 5 . .

Th e moment th is becomes red hot ,the oxy gen jet may be

turned on ,and the cut commenced AS soon as started ,the .

op e rator is able to carry o n at will -

.
1 34 OXY ACETYLE N E WELDI N G MAN UAL
-

certain point ,the more rapidly will the burning take place .

When submergin g the cutting torch ,it is presumed that th e

flame obtains what added oxyge n is necessary from the cut
ting jet and this to gether with the velocity of the flame and
its hydro gen envelop ing flame perm its the neutral flame
to continue burning.
 C HA PTE R X II

CARB O N B U R NIN G

( 55) 1 who THO S E

are fam il iar w ith gasol ine en gines w ill
know that after being used for some time ,the impur ities in

FIG . 86 .
—Remo vin g C arb o n fro m U S A rmy
. . T ruck ,b y th e Oxygen P ro c ess,
at th e Ordnance We lding S ch oo l .

the lubr ication o il and in the gasoline ,which is continually

being burned ,will form around the to p of the piston and
cylinder head in the motor When enou gh h as been deposited
.

1 35
1 36 O X Y ACETYLEN E WELDI N G MAN UAL
-

and a fe w h igh po ints b e come overh e ate d through long run

n ing,there will be a metall ic knock d istinctly heard when an
extra strain is b e ing ex e rted by th e motor Th is layer.

of impuritie s is call e d carbon and its prese nce means loss o f

power Owing to the construction o f most cylinder blocks ,
.

it is a very d iffi cult matter to r e ach this portion o f the block

without dismantling Th is requ ires skilled labor and means
.

much d e lay A method o f removing th is carbon by the o xy

.

g e n process has been dev is e d ,wh ich will save much t ime and
trouble .

( 1 56) To remove carbon from a gasoline engine ,first

Shut o ff th e gasoline in the l ine and allow the en gine to run
until all gas has been removed from the carburetor Th is .

is m e r e ly a safety me asure I f a vacuum feed is used ,the

.

vacuum tank is drain e d ,as it would r e qu ir e much tim e for the

e n gin e to consume th is amount o f gas Th e hood o f the car
.

is then removed and all parts o f the motor o n the S id e where

the burning is to be done are cover e d with asb e stos pap e r
or by a heavy piece o f canvas wh ich has pr e viously b e en
dampened This is to keep the sparks from dropp ing into
.

the apron or oily parts of the machine R emove th e spark

.

plu gs and see from the cond ition of these Spark plu gs wheth e r
the cyl inder is dry o r o ily A n o ily cyli nder will burn o u t
.

much more rapidly than when dry Th is can be detecte d

.

ve ry eas ily from the condition o f the spark plu gs I t is .

re commend e d that only the spark plu gs b e remov e d as th e

r e moval of the bonn e t or any large r portion will requir e
much mor e oxyge n and will not produce as satisfactory
results as when the oxygen is introduced throu gh a small
open ing .

( 57 )
1 Place the carbon remov in g apparatus ,wh i ch c o n

s ists o f the oxygen drum ,re gulator ,a length o f hos e and

carbon burning torch ,the latter being mad e up pr incipally
of a shut Off valve and a long l e ngth o f small copper tub ing
-
1 38 OX Y ACETYLEN E WELDI N G M AN UAL
-

when attempting h is first job ,but there is absolutely no

dange r .

( 1 58) I t must be remembered that oxygen itself does n o t

burn ,but merely assists the other inflammable mater ial in
burning,therefore it is only the carbon which i s contained
in the cyl inder that in th is case does the burn in g . As soon
as th is is all consumed ,there will be noth ing else to burn and
the sparks will die of their own accord When th is occurs ,
.

the operator will shut o ff his torch ,blow the cyl inder o ut
w ith compressed air and replace the spark plu g and then
proceed w ith the next cyl inder ,wh ich he will treat in the
same manner He must be sure ,howeve r ,that the p iston
.

in cyl inder number two ,o r whatever cyl inder he is workin g

o n, is mov e d to th e to p o f its stroke and that both valves in
that particular cyl inder are closed before he starts h is burn
in g
. A fter all cyl inders have been treated like numb e r one
;

and the spark plu gs are in pos ition ,the gasol ine is turned o n
(if the vacuum tank has been drained ,it is best to fill this) ,
and th e motor started ,with the exhaust cut o ff open
in order that any loos e part icles of carbon may be blo w n o ut .

( 1 59) Whi le th is process is in very comm on use , and

see ms to be very s imple ,there are many who go through
the steps without O bta ining satisfactory results I t is co n
.

side re d best , if poss ible ,in attemptin g carbon burn ing for the
first t im e ,to try it o n som e motor whi ch is about to b e over
hauled ,in order that the results may be studied so that the
operator will not go blindly o n ,without sho w ing some im
provem e nt M any times on ly the high po ints are burned
.

o u t ,which will free the motor temporar ily o f some o f its

knocks ,but withi n a week or so they will become evid e nt

again He who will become proficient in learni ng carbon
.

burning should apply himself and study h is results .

( 1 60 ) There are those who consider carbon burning in

rio u s to the motor o n account o f the h igh temperature flame
j u
 CAR B O N B UR NI N G 1 39

which they th ink is introduced But it is ignorance as to

.

the work in g principle of th is process that makes them th ink

th is When it is cons idered that a gasoline motor depends
.

upon a rap id success ion of internal explosions for its power ,

the folly of condemning a process of th is nature ,where ab so
lute ly no actual flame is used ,will be seen I t is only the
.

incandescent par ticles of carbon fly in g about that give any

heat at all After a cylinder has been burned or decarbonized ,
.

the hand can be placed upon it imme di ately ,without any

fear o f being burned Those motors equ ipped with aluminum
.

pistons may be handled in the same way as those of cast

iron ,and when properly used this method of decarbo ni zation
is very satisfactory .

( 1 6 1 ) M any times it is asked how often carbon burning

is to be recommended This will all depend upon the type
.

of motor ,its condi tion ,and to some extent ,upon the lub ri
catin g o il and gasoline used ,as well as the m ileage of the car .

I f a machine is being run continually ,it may be necessary

to have the carbon removed about every two months ,but
cond itions will ten d to lengthen or shorten this time as th e
case may be When the knocks are in evidence ,and the
.

loss of po wer is noticed ,it is time for the carbon to be re

moved ,and whe ther thi s is one month or two it is an error
to continue running the car wh ich is filled with carbon .

I nvariably the carbon burner is asked by h is customer whether

carbon burning will re gr ind valves ; this and many other
questions can be intelligently answered and exp lained to the
questioner s satisfaction if a careful study of the process is
’

made .

CON CLU S I ON

( ) I n drawing this elementary course in oxy acetylene

1 62 -

weld ing to a close ,the author wishes to again call attention

to the fact that th is course is merely to be cons idered as a
 OXY A C ETYLE NE WE LDIN G MANUAL
-

( Courtesy of the British Oxygen Co )

F I G 88 — h o o gra h h o in .

. .
P t p S w g S quare P iece Cut Out o f a S tee l B lo ck 9 Inch es

Co urtesy of the Davi s -Bourno nv ille Co

—Th i s .
)
F IG. 89 . is an E l e ctrically D rive n
Oxy ac e tylene
Cutti ng M ach in e
-

fo r M aki n g D uplica t e Cut s o n S te l fr m

e o a D rawi n D i e s an d man y
g .

I rr ul r Fo rm s m ay b e P ro duce d at Lo w Co st b y it
eg a
.
1 42 OXY ACETYLE N E WE LDI N G MANUAL
-

of only one apparatus will realize that there are many

such on the market ,each o n e o f which may have its adv an
tages ,but if the general rules ,as outl ined ,are followed ,he
will not have much d iffi culty or b e covered with confusio n
if called upon to operate d iffer e n t m akes o f apparatus for

F IG .
91 .
—
! uick ,P e rman e n t R e pairs are M ade on Large S upply Trucks in
th e UA rmy b y its Co rps o f Trai ne d W elde rs Th is Vi e w S h o w s an
. 8 . .

In dividual W e lding Unit in Ope rati o n at th e U S A rmy ( Ordn an ce )

. .

We ldin g S ch o o l .

the first time : I f he sees that there is gas pressure o n h is

l ines ,he should not hes itate ,thereby showing h is ignorance
of that particular type of apparatus ,rath e r let h im turn on
one valve ,and d irect the stream of gas toward h is nostrils .

He can then read ily determ ine whether it is the fuel gas o r
no t and kn owin g that oxygen will not burn he can turn h is
 C ARB ON B URNI N G 1 43

( Courtes y f Ben K S mith 0 S

o .
. . . Weldi
ng Co )
.

F IG
.
—Th i s Cylinder did
g en no t Re quire to be B o re d or h ave th er
any o

M ach i ne Wo rk Pe rfo rmed ,b ut w as P l ac e d in S e rvice D irec tly after

We lding and has b een S erving fo r o ver Th ree Y ears .
1 44 OXY ACETYLEN E WE LDI N G MAN UAL
-

fuel gas on and proceed without showing any concern I t .

