THES SS ERC OW OW * Ousi ve 4orKs a8 » Loc SL eee 15 7 > sees @RXS+ THE « ¢ eMGALBWIK + LOCOMOTIVE i BD eae, BALDWIN « LOCUMOTIVE « » 1 . wor Roni ~ ——— » WORKS © THE ORKSe THE « © + BAL DW + BALDWIN » LOCOMD LOCOMOTIVE « Wonkds eoWORKS ¢ THE + 6 © BALD #.% VALUWIN® LOCOMD iacemorr 5 WOR Work VRE @ + > BALBRIN « IN @ LOCOM@TITE COMOTINE WORKS T ‘ o a %: Lot OM . ORKS » THE!» + RALOWIN @ BALDWINS PCOMOTHIgS QAKS + > + @ Bee OWIN ARC WELDING The New Age in Iron and Steel Price $1.50 ~ 632 PUBLISHED BY THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO Copyright, 1926 by THE LINCOLN ELECTRIC CO. All rights, including translation, reserved for all countries including the Scandinavian countries. Printed in U.S. A. Published November 1926 [924 Table of Contents Chapter ) Page I), The New Age of Steel. . 0c 0 a2 ana. se pis Addenda. steels y ersus: Gast iron a ee. 23 Litre Ae eres | Makes Rav ating dat lie Pantene neater tne 31 III. What ns Welding i is s and What it Does. : os : rope aes Addenda. Oris ‘Methods Nt Weldine.. = ee 3 2 aes AN ee Fok ae Welding in General “Manufacturing.” 0). 57, V.. Strength of Arc Welded Joints.;.7.%. 7.3. enneene 11 VI. » § Fig. 4 Steel is six and one-half times as strong as cast iron in tension. NOTE—A complete semi-technical discussion of the relative strength and economy of steel as compared with cast iron will be found at the end of this chapter on pages 23 to 29. Page 5 Where arc-welded steel is substituted for cast iron, no patterns or core boxes are needed. All five motor frames and rotor spiders are made from the six standard steel shapes illustrated. Fig. 5 This means that a much smaller material inventory is required because the steel jobber carries all of these shapes in stock. Furthermore much less storage space is required. The illustration shows all material for the five motor frames and rotor spiders loaded on one shop truck. The total manufacturing cost is cut in half. Page 6 iron is assured. Other advantages which naturally flow from the substitution of steel for cast iron are: a. Cutting cost of development of new design. b. Elimination of pattern expense. c. Elimination of obsolete parts. d. Reducing of cost and amount of necessary machining. e. Reducing of building space for the same output. f. Reducing of the raw material in- ventory and the total material cost. The sum of all these savings will average at least one-third of the cost of any product now made from cast- ings if it is large enough so that structural steel can be applied to it, and many cases have come to the writer's notice where savings much in excess of sixty percent have been made by the substitution. Fig. 6 ROTATING TABLE A little ingenuity plus an arc-welder make it possible to substitute arc-welded steel for almost any casting at a distinct saving in cost. Here is a rotating table made of standard steel shapes. Page 7 THE DEVELOPMENT OF AN IDEA IN CAST IRON ——— rice 28 oe a cae : AY), yy fo? ag =) Make mold and. os if SOS pour casting. OOS EA im | Assemble complete product. AD be THE DEVELOPMENT OF AN IDEA IN or fe ARC-WELDED STEEL <2 Fig. 7 The welder works direct from rough sketches, often eliminating all machine work and always reducing the time and cost of assembly. . Page 8 Cutting Cost of Developing New Designs . How large the item of ‘“Develop- ment Work” looms in many an op- erating statement! How many firms could show a substantial profit if this item could be cut down in their annual budget! Consider, for instance, the de- velopment of an idea in cast iron: A manufacturer desires to de- velop new models. Days are spent -on the drafting board—days are spent in the pattern shop—more days in the foundry—and when thousands of dollars in time and money have been invested the first model is ready for test. Too often the tests are unsatisfactory and the whole costly process must be re- peated. Contrast such a proceeding with that where arc welding is intelli- gently employed. Rough sketches can go direct from engineering to welding shop. Patterns are unnecessary. Actual working models can often be brought together in a few days’ time. Think of the saving in invest- ment and the saving in valuable time in putting a new design on the market! Fig. 8 This annealing oven was built complete by arc welding. No detailed drawings were made. Forty-nine hours after rough sketches were given to the welding foreman the oven was ready for the brickwork. This oven is one of four recently built by The Morgan Engineering Company. Page 9 These plates and bars welded into a single piece make up the top of the turntable shown below. Fig. 9 TURNTABLE FOR AUTOMATIC MACHINE There is no pattern expense to be charged against this job. The base and turntable are made of standard bars and plates, arc-welded for strength and economy. Page 10 Fig. 10 The pattern storage of a well known manufacturer before adopting arc welding. Elimination of Pattern Expense Nor does the saving stop here. The interest on the investment in patterns, the expense of their stor- age, repair and insurance are items which can be largely eliminated where the product is welded in steel. Page II Fig. 11 Why use castings for sheave blocks re- quiring a separate pattern for every size and styleP Arc-welded steel is stronger, lighter and cheaper. Any size or style can be made from standard steel shapes. Fig. 12 Arc-welded steel will supersede cast iron for making bases for machinery of all kinds. Since steel is twice as rigid as cast iron the saving in weight is apparent. Illustration by the courtesy of The Parks Ball Bearing Machine Co., Cincinnati, O. Fig. 13 The base of this dynamometer is extremely rigid. It was also cheaper to build than a cast-iron base. Page 12 Lower Material Inventory The manufacturer who uses cast iron must in self protection carry a heavy inventory of all the different castings which may be called for on any of his models or designs. Very often this item is equivalent to a large percentage of his capital investment. It is an item which he must frequently borrow money to cover while the parts lie idle and profitless in his storage. By contrast the manufacturer who builds his product from steel needs only a small stock of the different standard steel shapes he uses from which his welding de- partment can fabricate in a few days the necessary supply for any order. This is because any one of a large number of different parts can be made up of standard steel shapes of the same size and style whereas a casting can seldom be used for any purpose other than the one for which it was designed. In actual practice one manu- facturer of a large line finds that his inventory of steel is less than eleven percent of the amount he used to carry tied up in iron cast- ings. Fig. 14 This small stock of standard steel shapes replaces a casting storage covering about one-half acre. Page 13 Fig, 15 s—Os Arc-welded steel replaced cast iron in the manufacture of this turbine pressure blower manufactured by the Robinson Ventilating Co., Pittsburgh, Pa. The welded steel base is lighter, stiffer and cheaper to build. Fig. 16 This combination circular rip and cross cut saw, 12 inch joiner and boring machine is supported by a frame of arc-welded steel. Strength, lightness and economy are the results. This is only one of the uses that the Parks Ball Bearing Machine Co., Cin- cinnati, Ohio, makes of arc welding. Page 14 No Obsolete Parts The organization has not yet been found that can estimate exactly the number of any given model that will be built nor even the number of parts of each kind that are needed for a given production. Finally with the best of esti- mates, breakage and mis-machining are to be reckoned with. And so it comes about that with the discon- tinuance of certain designs there are left many hundreds of obsolete castings which at best can be in- ventoried only at scrap value. This annual waste has been almost entirely eliminated in plants where welding is used to the fullest ex- tent. Fig. 17 | ROTOR SPIDER FOR ELECTRIC MOTOR i Cast Iron, Wt. 7014 Lbs. Cost of rough casting___-____------ $6.75 Peaharmcorte ne 2200. ie ool. n a 2.94 ee COAT ee eee $9.69 -Arc-Welded Steel, Wt. 4314 Lbs. 2 Cost. of rolled steel______________-_$1.28 7a ADOT 4 COST ee ee ee 4.37 Total cost DAU Gaate AN «ge ee GS Double elevator machine for use in a paper mill. The base of this machine is 19 feet long and is built of standard shapes joined by arc-welding. Page 15 Fig. 19 Fig. 20 END RING ON MOTOR CAST IRON ARC-WELDED STEEL Cost of rough casting_____________- $2.89 Cost of rolled steel__________ Pal! $1.126 Labor -cost (2, 22 ee a oe 195 Labor cost 22222 407 Total.-cost 20 ee ee $3.085 Total cost. soc. e $1.533_ Arc-welded construction costs less than one-half as much as cast iron. Fig. 21 Before arc welding was perfected machine bases were necessarily made by casting because there was no other method of getting the required rigidity. Now arc welded steel makes a more rigid base at a lower cost. Page 16 Little or No Machining Last, but by no means least, is the cost of machining cast iron to finish surfaces or for the necessary fit. This cost in large part is eliminated in welded steel where the surface is already hard finished by rolls and the sizes are so accurate as to de- mand no machine work. When it is necessary to machine rolled steel the part can be finish machined without allowing weeks or months to elapse between the roughing and finishing cuts. There is no necessity for seasoning as there are no locked up strains in rolled steel such as are so objection- able in cast iron. Fig. 22 Contrast the appearance of this rigid arc-welded steel base with the bulky, clumsy cast iron base generally used for machines of this nature. The arc-welded base is stronger and cheaper. Page 17 Fig. 23 Large foundry space required by manufacturer before adopting arc welding. Fig. 24 The small welding shop required to make the same parts. Page 18 Less Building Space But Greater Production What would it mean to the aver- age manufacturer if he could in- crease his production 100% in im- portant departments and at the same time cut in two his floor space? Such radical savings are not theoretical possibilities, they are actually being made in plants where important parts of the product are now made by arc welding instead of by casting. » Take, for instance, the produc- tion of certain frames averaging 20 inches in diameter and 3 inches thick. These were formerly made in a foundry where a production of 60 per day required a molding floor space of 600 square feet to say nothing of pig iron storage, tumbling barrel room, pattern stor- age, etc. Today that same frame is made by simply rolling a standard steel angle to circular shape and welding the ends. The total floor space for the en- tire operation including storage of stock does not exceed 300 square feet. The present cost of construction is such that no progressive execu- tive is overlooking such an oppor- tunity to make his present floor space more productive. Here again is that inevitable eco- nomic force which is ushering in the new age in iron and steel. Fig. 25 MOTOR BASE RAILS ARC-WELDED STEEL CAST IRON , Cost of rough casting_________--__$4.992 fen OtMeOSt ee oa) ) al 117 el ECOstte =. te $5.109 SWetstitew eh sce ok ak kk 77 Ibs Cost of rolled steel_____._.-._--- $1.536 Dabor: costes oo ee eee 617 ‘otal cost.2-_.. ee $2.153 Weight: eee = etree aes 66 Ibs. \ Fig. 26 The cost of making this huge manifold of cast iron would be enormous. By arc weld- ing both the weight and cost are materially reduced. Oil refining equipment of every sort is now arc welded. Photograph by courtesy of the Power Piping Company, Pittsburgh, Pa. Page 20 Why is Cast Iron used when Steel is better and cheaper? With all of the undeniable ad- vantages which steel has over cast iron the question must arise as to why industry has not discarded cast iron entirely except for a few spe- cial applications. The only answer is tradition. It is remarkable the extent to which tradition and custom rule our lives. The first railroad passenger cars were simply stage coaches on rails, For many years the automobile was merely a glorified buggy instead of a new vehicle to be used under entirely new conditions. It seems to be an unwritten law in designing any new product to make it look like the old rather than frankly to consider its purpose and then build it to suit that purpose. Thus it has become tradition that a machinery base, for instance, must be a rectangular bulky piece of cast iron difficult to cast, needlessly heavy to ship, and unnecessarily high in cost. We have.a feeling that the sec- tions of metal must be heavy and clumsy and that corners must be rounded—that supporting bases or pillars must taper from bottom to top. All of this is nothing more nor less than tradition. For years we YE~ SSS, SES SS ES, EY, NES, NE EP A wey Bae, Y s NS h--91 1@ @ 20-9, =? ae i iv. Sole ‘Ego Reiaieincees te = ae 4 3 Pah Sa ; % Ni~ ea al SAS = ‘ hd 3" re pl? /-L FZKZRABX 3-84- | 8-3 0BKR x3-10F 1) i-cHOCK #e-S4xZxo-Ilz RIV. ON IN- SRO" JACK IS IN PLACE LENL-SpIBx O73 O_O 9 0 0 0 6 6_b—-6—0B€ us (EB x3G X27“ | I-L-343XEK10-5B-N.S, | I~ L-BAZXZV SIFFS, 7-L- 10-55N S, Berge x Fs. W i) i) Nh ™ ) n\ - : > eo (0 SYMM ABT E Fig. 50 Think of the time wasted in laying out and punching the rivet holes in this structure. Welding will eliminate this waste. Page 35 Fig. 52 , \ Arc welding is replacing riveting in the manufacture of air ducts, ventilators, smoke breechings, conveyor housings and similar products. Here are two examples arc welded by Leitelt Iron Works, Grand Rapids, Mich. Page 36 Fig. 53 | | y | , Y} , i i IN LEAS | Driving rivets is laborious and slow, requiring from three to five men per crew. This work requires infinite care, in- finite skill—and all is unnecessary. More energy is wasted in punch- ing the rivet holes, which not only weaken the members, but which also require expensive equipment and labor. There is the tremendous economic waste of making every member larger and heavier than necessary throughout its entire length solely to provide the re- quired strength at the ends where the rivet holes have weakened the -member. Energy is wasted in driving rivets both in the shop and in the field— work that is slow and laborious and which requires expensive equip- ment. Fig. 54 One welder does the work of riveter, catcher, heater and bucker-up. Page 37 Fig. 55 Think of the time and money that it would have taken to rivet together this irregular- shaped pipe! McNamara Bros., Baltimore, Md., arc weld tanks of all kinds. An arc welded tank requires no calking and the joint is as strong as the plates joined. RR Arc Welding Saves Material Where Joints Are in’ Tension An arc welded joint is as strong as the members joined.