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BOOKLET NUMBER FOUR 
 
 AIRCO 
 WELDING 
 
 of 
 
 LOCOMOTIVE 
 FIREBOXES 
 
 AIR REDUCTION SALES COMPANY 
 
 NEW YOT(K 
 
 PRICE ONE DOLLAR 
 
 Copyright, 1919, Air Reduction Sales Co., N. Y. 
 
 Myograph \ 
 
<^p 
 
 
 MAY 27 1919 
 
 5)CI.A515667 
 
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 'fc 
 
 5. 
 
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FO%EfVO'RT> 
 
 HIS booklet treats of one of the 
 most valuable applications of the 
 oxyacetylene process to railroad 
 shop repairs — that of the welding 
 of locomotive fireboxes. The 
 abnormal heat strains to which 
 such fireboxes are subjected are the cause of 
 frequent leaks at the rivetted joints, and the 
 consequent laying-up of the locomotive for 
 repairs becomes a matter of first importance 
 to the motive power department. The Airco 
 process has been producing most gratifying 
 results in the correction of these weaknesses, 
 and it is now a matter of record in many rail- 
 road shops that the former lengthy periods for 
 repairs of locomotives have been greatly re- 
 duced by the substitution of the oxyacetylene 
 weld for the rivetted seam as well as for other 
 firebox repairs. 
 
 The efficiency of such work is shown by 
 the increased strength of joint, its tightness, its 
 added expansive characteristics, and the facility 
 and speed with which the repairs may be made. 
 The cost of the work is less than that of rivet- 
 ting, depending on the skill of the welder. 
 
 The methods of welding described in the 
 booklet have been devised with the assistance 
 of Messrs. George L. Walker, and R. T. 
 Peabody of the Airco Engineering Service 
 Department. 
 
CONTENTS 
 
 Page 
 
 Full-welded Fireboxes 7 
 
 Semi-welded Fireboxes 9 
 
 Semi-welded Half Side Sheets 11 
 
 Full-welded Half Side Sheet 13 
 
 Side Sheet Cracks 15 
 
 Full-welded Door and Flue Sheets 17 
 
 Patches on Firebox Sheets 19 
 
 Patches on Flue Sheets 21 
 
 Patches on Mudring 23 
 
 Door Collars . 25 
 
 Door Holes 27 
 
 Knuckle Cracks and Patches in Door and Flue Sheets 29 
 
 Building-up Worn Edges of Firebox 31 
 
 Full-welded Half Door Sheets 33 
 
 Half Door Sheets Rivetted to Side Sheets 35 
 
 Welding Steel Beams 37 
 
 Welding Various Kinds of Cracks 37 
 
 Welding Patches on Cylindrical Shells 38 
 
 Welding Locomotive Flues 38 
 
 General Welding in Locomotive Shop 39 
 
 Airco Service 40 
 
Page Six 
 
e 
 
 AIRCO WELDING OF 
 FULL-WELDED FIREBOXES 
 
 A FULL-WELDED FIREBOX is one which has all of its joints 
 
 f-\ welded instead of rivetted. The welded joint is stronger, 
 
 -*- -*- more economical, will not leak, and has more durable expansion 
 
 and contraction properties than the rivetted seam. The welding 
 
 should be performed as follows : 
 
 Operation 1. Place the firebox upon the mudring A B A B, 
 Figure 1, and bolt it fast. 
 
 Operation 2. Prepare to weld the outside, or water side, of 
 say the flanged flue sheet to the firebox, as shown at Figure 2, by 
 cutting a bevel of about 45 degrees all the way along its edge from 
 mudring to mudring. Now bevel the matched edge of the firebox in 
 like manner. The beveling should be done with an Airco cutting torch 
 set with a No. 1 tip. The best practice is to make the flange of th 
 flue and door sheets so as to include a row of radial ■ staybolts. See 
 Figure 4. 
 