’
m ight be said that confidence in one s self is the keynote of
success ,and this is imperative to make an expert welder ,
but to the man who studies the flame action o n his me t als
and appreciates the apparatus to the fullest extent ,there is a
very br ight future .

( 1 63 ) Th e welder who desires the best results should

procure the best apparatus poss ible to fill h is requirements .

Th e cost of such is only of secondary importance ,the hazard

attached to cheaply constructed apparatus and the loss o f
g a s , t ime and the execut ion of faulty work and the depre
’
c ia tio n o f the welder s reputat ion ,are matt e rs of vital im
portance Th e suppl ies too ,such as filler rods and the like ,
.
-

shou ld be obtaine d only from reliable w e ld ing companies

who have their own shops in wh ich they may test th e m I t .

is false economy indeed ,to att e mpt to save a few c e nts o n

’
fill ing materials ,fo r many dollars worth o f t ime and gas
may be lost o n account o f the failure of the metal added .

( 1 64) There are a few illustrations s e t forth her ein ,to

show what has been accompl ished in the way o f mach ine
construction used in adapting the oxy acetylene process to
-

the requirements of var ious manufacturers These will tend

.

to show to some extent what the future has in store for th is

wond e rful process .

( 1 65) I t has been r ightly stated that oxy acetylene

-

welding is ye t in its infancy Th e torches ,re gulators and in

.

fact all parts o f the apparatus are constantly being improved .

Th e process o f cutting cast iron m ust still be solved ,so it

will again b e stated that it behoove s thos e who are interested
in th is work to apply themselves to the great future in store
for them .
1 46 G LOSS AR Y

B RA! I N G Un itin g m e t als wit h b r ass o r b r o nze b y m eans o f h e at

. .

B RA! I N G W IR E A fille r ro d o f b r ass o r b r o n ze u se d in b razing

.
-
.

B UTT ! OI N T A j o in t m ad e b y b ut ting tw o edge s t o ge t h er

. .

CAP A m e t al co v er u se d to pro t e ct cyl in de r valve s

. .

C AR B O N B L O CK S C a rb o n in b lo ck fo rm U s e d to assis t in b u ilding
. .

up p art s t h at are to b e a dd e d Th e y m ay b e gr o un d to any sh ap e .

d es ir e d .

C AR B O N R ODS C arb o n in ro d f o rm Empl o y e d to sav e h o l es

. .

aro u n d w h ich th e m e t al is m e lt e d .

C AR B O NI! I N G F LAME A fl am e w it h an e xcess o f ac e tyl en e gas . .

C O NTRACTIO N Th e sh r ink age o f m e t al due to c o o lin g . .

C RO S S B AR Han d s c rew fo r adju s t ing th e p as sage o f gas t h ro u gh

-
.

th e regulat o r
C U TTI N G ! E T C e n tr al j et o f o xy gen issuin g fro m tip o f cutt in g
.

to rc h .

C UTTI N G TOR CH A to rch wit h o n e o r m o r e h e at in g j ets an d an

.

o xy ge n j e t ,u se d fo r cu tt ing m e t als in th e o xy ac e tyl e n e p ro c ess -

.

C YLI ND E R A t ank c o n t ain in g gas u n d e r pr e ss ur e

. .

D U CTI LE Th at p ro p e r ty wh ich p e rm it s m e tal b ein g fo rm e d o r

.

dr awn in t o d iff e r e n t sh ap es wit h o u t b reak ing .

E XPAN S I O N I n cr ease in siz e due to h eat ing

. .

FILLE R R OD A ro d o r w ir e u se d to supply additio n al m etal to th e

-
.

we ld .

FILLE T WELD A w el d m ad e in a co rn er . .

F LAM E P ROPAGATIO N Th e rat e at w h ich a flam e will tr av el . .

F LASH B ACK Th e b u rni ng b ack o f th e gase s to th e mix in g ch amb e r

.

o r po ssib ly f art h e r .

F LU X C h e m ical po wd e r u se d to d isso lve th e o xid es an d clean

.

th e m e t al wh e n w el d ing .

GAS E rro n eo u sly appl ie d to ac e tyl e n e gas al o ne B o t h o xyge n

. .

an d ac e tyl e n e are in th e f o rm o f gas .

G AU GE An in s t rum en t fo r m easur ing pr ess ur es o f gase s

. .

G E N E RA TOR A d ev ic e fo r m an uf acturin g gas U s u ally sp e c ifi e d

. .

as ac e ty le n e ge n e rato r o r o xy ge n ge n e r a t o r .

G RAI N Th e arran gem e n t o f t h e m o le c ule s o r cry s t als wh ic h m ak e

.

up a m e t al .

HORI ! O NTAL WELDI N G Weldi ng i n a le v e l po sit io n . .

I B E AM
-
A s t e e l b ar w it h th e cr o ss se ct io n o f an I
. S o m et im es -
.

c alle d E YE B EAM .

L INE Ho se o r p ipe carrying gas

. .
 G LOSS A R Y 1 47

M ANI FOLD A h e ad er w it h o u tlets o r b ranch es b y w hich sev eral

.
'

c y lin d ers o f gas m ay b e u se d in b atte rie s .

M O N EL ME TAL An all o y o f co pp er and nick e l . .

NI PP LE A sh o rt p ie c e o f p ip e
. .

OVE RHEAD WELDI N G W e ld ing w it h th e to rch o v e rh ead

. .

OXI DATI O N A c o m b in at io n w it h o xy ge n
. .

OX IDE . A c o at in g o r s c ale fo rm e d b y o xy ge n co m b in ing w ith m etal .

OXI DI! IN G F L AM E A fl am e w it h an e xc ess o f o xyge n gas

. .

OXYGE N A n o n in flam m ab le gas use d in o xy ac e tyl e n e w el ding

.
- -

an d c u t t in g .

OXYGE N C Y L IND E R A s t e e l tank fo r s t o r in g and sh ipp ing o xy ge n

. .

A v ail ab l e fo r c o mm e rc ial w o rk in 1 0 0 ,2 0 0 ,an d 2 50 c ub ic f o o t siz e s -

.

Th e o xy ge n is c o mpr e sse d as f ree gas to 1 80 0 po u n d s p r e ss u r e at 68

d egre es F ah r e n h e it .

PEE N I N G S t re tch in g th e s u rfa c e o f co l d m e tal b y use o f th e h amm er

. .

PE N E TRATI O N A t h o r o u gh w el ding c o mpl e t ely t h ro u gh th e j o int

.

o f th e p ie c e s o r p art s b e ing fu s e d .

P RE HEATI N G Th e h e at in g o f a m e t al p art p re v io us to w e lding

. .

G en erally use d t o p reve n t s t rain s o r d is t o rt io n fr o m c o n tra c tio n an d

e xp an sio n ; al so to sav e gas .

POOL A sm all b o dy o f m o l t e n m e t al fo rm e d b y th e to rc h fl am e
. .

P UDDLE S TICK A s t eel ro d fl att e n e d at o n e e n d,u se d to b re ak up

.

O xid es ,re m o v e d ir t an d b u ild up add it io n al me tal P art icul arly h elp .

ful in w e lding c as t al um in um .

P UDDL IN G Th e m an ip ulatio n o f th e filler ro d o r th e puddle stick

.
- ~

in s uc h a m an n er as to b re ak up o xid e s,re mo ve dirt , an d aid in se curing

a goo d f usio n o f t h e m e t al .

RE DU C IN G F LAM E ( S e e C arb o nizin g Fl am e ) . .

R E D U C IN G VALVE ( S e e R e gulat o r ) . .

RE G U LATO R A d e v ic e fo r re duc ing and m ain taining a unifo rm

.

pressu re o f gas fro m cy lin d ers ,ge ne rat o rs o r sh o p lin e s .

S CAL E A co a t in g o f o x id e o n f use d ir o n o r s t eel th at b reak s o fl as

.

th e m e tal c o o l s .

S CALI N G POWDE R A n am e given flux . .

S LA G Th e o xid ize d m e t al an d s cal e b lo wn o ut wh e n c utt in g

. .

SO LDE RIN G U nit ing m e t al s b y fusing w it h a d iffe r en t m etal wh ich

.

h as a m uc h l o w er m el t ing p o in t th an th e pie c e s to b e j o in e d
-
Th e use .

o f a l e ad , tin and z in c all o y is c all e d s oft s oldering Hard solderin g is .

sim ilar to brazing .

TACKI N G F using p ieces to ge t h er at o ne o r m o re p laces

. .
1 48 G L OS S A R Y

A c o pper or b rass no w eldin g o r cutt ing to rch

zzl e fo r a .

V An gl e o r gro o v e b e twe en tw o b e vele d e dges pr ep ar e d fo r w eldin g

. .

V B LO CK
-
. B lo ck cut o ut in th e sh ap e o f a V ,o r angl e iro n ,u se d in
lin ing up sh aft s .

VALVE A d e vic e fo r sh ut ting o ff th e p assage o f gas

. .

V E RTICAL WELDI N G We lding as appl ie d to an uprigh t po sitio n

.
~
.