* No part of the strength of the steel is punched out. The plates or beams at the: joint are up to full strength. Consequently, it is not necessary to make the members heavier through- out their length to provide for weak- ness at the joint as is the case in riveting. | It is possible to make tanks stronger by arc welding than by riveting, using the same weight of material, or it is possible to obtain equal strength with less material. If this saving in material were the only advantage of arc welding, its importance is so great that this modern method would replace the old-style practice. *See discussion of comparative strength of welded and riveted joints on page 115. Fig. 57 No tanks are too large to be arc welded. This picture was taken at the Heil Co., Milwaukee, Wis. Page 39 Fig. 58 There are 103 arc welded girders in this building. Albert Kahn, Inc., Architect. Page 40 Where Arc Welding Has Replaced Riveting The substitution of arc welding for riveting is not a vision of the future, it is used today on the very examples given above, steel build- ings, bridges and ocean-going ves- sels. In Detroit, the steel framework of a 12-story addition to the Peoples Outfitting Company build- ing is arc welded where the floor girdets frame into the columns. In Canton, a building for the Peerless Motor Sales Company was con- structed of arc welded steel at an estimated saving over riveting labor’ cost of approximately 25%. In the Province of Ontario, a highway bridge of three spans, 500 feet overall, carrying the heavy traffic into the city of Toronto, was constructed in 1923, of arc welded steel and concrete. The design of the bridge is unique. All of the steel work is made up of round bars. The steel carries the entire load, the concrete serving solely as a protection for the steel. Before this bridge was built the design was severely criticized by engineers not familiar with the possibilities of arc welding. However, the designer knew what could be accomplished. The bridge was built, and it met all required tests, and it was built at a cost far below that of riveted con- struction. Sea-going vessels and lake boats have been built complete by arc welding, both in this country and abroad. Today, that conservative arbiter of ship construction, Lloyd’s Register of Shipping, is permitting the wider application of arc weld- ing, as repeated tests demonstrate its especial fitness and economy. Fig. 59 Peerless Motor Sales Co., Canton, O. Not a single rivet was used in the construction of this building. All of the steel work is arc welded. The Morgan Engineering Co., Alliance, O., were pioneers in adopting arc welding for heavy structural work. Page 41 Fig. 60 Two views of Bottom-dump bucket used for handling rubber. Completely arc welded by The Cleveland Crane & Engineering Co., Wickliffe, Ohio. Welding Makes a Better Product at a Lower Cost It is not only on large spectacular work that arc welding is replacing riveting. The relative savings are equally important in many produc- tion industries for welding gasoline tanks, automobile truck bodies, burial vaults, coal weighing hoppers, concrete mixers, truck frames, water tanks, etc. ietercatiebe tiveted it can be arc welded cheaper, faster and better. The following pages show a few of the many arc welding applications. It is manifestly impossible to show more than a small percentage. In looking over these applications, bear in mind that arc welding was adopted because it saved the manu- facturer money, and made a better product. Most of the manufactur- ers of these products advertise the fact that their products are arc welded, because the public is be- ginning to realize that a welded product is a superior product. Whatever you manufacture, if iron or steel plays a part in it, arc welding can probably be applied to advantage. If your product is not arc welded now, it will be either by your company or your competitor. Fig. 62 Every joint between plates, every outlet flange and every stay bolt on the Ross Steel Boiler is arc welded. Ross Boilers are built for 30 lbs. working pressure but are tested to 50 Ibs. pressure which is practically the rupture point of the plates. The Ross Boiler is built by the Frost Manufacturing Co., Galesburg, III. ae ae ; Page 43 We cre prox te ba able (0. Innounce ted Fests’ ote og bo ERR EY pee ok SER DOSTERE BPOLLERS THE LARGEST TRUK Tang A PHL Wade five! fe tke eae PE ROL Rast e Bako. igs the) ee EES. oe Be a Beads Soh CDNA ewes Kucey AES BORIS Secon siaied SSUSGNT Exoronsyiidh eddy Coredyy dorect PH ACAD RL BSR foes heed Bo TROY Be ; . Hovellesx seynt | Fig. 63 An arc-welded product is a superior product. Note the representative manufacturers who feature welding in their advertising. Page 44 CHAPTER III What Arc Welding Is and What It Does HE startling claims made for arc welding in the preceding pages of this manual are almost be- yond belief. To eliminate casting and riveting—two fundamental manufacturing processes — would seem to be a wild and impossible vision, but that is exactly what arc welding will accomplish. Doubtless one’s first thought will be, that to bring about such _ revolutionary changes, arc welding must be a com- plicated process requiring elaborate equipment and great technical skill for its operation. Fortunately this is not the case. Before taking up in detail the manner in which arc welding is utilized in manufacturing, it will be well to describe briefly just what arc welding is and what it does. ae There is nothing mysterious about the process. The edges of the parts to be joined are brought to the proper welding temperature and fused together. The heat re- quired to fuse the metal is developed by an electric arc. An electric arc is nothing more than a sustained spark between two terminals or electrodes. In arc welding, the arc is formed between the work to be welded and an elec- trode held usually in the operator’s hand. The hand electrode may be either a metallic wire or a carbon rod. Either is held in a suitable electrode holder as illustrated in figures 67 and 68. When the metallic elec- trode is used the process is spoken of as metallic arc welding, and when a carbon electrode is used the process is called carbon arc weld- ing. Both methods have their par- ticular application as explained be- low. esative Electrode. Electrode The arc is formed between the work to be welded and an electrode held in the operator’s hand. Electric Power Fig. 64 Page 45 Fig. 65 There are three ways in which this base for an excavating machine can be made. One is by a steel casting, the second by riveted sections and the third by arc-welded The arc-welded construction is stronger than riveted construction and lighter than a casting of equivalent strength. sections. Fig. 66 Rocks weighing more than 1-ton each will be dropped 3 to 4 feet into this heavy-duty truck body. It is one of four similar bodies used by the Dolomite Products Company for handling rock from electric shovel to crusher. These bodies were designed and arc welded by the Genesee Bridge Company, Inc., Rochester, N. Y. ; The figures refer to the standard steel shapes used to make this body: 1. 3%” Bottom Plate. 5. 4”x10.5 Ib. I-beam. 2. 3%” Side Plate. 6. Ditto. 3. 4x5x% Tee. 7. 4x4x¥ Angle. 4. 4”x7.25 1b. Channel. 8. 2144x214, x % Angle. Page 46 Metallic Arc Welding In this process the arc occurs be- tween the work to be welded and a metallic wire. Under the intense heat developed by the arc a small part of the work to be welded is brought to the melting point almost instantaneously. The other end of the arc, the tip of the metallic wire, is likewise melted and a globule of molten metal forms. This globule is then carried across the arc and de- posited in the molten seat waiting for it in the work. The globule is actually carried across the arc and not dropped as gravity does nothing more than assist this deposition of metal when the work is flat. The fact that this globule of molten metal will be deposited overhead against the force of gravity is proof Fig. 67 Metallic Electrode Welding. The elec- trode in this case is a metal wire of small diameter and this wire gradually melts it- self away, furnishing metal for the weld. that the process is one of deposi- tion. It is this fact which permits the use of metallic arc welding in overhead welding which is im- possible by any other process. Carbon Arc Welding In carbon arc welding the arc is formed between the work and a carbon rod held in the electrode holder. The heat of the arc melts a small pool in the surface of the work to be welded. This pool is kept molten by playing the arc across it and extra metal is added by a filler rod to form the weld. Carbon arc welding is a puddling process, and is not applicable to vertical or overhead welding. Its greatest application is in automatic welding or in welding heavy sec- tions where much heat is required. Fig. 68 Carbon Electrode Welding. The opera- tor holds the carbon electrode with the right hand and feeds the filling metal into the weld from a rod held in his left hand. Page 47 Fig. 70 All steel dump body for Ford truck, manufactured by The Galion Allsteel Body Co., Galion, Ohio. Arc welding has superseded riveting wherever a permanent joint is required. Page 48 * The Simplicity of Arc Welding An arc welder usually represents an investment of less than $1000 and takes up about 15 square feet of floor space. Any workman cap- able of learning to set up work on a lathe or milling machine can learn arc welding in a comparatively short time. The current used for arc welding is of a lower voltage than that used on a house lighting circuit and is en- Fig. 71 Miscellaneous parts arc welded by The Link-Belt Co., Philadelphia, Pa. tirely safe in the hands of an ordi- narily skilled man. Adjustments or repairs which may be necessary can be made by an electrician. The equipment is simple in construction and in principle requires very little attention other than oiling. Com- plete data on various styles of arc welders and on the speed and cost of welding will be found in subse- quent chapters. Fig. 72 Keystone Driller Co., Beaver Falls, Pa., — arc weld round and square tanks as well as other equipment for the oil industry. Page 49 Fig. 73 Air pipe completely arc welded by Littleford Bros., Cincinnati, Ohio. Other products arc welded by this company include: Jacketed pressure tanks, fuel oil tanks, under- ground storage tanks, air preheaters, gear guards, lathe pans, conductor piping hoppers, chutes and other power plant equipment. Fig. 74 Portable conveyor manufactured by The Fairfield Engineering Company, Marion, O. The vertical members are arc welded to the axle, and arc welding is used on side _ Shields, gear covers and cross frame members. Page 50 How Steel is Joined by Arc Welding In joining steel by arc welding the metal deposited by the metallic electrode, or added by the filler rod in the case of carbon arc welding, unites with the steel and forms a solid integral joint. The metal added to form the weld is of the same chemical composition as the steel parts to be welded. It has the physical characteristics of cast steel. While the tensile strength of cast steel is less than that of rolled steel, it is possible by depositing enough additional metal to build the strength of any joint up to the strength of the parts joined. A com- plete discussion of the strength of welded joints will be found in pages 111 to 121 inclusive. There are four different ways of joining steel plates by arc welding These are: 1. The butt weld. 2. The lap weld 3. The fillet weld. 4. The rivet weld. Two styles of butt weld are illustrated in figures 75 and 76. The edges of the two plates are butted together and the weld made by de- positing the welding metal along the edges. In metallic arc welding, when the thickness of the plates is greater than 10 gauge, it is desir- able to scarf or bevel the edges as shown. (No scarfing is necessary when carbon electrodes are used.) The plates may be double beveled or single beveled. This type of joint is the most economical from the point of saving material. A single lap weld and a double lap weld are illustrated in figures 77 and 78. One piece is lapped over the other and the welded metal is deposited along the edges as shown. The double lap weld is used where maximum strength is required. The fillet weld is really a modi- fication of the butt weld. Figure 81 shows how the metal is deposited to form the weld. This method of construction has a wide range of applications. It avoids the use of Crp ainnansilal Sag maa TS Fig. 75 Butt Weld—Single bevel. RESTS COMERS nD, Fig. 76 Butt Weld—Double bevel. Fig. 77 Single Lap Weld. anna ea | Fig. 78 Double Lap Weld. Page 51 Fig. 79 Until it was definitely proven that an arc-welded steel flask was superior in every way to a riveted steel flask, The Shanafelt Manufacturing Co., Canton, Ohio, pro- duced both. Now their entire output is arc welded. Shanafelt steel flasks are made in many sizes and styles to meet all requirements. Fig. 80 These switch panels are all steel. Panels and brackets are arc welded. Page 52 : flange angles which are required in riveted construction. The rivet weld is used where it is not feasible to use a lap weld or a butt weld. Holes are drilled or punched through one of the pieces. This piece is placed against the piece to be fastened to it and the welding metal is deposited in the holes. A solid plug of steel which is com- pletely welded to both members is the result. This type of construc- tion is exceedingly useful when metal cannot easily be applied on the edges of the parts to be joined. This construction has many advan- tages over ordinary riveted construc- tion. The rivet weld will not loosen under a weaving strain because the welding metal is integral with the parts joined. Since holes are made in only one of the members there is no difficulty in registering. There- fore no laying-out or templates are required. Furthermore there are no protruding heads as in ordinary riveting. Fig. 81 Fillet Weld. Fig. 82 Rivet Weld. Fig. 83 Truck body manufactured by the Truck Equipment Co., Buffalo. N. a Page 53 LIVE COMEN Fig. 84 Platform and racks for use in manufac- turing plants must be strong enough to withstand hard use and light enough to be transported easily. Here are three styles which meet these conditions. Arc-welded by Lewis Shepard, Boston, Mass. RIN TYPE PL. Fig. 85 Arc welded skid grab for handling paper. One of many applications of arc welding made by The Cleveland Crane & Engineering Co., Wickliffe, Ohio, in the manufacture of material handling equipment. Page 54 ADDENDA TO CHAPTER III Other Methods of Welding As a matter of interest a brief descrip- tion is given here of other methods of welding which have a more limited range in general manufacturing. Each method has its field but none of them can ap- proach arc welding in speed, economy; dependability, or all around utility. There are four other methods of weld- ing, differentiated chiefly by the method of heating the work. These are: 1. Forge or fire welding. 2. Thermit welding. 3. Resistance welding. 