 Operation 3. Set the firebox so that the weld joint remains 
 open at its bottom, about 3/16", Figure 3, to allow for expansion, to 
 clinch the welding metal and insure a perfect weld through the vee. 
 Start the joint by welding it for about an inch just above the mudring, 
 say at 1, Figure 1, using 3/16" or J4" Airco welding rod, and an 
 Airco welding torch with a No. 8 tip. From a point about 10" up 
 from the mudring weld downward from 2 to 1. Then, continuing the 
 method, weld from 3 to 2, from 4 to 3 and so on. This practice will 
 prevent the spreading of the joint from unequal expansion. Add 
 enough welding rod to raise the surface of the weld about %" above 
 the original metal. If practicable, a second welder should follow the 
 outside welder and smooth-flow the joint on the inside while it is red 
 hot. This will be certain to make the joint tight. 
 
 Operation 4. Working from the inside, weld the firebox to the 
 mudring at the corners A and B, Figure 1. 
 
 Operation 5. Weld on the door sheet the same as the flue sheet. 
 
 Page Seven 
 
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 Fig. 6 
 
 I 
 
 \ 45° 
 
 Fig. 8 
 
 Side 
 Sheet 
 
 Fig. 9 
 
 wU 
 
 ■hW 
 
 Fig. 7 
 
 Page Eight 
 
AIRCO WELDING OF 
 SEMI-WELDED FIREBOXES 
 
 A SEMI-WELDED FIREBOX is one in which welding is substi- 
 h\ tuted for rivetting along the lower vertical joints of the flue 
 **■ and door sheets with the side sheets. This practice is followed 
 where it is desired to avoid rivetted joints in the fire zone, and some 
 shops also weld the bottom horizontal joint of the firebox and the 
 mudring for about 12 inches both ways from each corner. The chief 
 advantage of this welding is the elimination of leakage. The work 
 should be done as follows : 
 
 Operation 1. Bolt the firebox to the mudring, and rivet the 
 flue and door sheets to the side sheets down to within about 36" from 
 the mudring. Omit the rivet holes along the corner joints to be 
 welded from 1 to A, Figure 5. Also leave out temporarily the rivets 
 next to the top of the joint at 1. 
 
 Operation 2. Prepare the side sheets as shown in Figures 6 and 
 9, by cutting into the flange about %" so that it can be set down flush. 
 Butt the joints and bevel both edges at about 45° on the outside of the 
 firebox, using an Airco cutting torch with a No. 1 tip. Leave a 3/16" 
 opening at the bottom of the vee. Some welders have used a lap weld 
 like that of Figure 7, but it does not make a strong, tight joint. The 
 butt weld as shown in Figure 8 is the best for this work. 
 
 Operation 3. Tack-weld the flange at 1, Figure 5, using an 
 Airco welding torch with a No. 8 tip, and 3/16" or y±' Airco welding 
 rod. 
 
 Operation 4. Starting on the outside at about 10" below 1, 
 weld from 2 to 1. Then from 3 to 2 and 4 to 3. Complete the joint 
 by welding on the inside from A to 4. Weld the other three corners 
 in like manner. 
 
 Operation 5. If a second welder is available, the weld should 
 be flowed on the inside while being made. 
 
 Page Nine 
 
45i|fcf«45 
 90* 
 
 Fig. 10 
 
 Fig. 11 
 
 Fig. 12 
 
 Fig. 13 
 
 Page Ten 
 
AIRCO WELDING OF 
 SEMI-WELDED HALF SIDE SHEETS 
 
 SEMI-WELDED HALF SIDE SHEETS are those which are 
 welded along the horizontal joints to the crown sheets, and are 
 rivetted to the mudring at the bottom and to the door and flue 
 sheets at the ends. 
 
 The welding of the long seams should proceed as follows when 
 the door and flue sheets have not yet been set : 
 
 Operation 1. Bevel the edge of the half side sheets and the 
 corresponding edge of the crown sheet, as shown in Figure 10. Use 
 an Airco cutting torch with a No. 1 tip. 
 
 Operation 2. Screw in the second row of staybolts, and bolt 
 the sheet to the mudring before starting to weld. To avoid delay, 
 however, all of the staybolts except the rows adjacent to the weld, may 
 be screwed in and set, and the side sheets rivetted to the mudring 
 before the welding is done. 
 
 Operation 3. Weld about 2" of the joint at 1, Figure 11. Then, 
 beginning at 2, about 10" from 1, weld back to 1, from 3 to 2 and so 
 on to the end of the joint. Use an Airco welding torch with a No. 8 
 tip, and 3/16" or y±' Airco welding rod. 
 