WELDI N G R OD M at erial u se d to supply addit io n al m e t al to th e

.

wel d ( S ee Fille r ro d )
.
-
.
1 50 LE C TU R E S

si mp l e m ann er,b etw een o xy ge n and a c e ty len e regul ato rs ,wh e n no

gau ge s are a t ta c h e d ?
( 5 ) Wh y d o e s th is di ff e re n c e e xist ?
8 ( 0 ) Wh y sh o uld all t e n sio n up o n d iap h ragm sp rings b e re m o v e d
.

b e f o r e a dm it t in g gas un d e r p re ssu re t o th e re gul a t o r ?

( b) Can a r e gul a t o r w h ich h as b ee n ab u s e d in t h is m ann er b e
re p air e d ?
( c) W h at can b e e mpl o y e d as a fi t ting sub stitute fo r gallilith ?
9 Explain w h y th e h igh p re ssure gauge o n th e a c e ty l e n e re gu l at o r
-
.

c anno t b e u se d as an in d e x to th e c o n t en t s o f th e at t a ch e d cyl in d e r o f
gas in e x ac t ly th e sa m e m an n er as th e o xy ge n h igh p ress u re gau ge
!

-
.

1 0 Wh y is glyc e rin e use d as a su b s t itut e fo r o il w h en r e gr in d ing

.

to rc h v alv e se a ts w it h e m e ry p o wd e r ,an d w it h l ea d o xid e in th e

- -

c aul k ing o f l eaky j o in ts alo ng th e l in e ?

LE C TURE NU M B ER TWO

S ub j e c t— OP E RATI O N
I (0 ) U n d er wh at p ress u re is o xy gen gas re c eive d in th e c yli lers
.
n

use d c o mm e r c ial l y ?

( b) D o e s th is p ressur e v ary to any great e x te n t wit h c h ange s in

te mp eratur e ?
2 .
(0 ) Un d er wh at p ress u re is ac e ty l en e gas re c e iv e d in th e cyl in d e rs
use d c o mm e rcially ?
( b) D o e s th is p ress u re vary to any great e x te nt w it h ch an ges in
te mp erat u re ?

3 ( a) I n se ttin g up app ara t us fo r th e fi rs t t im e ,o r in at t a c h in g

-

re gul ato rs to n e w cylin d ers ,w h at p re c aut io n sh o uld b e o b s erv e d

regard in g c ro ss b ar o n re gul at o r s b e f o r e th e gas is t ur n e d o n ?
-

( b ) W h e re sh o uld t h e o p e ra t o r s t a n d w h e n t ur n in g o n th e gas ?

4 ( a) Ho w muc h p re ss ur e sh o uld b e pl ac e d o n t h e o xy ge n h o se ,
.

wh e n th e to rch v al v e s are c lo se d ,b e f o re starting to o p e r at e wit h a

-

m e d ium siz e d t ip ?
-

( b) Ho w m uc h p ressure sh o uld b e pl ac e d o n th e ac e tyl e n e h o se ,

wh e n th e to r ch v alve s are cl o se d ,b ef o re s t arting t o o p e r ate wi t h a
-

m e d ium siz e d tip ?

-

5 (0 ) A ft e r b o th th e o xy ge n an d ac e tyle n e gases are in th e l in e

. .

h o ses as far as th e to r c h , w h ich val v e o n t h e t o r c h is o p e n e d firs t in o rd er

to ligh t ?
( b) Wh at wo ul d h app en if th e o th er r valve w er e Op en e d first ?
to c h -
 LE CTURE S 1 51

( c) Wh at wo ul d l ik el y r if b o t h val ve s w e r e o p e n e d b e fo re t o rc h
o cc u

w as l igh t e d ?
6 .
(a) Ho w po ssib le ,wh en l igh ting to r c h ,to d e t e rm in e w h e th r
is it
e no ugh p r ess u re is o n th e ac e t y l e n e l in e w ith o u t l o o k in g at gauge ?

( b) Ho w is it p o ss ib le ,in th e case o f o xy ge n p ressure ?

7 ( a) W h a t is m ean t b y a n e utral fl a m e ?
.

( b) Ho w h o t is a n e utral o xy ac e tv le n e fl am e ?
-

( c) I s th e t e mp e ra ture o f a n e u tral fl am e th e sa m e wh e th e r large 6

sm all tip is use d ?

8 ( a ) I f too m uc h ac e ty le n e gas is use d , h o w will th e fl am e b e

.

affe c te d ?
( b) Wh at a c tio n w ill th is h a ve o n th e w e ld ?
9 ( ) a
. I f t o o m u c h o xy ge g
n as is u s e d ,h o w w ill t h e fl a m e be a e
f
f ct e d ?

( b) Wh a t act io n w ill th is h av e o n t h e w e ld ?
1 0 ( 0 ) Exp lain b rie fly h o w a pp arat us is sh ut o ff,w h e n n o t to b e
.
-

use d fo r s e v e ral h o u rs o r m o re .

( b) Wh y sh o uld p art icul ar c ar e b e t ak e n to se e th at a c e ty le n e cyl

in d e rs are t igh tl y c l o se d w h e n e mp ty ?
( 6 ) Wh at ac tio n d o es o xy ge n h av e o n o il s an d gre as es ?

LE C TURE NU M B ER TH REE

S ub j e c t— WELD I N G O F C AS T IR O N
( P art One)

I ( a) Ho w is it p o ssib l e to distingu ish cast iro n fro m such m e tals

.

as m allea b l e iro n ?

( b) Fro m s e m i cast iro n ?

-

( 6 ) Fro m cast ste el ?

( a) Wh at k in d m etal is use d in m ak ing filler ro d us e d in th e
“ -
2 .

w el d ing o f c ast iro n ?

( b) Wh at ge n e ral rul e c an b e l aid d o w n as t o t h e re l atio n o f th e m e tal
“
in th e fille r ro d to t h e m e tal to b e w e l d e d ?
-

3 ( a) W h at ar e th e c h arac te r is tic s o f go o d c ast i ro n fille r ro d s

-
.

( b) Can p is t o n rin gs an d o t h er s m all s c rap s o f cast iro n b e use d

fille r ro d s ? Expl ain w h y
“
s uc c e ss full y as
”
-
.

4 ( a) W h at is th e p urpo se o f a flux ?
.

( b) I s a flux use d in th e w e ldin g o f cast iro n ?

5 ( a) N am e o n e f o rm ul a fo r m ak in g a c ast ir o n flux?
-
.

( b) Ho w o ft en is th e flux appl ie d ,an d b y wh at m ean s ?

( 6) I n w at co n dit io n are fl ux es k e pt w
h h e n n o t in u es ?
1 52 LE C T U R E S

6 .
(a ) Ho w sh o ul d th e fl am e b e h e ld in th e w e ld in g o f all c ast iro n ?
“
( b) Wh e n an d h o w is th e fille r ro d a dd e d to th e w e ld ?
”
-

7 ( a ) N am e th e o n e pr in c ip al c a u s e o f b l o w h o l e s an d h a rd spo t s
.
-

in th e w eld .

( b) M e n t io n so me th e rs
of th e o .

8 ( a ) Wh e n is it adv isab l e to gr in d ,
. or V o ut ,th e e n d s o f th e p ie ces
to b e w e l d e d ?

( )
b W h e n is it n o t a dv is ab l e ?

9 ( 0 ) D o e s th e appl ic a t io n o f h e a t ca u s e co n t ract io n o r e xp an sio n in

.

m e t als ?
( b) Are t h e r e any e xc e p ts to t h is rul e ? N a m e o n e .

IO (0 ) W e r e tw o c as t ir o n b ars m eas ur in g 2 x I 2 in ch es an d ! in ch
.
-
p

th ick ,to b e w eld e d e n d to e n d,wh a t pr e ca ut io n sh o uld b e o b serv e d in

l ay ing o ut if th e fi n i sh e d jo b is to m e as ur e ju s t 2 4 in ch e s l o ng?
.

( b) I n wh a t re sp e ct w o uld t h is pr o b l e m d iff e r w ere th e b ar s o n ly 6

in ch e s o r igin ally an d th e fi n ish e d jo b to m e as ur e 1 2 in ch es o v e r all ?
( 6 ) I s th e a ct io n o f t h e m e t a l in t h e w e ld a c o n stan t ,o r a variab l e
quan t ity d ep en d ing up o n t h e l e ngt h o f th e b ar in t h is p ro b l e m ?

L E C TU RE N U M B E R F OUR
S ub j e ct — WELDI N G O F C AS T I RO N
( Part Tw o )

I I ( a). Ho w c o uld po k e ,b ro k en m idw ay b e tw ee n th e h ub and rim ,

a s

o f a 2 4 in c h ,4 sp o k e w h ee l ( o t h e rw ise in t a ct ) b e w e ld e d w ith o ut p re
- -

h e at in g ? ( U se a sk e tch if n e c e s sary to m ak e m e t h o d cl e ar ) .

( b) I f a w h e e l o f lik e s iz e w e r e b r o k e n o n ly in th e rim ,m idway

b e tw e e n spo k e s ,e xpl ain pr o c e dur e in w e ld ing w it h o ut pr e h e at ing .