4. Oxy-acetylene or gas welding. Forge welding is the method of the blacksmith shop. The metal is heated in the forge and hammered on the anvil. Because of its cost and obvious slowness this method is not a process which can be used widely in production manu- facturing. For certain classes of work this process has been improved by the development of heating furnaces and power hammers. tions, however, is extremely narrow. In structural steel construction as used in building it is obviously out of the ques- tion to use forge welding. Thermit welding is essentially a cast- ing process. The heat is produced by the chemical combination of iron oxide and powdered aluminum. When this mixture is ignited it generates tremendous heat and releases molten metal which unites with the parts to be joined thus forming a weld. It is necessary to pro- vide moulds to confine the molten metal the same as in any casting process. © Thermit welding has a certain usefulness in the repair of heavy parts but because of the necessity for moulds and dams it is not practicable for production welding. In resistance welding the necessary heat is produced by an electric current. In this process the pieces to be welded are placed in contact and an electric current passed across the junction. Be- The range of applica- © cause of the imperfect contact the re- sistance to the passage of the electric current is high. The heat produced by this action causes the metal at the junc- tion to become plastic and when the de- sired plasticity. has been reached the pieces are forced together and a weld results. This process is used chiefly in spot welding of surfaces usually of rather light material. It has a limited application in general manufacturing. In oxy-acetylene or gas welding a flame produced by the burning of oxygen and acetelyne is played upon the surfaces to be joined and the extra metal is added to the junction by the melting of a filler rod of suitable composition. Gas weld- ing has a wide application in repair work where the amount of welding is not large. It is also used to a certain extent in general manufacturing. Notwithstanding the comparatively low first cost of equipment, the high operat- ing cost makes it less economical than arc welding for production work. It is very difficult to weld vertical seams or overhead seams because gas welding is a puddling process. That is, the molten metal forming the weld is in a small pool over which the flame is con- stantly played. Making a weld consists largely in causing this pool to move by melting metal away ahead of the pool and letting the metal cool behind it. A further disadvantage of gas welding is the fact that the heat is applied to the metal externally. The flame rebounds and spreads considerably away from the locality where the weld is to be made. This frequently causes warping of the parts unless elaborate precautions are taken which necessarily increase the cost. The cost of the heat used by this process is about three times as great as with the arc process and less than one- third is used in the weld—the rest is blown away by the action of the flame itself. Page 55 Fig. 86 Snow King, the rotary snow plow manufactured by the Imperial Machine Company, Minneapolis, Minn. Arc welding accounts for the sturdy strength of this machine. Fig. 87 The cutting edge, stiffener braces and rotor blades are all arc welded. Notwithstanding the severe service which the rotor blades encounter, such as striking rocks and fence posts, there have been no failures of the welds. Page 56 CHAPTER IV Arc Welding in General Manufacturing HE shop superintendent or the designer who does not know arc welding is probably losing money for his firm. He is authorizing drilling, punching, reaming, bolting and riveting where arc welding will do the work better and cheaper. He is using iron castings where arc- welded steel would be cheaper and stronger. The arc welder is a production tool. In modern manufacturing it is as fundamental as the lathe, the drill press or the milling machine. It is just as important for the up-to- date designer to know arc welding as it is for him to know the funda- mentals of forge shop practice or machining methods. Firms that, have been the first to redesign their products for arc weld- ing are reaping the profits which come from lowered costs. The wide range of products illustrated in this book barely indicate the possibilities of this process. New applications are being made daily and every new application means that some one has found a way to make his product better, or to make it at a lower cost. Fig. 88 Well pumping rig redesigned for strength and economy. The left hand picture shows riveted construction with cast-iron pump housing. The right hand picture shows the same equipment built of arc-welded steel. Photographs by courtesy of American Crane Co., Friendship, N. Y. Page 57 Fig. 89 Use standard steel shapes. Many styles and sizes are carried in stock. Above are only a few of them. Page 58 edestenitg for Arc Welding When the engineer comes to realize that welded joints are stronger than any other method of joining metals and at the same time the least ex- pensive he will have learned the most important step in redesigning for economy. The next important step is the realization that practically’ any part that can be made in cast-iron can be made up of standard steel shapes welded together. At first glance this seems almost unbelievable but a thorough analysis will prove the truth of this statement. Steel shapes are available in a wide variety of A few of these are reproduced in figure 89. It is some- styles and sizes. times necessary to bend or roll these standard shapes to produce the part required, but steel has such a large price advantage over cast iron that this can usually be done at a saving. Sheets Plates Castings or Forgings to Plates Tubes and Pipe Channels, Angles. Bars Ete. Angles Fig. 90 Welding is the strongest method of joining steel parts and the least expensive. Page 59 Fig. 91 The Ljungstrom Air Preheater, manufactured by The Air Preheater Corporation, Wellsville, N. Y., is a remarkable example of equipment designed to be produced by arc welding. This preheater is built in various sizes up to 18 feet in diameter and 21 feet high. Casting the moving parts would make them too heavy to function properly to say nothing of the prohibitive cost. Riveting would be too expensive and would likewise increase the weight unnecessarily. Arc welding is the only method by which this equipment can be economically manufactured. Fig. 92 re Fig: 935 The rotor of the Ljungstrom Air Pre- Upper and lower section of housing for heater. All joints are arc welded. No the Ljungstrom Air Preheater. Sections other method of making this rotor would are bolted to facilitate shipping. All per- give light weight, low cost and necessary manent joints are arc welded. strength. Page 60 Replacing Castings by Arc-Welded Steel When redesigning a casting for arc welded steel : First. Study the casting and de- termine definitely just what its func- tion is in the machine and what re- quirements it must meet. When this is done it is a simple matter to decide whether or not a suggested change in form or shape is allowable. Second. Analyze the casting into its component parts and choose the standard steel shapes which will do the same job that the various parts of the casting are called upon to do. If the point of view is cultivated of looking at every casting as an assembly of parts rather than as a composite whole this analysis of shape comes naturally whenever a new casting presents itself. CAST IRON Third. all parts of a particular casting can It sometimes occurs that be replaced by standard structural steel except some detail which is necessarily of peculiar shape. In this event, the rolling or bending fix- ture will take care of a very large percentage of these cases by chang- ing the form of the standard steel shape to make it conform to the re- quirements of the design. The roll- ing of a standard angle into a cir- cular ring is an example of this. Fourth. some details which do not seem There may still occur susceptible to the rolling or bending (which are very rare) recourse must be processes. In such cases made to a cast or pressed steel part. ARC-WELDED STEEL Fig. 94 The most intricate casting can be replaced by arc-welded steel. Page 61 Fig. 95 The Killefer Manufacturing Co., Los Angeles, Calif., manufac- ture a wide variety of road building and agricultural ma- chinery. They state,—“‘Arc welding is used in so many places that it is impossible to give a complete list of our welding operations.” Arc welding enables The Euclid Crane and Hoist Company, Euclid, Ohio, to sell this efficient scraper at an extremely low price. It is built for rigid service. All perma- nent joints are arc welded. Page 62 ‘ Redesigning the Entire Product The range of products made from iron and steel is a vast one. To at- tempt to give detailed instructions on how to redesign every product for arc welding would be both pre- sumptuous and futile. A detailed description of the method of rede- signing a concrete mixer would not interest the builder of highway bridges—yet in both of these prod- » ucts arc welding can be utilized to advantage. Only the fundamental principles -of redesigning for arc welding fall within the scope of this book but it is believed that with a knowledge of these principles the designer will have no difficulty in applying them to his own product. Fig. 97 There are two reasons why The Jaeger Machine Co., Columbus, O., use arc welding on this concrete mixer. One is to keep the cost down, because the market is highly competitive. The other is to give this mixer the husky strength to stand up under the service expected of Jaeger equipment. Page 63 ___ Container. & Cover Ja Pfu : ‘A SN wl SS oe; ,/ “Le. MOL — | ha A<—ss Ue ay) O n Z. p (ore ae Container | LS 2 ( Cover | Container jj Cover 4 — SS 7 Yh 11 1h Y ce Base Base Coveiner , Fig. 98 The structural parts of every machine may be classed as either bases, covers or containers. Page 64 Bases, Covers and Containers Notwithstanding the diversity of products manufactured from iron and steel, there are still some char- acteristics which are common to all. It will be found upon careful analysis that every structural part of any, machine, structure, or piece of equipment can be classified in one or more of these three classifications —bases, covers, and containers. It may be a new conception to think of all structural machine parts as being so simply classified, but a little thought will show that this is true. Some parts may fall in both classi- fications. A worm gear housing, for instance, may be classed both as a base and as a container if it serves to support, as well as enclose, the moving parts. This, however, does not make the classification any less Fig. 100 valuable for the purpose of this discussion. Figure 98 shows two widely dif- ferent pieces of equipment with the various parts labeled in accordance with this classification. In this Worm Gear Housing the Base is also a container. Manufacturers of fans and blowers have been among the first to redesign for arc welding. Steel has replaced cast iron throughout in the construction of these models built by the Robinson Ventilating Co., Pittsburgh, Pa. Page 65 Fig. 101 Backfiller manufactured by The Killefer Manufacturing Com- pany, Los Angeles, Calif. The rocker arms on this machine are made by arc welding extra- heavy pipe to a steel casting. This company arc welds all kinds of agricultural machinery. Any Base Can Be Built of Arc Welded Steel The term base, as used here, is intended to embrace every part whose chief function is to support. It includes: Brackets, Beds, Legs. Superstructures. Outboard bearings, Pedestals. Arms, Goosenecks, End Brackets. Bearing boxes, etc. At present, by far the majority of bases are made of cast iron. Riveted steel is also used, but this discussion has to do chiefly with re- designing cast iron bases on the assumption that where riveted steel is now used the application of arc welding is obvious. Fortunately, redesigning for arc welding is a comparatively simple matter. It is much less difficult to design a machine base of arc welded steel than to design the same base in cast iron. It is not necessary to allow for casting shrinkage, draft on patterns, cores or fillets. The designer works directly for the ultimate result, un- hampered by limitations of the cast- ing process which make it impossible to cast the most efficient sections. Fig. 103 A fine example of light, strong and economical construction for machinery bases. This machine and many others manufactured by The Parks Ball Bearing Machine Company, Cincinnati, O., are arc welded throughout. Page 67 Fig. 104 Assembling the 300-ton press brake illustrated below. This picture gives an idea of the size of this huge machine. Steel is superseding cast iron in the manufacture of machine tools where great strength is required. Fig. 105 300-Ton Press Brake manufactured by the Cincinnati Shaper Co., Cincinnati, Ohio. This machine is 11 feet 9 inches high. Note how rolled steel has replaced cast iron. Arc welding is employed to give this machine its extreme rigidity. Page 68 First, analyze the purpose of every part of the base. Then de- termine the stress to which every part is subjected. It is usually a simple matter to determine whether a member is in tension or compres- sion. If it is subjected to both stresses, the designer can usually tell which stress is the more im- portant. He can also determine with sufficient accuracy, the amount of the stress, which, of course, governs the size of the members. This is fundamental to all designs, whether the base is to be made of cast iron, riveted steel or arc welded steel. The next step is simply to select the standard steel shapes which will best meet the above conditions. Join the standard steel shapes by arc welding with the assurance that the joints will be as strong as the mem- bers joined. The entire base will be an integral piece of steel—lighter in weight, stronger and less expen- Since steel is stronger than cast iron the various sive to manufacture. parts of the base can be made smaller. This may change the ap- pearance of the base somewhat but will in no way interfere with its utility. Ge Tensor Tensor Compression Fig. 106 Every structural part of any machine is subjected to either tension or compression or bending. Page 69 Fig. 107 Special-purpose trucks of all descriptions can be made quickly and cheaply by arc welding. Here is one that was built to facilitate unloading steel shapes. Fig. 108 The frames of these dryer cars are made of 3”x3”x!4” steel angles bent around a form and arc welded, making a solid, rigid one-piece frame. These cars are manu- factured by The Hadfield-Penfield Steel Company, Bucyrus, Ohio. , Fig. 110 Base for direct connected motor driven machine. In this manual are illustrated many different styles of bases which were built on this principle. It is not feasible to describe them all and in most cases the pictures them- selves are self explanatory. In figure 110 is a simple example. This type of base is suitable for any direct connected motor-driven unit ‘such as a pump, a crusher, a gener- ator, elevator engine, etc. As the illustration shows it is made entirely from standard steel shapes. Pig uit Elevator base redesigned for arc welding by the Houghton Elevator Company, Toledo, Ohio. Sean rie ek eee ETS BES BO 2 a ir The cost figures are convincing. Weight Cost fl Ay ee apg A P Se A 184 Ibs. $11.04 BS strength Se by ye ues see ae, 109 lbs. 5.45 Fig. 112 Arc-welded bases need not be awkward. While the bases for these machines look different from the traditional cast-iron bases, they are graceful and workmanlike. They are also cheaper than cast iron and stronger. Page 72 Typical Base for Floor Grinder Another example is a base for a machine such as a floor grinder, a polishing wheel or an arbor press. The machine base in this case is simply a support to bring the work- ing parts to a convenient height. Of course, the base must be reason- ably rigid to