 Operation 4. The door and flue sheets should now be rivetted in. 
 
 Note a: If the side sheets are to be put in after the door and flue sheets have 
 been set, the flanges of the door and flue sheet should be heated and raised, as 
 shown in Figure 12, in order to allow the part of the joint under the flange to be 
 bevelled. 
 
 b: When new door and flue sheets are put on, the adjacent rivets A, Figure 
 12, should be left out until the welding is done. 
 
 c : Figure 13 shows the practice of welding the end of the long seam when 
 it is desired to change an old rivetted joint to a welded one. The vertical weld 
 should be carried to the second rivet each way. 
 
 Page Eleven 
 
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 10-R- - 
 
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 ["°o o°o%^Sy 
 
 Fig. 16 
 
 Page Twelve 
 
A 
 
 AIRCO WELDING OF 
 FULL-WELDED HALF SIDE SHEET 
 
 FULL- WELDED HALF SIDE SHEET has no rivetted joints at 
 the top or sides, all three edges being welded. The work should 
 be performed as follows : 
 
 Operation 1. Cut out the flange of the door or flue sheet next to 
 the joint of the crown and half side sheets, as shown at A and D, Figure 
 14. Then bevel the flange, including rivet hole C, and set it flush with 
 the half side sheet. L T se an Airco cutting torch with a No. 1 tip. 
 
 Operation 2. Bevel the crown sheet, including the rivet hole B. 
 
 Operation 3. Set the side sheet so that a V^ f space is left at its 
 top and sides, and then bevel those edges. If this sheet is not rivetted 
 to the mudring, bolt it fast. 
 
 Operation 4. Screw in and set all staybolts except those next to 
 the welds. 
 
 Operation 5. Now weld the horizontal seam for about 1" at 1, 
 Figure 15. Then from point 2, about 10" from 1, weld back to 1, and 
 from 3 to 2, continuing until the joint is completed. Use an Airco 
 welding torch with a No. 8 tip and 3/16" or 14" Airco welding rod. 
 
 Operation 6. Start about 10" down the vertical joint of, say, 
 the door sheet at 10L and weld up to 1, Figure 15. Then from 10" 
 below 10L at 11L weld back to 10L, from 12L to 11L, and so on to 
 within a few inches of the mudring. 
 
 Operation 7. Weld the flue sheet joint the same way as the 
 door sheet, from 10R to 9, Figure 15, from 11R to 10R down nearly 
 to the mudring. Weld the bottom of the joints to the mudring at 15L 
 and 15R last. 
 
 Note: When the flanged joints of the door and flue sheets are in good con- 
 dition, but the rest of the plate needs renewing, a good job may be performed 
 by setting in the half side sheet, as shown in Figure 16. It should be tacked at 1. 
 Then weld from 2 to 1, 3 to 2, and so on, following the practice described above. 
 
 Page Thirteen 
 
Fig. 17 
 
 Fig. 18 
 
 %Hl — \\-y*' 
 
 Fig. 20 
 
 4* 
 
 Fig. 21 
 
 Fig. 19 
 
 Fig. 22 
 
 Fig. 23 
 
 Page Fourteen 
 
AIRCO WELDING OF 
 CRACKS IN SIDE SHEETS 
 
 CRACKS IN SIDE SHEETS between staybolt holes are not 
 easily welded, because of the difficulty of making proper allow- 
 ances for expansion of the metal. In fact, if a side sheet has 
 many cracks like those shown in Figure 17, it would be better to put 
 in a new sheet rather than resort to welding. Much welding of side 
 sheets is being done, however, and the following method may be 
 successfully used when the staybolt holes are to be closed: 
 
 Operation 1. To weld a crack like that of Figure 18, bevel the 
 sides of the hole and crack, as shown in Figure 19, using an Airco 
 cutting torch set with a No. 1 tip. 
 
 Operation 2. Prepare for each hole a soft steel disc about 3/16" 
 thick and of, say, y±' smaller diameter than the hole. Bevel the edges 
 of the disc, as shown in Figures 20 and 21. Melt a piece of welding 
 rod to the disc, to serve as a holder, hot-bending the rod, as shown 
 in Figure 22. 
 