S m z d w h l r k ly h — c an w e ld b e m ad e w it h o u t
( )
c a e s i e e e b
, o e n o n in u b ;
pr eh e a t in g? G iv e r easo ns fo r so t h ink ing .

(d) W e r e b r e ak s ( a) ,( b) an d ( c) all pr ese n t in sam e wh e e l ,w ith rim

fr actu re o n o ppo sit e sid e o f adj o ining spo k e fr o m b r e ak in h ub ,sh o uld
w e ld ing b e st art e d at rim o r h ub ? Wh y ?
1 2 ( a) I n th e b u ild in g up o f b r o k en o r m issin g t e e t h in cast iro n
.
-

gea r s ,w h a t pr o c e dur e is n e c e ss ary wh e n no c ar b o n b l o ck s are a v ail ab l e

fo r f o rm s ?
( b) I f c e rt ain c arb o n c e n t e r s fro m dry c e ll b att e rie s a re o b t ain ab l e
h o w sh o uld t h e y b e tr eat e d b e f o r e al l o w in g m o lt e n m e t al t o co m e in
dir e ct c o n t act w it h t h e m ?
 1 54 LE C TURE S

LE C TU RE NU M B ER S E VEN
Sub j e c t— E ! U IP ME NT
1 D es c rib e th e o p e rat io n ,s t e p b y s t ep ,tak e n to se t up an o xy
.

ac e ty l e n e w el d in g plan t ,fro m th e asse m b l in g o f th e p art s ,righ t t h ro ugh ,

u n t il a n e ut ral we ld ing fl am e is o b t ain e d ( I f a S k e tc h ,w it h th e gas
.

cy lin d ers an d p arts num b ere d 1 ,2 ,3 ,e tc ,w ill assist in m ak ing descrip

.

t io n cl ear ,it m ay b e use d ) .

2 ( o ) I s it d e sirab l e to h ave a pl an e d m e t al ,o r a b rick to p t ab l e fo r

.
-

w el ding pu rp o ses ?
( b) Explain w h y .

3 Out lin e an d d es c rib e b rie fly ,

. a s impl e m e t h o d o f b u il d in g a po pu l ar

t yp e o f w el ding t ab l e .

4 ( a) W h at is th e n am e an d s tyl e o f b rick s u s e d in th e w e ld ing sh o p ?

.

( b) N am e at le ast t h r e e pu rpo ses fo r wh ich t h e se b r ick s are u se d .

5 (0 ) Wh y d o es an e m e ry w h ee l p lay suc h an impo rt an t p art in th e

.

o xy a c e tyl e n e w e ld in g in du s t ry ?
-

( b) Wh y is it d esir ab l e to h av e a fl e xib l e sh aft att ach m e nt fo r th e

e m e ry w h eel , if po ssib l e ?
(6 ) Nam e so m e o f th e imp o rt an t th in gs a fl e x ib l e sh aft at t ac h m e n t
is used fo r in th e pr e p arat io n an d fin ish in g o f w e ld s .

6 ( a) I n w h a t kin d o f c o n t ain ers is r e t o rt c e m e n t p urc h ase d in th e

.

co mm e rc ial wo rld ?
( b) Wh ere is re t o rt c e m en t u se d in th e w eld ing S h o p ?
(6 ) Ho w d o e s it d iffer fro m th e o rdin a ry cl ay o r put ty ?
7 ( a) Wh y sh o ul d a b l a ck sm it h fo rge b e add e d t o th e w e ld ing
.

sh Op e q u ipm e n t if o n e is o b t ain ab l e ?

( b) Wh at tw o impo rt an t t ask s is a fo r ge u s e d fo r in th e w e ldin g

sh o p ?

8 ( a) I t is esse n t ial t h a t se v e ral p ail s o f w a t e r b e l o c at e d t h r o u gh o ut

.

th e sh o p ; w h y sh o u ld t h is b e n e c essary ?

( b) M en tio n a fe w ins t an c es wh e r e wat er is r e qu ire d in t h e we ld ing

sh o p .

9 Expl ain fully w h y gre at c are sh o ul d b e e x e rc ise d in v e n t il ating a

.

s h o p w h e r e c o mm er cial w el d ing is b e in g do n e .

1 0 (0 ) D e s crib e o ne simple m e t h o d Of co n s truct ing a flux b o x

. .

( b) W h at a dvan tages h as this typ e O f c o ntain er?

 LE C T URE S 1 55

LE C TU RE NU M B E R E I G HT
S ub j e ct — R E PAIR S
I Wh at is th e b e st m e t h o d o f lo c at in g a leak in eith er th e o xygen o r
.

ac e ty l e n e lin e s ?

2 .I f a l eak w ere f o u n d in a gro u n d seat ,h o w c o ul d it b e s t o pp e d if

th e n ut o n t h e c o upl in g h ad b een s cre w e d up as far as po ssib l e ?

3 N am e o ne m e t h o d o f at t ach in g c o n n e c tio n s to h o ses so t h at th e y

.

will no t b lo w o ff o r pull o ff wh en p ressure is applie d .

4 Ho w c o u l d e it h er an o xy ge n o r ac e ty l e n e h o se th at h ad b e e n
.

b urn e d o r o t h e r w ise in j ure d ,b e re p aire d to Wit h s t an d t h e g as pr es s ur e ?

5 Ho w c o uld regul a t o r b e o p e ra t e d if th e c ro ss b ar f r p ply in g p res
-
. o a

s ur e up o n th e d iap h ragm sp rin gs w er e lo s t ?

6 (a) W h at p ro c e du e wo ul d b e n e c e s sary to m ak e c o nn e ct io n if
.
r

c y lin d e r w e re s upp l ie d Wi t h an ad ap to r w h ich w o ul d n o t fi t th e regu l a t o r

co n n e ct io n and it c o ul d n o t b e c o upl e d up d ire ctly ?

( b) R eal iz ing th at all c y lin de r c o nne ct io n s ab o u t a re gul a t o r are ge n
e rally s uppl ie d w it h a ! in ch t ap e r p ip e t h r ea d ,
w
w h y do all m an uf a ctu rers

so ld e r t h e m in ?

7 Explain w h y o xy gen h igh p ress u re gau ge s are c o n st ruct e d w it h a

-
.

lo o se b ack and a so l id fro n t .

8 ( 0 ) W h ere is th e fi r s t pl ac e to see k tro u b le in a ga u ge if it l e ak s ?

.

( b) Can s u ch l eak s b e re p air e d ?

( 6 ) D es c rib e m e t h o d .

9 I f e it h e r a h igh o r lo w p ressure gau ge w e re inju re d b e y o n d th e

-
.

rep air s t at e h o w co uld weldi ng plant b e k e p t in o p e rat io n w it h o ut it ?

1 0 (a ) W h a t wo uld b e th e t ro ub l e ,in sh utt in g o ff a w el d in g pl an t ,
.

if th e re w e re a r e a d in g o n th e h igh pr e ss u re gauge an d n o n e o n th e lo w
-

press u re gau ge ,aft er pe rm itt in g gas to e s c ap e fro m th e h o se ?

( b) Ho w co ul d th e re adin g o n t h is gau ge b e b ro ugh t b ac k to ze ro ?

LE C TURE NU M B E R N I NE
S ub j e c t— S TEEL WELDI N G
( P art One)

I .
(o ) I s th e w el d ing t l m o re
o f s ee or l es s difficult th an cast iro n ?
( b) E xplain w h y .

2 ( a) Wh y is th e c h o ic e o f th e w e ld in g tip so im po rt an t w h e n wo rk ing
.

t
on s e el?
1 56 LE C TU RE S

( b) Wh at w ill resul t if th e tip is too large ?

( 6 ) I f to o s m al l ?
( ) Wh y is th e ch o ic e o f a
“
3 . 0 filler -
ro d of a c o rre ct size so im po r
tan t fo r t w e ld in g?
s e el
“
( b) W h at w ill h app en if th e filler ro d is to o large ? -

( 6 ) I f to o sm all?
4 ( a ) Wh at k in d o f a filler ro d is u se d in w el d in g steel ?
”
-
.

“
( b) G iv e a gen eral ru l e c o v e ring rel at io n o f filler ro d to th e m e t al
”
-

b e in g w e ld e d in all cases , b ut o n e o r tw o .

( c) N a m e o n e e xc ept io n .

5 (o ) I s a flux ( o r s c al ing p o wd er) n e c essary in w el ding ste el ?

.

( b) Explain w h y .

6 ( a) Ho w is th e fl am e adj us t e d fo r s t e el w e ld ing?
.

( b) W h at k in d o f a fl am e is gen e rally u se d in finish ing st e el wo rk ?

( 6 ) Wh y is t h is do n e ?
7 ( a) Ho w is th e fl am e h el d wh en e x e cut ing a s tee l w el d ?
.

( b) Ho w is th e fille r ro d h e ld wh en m ak in g a s t ee l w el d ?
“ -
”

8 ( 0 ) I s it n e c e ssa ry t o
. V o ut o n s t ee l th e sam e as o n cast iro n ?
”

( b) Expl ain w h y .