avoid undue vibration. To make a base of this nature of welded steel, a standard I-beam serves as the column support. Two flat plates welded on the foot of the I-beam provide the large floor bear- ing. Welded braces made from steel plates give the necessary stiffness and another flat plate forms the bed for the working parts. The entire base can be built before the pattern shop could lay out the core box for a cast iron base and at a fraction of the cost. Fig. 113 : The welded steel base is more rigid than the cast iron base costs less and requires practically no machining. Page 73 Trev CS | nay - wea 9+ Ros Fig. 114 Boring mill bases have always been made of cast iron. Below is a similar base of arc-welded steel. An All Steel Lathe Examples might be multiplied, but the truth is apparent that the sole purpose of any base is to sup- port the moving parts, whether the machine is a grinder, a concrete mixer, or a portable coal loader. The best base is the one which has the necessary strength and rigidity and which can be built at the lowest cost. Let us consider another example of a machine which has heretofore been made of cast iron, namely an A lathe con- sists fundamentally of four parts—a ordinary engine lathe. bed, a headstock carrying the driv- ing mechanism, a carriage which slides along the ways on the bed, and a tailstock. The purpose of the bed is simply to support the moving parts and keep them in alignment. It is extremely important that the bed be sufficiently rigid so that it will not deflect under the pressure exerted against the lathe tool. In other words, the greatest stress is a bending stress. Since cast iron is weak in flexure, lathe beds are built with a very deep web to provide the necessary rigid- ity. tern from the sand in the foundry, In order to draw the bed pat- the shape of the casting must be made radically different from the shape which would withstand the greatest bending stress. This is one of the limitations of the casting process. Now suppose this lathe bed to be made of welded steel. Since it is called upon to withstand a bending stress, the steel section best suited for this purpose is chosen, that is, the standard I-beam. Instead of the heavy cast iron base, two I-beams would be solidly joined together by arc welded cross braces. The legs would be made of either I-beams, standard channels or angles depending on the design. Hardened steel ways screwed to — the tops of the I-beams would re- place the cast iron ways, providing a simple means for renewal when badly worn. Because of the greater strength of steel and because the most effi- cient sections can be used, a welded steel lathe would be stronger, lighter and cheaper than a cast iron lathe. Obviously it would not look the same. Its first appearance would doubtless cause smiles from users accustomed to the flowing curves and deep fillets of cast iron construc- tion. Fillets and curves, however, are but evidences of the limitations of cast iron and it will be only a short time before steel bases are accepted as standard on most machine tools. Page 75 Fig. 116 Gear Guards of every size and description are arc welded by the Link-Belt Company, Philadelphia, Pa. Page 76 Make All Covers of Arc Welded Steel The term covers, in this classifica- tion, is intended to include: Gear guards. Doors. Pulley housings. Dust covers. Lids for ‘oil wells, etc. The purpose of covers on any machine is either to protect the in- ternal mechanism from damage from the outside or to shield the moving parts so that they them- The gears on these overhead crane trolleys are enclosed in guards of arc-welded steel. selves will not be a source of dan- ger. Usually covers are not sub- jected to any considerable stress, and consequently the lightest cover is the best cover provided it has the requisite stiffness. Gear guards probably are the widest used form of covers. The former method of making these was either by casting or by riveting steel. Cast gear guards have all the disadvantages of any cast-iron prod- This is one of the many applications made by the Whiting Corp., Harvey, III. _ Fig. 117 Pager ey OCONEE Fig. 118 Arc welding is used extensively by the Butler Bin Co., of Waukesha, Wis., in the manufacture of their batch measuring hoppers and other products. Fig. 119 Conveyor buckets arc-welded by The Link-Belt Company, Philadelphia, Pa. Page 78 uct which include high cost and un- necessary weight. Riveted gear guards, while utilizing less expen- sive steel, require flanging or flange angles, so that the cost to manu- facture is often higher than that of a casting. Furthermore, the rivets have'a tendency to work loose under the constant vibration to which gear guards are subjected. The construction of arc-welded gear guards is simplicity itself. Sheet or plate is cut to the proper shape and the edges welded so that the entire part is an integral piece of steel. Gear guards of this nature may be made dust tight and oil tight and the cost is a fraction of that for other methods. Covers other than gear guards can be made in the same manner. Use standard steel sheet or plate Laundry Machinery Co., Mass. The cylinder, gear guards and many other parts of the Henrici washer are arc welded. This is one of large num- bers of models built by the Henrici Boston, form if necessary and weld all joints. An example of a cover known to everyone is a door such as is used on a milling machine and very fre- quently on other machine tools. This door carries no part of the load on the machine, and is only subject to breakage through being struck. However, because cast iron is ex- tremely brittle in thin sections, doors are cast in sections many times ° heavier than would be required if steel were substituted. Doors of this nature can be easily made from flat stock stiffened where necessary by welding on ribs or angles. Hinges and knobs can like- wise be welded on and the cost would be less than for any other style of construction. Page 79 OUTSIDE WRAPPER SHEET 000000000 oe OO0000000 60000000000 O 99000000000 00000000000 00000000000 00000000000 00000000000 000000000 0000000 REAR TUBE SHEET FIRE DOOR RING FRONT TUBE SHEET 0000000000 00000000000 000000000 0000000 FIREBOX REAR HEADER AND TUBE SHEET FIREBOX FRONT HEADER = WRAPPER SHEET Fig. 121 All seams of this heating boiler are arc welded. Note the simplicity of construction. Only seven steel plates are used. The Heggie-Simplex Co., Joliet, Ill., manufacturers of this boiler, arc-welded all of their various models. Page 80 Arc Weld All Containers The classification containers is extremely broad and includes: Tanks of every description. Boilers. Hoppers.. Drums, Bins. Chutes. Mixing chambers. Tumbling barrels. Vats. Revolving driers. Dump cars. Clamshell buckets. Annealing pots, etc. Tanks will be considered first be- cause their use is more general than any of the other items in this classification. The first requisite of a tank is that it be tight. It must also have sufficient strength to withstand the internal pressure to which it may be subjected. In pressure tanks the plates and joints are in tension. In riveted construction, which was formerly the only method of mak- ing pressure tanks, the strength in tension of a riveted joint is always less than the strength of the plates joined. ‘This is because the plates are weakened at the joint by the rivet holes. To obtain the necessary strength it is therefore necessary to provide: for this weakness at the joints. Since the efficiency of the usual riveted joint varies from 45% Fig. 122 Arc-welding is the approved method of making tank trucks for transporting in- flammable liquids. This one was built by the A. F. Robinson Boiler Works, Boston, Mass. There are no rivets to work loose and start leaks. Page 81 Fig. 123 Arc-welded water tanks are superseding riveted tanks because they do not require periodic recaulking, This one was built by The Leitelt Iron Work, Grand Rapids, Mich. | Page 82 to 75%, the increase in the thickness of the plates to provide for this is considerable and represents a large part of the cost of any tank. In arc-welded construction the joints can be made as strong as the plates joined. It is not necessary to make the plates thicker throughout their length to provide for the re- quisite strength at the joint. The plates are no more apt to fail there than at any other point. Here, then, is one great saving by using arc welding in place of rivet- ing. Furthermore, the actual cost Fig. 124 This Bousman Still is used for reclaiming gasoline and other solvents used for dry cleaning. The Bousman Manufacturing Co., Inc., Grand Rapids, Mich., have found that arc-welded stills cost less and last longer than riveted stills. of making the welded joint is less than that for making a riveted joint. In tank work there is still another advantage. In riveted tanks the method of making tight joints is by peening the metal along the edge of the plates into the joint by means of a caulking tool. This method is a makeshift at best and is also ex- pensive. It is frequently necessary to recaulk after the tank has been in service a short time. Arc welded tanks are tight because the plates are solidly joined, making the tank actually a single piece of steel. In addition, a welded tank resists cor- rosion better than a riveted tank, and avoids leaks around rusted rivets. Fig. 125 No one wants a leaky gasoline or oil tank. That’s why the S. F. Bowser & Co., Inc., Fort Wayne, Ind., arc welds the seams of this tank and many other styles of dis- pensing tanks. An arc-welded seam for- ever eliminates caulking. Page 83 Fig. 126 Locomotive tender built by the Baldwin Locomotive Works, Philadelphia, Pa. Arc-welding has replaced riveting throughout. An arc-welded joint withstands vibra- tion better than.a riveted joint. Fig. 127 The interior of a large fuel oil storage tank built in accordance with the New York City Building Code. This tank is stayed with 15%” steel rods on 24” centers. Stays and plates are completely arc welded. The Lancaster Iron Works, Lancaster, Pa., has made these tanks for the Equitable Life Building, Federal Reserve Bank, Waldorf Astoria Hotel, Astor Hotel, Belmont Hotel and others. Page 84 In making tanks by arc welding, the plates may be joined by butt . welding, by single lap welding or by double lap welding. The butt weld has the advantage of great strength and also saves material. The cost of fitting and scarfing the plates, however, often offsets the saving in material. Where the tank is used for storage purposes and is not sub- jected to high pressure, the single lap welded joint may be used. For pressure tanks the double lap weld is recommended as this joint is as strong as the plates used. Various methods of welding the heads in tanks are illustrated in figure 138. Very large tanks may be strengthened by stay rods, welded at all intersections as illustrated in figure 127, Containers other than tanks can also be made by arc welding cheaper than by riveting or casting. Ex- amples, including conveyor buckets, concrete mixing drums, compensator housings, and many others, are il- lustrated in this manual. The de- signer will have no difficulty in see- ing how arc welding is utilized in making these and will doubtless find many suggestions which he can apply to his own problems. Fig. 128 The oil pan on this turret lathe, manufactured by The Warner & Swasey Co., Cleveland, Ohio, is made of arc-welded steel. Page 85 but to make this part by rivet- ing 8 flat pieces plus 12 pieces of angle are required. A total of 20 pieces to do the work of 8. To say nothing about the cost of punching rivet holes and driving rivets. Page 86 Arc welding saves material. To make this part by arc welding—8 pieces of flat stock are required, Fig.0129 Arc-Welded Wheels Arc welding is used extensively in the manufacture of wheels for vari- ous purposes. . One example is the wheel for a shop truck, illustrated in figure 130. Like many similar wheels this wheel was formerly made of cast iron. The manner in which steel was sub- stituted is clearly shown in the il- lustration. The rim is formed by rolling a standard T-bar into a circle The hub is made from a short length of and welding the junction. standard pipe and the spokes are flat bar stock. All parts are welded and the result is an all-steel wheel, stronger than the cast iron wheel and weighing but one-half as much. The cost of the cast iron wheel was $1.85 each and the cost’ of the welded steel wheel $.68—a saving of more than sixty percent. Fig. 130 WHEEL FOR SHOP TRUCK ARC-WELDED STEEL, WT. 12.5 LBS. Cost of rolled steel________________ $ .35 Pea UaTMCOSt=. ee eee ok 33 ipraieecontas.- = 2... et $ .68 CAST IRON, WT. 25 LBS. Cost of rough casting________-____-_ $1.75 Danorecostie t= oe oe ee ce .10 rrotalincosts. cee $1.85 The arc-welded wheel is not only cheaper to make but weighs one-half as much as the cast iron wheel. Page 8&7 Fig. 131 There is not a single bolt or rivet in this 114-ton coal bucket built by the Godfrey Conveyor Company, Elkhart, Indiana. It is arc-welded throughout for strength. Page 88 Fig. 132 Eighteen foot band wheel built by the Oil Well Supply Co., Oil City, Pa. By are- welding the T-iron stiffener to the rim, 176 rivets were eliminated. In addition to reducing the cost, arc-welding made a better product. The smooth outside face of the wheel means longer life to the driving belt. Large hand wheels such as are used extensively on road building machinery are now made by arc welding from standard pipe of various sizes. The rim of the wheel in figure 133 is made by rolling up a circle of 14%” pipe. The spokes are of pipe of a smaller diameter weldéd to the hub. One large manufacturer reports that he keeps two arc welders constantly busy making hand wheels of this nature. Fig. 133 Hand wheel made of 114” pipe with 34” spokes. Arc welded at all joints. Photo- graph by courtesy of Killefer Mfg. Co., Los Angeles, Calif. Page 89 Se oe rn Fig. 134 Fig. 135 Single Lap Weld. Suitable for thin sec- Double Lap Weld. This joint can be tions or where great strength is not re- made as strong as the members joined. quired. Note saving in material over double lap riveted joint. Fig. 136 Butt Weld. This is a 100% joint. The amt edges of the plates should be beveled as Fig. 137 shown. Double riveted joints. B C Fig. 138 Three methods of welding flanged heads in-cylindrical tanks. Method C is the best practice where maximum strength is required. ME LLL YUH /000 Z y Y Y j Yj Z GUSSET LETUL Fig. 139 Fig. 140 Method of welding brace in place of rctags Welded corner stiffeners. riveting. Page 90 Typical Welds and Short Cuts Too much emphasis cannot be placed on the economy of using standard parts in arc-welded con- In addition to rolled steel shapes,—standard pipe and struction. pipe fittings, standard hinges, stand- ard bolts and nuts and similar parts can often be used to take the place of special castings or forgings. The drawings on pages 92 and 94 show typical details of arc welded construction making use of stand- ard parts. These drawings merit study. To appreciate the economy of these construction details, it is necessary to visualize the procedure required to get the same results by some other method. Suppose, for instance, a single T-bolt were required. This T-bolt could be hand forged, or it could be cast of malleable iron or steel. Any one of these methods would require much more time and would be far more expensive than arc welding. A round steel bar welded to a standard bolt solves the prob- lem. As another example, suppose that it were desired to fasten a piece of pipe to a channel beam. If a strong, rigid joint were required, it would be necessary to make a _ special clamp, either cast or forged, to hold the pipe. This clamp would have to be bolted or riveted to the channel beam which would mean drilling four holes in the clamp and in the beam. Then would come the actual assembly. Fig. 141 Machine parts manufactured by The Jaeger, Machine Co., Columbus, O. Can any designer think of a more economical method of making these parts? Page 91 4))\ AMDT, P CSTE L(t LCL SLD oe Fig. 142 Typical welds and short cuts. vid Page 92 . By arc welding the procedure is much simpler. The pipe is placed in position and molten steel deposited along the edges, making pipe and beam an integral part. The entire job would be finished in less time than it would take a draftsman to make a drawing of the clamp. Some of the sketches reproduced here are actual details of equipment in regular production, others are suggestions only. The only limit to the use of standard parts is the in- genuity of the designer. Another important feature of arc welding is the possibility of build- ing up pads, lugs and bosses. Where such a raised projection is necessary it can be made either by welding on a small piece of steel of the proper shape or by depositing metal from the electrode and actually building up a solid homogeneous pad. Fig. 143 Pads and bosses can be built up by de- positing metal. The illustration shows a cross section of such a pad. Frequent examples of this practice are illustrated in this manual. Fig. 144 Standard products can be used for special purposes when the designer possesses ingenuity and an arc welder. Here are four money saving examples used on products manufactured by The Jaeger Machine Co., Columbus, O. Page 93 Fig. 145 Typical welds and short cuts. Page 94 Fig. 146 Arc welding is now used by most manufacturers of tank trucks because an arc welded seam remains permanently tight. The Heil Co., Milwaukee, Wis., manufacturers of all kinds of tanks, were pioneers in the adoption of arc-welding. Truck bodies of every description are arc welded by the Truck Equipment Co., Buffalo, N. Y. Welding makes every plate and every brace a single integral piece. Page 95 Fig. 148 The Giant Slide at Riverview Park, Detroit, Mich., affords pleasure to thousands of persons each season. Their safety depends on arc-welded construction. Page 96 ae ohige Arc Welded Design for Structures The use of arc welding for join- ing the structural steel framework for buildings and bridges is an ac- complished fact. A few of the structures made by arc welding were mentioned in an earlier section of this manual. The reason for using arc welding instead of riveting was solely because welding was better and more economical. It is entirely possible to arc-weld the framework for the tallest skyscraper, and eventually arc welding will largely replace riveting in this field. One of the largest manufacturers of fabricated steel has carried out extensive experiments on arc weld- ing. Their experiments have con- vinced them of the entire reliability of arc welding and also of the sav- ings possible by this method. The photographs reproduced here show- ing typical welded connections were taken from actual members used in construction work by this company. The details of arc welded designs are very little different from the de- tails of riveted designs. Figure 149 shows the main girder of a crane runway. This girder consists of a web plate, two angles on the bottom flange, and two an- gles and a cover plate on the top flange. The illustration clearly shows the method of welding a con- tinuous bead for a distance of 30 inches from each end of the girder, and tack welding the intermediate distance. Fig. 149 ‘Main girder of runway for 100-foot span overhead traveling crane. Page 97 Fig. 150 Roof trusses of arc-welded steel are made for any span from 40 to 60 feet by the Massillon Steel Joist Co., Canton, O. Fig. 151 Arc-welding made the Massillon Bar Joist possible. The design of this joist permits running pipes and conduits in any direction. There is the further advantage of light weight. Manufactured by The Massillon Steel Joist Co., Canton, Ohio. Page 98 Fig. 153 End view of plate and angle girder. Bars instead of an- gles are used for web braces. Figure 153 shows an end view of this girder. It will be noted that bars instead of angles were used for the web braces. This is possible because of the great strength of the fillet welds. _ Figure 154 shows a plate welded by a fillet onto an I- beam. The strength of this con- struction was questioned by one of the men in the erection shop and it was decided to make a real test. One man with a twelve pound sledge struck the plate 16 times on one side and 30 times on the other side with- out doing more than bending the plate. A battering ram, weighing 587 pounds, was then suspended from the crane hook and after 46 blows were struck the weld showed no failure. Fig. 152 Fig. 154 Column for supporting crane runway Forty-six blows with a 12 pound sledge for 100-foot span crane. made no impression on this weld. Page 99 Fig. 155 The Diamond Hardware Mfg. Co., Pittsburgh, Pa., are weld steel roof trusses for small garages, warehouses and factories. These were formerly riveted, but arc weld- ing was found faster and less expensive. 2 Fig. 156 Page 100 —sI*. | Fig. 158 Figure 157 shows the method employed for welding a lintel used in a brick and steel building in Can- ton, Ohio. This carries a cover plate for the brick wall and also a shelf angle to support the floor joists. The tack welds are about four inches long. Figure 158 shows the method of welding end-connection angles, and seat angle construction is shown in figure 159. Page Ior Fig. 157 Fig. 159 Fig. 160 Template for drilling machine base. The template as well as the product is arc welded. Fig. 161 Jigs and fixtures arc welded by The Jaeger Machine Company, Columbus, Ohio. Page 102 Fig. 162 Punches and strippers made by arc welding. This illustration deserves close study. Arc Welding in the Tool Room Manufacturers have long been accustomed to high costs on special tools such as punches and dies and on jigs and fixtures. It is to be ex- pected that where only one or two similar tools are made, that the cost will be considerable. However, arc welding will reduce these costs. The toolmaker who knows arc welding is in a position to produce special tools more quickly and more economically. Figure 162 shows several punches and strippers made by arc welding. Steel plate replaces castings, eliminating pattern ex- pense. The cost of machine work is reduced by welding on projec- tions and lugs instead of machin- ing these parts from solid steel. Arc welding changes the entire conception of machine shop practice because now it is possible to add metal as well as remove it. The metal added is as homogeneous as rolled steel itself. At last the much sought for “adding on tool’ is here. Figures 161 and 163 show ma- chining jigs made by arc welding. Patterns are entirely eliminated. Think of the saving in time to pro- duce these jigs! Standard steel sections are used. The toolmaker puts them together. He does not wait for the patternmaker or the foundryman, but builds direct from his own sketches. Fig. 163 Jigs and fixtures made by arc welding. Page 103 Fig. 165 Steel replaces cast iron in the Robinson Furnace made by The A. H. Robinson Co., Cleveland, Ohio. All seams are arc dA, aly welded. Fig. 164. Dirt and gas cannot escape ; through walls of arc-welded steel. This seamless furnace is made by The Water- man-Waterbury Co., Minneapolis, Minn. A Fig. 167 ; Arc welding is used to give added stiff- Fig. 166 ness to the American All Pressed Steel The Foamite mixing chamber for dis- Shafting Hanger, made by American Pul- charging Firefoam is built of arc-welded ley Co., Philadelphia. Steel hangers steel. This equipment is manufactured ‘ weigh about half as much as cast iron by Foamite-Childs Corp., Utica, N. Y. hangers. Page 104 ved Pepe ep! There Is Real Selling Value in Being Different In redesigning don’t try to copy the appearance of the old design— the new design, if successfully en- gineered, will be sufficiently better and less expensive to overcome any sentimental attachment which tradi- tion-bound customers may have for bulky, massive, cast iron structures. There is a real selling value in being different, particularly when your product costs Jess to produce than your competitor’s. Freight is often a bar to good markets, and every pound that you can cut off of the weight of your product repre- sents money saved in transportation costs, whether you sell your product f. o. b. factory, or at your custom- ers door. Weight saved means money saved all along the line and on a cents-per-pound basis you will more than have the edge on cast iron competitors. Aim to design something which will do the work in the best possible way and take advantage at the same time of the strength, low cost and lightness of steel. Fig. 168 Dube Water Heater and Garbage Burner built by Grand Crossing Boiler Works, Chicago, III. Note how the water tank is supported on a base made of standard pipe arc welded at the joints. The tank is also arc welded. Page 105 Fig. 169 Arc-welded barrel and drum racks built by Lewis Shepard Co., Boston, Mass. These racks are built of channel sections and combine great strength with light weight. Fig. 170 Cradle for supporting tank on motor truck. Built by The Heil Co., Milwaukee, Wis. Page 106 The Arc Welder in Maintenance Work The master mechanic or mill- wright will find many uses for arc welding. In erecting countershaft- ing or in mounting motors for in- dividual drive machines, supports of SrGuciittamecteel can be erected quickly and at low cost. Figure 171 shows a superstruc- ture for carrying the shafting for a cylindrical grinder. Light standard angles are used and all joints are arc welded. Notice the manner in which the I-beam for carrying the chain fall block is supported. Fig. 171 Countershafting support for cylindrical grinders. Note the method of supporting I-beam for chain fall block. Page 107 Fig. 172 The truck for this portable unloader, built by The Burch Plow Works Co., Crestline, O., is arc welded for strength and rigidity. There are countless other machines now riveted or bolted where arc welding will add'‘to the strength and at the same time reduce the cost to manufacturers. Fig. 173 The base of this self-contained refrigerating unit is made of arc welded steel. Photo- graph by courtesy of Baker Ice Machine Co., Inc., Omaha, Nebraska. Page 108 Twelve Points to Remember in Redesigning 1. The I-beam is the stiffest structural shape for its weight that can be designed. Use it for col- umns, or for transverse members to resist compression or bending. Z. The angle is strong in both compression or bending, and has the advantage of lending itself readily to arc welding. 3. Welds should be put out of sight to eliminate finishing. 4. Do not go to a special shape unless absolutely necessary, special shapes often mean costly delays. There is usually a way out. if the problem is studied thoroughly. 5. Don’t feel that it is necessary to make the entire structure of rolled steel. Use castings, forgings or stampings where they are more eco- nomical. Arc welding is a new tool, not a fad. 6. A lap weld may save many times the cost of making a butt weld by facilitating assembly and by the elimination of accurate fitting. or heavy plate. Fig. 174 ‘Arc welding is the most economical method of joining metals whether it is thin sheet 7. Chamfering the edges may be, but is not usually, necessary. 8. Use tack weld for assembly and after the structure is assembled, completely weld up the structure. Surprising economies are effected in this way. 9. Use carbon electrode welding when the section is heavy and easy to get at, as it is faster and more economical. 10. Don’t expect that you can re- design all of your apparatus at once. Speed is necessary, but speed and ideas do not always go together and ideas are more important. 11. Don’t forget that the product you are now making will eventually be made by arc welding. The man who gets the answer first will be the leader and will reap the rewards of the leader. 12 .otr engineering department must be “welding minded.” Weld- ing is a more useful tool to you than your drawing instruments. These parts are manufactured by The Jaeger Machine Company, Columbus, Ohio. Page 109 Fig. 175 Arc-welded reinforcing for concrete bank vaults. When this rein- forcing is installed every joint is welded, making an integral barrier of steel concrete reinforcement. Vaults of this construction defy fires, earthquakes and organized attacks of mobs. This is one of the applications of arc-welding made by the Massillon Steel Joist Company, Canton, Ohio. Fig. 176 Lewis-Shepard jacklifts are noted for their sturdy construction. Arc welding helps to ; maintain their reputation. . Page r10o CHAPTER V Strength of Arc Welded Joints T has frequently been stated in this manual that arc welding is the strongest method of joining steel parts. To those who have heretofore thought of welding as a sort of patching process, this state- ment may come as a surprise. It is, however, a literal fact that 100% joints are regularly made by arc welding, and the following discus- sion will show how this is possible. Strength of Butt Welds Let us consider, first, the butt weld. This style of joint is used chiefly where the parts are in ten- sion. Since the metal comprising the weld has the properties of cast steel, its tensile strength is the same as that of cast steel. This is less than the tensile strength of rolled steel. However, by depositing a sufficiently large cross section of metal, the tensile strength of the weld can be built up to an amount equal to, or greater than, the strength of the plates joined. Ifa bead equal to 15% of the thickness of the plate be deposited on both sides, the strength of the weld will be equal to the strength of the plate. Strength of Lap Welds In a lap weld subjected to tension the weld is subjected to a bending stress as well as a tensile stress. The amount of the bending stress de- pends on the thickness of the plates. In practice it has been found that when a bead of welding metal equal to the thickness of the plates is de- posited on both edges, as shown in the illustration, the strength of the weld will be approximately equal to the strength of the plates joined. Fig. 177 A single lap joint should not be used to join thick plates. The stress on this joint is not pure tension, but a combination of tension and bending. Fig. 178 In riveted construction it is customary to use a butt strap as shown. Fig. 179 In arc-welded construction it is only necessary to weld both sides of the plates. This joint is as strong as the members joined. In a lap weld the metal comprising the weld is in shear. It may be in either transverse shear or longitu- dinal shear. Experiments have shown that welds in transverse shear are stronger than welds in longitu- dinal shear. In sketch 180, the metal deposited along the