9 .
( o ) I s a s t e e l w e ld as s t ro n g as t h e o r igin al m e t al if n o t b uil t up ?

( b) Expl ain w h y .

1 0 .
( a ) I s th e s am e pro v isio n m ad e fo r e xp ansio n and co n tra c tio n
o n s t eel as o n c as t ir o n ?

( )
b G iv e reaso n s fo r so t h i nk in
g .

LE C TU R E N U M B ER TE N

S ub j e ct— STEEL WELDI N G

( P art Tw o)

I I (a) Wh at is m ean t
. crate r in stee l w el din g?
by a

( b) Ho w are th ey re m o v e d fr o m th e w e ld ?
1 2 (a ) Wh at are so m e m e t h o ds an d m ark s o f d ist ingu ish ing s t eel
.

f ro m o t h er m e t als ?
( b) Ho w is c ast s t ee l di stingu ish e d fro m c ast iro n ?
I 3 (a ) Name so me o f th e q u al ifi ca t io n s o f a go o d filler ro d fo r
.
-

m il d s t ee l w e ldin g .

“
( b) I n w h at m ann e r do es th e filler ro d d iff er fo r th e all o y e d an d
-

h igh c ar b o n s t e e l s ?
-

I4 (0 ) I n b ringing th e n eut ral fl am e in co n t ac t wi t h t h e m e t al o n a

.
1 58 LE C TURE S

( b) Wh at are so m e o f th e pr e ca ut io n s t ak en in wo rk o f th is k in d ?
2 6 ( a) Wh en aut o m o b il e p ro p ell er sh aft s an d rear a xl es b reak ,it is
.

ge n e rally a dj o inin g th e s qu are end . I s it adv isiab le to w el d t h is sh o rt

pie c e on?

( b) W h at is th e co rre ct pro c e du re in a c ase o f th is kin d ?

2 7 .
(a) I f a c ase h ard ene d ring ge ar is to h av e its tee t h b uilt up o r
- -

n e w o n es add e d ,h o w is it h an dle d aft e r w el d ing?

( b) Sh o uld all c ase h ard en e d w o rk b e so t re at e d af ter w e ldin g?
-

2 8 .
(a) I n w e lding tw o pie c es o f m e tal ,o ne o f wh ich is c o n sid erab ly
ligh ter t h an t
th e o h er,h o w is th e fl am e h el d in o rd e r to b ring b o t h pie c es
to a fu sio n at t im e ?
th e sam e
2 9 .
(a) I f a steel w el d w ere to b re ak in th e l in e o f w el d ,h o w sh o uld it
b e p re p are d if it is to b e r e w el d e d ?
( b) D o es th is p ro c e dur e a ppl y o n ly to stee l ?
3 0 W ere a h o l e 6 in ch e s s q u ar e in a S h ee t o f s t ee l to b e w e ld e d up
.

with o ut p reh e at ing,wh at wo ul d b e th e app ro xim at e size o f th e p at ch

necessary an d h o w w o uld it b e p rep are d , in o r d er to tak e care o f th e exp an
sio n and co n tractio n strains?

LE C TU R E NU M B ER TWEL VE

S ub j ec t—S TEEL WELDIN G

( P art F )
o ur

31 .
(0 ) Wh y sh o ul d a st e e l w el d o f any k ind be x t d
e e cu e as rap idly
as po ssib le ?
( b) W h at will h app en if st eel is k e pt in a h e at e d co n dit io n to o l o ng?
( 0 ) Wh y sh o ul d a ch ange b e in evid en c e un d er th ese co n dit io n s ?
“
3 2 .
( 0 ) Exp l ain w h a t is m e an t b y a d ish e d p atc h ,fo r b o iler o r
”

th in arm o r pl at e ?

( b) D raw such a p atch .

( 6) Ho w is a p at ch o f t h is n atu re p rep are d ?

“
33 (a) W h at is m ean t b y a
. co rrugat e d p at ch fo r b o iler o r thin
”

arm o r p l at e ?

( b) S k e t ch such a p atch .

( 6) Ho w is t h is k in d o f a p a tch p rep are d ?

3 4 ( a) Wh at a dv an tages h as a co r ru gat e d p at ch o ver o n e th at is
“
.

dish e d ? ”

( b) W h ere are co r ru gate d p atch es use d e xt e n siv e ly ?

35 .
( a ) H o w a re b o iler fl ue s pr e p are d fo r re t ipp in g? -
 LE C TU R E S 1 59

( b) S k etch a simpl e j i g fo r h o l d ing such p ie c es in p l ac e fo r w el di ng .

3 6 ( 0 ) D es c rib e h o w l ength s o f va r io u s siz e d p ip e can b e w el d e d

.

to ge th er en d to end .

( b) W h at p re cau tio n s are ne c essary wh e n e x e cut ing suc h w e ld s ?

3 7 ( a) Wh en w el d ing l ar ge s teel c as t ings w h y is it alm o s t al w ay s
.

a dvisab le p reh e at th e w o rk ?
to

( b) Wh y is p reh e ating so n e c e ssary on v an ad ium an d o t h er a ll o y e d

t l
s ee s ?

38 Wh y is it d e sirab le to ch ip o ut th e san d an d t hin s c al e fo rma t io n s ,

.

in an d aro u n d b lo w h o le s in s te el c as t in gs b e f o r e fi ll in g in ?
-

39 (0 ) Wh y do th e m aj o r ity o f go o d w e ld e r s b e n d t h e ir s t eel fille r

.

ro d s at righ t angl e s ab o ut 6 in ch e s fro m th e e n d?

( )
b W h y i s n t th is b e
’
in g d o n e o n c as t iro n ?

40 (a) Wh at a dv an t age is t h e r e in m ak ing a v e rt ical w e ld f ro m th e

.

to p d o wn , rath e r th an s t art in g f ro m th e b o tt o m an d w o rk ing up ?

( b ) I n w e l d in g o v erh e a d w h y is i t so im p o rt a n t t h a t th e w o rk b e in a

m o l t e n stat e b e fo r e a dd in g th e filler ro d ? -
”

( c) I n o verh ead w el ding,w h y d o e sn t th e m etal dro p w h en in a m o l te n

’

s tate ?

LE C TURE NU M B ER TH I R TEEN

S u b j e c t— OX Y AC T
-
E YLE NE C U TTI N G
1 Expl ain f ully wh ich p arts o f an o xy ac e ty l e n e cu ttin g p lant are
.
-

different fro m a w el d ing u n it .

2 (a) I f th ere is a d iffere n c e in e it h e r o f th e re gula t o rs ,m e n tio n

.

w h ich o n e it is .

( b) Wh at is th e d iff eren c e ?
( 6) Wh y is it n e c essary ?
3 ( o ) I s it po ssib l e to w el d w it h a c uttin g to rch ?
.

( b) Wh at pr e ca u tio n is n e c essary if t his is do n e ?

(0 ) Wh y isn t th is p ro c e ss u se d ?
’

4 E xp l ain h o w c utting c an b e d o n e w it h th e w el ding to r ch if n ec es

.

5 .
( )
a In cut t ing c y l ene pro c e ss ,w hich d o es
b y th e o xy -a e t th e
c u ttin g,th e o xy gen j e t o r th e n e ut ral fl am e ?

( b) Wh at actio n h as th e o xy ge n j e t o n th e m e tal?
(6 ) Wh at p art d o es th e n e utr al fl am e pl ay in cutt in g?
6 Can o xy gen o r a c e ty l e n e u n d er s u ffi c ien t p ress u re b e m ad e to
. c ut

in dividually ? Explain f ully .

 1 60 LE C TURE S

7 Wh y is it sp ecially imp o rt ant th at arm o re d h o se b e use d

. on th e
o xy ge n l in e w h e n m ak in g h e avy cu ts ?

( Giv e at l e ast t w o re aso ns ) .

8 ( a) Ho w is a c utting to r ch l igh te d ? D es crib e in d etail

. .

( b) Ho w is cut s t art e d o n m e tal ?

(0 ) Ho w is to rc h h el d in re gard to m e t al b eing c ut ?
9 (o ) I s it po ssib l e to s ucc e ss fu l ly c ut c ast iro n ?
.

( b) Wro u gh t iro n ?
( 6 ) C as t s t e e l ?
(d) R o lle d st ee l ?
1 0 (a) C utt in g can b e d o n e
. d r w at er wit h o rd in ary cutt ing appa
un e

ratus ; w h y do esn t th e flam e go o ut wh e n s u b m e r ge d ?

’

( b) Wh at add it io n al e q u ipm e nt is gen eral ly u se d in un d erw ater

cut ting?

LE C TU RE NU M B ER F OU R TEEN

S ub j e ct— B RAS S WELDI N G

1 . Explain as fully as po ssib l e th e ch ie f c h arac teris t ic s of a

filler -
ro d fo r b rass w el d ing
”
.

2 .
(o ) Is w el ding b rass ?
a flux u se d in
( b) Wh at is o ne w ay o f m ak ing a go o d flux fo r b r ass ?
3 ( a) W h at k in d o f a fl am e is use d in b rass w e ld ing ?
.