edge c is about 30% stronger than the same metal laid along edges d or e. Metal deposited along edge c is about 30 percent stronger than the same metal de- posited along edge d or e. Page Iii 20000 19000 TENSION OF FLUSH TOPWELD —— Sea ae eae revel leas re CROSS SHEAR an AS je i Bats fe SSRREeee Teel ey 3 ve Tk G 8 1 4 i 16. se (A) Fig. 181 Rupturing force per linear inch of weld. Page 112 Strength of Fillet Welds The strength of fillet welds de- pends entirely upon the amount of metal deposited. If sufficient metal is deposited on both sides of the plate, the strength of the weld can be made far greater than the strength of the plates them- selves. Strength of Rivet Welds The rivet weld is not used pri- marily for strength. It is not pos- sible to obtain a 100% joint by this process any more than a 100% joint can be made by ordinary rivet- ing. The rivet weld is stronger than ordinary riveting, because the welding metal completely fills the hole and is integral with the plates themselves. There is no possibility of weaving in a rivet- welded joint. Rupturing Force Per Linear Inch of Weld The chart reproduced on Page 112 shows the rupturing force per linear inch of weld. From this chart the proper length of weld for any style of joint can be computed. The values given are conservative and designs based upon them will be amply safe. Since these are ruptur- ing forces they correspond to ulti- mate strength given in tables on strength of materials. In applying these figures the customary factor of safety should be used as in the case of ultimate strength of other mate- rials. In the case of welds less than 6” long it is customary to add 4” to the theoretical length of weld to allow for the starting and stopping of the arc. The curves for both cross shear and longitudinal shear are based upon bead sections con- vex outward as shown in Figure 181. Greater convexity will in- crease the strength and lesser con- vexity will decrease the strength. Page 113 EFFICIENGY OF KWVEIEL [= MGI wg « WOW y — any, RIVETS /17 RIVETS 1/7 DR/FAL\ P/AY PUTLH >| EFFICI- P/TLH | EFFICT- HYCHENVILY~ 77 \WILHES|LEVILY-77 SIPIGLE RIVETEPR STEEL SOUTTS 2 w |_& YHA SD fF cS © fe IN yee ~~ ve) mH Ps OO a Ia HD |p BV [8 [S/S \ GD |) | aes | 345 MN KN AN Q&A A Wy IN \ (y pS) % N Oy N w RNY yd ww LD \ Ler p=Ftren Or kivars, os Diarra rer Ot Ceivenkivers s 7° LPCIt gency 2a Kerio le FrRen6TH OE Solyt [OFTRENETH LF Soup Farres Then a= 3%x.50 Fig. 182 Page 114 Comparative Strength of Welded and Riveted Joints In an-analysis of the strength of welded joints it is convenient to compare the welded joint with the corresponding style of riveted joint. The simplest form of welded joint is the lap weld. This welded joint corresponds to a lap riveted joint. It may be single lap welded or double lap welded just as a joint may be single riveted or double riveted. In a lap-riveted joint there are three ways in which failure may occur : 1. The plate may crack along the line of rivet holes. 2. The rivets may shear off. 3. The plates may tear out at the ends. In a riveted joint designed for maximum strength in tension the rivet spacing, size of rivets, and distance from end of plate must be carefully determined. In practice tables are used, based on theoretical computations plus the results of practical experience. Such a table is given on page 114. It will be seen from this table that the efficiency of a properly made riveted joint ranges from 45 to 76 percent. In welding, the plates to be joined - are not weakened by punched holes. Therefore, it is apparent that two of the three causes of failure in riveted joints are avoided by welded con- struction. The plates at the joints are full strength, and are no more liable to fail at the joint than at any other point along their lengths. Fig. 183 Riveted joints fail in three ways. Plates crack along line of rivet holes. Rivets shear off. Plates tear out at end. Page 115 Fig. 184 Kiln Accelerator Fan, manufactured by Robinson Ventilating Co., Pittsburgh, Pa. The fan blades, formerly of cast iron, are . ; now arc-welded steel. Welding has super- Fig. 185 seded riveting throughout. Fig. 186 Seat assembly for Ford chassis completely arc welded by W. C. Nabors, Mansfield, La. Page 116 A handy table is reproduced below, showing the size of weld, equiva- lent in strength to rivets of various sizes. In computing the size of welds equivalent in shearing strength to rivets of various diameters, the same factor of safety has been used in both cases. These values for length of weld are derived from the curve of cross shear in Figure 181. A safety factor of 4 was used and a %4” added to the theoretical length. In case rivets are to be replaced by weld in longi- tudinal shear the table may be re- computed by the use of the curve for longitudinal shear in Figure 181, “or substantially the same results Fig. 187 Cross section of a riveted joint. Note how, in cooling, the rivets have shrunk away from the sides of the rivet holes. This illustrates one great weakness in riveted construction. may be gotten by simply increasing the length of weld given in the above table by 30%. SHEARING VALUES FOR WELDS AND EQUIVALENT SIZE OF RIVETS ly” Bead Value inch of Value Bead, Ibs. inch of Rivet at 10000 Bead, Ibs. Size of Rivet, inches Length of Bead, Shearing Value of Shearing per Shearing per 4” added to theoretical length of weld. ts Bead Length of Bead. 34’ Bead Value inch of Value Bead, lbs. inch of Value Bead, lbs. inch of Bead, lbs. Shearing per Shearing per Shearing per 3200 3200 3200 | 3 1%| 4100 2341 4100 4100 Page 117 = Hige 9078 lbs. pela failuce 22,000 /bs. -& ers G. Hicé Fig. 188 ; Tension tests of welded and riveted joints. Page 118 | Tests of Welded Joints to the same test as the riveted sec- tion and after 24,900 alternations, failure occurred in the channel out- A striking example of the super- iority of welded joints over riveted joints, where subjected to alternat- side the weld. ing stresses, is illustrated by the two tests described below. For the first test a section was made up of the same material and by the same methods as used in the manufacture of a well known motor truck frame. This section was sub- jected to repeated alternating stress by mounting it on a shaper base as shown in the illustration. At 200 alternations of the stress the top rivets in the gusset plates became loose. The second and third pairs of rivets in the gusset plates failed, as shown on the chart below. Next the five rivets in the angle connected to the channel worked loose. Fol- lowing this the two upper rivets at the far end of the I-beam section be- came loose, and failure occurred where the channel section had been weakened by the rivet holes. Fig. 189 In the welded test sample the angle stiffener was omitted, as ex- perience had shown that it was not required. The piece was subjected Fig. 190 FESULTS OF TEST. SYIOW/NS PROGRESSIVE PAHILURPE QF FIVETEO PIECE ANO HIGH RESISTANCE TO FAILUPE OF ELEETRIC ARC WELDED PIECE Se oe 1 -----| ee SN | feat | ae Pee wa | . eee ad 8 i —— w S eee pase w L easy Leas | & arse ce ae Fy Svar oc BN 59 ee eo 4000 23.000 Alternating stress test riveted joint—welded joint. Page 119 Since in riveted construction, the actual strength of a joint is mate- rially lessened the instant that one rivet works loose it is apparent that 200 alternations in the stress were sufficient to cause incipient failure. On the other hand in the welded construction, the joint proved stronger than the members joined. We The results of a similar test with a Bek simple T-section are shown graphic- ally in the chart below. Here again the riveted joint failed where the members had been weakened by rivet holes. The welded joint proved far stronger and failure oc- curred outside the weld. Fig. 193 FPESULTS OF TEST: SHOW/NG PROGRESSIVE FA/LUAE OF AWETED VOINT AND HIGH DEGHEE OF AIG/OITY OF WELDED JOINT wee) | _| | | | | s | . x B4R FA/ILEO \THRU N) PRIVET HOLES GAP FAILED Ra Ny kt 1000 3000 SOOO HO 6200 F000 QE SHO Fig. 194 | Alternating stress test riveted joint—welded joint. Page 120 Welded Joints Are Reliable Naturally the human element en- ters into the construction of a welded joint just as it does into the con- struction of a riveted joint. A riveted joint, even though correctly designed, may not develop its full strength because of improper work- manship. It very frequently hap- pens, particularly in field riveting, that the holes in two members do not register properly. It is neces- sary then to ream the holes before the rivet can be driven. This re- sults in an oval shaped hole which the rivet can not possibly fill. The rivet itself is deformed and the joint will be far below its com- puted strength. In structural work it is frequently necessary to force the rivet holes into alignment by driving drift pins. This means that when the joint is complete there will be an additional stress on it, due to the tension in the member forced into place. There is the additional danger of driving burned rivets or rivets which are too cold. Both of these are well recognized causes for failure in riveted joints. It is a fact that because of lack of familiarity with the welding process there exists a prejudice on the part of some people against welded con- struction. If one will stop to realize that every time one rides on a steam train his very life depends on the strength of arc welding, it will be seen that this prejudice is unwar- ranted. Arc welding is used ex- tensively in the manufacture and maintenance of steam locomotives. The boiler flues are welded into the back flue sheets, broken cylinders and even broken main frames are repaired by arc welding. It would be difficult to conceive a more severe test of dependability, or a test where a failure would be more dis- astrous. Welded joints can be inspected with the same degree of certainty as riveted joints. Visual inspection can not be depended upon one hun- dred percent in either case. If proper workmanship is employed a welded joint can be relied on to de- velop its theoretical strength. Fig. 195 Arc welding the main frame on a passenger locomotive. found of the dependability of arc welding! What greater proof could be The railroads were among the first to see the possibilities of arc welding. Page 121 Fig. 196 The frame for this foundry sand cutting machine was formerly made by riveting at a cost of approximately $200.00. Arc welding reduced this cost to less than $60.00. Manufactured by the Production Equipment Co., 1521 Windsor Ave,, Cleveland, Ohio. CHAPTER VI The Speed and Cost of Welding RC welding is cheaper than riv- eting and cheaper than any other method of welding. This is true because in arc welding, power is utilized more efficiently than in any other method of joining metals. The power required to operate an arc welder is just about equal to the power required to operate one com- pressed-air riveting gun. The labor cost is of course much less than for riveting as one welder does the work of an entire riveting crew. Arc welding utilizes power more Tv * 8 Pitre Fig. 198. Comparative costs of riveting, gas welding and arc welding based on continuous operation. efficiently than gas welding because the electric current is transformed directly into heat and the heat is developed within the metals to be welded. In gas welding, heat is generated by the burning of gas which was originally produced by electricity. This process of trans- forming electric current into heat is indirect and therefore wasteful. Furthermore, the heat is developed at a point outside the weld and a large part of the heat of the flame is dissipated. Page 123 iepemmero red rialarlwaiba |] 7 ja Tadd OR A A baw | VI Ly iy fe cups da me ce ji a nea an fe ea avait i . ya Sune HBen ie b's feet pil 27s vA | Te ie sn aD Wa raise aa alate oe ati ate en - Host itil HeGe ia Z. TREE ea rte ae 3 Rte Ase BL oa SiH Mae nue ff ee ae Heal rat atte FAA Een i al eet AT TABS Bb A ce ae fF A Seal vl te (ane oe pee a Hae et tL ae a Slab aut ay Ly atti Hin apalEne ae Et At a eect ae / 7 Af ce Hi 4 ee il eve a Brea a eo ce 2 ie eee eerie sealed Las WELL 26s! i rH -“Gaa G ae pases aioe | 4 EF ; Hd : Se ; i aPeaits : : ae ee at jiicieen tne poe a iit a . a ie oe an Pe fh ie ee a s Eyes race tle Se Ga ew ee ie YAS | Eee ane et eu ee a ueua uae ACSA Ee zg (a eae ante Ele et tae gti a ae ae gees muni ttt 8 HH YICE a cee a Hina mean Be tras ‘ne HERE ‘aa ce at seausaus pe tt ne) Sia: tHE PHT cette pearteetl Ha Hi frais FEE EESeeer Seees Oo 70 a INCHES OF W. ELD Pade oh Wf2b/es Fig. 199 ‘Piece work speed for horizontal fillet welds with metallic arc. No allowance for set up or fatigue included. "OEE "ON JOA M3N a ¥3883 PF 1953NIy Page 124 Cost of Arc Welding Compared to Other . Methods of Joining Metal The chart reproduced in figure 198 shows the relative cost of joints, single riveted, double riveted, gas welded and arc welded. The cost is given in dollars per foot of seam for metal of various thickness from ¥% inch to 1 inch. . It will be seen, throughout the entire range, arc welding is the least expensive pro- cess. The costs given on this chart (Fig. 198, page 123) are direct costs and do not include any charge for depreciation or upkeep. Gas welding is frequently used in repair shops where welding is inci- dental to the general repair business. This is because the first cost of equipment for gas welding is less than the cost of an arc welder. While the investment in an arc welder is not large (usually less than $1000) it is still an item for the small shop. DAILY COST Cc ae A 8 OF TE On However, when the amount of welding is more than three linear feet of weld per day, arc welding is more economical than gas welding. This is shown graphically by the chart reproduced in figure 200. On this chart is a curve showing the fixed charge at 17 cents per day. A second curve shows the daily cost of gas welding with the fixed charge reduced to zero. ‘That is, it is as- sumed that the equipment for gas welding cost the user nothing. The fixed charge for the arc welder is taken at 60 cents per day. Even on this basis it will be seen that arc welding is far less expensive for production welding. The chart figure 198, showing the cost of arc welding per foot of seam for various thicknesses of metal, is sufficiently accurate for purposes of comparison. It is, however, not suitable for estimating purposes. 10 Feet of 14” weld per day. Fig. 200. Daily cost of operating a gas welder and an arc welder. Gas welding costs shown both with and without fixed charges. Page 125 it rH hoe co HH oy ryt 22 OHSRS 2O0N8 88085 SSRs Fonte eeE: Pt 4 2208 seeesaaee8 on r + 57? Cee epriEie if i. ce L HE a He Evista 2s Hi ate Hai cae 4 iti Q oe eat an oF are a : oe aSRERI IE Th salve ee ile . 8 so BE ae ae Aes Se HEdietniieitint ici pee a ua oo BRIE BEE Ht = Hi . ae cpt Eimstl HH site iatiittnit: | pina ais eed etal Sa iH The Hutte ESE an alii E Sess ee nae 3 ES siliztal faa tiiifits asad te iti irate HMiee eee TE HEH HE HE HEH ce ae TIE Leal giit Siaitaes ef ena eee qe at ft poe eee al aa EEE zeae ee eet TE EE i 4: o 3 ah df Cs: a “ a z& o = 7 CS SIEE HULLET @ Fig. 201 Piece work apg for horizontal fillet welds with metallic arc. No allowance for set up or fatigue included. if pays “esas Page 126 The Speed of Welding It is important to know that the speed of welding and consequently the cost of any job can be estimated in advance with the same degree of accuracy that the cost of any ma- chining operation can be estimated. Most production welding is done on a piece-work basis and the problem of determining rates for any kind of welding becomes very simple when the principles are understood. The following paragraphs give the theory of determining welding speeds: The time required to make a weld varies directly with the rate at which the metal is melted. It is therefore necessary, first, to know the rate at which an arc welder will deposit metal. This is found by reference to a curve such as is reproduced in figure 202.* The nature of the weld determines the size of the electrode and also the proper current to be used. Knowing these, the amount of metal deposited per hour is read directly from the curve. Divide the amount of metal to be deposited (in pounds) by the rate of deposition and the result is the time required to make the weld. DIAMETER OF ELECTRODE “ H +A wy POUNDS OF| ME7HWL mle PER WOUR N 25 50 75 100 125 150 175 200 225 250 275 300 Fig. 202 Pounds of metal deposited per hour by metallic arc. *NOTE—The rate at which metal is deposited is not the same for all makes of arc welders. The curve reproduced in figure 202 shows the rate of deposition for the Lincoln Stable-Arc Welder manufactured by The Lincoln Electric Co. It should not be used in computing the speed of welding with any other make of arc welder as all arc welders are not equally efficient. Page 127 ZZ a |e ee ee LATERL | 7 t 2) oa, 2 eek | eRe Pa ney Fig. 203 Piece work speed of welding 60° double bevel. Metallic arc. Page 128 Curves Showing Speed of Welding In practice it is usually not neces- sary to go through all of this compu- tation to determine the speed of welding as the figures have been worked out for all typical welds. Curves reproduced in this chapter show the speed of welding for vari- ous styles of welds. The time re- quired to make any ordinary weld can be read directly from these curves.* No allowance is made for set up time or for fatigue of operator in these curves. Naturally the time which the operator is actually de- positing metal will vary with the nature of the work.’ An average would probably be about sixty per- cent: The person in charge of piece work rates will quickly learn what percentage of actual operation can be expected for different classes of work, *NOTE—These curves are based on the rate at which The Lincoln Stable-Arc Welder will deposit metal and will be found very accurate for determining welding speeds with that machine. These curves should not be used in determining the speed of welding with other machines for reasons explained in the previous foot note. Fig. 204 Eight and three-quarter hours were required to rivet the drum on this concrete mixer. It is now arc welded in five hours. This is one of many applications of arc welding . made by The T. L. Smith Co., Milwaukee, Wis. Page 129 MIO of. eae LISS TLE TET 2 N " Fig. 205 Piece work speed of welding 60° single bevel. Metallic arc. Page 130 The Cost of Welding The cost of welding is found by multiplying the time required to make the weld by the hourly rate. The hourly rate includes: Cost of labor. Cost of welding wire. Cost of current. The cost of labor is the largest item for all classes of welding. Rates vary widely but the rate of 80 cents per hour is assumed for this discussion. The cost of welding wire is the next largest item. This varies di- rectly with the amount of metal de- posited. When welding continu- ously a welder operating at 250 am- peres, with 1% inch electrode, will deposit about 61% lbs. of metal per hour. This figure should be in- creased by 20% to cover waste, making the amount of welding wire required for continuous operation, 7% \bs. per hour. At 8 cents per pound, the cost of welding wire would be 60 cents per hour. In actual practice the welder will operation. not be in continuous Some time must be allowed for setting up work and for fatigue of operator. Assuming that the weld- er is in actual operation 60% of the time, the cost for welding wire will be 36 cents per hour. The cost of current is the smallest item. This cost varies with the power rate per K. W. H., and the percentage of time that the welder is in actual operation. Assuming a power rate of 2 cents per K. W. H., the cost of power for continuous operation, will be approximately 13 cents per hour. The sum of these items gives an hourly rate of $1.29 for 60% operation, Sixty per cent operation was chosen for the discussion above be- cause it represents average condi- tions. There will frequently be cases where the percentage of opera- tion will be much higher than this. When this is true, the hourly rate will increase slightly as more weld- ing wire and more power will be required. Fig. 206 Eight hours were required to drill, fit up and rivet the load bucket illustrated on the left. The welded bucket was completed in 414 hours,—a net saving of 3, hours. Photographs and data furnished by the W. E. Dunn Mfg. Co., Grand Rapids, Mich. Page 131 = SP ey Ae Fig. 207 Piece work speed of welding 90° corner weld. Metallic arc. Page 132 Overhead g The overhead cost includes the same elements of first cost of equip- ment, cost of floor space, light, heat, etc., that are figured for any other production tool. There is usually a very great saving here. Since prac- tically all factories are supplied with electricity, there is no space required for auxiliary equipment such as air compressor, or gas generator, which are required for riveting, or gas welding. The arc welder takes up very little space and in many plants is mounted on a portable truck and moved from place to place as the work requires. Method of Figuring the Cost of a Typical Weld Fig. 208 PROBLEM Figure cost to make a single lap-welded joint 72 pg ce long, between two plates 14 inch thick. First Step. Determine time required to make the weld, assuming con- tinuous operation. This is found by referring to the curves reproduced in figure 199. The curve for plates % inch in thickness shows that to weld 12 inches of seam requires approximately 514 minutes. To weld 72 inches, assuming continuous goon: will require 72/12 < 5% or 33 minutes. Second Step. Determine the percentage of time that the welder will actually be depositing metal. This depends on set-up time, etc. For this example let us assume 60% operation. The total elapsed time will then be: 33 & 100/60 or 55 minutes. Third Step. Compute cost of the weld. Since the hourly rate for an arc welder for 60% operation is $1.29, the cost of making the weld described above is: $1.29 & 55/60 = $1.18. Page 133 Fig. 209 The old tradition that steel pipe would not last underground has been effectually killed. Today, by far the greatest amount of land pipe is made of steel. Steel pipe is made most economically on automatic arc welders. Here is a stack of 20” diameter pipe arc welded by The Lancaster Iron Works, Lancaster, Pa. ee Fig. 210 The National Grave Vault Co. gives three reasons for substituting arc welding for riveting in the manufacture of grave vaults. They are: More permanent construc- tion, better appearance, and lower costs. This company was among the first to adopt , automatic welding. . Page 134 CHAPTER VII Automatic Arc Welding HE automatic arc welder is literally a sewing machine for steel. By this remarkable machine the edges of two pieces of steel plate can be joined with the same facility that a seamstress joins the edges of two pieces of silk. In automatic arc welding the edges of the plates to be welded are held firmly in the proper position for welding by a jig or fixture. The electrode forming one end of the arc is moved automatically along the seam or the work itself is moved past the electrode at the proper speed to insure a perfect weld. Pro- vision is made for feeding down the ELECTRODE HOLDER WORK TO BE WELDED electrode, as it 1s consumed, at ex- actly the proper rate to maintain a steady uniform arc. Once the correct speed of feeding has been determined it is only neces- sary to place the work in position and start the arc. There is no more spectacular operation in the entire field of manufacturing. A machine which joins solid pieces of steel with a joint of equally solid steel, the en- tire process unaided by human hands, is a far cry from the old method of pegging steel together with rivets. SOURCE OF CURRENT Fig. 211 Diagrammatic view of Automatic Welding Process. Page 135 Fig. 212 There are no rivets to rust or corrode in this arc-welded stack, built by The Leitelt Iron Works, Grand Rapids, Mich. * Page 136 Field for Automatic Welding The field for automatic welding is wherever similar steel parts are to be joined in production quantities. The shape of the product, the length of weld, the weight or thickness of the steel are of minor importance. If the quantities are sufficiently large, automatic welding will re- duce the cost of making joints. In addition to the obvious appli- cations such as the manufacture of gasoline tanks, the automobile in- dustry utilizes automatic welding in making rear axles, frames for self- starter motors and many other products. Range boilers and grave vaults are welded automatically. steel) pipe up to 65, inches in diameter has been welded auto- matically with astounding savings. Crude oil storage tanks of large pro- portions are welded by a most in- genious self-propelled welding head which follows the seams with un- canny accuracy and joins each seam with a permanent leak-proof joint. If steel is to be joined to steel in automatic production quantities, welding should be investigated. Fig. 213 Welding inside seam on small tank. Page 137 Table of Speeds and Costs of Automatic Electric Arc Welding ———_, Joint Before Welding (SD rey Joint After Welding Joint Before Welding THe eee Joint After Welding Gauge of Material 14 12 10 ve Speed in Foot per Hour 5 135 105 80 65 0 275 300 a 35 Data for Butt Weld (One Side Only) Gauge of Material ... 18 16 14 12 10 rs Yy 3% 1" 5% 34 Speed in feet per hour} 170 160 150 100 75 60 40 25 17%! 14 10 Current (Approx.) ...| 275 300 325 350 375 400 450 550 650 700 750 Size Filler Rod GApprom hin. 33 % % 33 is is Ye |x [4x56 | xd | ox34 Size Carbon (Approx.)| 14 4 Y yy 15 15 x% 4 6 4 4 Total Cost per Foot. . |$.0097} .0110] .0119] .0187] .0252] .03 .048 085.) 23317) sl 7021222383 YY \y yy 4 .0084 a al Wee .0158 .0200 NOTE: On lap weld no filler rod is used. ey Joint Before Welding =A [— Joint After Welding 4 45 400 i6 .0291 SN wt wong NOTE: On edge weld no filler rod is used. These costs include Power at 3c per K.W.H., Metal Electrode at 8c per pound, Carbon Electrode at 13c each, Labor at 60c per hour and cover welding time only. Owing to varying conditions in different plants it is manifestly impossible to give actual costs, includ- ing set up time. If the work is properly organized the arc should be running 75 to 80 percent of the time. Page 138 The Automatic Welder Makes Perfect Welds . In quality of work the automatic welder equals or betters the work of the most experienced manual welder operator. The length of the arc and the rate of feeding are con- . stant and the welds produced are uniform in strength and appearance. The amount of current required for each job and consequently the amount of heat for perfect welds, can be determined once for all. An automatic welder can be set up for a particular job with the same de- gree of exactness that the indexing head on a milling machine can be set for cutting gears. Fig. 215 Upper and lower side of seam made by automatic arc welder using carbon elec- trode. Note how the weld is reinforced on the under side. This is made possible by the use of copper strips which in effect form a mold for the molten metal. Fig. 216 Range boilers produced by Automatic Arc Welding. Note the edge welds on bottom. Page 139 Welding the girth seams on oil tank using a rotating fixture. Speed of Automatic Welding An automatic welder never tires. This is one reason for the greater welding speeds obtained by auto- matic welding over manual welding. The speed of feed can be adjusted for maximum production and this speed can be maintained without in- terruption. This, however, is not the only factor which accounts for the high speeds possible in auto- matic welding. The greatest factor is the utilization of the carbon elec- trode arc instead of the metallic electrode. Page 140 Fig. 218. Automatic welding on gravevaults. Carbon Electrodes Are Used for Automatic Welding The most successful automatic welders utilize the carbon electrode process. As explained in Chapter III, this is a puddling process and The heat of the arc melts the edges to be not a deposition process. joined and where additional metal is required it is supplied by a filler rod which is laid along the seam prior to welding. The small pool of molten metal underneath the arc is kept in bounds by water-cooled copper strips which in effect form a mold. The edges of the plates to be joined and the metal supplied by the filler rod are melted simultaneously and as the arc moves along the seam this molten pool cools and solidifies, forming a solid homo- geneous weld. By this process oxidation is at a minimum because only the very small surface of the molten metal is in contact with the ait. Since the edges of the plates and the metal added by the filler rod are in the molten state at the same in- stant and cool at the same time there is no possibility of laps or seams by this process. With a carbon electrode there is no limit to the amount of current Page 143 that can be used. With a metallic electrode there is a very definite limit to the amount of current. This limit is the amount of heat which the tip of the electrode itself will stand. Obviously if it were attempted to ~ put a very large current through a small metallic electrode the electrode would burn up almost instantane- ously. the small currents suitable for weld- Even with comparatively ing on light material the problem of feeding metallic electrodes is much more difficult than the feeding of carbon electrodes. A much finer adjustment is necessary, requiring intricate mechanism which is not re- quired on a carbon electrode welder. Automatic welding with the car- ° bon arc is more economical than with the metallic arc for two rea- sons. First the speed of welding is greater, and second, the cost of filler metal is less with the carbon arc process. The speed of welding is greater because more heat can be utilized at the arc which means that metal is melted faster. The cost of filler rod is less be- cause a smaller amount is used and also because the cost per lb. of the mild steel rod or strip which is gen- erally used in carbon are welding is less than the cost per lb. of the spe- cially prepared wire which must be used in the metallic arc process. Page 142 Twelve Inch Pulley Weight Cost eecee TOR ee ee Poelbs wer Viaterial 22s oe $7.90 Labor ee eee 2.99 $10.89 Matetial.aee ae 31.20 pteel aa —--- = -=-=-—-+ ~~~ ---- ~~ GTA ky NE i 185 3.05 Wall Box Weight Cost UP LATS Ae at ana 35 Ibs. $2.10 Material... 3. ee. $ .42 Steel ----------____------------- 14 Ibs Lahore 2S ee 30 he Support Weight Cost CrastmiCOite we ee eee Lk 27 lbs. $2.27 Material _________ sien We $ .42 has Do ay i TR se 140 1bs.