( b) Wh y?
4 . wh at po sit io n is th e fl am e h e ld in w el d ing b ras s ?
(a ) In
“
( b) Ho w sh o uld th e fille r ro d b e h e l d ?
”
-

5 (o ) I s it a dv isab l e to V o ut o r b u rn o ff th e e n d s o f b rass wo rk to
”
.

be we ld e d ?
( b) Explain w h y .

6 ( a) Wh at c auses th e d ense w hite fum e s to app ear wh en f using

.

b rass ?
( b) Wh at is u r w el d s b e ing po ro us ?
ca se o f b ass

7 Wh y sh o ul d b r ass wo rk n o t b e d is tur b e d w h e n red h o t ?

.

8 W h at is th e m o st d iffi cul t p art o f b ras s w e l d ing as a w h o le ?

.

9 Wh y are b rass w el d s gen erally co o le d in w ater as so o n as fu sio n is

.

c o mple te d ?
1 0 Wh y is it diffi cult fo r th e b eginner to w el d h eavy pie ces o f
.

b rass ?
 1 62 LE C TURE S

th e en tire valve cap or b o nne t

”
wh e n b urnin g c arb o n in a gas
e ngin e ?

( b) Can it b e do n e e it h er w ay?
4 .
(0 ) D o es it m ak e a d iff ere nce if th e ca rb o n is h ar d an d d ry in th e
c ylin der ?
( b) Wh at wil l h elp in such c ases ?
5 (a) I f th e cylin d er is rat h er o ily d o es th is m ak e a difleren ce ?
.

( b) D o es th e pre sen c e o f o il aid o r re t ar d c o m b u s t io n ?

6 (a) W h at pr e c autio n s are n e c essary b e f o re carb o n b urning is
.

att em pt e d ?

( b) Ho w is asb e s t o s p ap er use d in carb o n b u rnin g?

( 6 ) N am e a go o d s u b st itut e fo r asb esto s p ap er w h e n c arb o n b u rnin g .

7 ( a ) I s t h e r e any d an ger o f w arp ing th e v alv es and o v e r h eat ing th e

.

cyl in d er an d p is t o n wh en b ur ning c arb o n ?

( )
b W h a t is t h e e ffe c t o f c arb o n b urn in g o n alum in um p is t o n s ?

8 (a ) W h at pr e ssure is us e d o n t h e o xygen lin e fo r c arb o n b u rni ng?

.

( b) Will c arb o n b u rn ing re grin d v al v es ?

-

9 (a) Ho w l o n g S h o uld th e b u rn ing b e d o ne ?

.

( b) Ho w o ft en is c arb o n b urn in g re c o mm e n de d fo r a gas en gin e ?

( 0 ) I f t h e r e are any c arb o n p art icl es o r san d l eft in th e cyl in de r af ter
b ur n ing is d o n e h o w are th ey re mo v e d ?
1 0 D e s c rib e h o w t h e c ar b o n is r e m o v e d fr o m a f o u r cyli n d e r en gin e ,
.
-

p ay ing p articular att en t io n to d e t ails such as l igh t ing,wh ich pa rt o f th e

h ea d t h e t o rc h is p lay e d o n first ,w h at d o e s th e b u rn ing an d w h e re t h e
c arb o n go e s .

LE C TURE NU M B ER S E VENTEEN

S ub j e ct— P R E HEATI N G A GE N C IE S

1 ( ) Wh at is m e ant b y p reh e at ing as appl ie d to th e o xy ac ety l ene

. a -

w elding in d ustry ?
( b ) W h at ar e s e v e ra l fu e l s w h ic h c an b e u s e d v e ry s ucc e ssfully fo r

p reh eat ing?

2 N am e th e t h ree p rin cipal reaso ns w h y p art s to b e w el d e d are gen
.

e rally p reh eat e d .

3 ( a
.
) W h y is c h ar c o al c o n s id e r e d th e b e st p reh e atin g age n t fo r gen

e ral w el d ing?

( )
b W h y s h o u l d it n o t b e u se d to a n y grea t e xt e n t in c l o s e d ro o m s dur

in g th e w inter m o n ths ?
 LE C TURE S 1 63

( c) I f u se d du ring th e w in te r w h at p re c a ut io ns are O b se rve d ?

4 ( a) M e n tio n tw o m at e rial s w h ich are use d extensive l y fo r b uild ing
.

up o v e n s an d d o in g th e pr e h ea t ing .

( b) W h a t k in d o f b rick is use d ?
5 (a) Ho w much sh o u l d c ast iro n b e p reh eate d ?
.

( b) B rass o r b ro n ze ?
( 6 ) Al um in um ?
6 S k e tc h an d d e s c rib e h o w a t e mp o rary b rick p reh e at in g o ve n sh o u l d
.

b e b u il t ,giving all d im en sio n s ,s uc h as : l e ngt h ,w idt h an d h eigh t and

re aso n s fo r t h e m .

7 Expl ain h o w a c v linder b lo ck w it h a b ro k e n w a t e r j ack e t is se t

.

up fo r pr e h eat ing ; h o w o v en is b u il t fo r ch arc o al fire ; h o w fire is s t art e d ;

h o w b lo ck is p ro t e ct e d w h il e w e l d ing and h o w it is r e tu rn e d to a c o l d
s t ate .

8 ( a) W h at p re c aut io n s a re n e c e ssary in se tt ing up a n d pr e h e at in g

.

al uminum ?

( b) I f pie c e is to b e tu rn e d wh il e in th e fire ,w h a t p ro v isio n is m a d e in

b uild ing up o ve n ?
9 I n w h ic h c ases is p reh eat ing ab so l u tel y n e c es sa ry in o r d e r to m ak e
.

a s at is f ac to ry w e l d ?

IO (0 ) G iv e a sk e tch sh o w ing a pr eh eating to rch fo r use o n illuminat

.

ing gas an d c o mp r e sse d air, w h ic h can b e c o ns t ru ct e d v ery e asily

.

( b ) Wh y are pr eh e a t in g to rch es n o t p o p ul ar fo r gen e ral w el d ing ?

( )
6 W h e re are th e y us e d in n um b e rs ?

LE C TURE NU M B ER E I G H TEEN
S ub j e ct— A L U MI N U M WELDI N G
( Part One)
1 .
(o ) w el ding o f alum inum ,m o re o r less d ifficult
I s th e th an such
t
m e ls
a a s c as t iro n a n d s t e e l ?

( b) Explain w h y .

2 .
( a) N am e th e tw o m e t h o d s o f m ak ing al uminum w el d s .

( b) Can th e y b e c o m b in e d ?
(6 ) Wh y?
3 .
( ) W h aat k in d o f a fill e r ro d is use d in w e l d ing al um inum ?
-

( )
b I s a flux u s e d ? W h y
?
“
4 ( o ) I s a c as t o r dr aw n fille r ro d pr e f e rre d ?
-
.

( b) N am e th e tw o im po rt an t m e t als w hich sh o ul d b e p re se n t and th e

“
p erc en tage o f e ach in th e fille r ro d -
.
”
1 64 LE C TURE S

5 .
(a) Ho w d th e fl am e b e adju s t e d fo r alum in um wel ding?
sh o ul

( b) Ho w is th e fl am e h e ld in r e l at io n to th e w o rk ?
6 ( a) Ho w is th e filler ro d a dd e d ?
“ -
”
.

( b) I n w h at re s pe ct do e s t h is d iff e r f ro m all o th e r m e t als ?

( 6 ) Wh y c an t h is b e do n e ?
7 ( a) N am e th e p rin c ip al ch a r act e ris t ic s o f alum in um w ith re gar d
.

t o h e at .

( b) W h at o th e r m e t al act s in a s im il ar m ann e r ?
“
8 ( o ) I s it n e c essary to V o ut alum inum fo r th e m e re aso ns
”
. sa as

o th er m e tals ?
( b) E xplain w h y .

9 ( a) W il l an alum inum w el d ing b e as s t ro ng as th e o r igin al?

.

( b) G ive re aso ns .

1 0 (a) Wh at k in d o f a t o o l is use d to aid in m ak ing an aluminum

.

w el d by m o st w el de rs ?
( b) Ho w is such a to o l m ade ?

LE C TURE NU M B ER N I NETEEN

S ub j e ct— A LU MI N UM WELDI N G
( P art Ttoo )

1 1 .
(a ) W h at k in d of files are use d to fin ish alum in um we lds ?
( b) wh at re sp e c t do t h ey d iffer fro m th e o rd in ary k in d ?
In
1 2 ( a) I n w hic h h an d is th e w e ld ing t o rch h e ld in alum inum wo rk ?
.

“
( b) I n wh ich ,th e fille r ro d ?
”
-

( c) Th e puddle s t ick ?
1 3 (a ) Wh at m ate rial s are u se d to b ack up alum in um wo rk fo r
.
-

pr eh e at ing?
( b) D es c rib e fu ll y h o w alum in um is b ack e d up pre v io u s to pre
-

h eat ing , in o rd er to pr e v e n t th e c o llap se o f m e t al w h il e w e ld ing .

1 4 (a ) Ho w q u ick d o es th e h ea vy c o at ing o r a lum in um o xide fo rm

.

o n a c le an h o t p ie c e o f al um in um ?

( b) Will th e m e t al flo w to ge th e r wh e n t h is o xid e is pr e se n t ?
( 6 ) Ho w is it o v e rco m e ?
1 5 ( o ) I s it advisab l e to w el d al um inum fr o m o n e s id e o nly o r f ro m
.

b Oth sides ?
( b) Wh y?
1 6 . In p reh e at ing a lum in um w it h ch arc o al ,wh at pr e c aut io ns are
1 66 LE C TURE S

c ase were to b reak ab o ut 3 o r 4 in ch es fro m th e b o dy o f th e cas e ,co ul d it

b e w e ld e d in pl ac e w it h o ut d ism an tl ing th e m o to r?
( b) E xpl ain in de t ail h o w such an arm sh o ul d b e w e ld e d .

2 8 D ue t o th e c o n t r act io n an d e xp an sio n ,it is ve ry diffi c ul t to

.

h ave th e b o l t h o l e ,in th e en d o f an al um in um s u sp ensio n arm th at h as

b e e n w eld e d ,re t urn e x ac tly to its f o rm er p o sit io n. Ho w is t h is diffi
culty p ro vid e d fo r?

2 9
.
(0 ) S h o uld a se c tio n o f an al um in um c ran k c ase b e m issing,wo u l d
“
it b e ad v isab le t o b u ild up a n e w p art w it h th e hller ro d o r to c ast a
”
-

n e w p ar t in a m o l d an d t h e n w el d it in ?

( b) Un d er wh at co n d it io n s sh o uld th e ab o v e b e d o n e ?
30.
( a) I f it w ere f o un d th at an al um in um cr an k c as e af ter b ein g
w eld e d ,h ad o ne co r n e r ab o ut —in ch lo w e r t h an th e res t o f th e case and
it h ad n o t affe ct e d any o f th e b earings, co uld it st ill b e re claim e d ?
( b) G ive pro c e dure.
 I N DE X

A Ap paratus ,eme ry wh ee l ,nee d o f,4 1

h igh pre ssure we ldi n g ,2 0
-

Ab so rb e n t ,ac e t o n e as an ,2 6 ,3 1
lo w pr essur e we ldi ng,1 9
-

asb e s t o s as an , 31
m e dium pr essur e we ldin g,1 9
-

c h arc o al as an ,3 1
me tal to p tab le , disadvan tages
mi ne ral wo o l as ,8 1
Ac e to ne as an ab so rb en t ,2 6 ,3 1 of ,39
Ac e tyle ne cylin de rs ,c o n structio n o f,
mi x i n g c h amb e r s , 2 1

o il s an d gr ease t o b e av o ide d , 37
31
o xy ac e tyl e n e ,
-
fo r cutti ng,1 2 5
A ce tyl e ne gas ,t empe r ature o f flame
re gul a to r ,2 2
o f, 1

Adapt e r ,types o f,4 6 ty p e s o f, 2 4

r e quir e d in we ldi n g ,1 9— 2 6
Alumi num ,b acki n g up in weldin g,1 I 4
r e pl acin g l o s t cr o s s — b a r,4 6
ch arc o al in we lding,1 1 6
se tti n g up , m a nn e r o f, 3 1 , 3 2
co n tractio n an d e xpans io n in
S h o p e quipme n t , 39, 43
we ldi ng,1 1 6
sh utti n g Of f ,pro c e dur e in , 3 5
clamps,use o f in welding,1 1 5
crank case s ,we ldi ng,1 1 8 A pp a ra tu s r e pair s ,

ad apt e r s , ty p e s o f, 46
hlle r ro d s in we ldi n g ,1 1 2 ,1 1 5
-

g au ges , o p e r a ti o n o f, 49
fl ux me th o d o f weldin g,1 0 9 ,1 1 1
g au ges , saf e ty , 47, 48
o xida ti o n o f b righ t s urfac e s in
h o se cl amp s , 45
welding,1 1 3
h o se ,r e pairi n g l eaky , 45
preh ea tin g in we ldi ng,1 1 6 ,1 1 7
preh ea ting,m e th o d o f,5 2 l eak s , m e t h o d o f l o ca ti ng , 44

puddl e and fl ux sys te ms o f l e aky t h r e ad s , r e p a iri ng , 44

we ldin g c o mpare d ,1 1 I A sb es t o s as an ab so r b e n t , 3 1

in alumi n um we ldi ng,1 1 6

puddl e me t h o d o f we lding,1 0 9 ,1 1 1
p ap e r c o v e r pr o t e cti o n , 55
s t rai n s ,avo idi n g in t e rn al ,1 1 8
A ut o mo b il e fr ame , w e ldi n g , 9 1
su spe ns i o n ar m o f cr ank case ,
repa iri ng,1 1 8 A ut o mo b il e , pr o pe lle r sh aft s , w e ldin g,

tip u se d in we ldi ng, 1 09

9 5
—
we ldi ng,1 0 9 1 1 7 A xl es, aut o mo b il e , w e ldin g, 9 5

we ldi n g fro m o ne side ,1 1 4

Apparatus ,classes o f we ldin g,1 9 B
de sirab ility o f se cu rin g th e b e st , B lo w h o le s,c au se s o f,6 5
1 44 B o il e r flues re tipping,9 8,99
1 67
1 68 I N D EX

B o il e r , co rru gat e d pa tch es ,1 0

“
2,1 0 3 C as t iro n ,weldin g o f,meth o d s o f
'
“
di sh ed pa tch es in repairs
”
to ,1 0 1 di sti ngui shin g me tals,
“
L patch e s in r epairi n g,1 0 3
”
60
repai ri ng ,99—1 0 1 preparati o n s fo r,6 7
B o rax as a b rass flux ,1 0 7 pro ce dure in ,63 ,64 ,6 7 7 0-

B rass ,all o y o f,1 0 6 s ucc essful we ld ,crit e ri o n

fille r ro d in we ldi ng,1 0 6

-
,7 s
of

flux in we ldi n g,1 0 7 tip,s ize o f,63

fume s in w e ldi ng,1 0 8 C as t s t ee l ,pro c e dur e in we ldin g o f,88
me lti ng po i n t ,1 0 6
-
C h arc o al as an ab so rb e n t ,3 1
B ras s welding ,1 0 6 1 0 8
-
as pr e h e a ti n g age n t ,76
B ro nze fo r we ldi ng purpo se s,1 2 3 in a lumi num we ldin g,1 1 6
we ldi ng malle ab l e iro n with ,1 2 1 Clamps ,i n advi sab l e in we ldin g alum
i n um ,1 1 5
C Co n tracti o n and e xpan sio n in alum
C arb o n b ur ni ng,1 3 5—1 44 i num weldi ng ,1 1 6
in gaso li n e e n gi n e ,1 3 6 1 3 9
- in pre h ea ti n g, 53
t h e o ry o f,1 3 9 in we ldi ng s t ee l ,87
C arb o n izi n g flame ,3 4 C o n tractio n o f me tal in we lding,pre
C as t iro n ,we ldin g o f,58—80 v e n t io n o f ,7 1
b lo w h o le s , c au ses o f,6 5 Co rruga te d patc h ,me th o d o f m ak
”

ch arco al a s preh e ati ng ing,1 0 2 ,1 0 3

age n t , 76 Crank c ase s ,alumi num,repa1 r1 n g,1 1 8
co mb us ti o n h ead o f cyl Crank sh aft s,we lding me th o ds,9 3 ,94
i n de r ,repai ri ng,7 8 ,7 9 Crate r ,deve lo pme n t an d r emo val o f,
c o n tracti o n o f me tal s in , 88
prev en tio n o f,7 1 Cr o ss b ar,re pl aci ng lo st ,4 6
-

e xpan s i o n an d co n trae Cutti ng b y o xy ac e tyle ne pro ce ss,6

-

tio n o f me tal s,6 5—6 7 Cutti ng with o xy ac e tyle n e ,1 3 5—1 3 4

-

fill e r ro d, 61 Cutting t o rch ,weldi ng t o rch and,

flux a clean si ng agen t ,6 1 co mpare d ,1 2 7
fl ux ,man ne r o f applica Cyli nde r b lo ck ,r epai ri ng c as t iro n
-

ti o n o f,6 2 gas o lin e e ngin e ,7 5,76

fl ux , s imple sub s titut e Cyli n de r b o re ,de vice fo r po li sh ing,
fo r,6 1 7 9 ,80
gas o lin e e ngi n e cylin de r Cylin ders,ace to ne as ab so rb en t in ,2 6
b l o ck ,r epa irin g,7 5 ,7 6
gear wh ee l t ee th , t h r ee D
ways o f r est o ring,
b r o ke n ,7 1 —7 4 D e ca rb o niza ti o n o f aut o mo b il e e n
h a rde n i n g part s b y use o f gin es ,1 3 6 ,1 3 9
carb o n izi ng fl ame ,7 4 D eman d fo r o xy ac e tyl e n e o pe ra to rs ,
-