- oLabor.be see eee 23 65 Fig. 219 Striking examples of the substitution of arc welded steel for cast iron. The Baker- Perkins Company, Saginaw, Michigan, who developed these applications supplied the cost figures. Page 143 ‘ Fig. 220 Spherical tank in course of erection by the Chicago Bridge and Iron Works, fabri- cators of Horton Steel Tanks. This “Hortonsphere” is arc welded throughout, making it the most economical as well as the strongest type of storage tank that can be designed. . Fig. 221 . Mast head fittings built by the Chicago Bridge and Iron Works for use in connection with erecting “Hortonspheres.” Page 144 Fig. 222 Dump cart arc welded by the Euclid Crane & Hoist Company, Euclid, Ohio. All permanent joints are arc welded. cok : ee | \ a j > \ \ 2, \ os Fig. 223 Wrought iron doors in the home of Harry K. Thaw, Pittsburgh, Penna., arc welded by the Jansen Art Forging Company, Cuyahoga Falls, Ohio. Arc welding effects great economies in the manufacture of ornamental iron work. Page 145 Fig. 224 Electric heater arc welded by Littleford Bros., Cincinnati, Ohio. Fig. 225 The Detroit Stoker, Detroit, Michigan, have cut manufacturing costs to a minimum by arc welding. Coal hoppers, drive chain guards and trench floor plate frames are among welded parts shown in this photograph. Page 146 Advertising Section The Lincoln Electric Co. General Offices and Factory: Cleveland, Ohio The Lincoln Electric Company, of Canada, Ltd., Toronto-Montreal European Representatives: Allen-Liversidge, Ltd., London Distributing Agencies in all Principal Cities EXCLUSIVE AGENCIES WITH STOCK Ft. Worth, Texas Houston Seattle Los Angeles New Orleans Portland Kansas City San Francisco BRANCH OFFICES Baltimore Charlotte, N. C. Davenport Indianapolis Minneapolis Pittsburgh Boston Chicago Detroit Lancaster New York City St. Louis Buffalo Cincinnati Grand Rapids Milwaukee Philadelphia Page 147 ADVERTISING SECTION The Equipment for Arc Welding LL of the welding on the vari- ous products illustrated in this manual was done by the Stable Arc Welder, manufactured by The Lin- coln Electric Company. The Stable- Arc Welder is built in a complete range of sizes and styles to provide for any class of work and any operating conditions. All of these types consist essen- tially of: 1. A standard motor driven by the shop power lines. (This motor furnishes the power for driving the welding generator. Where electric power is not available, gasoline en- gine or belt driven welders are supplied. ) 2. A specially. wound generator delivering current at the proper voltage for welding. 3. A stabilizer acting as a reser- voir of current. 4. A control panel with simple knife switches and meters for ad- justing the amount of welding heat. Fig. 226 As built in the larger sizes. Stationary panel type. Page 149 The Stable-Arc Generator The design and construction of the welding generator partly ac- counts for the uninterrupted flow of heat which is possible with the Stable-Arc Welder. This generator is wound with what is termed a bucking series field which with the laminated steel frame produces a welding current with the proper characteristics described in the pre- vious chapter. Not only the pole pieces but the complete magnetic circuit of the Stable-Arc Welder is laminated, that is, built up of steel laminations or sheets. The electrician will readily understand that this type of construction permits a very rapid change in the magnetism or “flux density” and this in turn makes it possible for the electric current to adjust itself instantly to any de- mand. Fig. 227 Stationary platform type. Built in 200 and 300 ampere sizes. Page 150 The Stabilizer In addition to the laminated steel generator the Stable-Arc Welder is provided with a stabilizer which, in electrical terms, is simply an in- ductance in the welding circuit. This stabilizer acts on the electric current much like a flywheel does on any other piece of machinery. It stores up energy which permits the machine to take care of extraordi- nary demand without difficulty. A Steady Arc Means Good Welds Because of the laminated frame construction and _ stabilizer, the Stable-Arc Welder produces an arc which is steady and easy to main- tain. This means better and faster welding. Frequent breaking of the arc and the necessity of frequent starting produce a brittle and porous condition in the weld. The best welds are made where the arc is kept steadily in operation and the metal thus deposited is homogeneous and strong. Fig. 228 Gasoline engine driven type. Built in 200 and 300 ampere sizes. Page 151 Methods of Driving the Welding Generator The Stable-Arc Welder can be 3. Belt drive. operated by any of the following In the majority of cases electric SSE current 1s available wherever weld- 1. An electric motor operating on ing is to be done. This is the most either direct or alternating current satisfactory and economical method of any standard voltage. of operating the welder. 2. A gasoline engine direct con- nected to the welder. bd Fig. 229 Belted type. Built in all sizes. Page 152 Types of Stable-Arc Welders Stable-Arc Welders are built in sizes of 200 amperes to 1200 am- peres, rated in accordance with the standards of The Electric Power Club. They are mounted in various different ways. to suit different op- erating conditions. The various types are: 1. Stationary Platform Type. This type is built in 200 and 300 ampere sizes. The entire equipment is mounted on a structural steel base and is furnished completely wired and ready for operation. 2. Portable Truck Type. This type is built in 200, 300 and 400 ampere sizes. The entire equip- ment is mounted on an all-steel truck which can readily be moved to the work. This type is also completely wired and ready for immediate use. 3. Belt Driven Type. This unit is built in all sizes. The equipment consists of generator, stabilizer, control panel, and neces- sary wiring. The driving motor is omitted. A pulley mounted on the shaft of the generator permits driv- ing from the countershafting. 4. Gasoline Engine Driven Type. This unit is built in 200 and 300 ampere sizes. A 4-cylinder heavy- duty engine is direct connected to the welding generator by a large flexible coupling. The entire equip- ment is mounted on a rigid arc- welded steel base. 5. Stationary Panel Type. This unit is built only in the larger sizes. The motor and gen- erator are mounted on a steel base. The control panel and stabilizer are separate and can be placed in the most convenient location for pro- duction work. Fig. 230 Portable truck type. Built in all sizes. Page 153 Automatic Stable-Arc Welders Automatic Stable-Arc Welders have been built in a wide variety of forms for highly special products. To describe all of these would un- necessarily complicate this work. All forms consist fundamentally of the following items: 1. Fixture for holding work in place. These fixtures generally con- stitute the base of the automatic welder serving to support the elec- trode holder and the feeding mech- anism. 2. Device for moving the arc along the seam. In some types of automatic welders the arc is moved along the work and in other types Fig. 23 the work itself is moved. In every case there is provision for accurate- ly controlling the speed of the feed by a small variable-speed electric motor. 3. Automatic electrode holder. This holder automatically feeds the electrode down as it is burned away in welding and maintains the arc at the proper length. 4. Source of welding current. A standard Stable-Arc Welder set furnishes the power for the auto- matic welders. The steady unin- terrupted flow of heat which is de- livered by these machines accounts for the remarkable output made on Lincoin Automatic Welders. ae - " ? : Welding longitudinal seams on steel pipe at the Steel Tank and Pipe Company, West Berkeley, Calif. Pipe sections are 30 feet long and range from 48 to 60 inches in dia. Page 154 Types of Automatic Stable-Arc Welders Horn Type The Horn or Mandrel type is il- lustrated in figure 232. This ma- chine welds outside longitudinal seams for cylindrical work such as range boilers, steel barrels, pipe, etc. Steel plate is rolled into shape and the edges to be welded are held rigidly in place by clamps. The lower clamp is a part of the base of the machine. The upper clamp is operated either manually or by means of compressed air. The welding head is driven along a horizontal arm by means of a small variable-speed electric motor. This welding head carries a mecha- nism for feeding down the electrode as it is consumed. Welders of this type are built in lengths of 4, 8, 12, 16 and 20 feet. Fig. 232 HORN TYPE OUTSIDE SEAM WELDER This type is used for welding the longitudinal seams on range boilers, tanks, barrels, pipe, etc. It is built in lengths of 4, 8, 12, 16 and 20 feet. Page 155 Base Type Figure 233 illustrates the Base Type Inside Seam Welder. This machine is used for welding large pipe or tanks. The operation of this machine is identical with that of the Horn Type except that here welds are made on the inside. Be- cause of the large size of the work handled, the holding clamps are operated hydraulically. The Base Type Welder is built in lengths of 20, 24 and 30 feet. It will handle pipe 40 inches in diameter and up. Fig. 233 Base type inside seam welder. This type is made in lengths of 20, 24 and 30 feet. It will weld pipe 40” in diameter and up. Page 156 Head Welder The Head Welder, illustrated in figure 234, is used extensively for bottoming range boilers, steel barrels and small tanks. The welder makes what is known as an edge weld, no filler rod being required. The work to be welded is mounted on a ball bearing rotating table. The weld- ing head is carried by a horizontal arm supported by a vertical column. Provision is made far varying the speed of rotation of the table by varying the speed of the motor and by gear changes. Fig. 234 Head Welder. This type is used extensively for bottoming range boilers, tanks, etc. It makes an edge weld requiring no filler rod. Page 157 Girth Welder The Girth Welder, illustrated in made for controlling the speed of figure 235, consists of a rotating fix- rotation to obtain the proper speed | ture and a stationary support for of welding. Where it is desired to the welding head. The set up tank weld inside seams the Tractor Type is mounted on the rotating fixture of automatic is used as described and the arc started. Provision is on next page. Girth Welder. This machine is used for welding the girth seams of large tanks. The tanks are first tack welded and then placed on the rotating fixture. The welding head mounted on the arm overhead completely welds the outside seams. For welding the girth seams on the inside the tractor welding head is used. Page 158 Tractor Type The Tractor Type Welding‘Head, illustrated in figure 236, is used for a wide variety of work. This de- vice carries a self propelling mech- anism as well as mechanism for feeding the electrode. There is also a guide which enables the weld- ing head to follow a seam auto- matically without manual guidance. The operation of the Tractor Type is almost uncanny. Used in conjunction with a rotating fixture such as is described above, this de- vice automatically welds the inside Its girth seams of large tanks. speed of travel is adjusted to the same rate as the speed of the rotat- ing fixture except that it travels in the opposite direction. The seam passes under the arc and a perfect weld results. This type of automatic is also used for welding longitudinal seams on large work such as the bottoms and roofs of oil storage tanks. Only lap joints are welded by this ma- chine. Fig. 236 The Tractor Type Welding Head. This welding head is self propelled by a small variable-speed motor. It carries the carbon electrode together with the mechanism for feeding down the electrode as it is consumed. The tractor is used in connection with a rotating fixture, for welding inside girth seams for large tanks. It is also used for welding longitudinal seams on a great variety of work. Lincoln Engineering Service The large number of Stable-Arc Welders in operation and the re- markable work which they are doing is a testimonial.tc the -sérvice® ° renderéd by Lincolri ° engineers: Every manufactutet ccnsideritig re-: ing is urged to submit his problem to the engineering staff of this com- Pans Plein eexperictice sie rede. igning covers a vast range of prod- “ucts. They’ are prepared to assist manjutactarers i in redesigning and in designing his orcducts to take ad-'»» working out production problems of vantage of the economy of arc weld- all sorts in connection with welding. Page 159 INDEX A wistoumatic “Welding.” ..ta.cs.encee 135 B BABOS Sos dati ein GOL eee 65, 67 Botlers,. “Welded. .0 0 tok act se tee 33 butt? Welds, Strength cor... asks 111 Cc Sarbon Are: Welding tides eee sk. ce 47 Carbors Blectendes:.inccaiut materi cee tees 47, 141 Cast Iron Compared with Steel...cccccccccocees bee eG: Cast il ron, Stifinese mar no noe Pay CAI Cast Iron, Safety” Factors:iis ccc kc 25 Cast Iron, Strength in Bending.......ccccsse 29 Cast Iron, Strength in Compressionneee...c00 23 Cast Iron, Strength in Tension......ccccccccccssoee 27 Cast-Iron, Structure. Of 2-2, .nhiec nn 23 Costo£ | Weldinw iweriuiee ns te ee 123 D Designs, Developments of N€Weeecccccccccccscssee 9 E Equipment for Arc Welding..eccccccccccssccccsces 149 F Fillet Welds, “Strength “ofc 4.4006..04.) 113 Fixtures, Are Welded... cdscctotecsscsconecoccc 103 G kong Welding, Cost often eee 125 J Jigs; Sado wW elded ip lanwkohn a eee 103 L Lap Welds. Straarth. Gf. «2-4 o eee 111 Rather alD Steel oc tem oe) 6 eee 75 M Maintenance of Arc Welding Equipment.... 49 Maintenance, Application of Arc Weld-: MILES EO Ss ioesragienctsdinvecosetas seston: othe eee 107 Metallic Ave. Welding7.s..05......0 47 P : Patterns, Elimination. Ofpeuws.2e ee 11 R Rivet Welds; Strength Ofscccjsecoecserssssecreosecss 113 Riveted Joints, Efficiency totie04 See 114 Riveted Joints, Strength Compared to Welded iscctscccasasenecstvssternee aan a Le Riveted Joints, Inspection Of.........c0.sescseccsceeos 121 Riveted Joints, Reliability “Of ....c:cccessssssccose Dod Riveting, Cost of..:.i.cis eee Re Rivets, Shearing - Valuéuvia.c eee 117 Rupturing Force, Linear Inch of Weld..112, 143 Ss Safety Factors, Steel and Cast Iron............ 25 Speed -of Welditig:....c.:cas8ese eee 123, Stabilizer. ..:sccissesevetasee eee Ae ey | Steel Cost Compared with Cast Iron........ 5 Steel Compared to’ Cast” Iron.a. aoe Sy es Steel, Stiffness’ (6f.ci..dtccee eee ei Ar) Steel, Strength “of. eee Sees Steel, Strength’ in Bendingicc. oe 53.25 Steel, Strength in Compression..........cccssses Ze Steel, Strength in Tension.cs...u5. ee 527 Steel, Structure. Of), c.1,000cce ee 23 Steel Structures © ....dcsssessiecizue eee 97 Strength of Welditig,...i..:.0n eee 111 T Tanks, Welded..is,.csccusueeeec eee 23 Tool Room, Arc Welding in.22)..Jateeaee 103 Ww Welded Joints, Inspection? of.4,..0.4055 eee mie! Welded Joints, Reliability of....5.250.0:0e 121 Welded Joints, Strength Compared to Riv- CLING — breciasesecsos sdatecdssaneieeeee ee 115 Welded Joints, Tests of. ....5.0.50 ee 119 Welds, Shearing Values.ic....cccscscreeuse kee tay, Welds, Types: O£,..ccsccssacecsstecr ties sent ee 51 Welds, Typical Short) Cats.2.) 5 91, 92, 94 Welding, Automatic. es AEA RSA ea As Nes Cease: PARAM i od Ss wi ers pe cose rer iF Tali}