lugs ,we ldin g o n cylin de r I 7

b lo ck , 80 D i sh e d pa tch in b o il e r r epair s ,1 0 1
1 70 I N D EX

0 Oxy ac e tyl ene cutting,1 2 5—1 3 4

-

Oils and gr ease ,impo rta nc e o f av o id appa ra tu s fo r,1 2 5

in g use o f,
37 a rr an ge me n t o f o xyge n lin e ,1 2 5

Ope ra tio n in o xy ace ty le n e we lding,

-
cutting t o rch ,extempo rizing a ,
—8
2 7 3 1 32
Ope ra t o r ,s tanding p sitio n o f,re
o flame ,cutti ng unde r wa te r with ,
l ative to wo rk ,3 2 1 33
Ove rh ead we ldi ng,1 0 5 fl icke ri ng o f o xyge n j e t ,1 2 7
Oxidatio n o f b ri gh t surfac es in alum i h i gh — pressure and lo w pressure
-

n um , 1 1 3 r e gulat o rs c o mpared ,1 2 7
Oxidizin g flame ,3 4 h o se ,armo r e d ,in ,1 3 3
Oxy ace tyl e n e ,cutti n g me t al s with ,
-
pre ssure o f ace tyl e ne and
6 o xyge n , 1 2 9

fl ame ,va ri e ti e s o f ad ius tm en t o f, s t ee l an d c as t — iro n ,1 3 1

32 ,33 t o rc h in prepa ri n g s teel ,1 3 1
in airpl an e c o n s tructi o n ,9 t o rch ,cutting an d we lding c o m
in aut o mo b il e man ufactur e ,1 0 pared ,1 2 7
in b o il e r sh o ps ,1 0 t o rch ,usi ng cuttin g,fo r w e ldin g
in b r ass an d co ppe r wo rk ,1 0 purpo ses ,1 3 3
in c o mme rci a l we ldi ng ,I I Oxy ac e tyle ne welding,appara tus re
-

in e l ectric railways ,1 1 quire d in ,1 9—2 6

in fo un dri e s , 1 1 a fu s i n g pr o ce s s , 62
in l ea d b urni ng, 1 2 aut o fr ame r e pair s ,
-
4
in lumb e r mill s ,1 2 classes o f apparatus ,1 9
in m ach i n e sh o ps ,1 2 co n tain e rs , seamless,
in man ufacturi ng,1 2 t h r o ugh use o f,3
in mi n es ,1 3 de fin itio n o f,1
in pip e wo rk ,1 3 fire b rick tab l e ,
-
39
in pla t e we ldi n g ,1 3 future o f,1 7
in po we r pl an t s ,1 3 gro wth o f pr o cess , 8
in r ailr o ad wo rk ,1 3 lo co mo tive frame s ,4
in r o lli n g mills ,1 4 me tal to p tab le ,di sa dvan tage s
-

in sh e e t me ta l ma nufa cture ,1 5 o f, 39
in sh ipya rd s ,1 5 mixing ch amb e rs,2 1
in th e f o rge sh Op ,1 1 o pe ra ti o n in , -
2 7 38

in tract o r in du s try ,1 6 principl e o f,1 2 5

lake b o ats cut apart b y,8 repairs th r o ugh ,3 ,5
o p e rat o r s ,demand fo r,1 7 sh o p e quipme n t , —
39 43
scr ap cut up b y , 6 varie ty o f applica ti o ns o f,3
scrap yard s , 1 5 Oxyge n ,cylinde rs,2 7
s tructura l s t ee l , 1 5 ga s ,re sult o f to o much , 35
to rch as fire departm en t t o o l ,7 o fli c e o f in c o mb u s ti o n , 2 7

t o rch c an b e use d un de r wat e r ,8 tab l e o f diffe ren t pressure s o f,

vari ed uses o f,9 a t vari o u s t empe r a tur es ,2 9
 I ND E X 1 71

S pa rks ,ch aracte ri stic th ro wn o fl b y.

e me ry wh ee l , 59
P re h ea ting,aluminum ,1 1 7 Spri ng s ,we ldi ng,fut ility o f,9 2 ,93
’

t pape r fo r o ve n ,55
asb e s o s S t ee l ,aut o mo b ile frame ,weldi n g,9 1
ch arco al in ,53 aut o mo b il e axl e s , we ldi ng o f,9 5
e xtra cti o n an d e xpa n s i o n in ,53 aut o mo b il e pro pelle r s h afts,
draft s ,pro t e cti ng wo rk fro m ,in ,54 welding,9 5
fu el s u se d in ,53 b o il e r flues ,re tippin g ,9 8 ,9 9
in alumi n um wo rk , 1 1 6
b o il e r r epa ir s ,99 —1 0 1
o ven s , 56 ca s t ,pr o c e dure in we ldin g,88
reaso ns fo r,5 1
,
se ttin g up wo rk 56

t o rch fo r,b urni ng city gas ,54

co n structi o n an d e xpansio n in
weldi ng,8 7
co rruga t ed patch ,1 0 2 ,1 0 3
”

va ri e d h ea ts fo r diffe ren t me t al s,5 2 crank sh afts ,weldin g o f,93 ,9 4

-

P reh eati g ag ci ,5 5 7 —
n e n es 1
crat e rs ,fo rmatio n o f,in we ldi ng,
fire — b rick o v e n ,54 88
o ven s , 55, 56 de finitio n ,8 1
to rch ,b urning city gas ,54 dis h e d patch ”
in b o il e r repair s,
P ro pe ll e r sh aft s ,we lding aut o mo b ile , 1 0 1

95 fill e r -
ro d use d
we ldin g,8 2
in
P uddl e me th o d o f welding alumin um , fille r ro d to b e u s e d in we ldi ng,
-
97
flame co n tro l in we ldi ng,8 1 8 2
h ard spo t s ,fo rma ti o n o f in we ld
R ing ,8 9
h ea t treatme n t in we ldin g un
R egula t o r ,ca re o f,2 5
e qu al s iz e d pi e c e s ,97
co n st ructi o n and actio n o f,2 2 ,2 3
in t e r nal s tr ai n s in we ldi n g,1 0 0
t ype s o f,2 4
R i ng gea rs ,b uilding t e e th o n case L pa tch es ,1 0 3
h a rde ned ,
me tal s ,me th o d s o f dis tinguishing
96
in weldi n g, 87
R e to rt c eme n t ,4 2
me th o ds o f welding,8 2 —86
o ut s id e appea ran ce s in w e ldin g, 87
o ve rh ea d we ld ing , 1 0 5

Sh ee t s t eel and iro n ,welding,89 sh ee t , welding,89

S hips ,repairs to se ize d Ge rman spee d r e quir e d in we ldin g, 97
ace tyl e n e pr o c es s ,5 springs,i na dvi sab ility o f we ldin g,

S h o p e quipmen t ,39— 43 92 ,
93
b l acks m it h f o rge , 42 susc epti b ility o f wh en mo lt en,9 7
ca rb o n r o ds and b lo cks,4 3 tee th ,b uilding up o f,96
e me ry wh e e l , 41 ve rtical weldin g o f,1 0 4
fire b rick tab l e ,
-
39 weld ,b ro ken ,me th o d o f repair
flux c o n ta i ne r , 42 ing,9 6
re to rt cemen t ,4 2 welding,di ffi culties o f,8 1 ,9 2
v en tila tio n ,4 3 S t eel welding,8 1 —1 0 5
1 72 I ND EX

We lding,me th o d s of dis tingui shing

b e tweenme tal s,58
Tab l e of difleren t pressures o f o xygen p rks
s a in d e t e rmi n in g kin d of
a t va ri o u s t e mpe r a tur es ,2 9
me tals in ,58
Tank s i n flammab l e gase s ,c auti o n to
We lding o f s t e el ,8 1 —1 0 5
b e u se d in we ldi ng,1 0 3
b ro k e n we ld ,mann e r o f re
Tee th , b uildin g up o f, 96 pairi ng,9 6
Tempe ra ture o f ace tyl ene gas fl ame , 1
cas t ,pro ce dure in ,88
Tip, s ize o f in we ldi ng , 63
co n tracti o n and e xpansio n
in ,87
crank sh afts ,9 3 ,94
cra te rs,fo rma tio n of in ,88
Ve n tilati o n ,56 ,1 0 8 filler -
ro d in ,9 1
impo rtance o f in welding sh o p ,4 3 h ard spo t s, fo rmatio n of
Ve rtical we lding,1 0 4 in ,
89
V in g me t al in weldi ng,
-
63 h ea t tr eatmen t in un e qual
s iz e d pi e c es ,
97
me th o d s o f,8 2 —86
o v e r h ead we ldi n g ,1 0 5

Welding,alumi num, 0 9—1 1 1 7 spri n gs , futility of weld

b rass,1 0 6—1 0 8 in g,
93
ca st iro n ,pro c edure ,6 7—7 0 tee th ,b uildin g up o f,96
mall eab le iro n ,1 2 0 —1 2 4 vertical we lding,1 0 4