 Operation 3. Set a No. 7 tip in the Airco welding torch and 
 use 3/16" or y± f Airco welding rod. Place the disc in the hole and 
 melt down the upper edge a, Figure 23, to tack the disc in position. 
 Preheat the metal between the two holes at xxxA, Figure 18, and keep 
 it red hot. Melt off the rod and complete the welding of the disc into 
 the hole. Now allow the hot section xxxA to cool with the weld at 1. 
 This provides for uniform shrinkage. 
 
 Operation 4. Weld hole 2, Figure 18, in the same way, and 
 then weld the crack from 2 to 1. Preheat the section xxxB when 
 welding the last hole of that line. The weld should be reinforced, as 
 shown in Figure 24. 
 
 Note: In some cases where it is not practicable to replace a badly cracked 
 side sheet by a new one, or to put on a patch, the welding may be done as follows : 
 
 Operation 5. Referring to Figure 17, preheat the top of the left row of 
 holes at xxxa. Then weld in hole c of this row. Preheat the area xxx down to 
 d, as well as that at xB. Weld the crack at the bottom of the hole e of the first 
 row, then the staybolt hole e, the crack at the top of this hole, and finally weld 
 the joint around the head of the staybolt d, which is assumed to be in good con- 
 dition. Reheat the area xxxa to relieve the shrinkage strains, and let the job 
 cool down before proceeding with the other rows. 
 
 Operation 6. Weld the last row on the right next by preheating at xxxa, 
 filling the holes at d and e, and then the crack between them. Reheat the lower 
 part of the row at xxx, and allow the whole job to cool uniformly. 
 
 Operation 7. Now weld the second row from the left in the usual way, and 
 allow the sheet to cool again. 
 
 Operation 8. Weld the third row from the left last, which is done in this 
 case because it is the longest continuous crack. 
 
 Page Fifteen 
 

 Page Sixteen 
 
AIRCO WELDING OF 
 FULL-WELDED DOOR AND FLUE SHEETS 
 
 THE method to be followed in preparing to weld door and flue 
 sheets is similar to that described for full-welded fireboxes, as 
 shown in Figure 25. In the full-welding of door and flue 
 sheets, .however, the work is done on the inside at all the joints except 
 the one with the crown sheet. That part of the welding is to be done 
 on the water side, unless the radial staybolts are in the door sheet, when 
 the welding must be completed from the inside. 
 
 Operation 1. Fit and bolt the door or flue sheet to the mudring. 
 
 Operation 2. Bevel both edges of the vertical joints on the 
 inside, leaving a 3/16" opening at the bottom of the vee. See Figure 
 26. Use an Airco cutting torch with a No. 1 tip. Now bevel the 
 joint with the crown sheet on the outside. The door and flue sheets 
 should be flanged, as shown in Figures 27, 28 and 29. 
 
 Operation 3. Tack weld the joint for an inch at Rl, Figure 25. 
 Then drop down about 10" and weld from R2 up to Rl, from R3 to R2, 
 so continuing to R5 and welding last at A on the mudring. Use an 
 Airco welding torch with a No. 8 tip, and 3/16" or 14" Airco welding 
 rod. 
 
 Operation 4. Assuming that the radial staybolts are not in the 
 door sheet, both the door sheet and the flue sheet should be welded on 
 the. water side to the crown sheet, starting at c, about 10" from Rl, 
 Figure 25, and welding back to Rl, from d to c, e to d, on over to LI 
 and then welding on the inside of the firebox from L2 up to LI, thus 
 welding along until the sheet is finally completed at B on the mudring. 
 
 Page Seventeen 
 
Fig. 30 
 
 Cross-Section 
 of Fig. 30 
 
 Fig. 31 
 
 Fig. 32 
 
 Fig. 33 
 
 Fig. 34 
 
 Me" 
 
 
 m 
 
 Fig. 35 
 
 Fig. 36 
 
 Page Eighteen 
 
AIRCO WELDING OF 
 PATCHES ON FIREBOX SHEETS 
 
 PATCHES FOR FIREBOX SHEETS should be triangular in 
 shape whenever possible, the reason being that the sides of the 
 triangular patch do not run parallel with the rows of holes, and 
 weaken the joint, as would a rectangular patch. 
 
 WELDING ON PATCH OF FIGURE 30: 
 
 Operation 1. Bevel the edges with an Airco cutting torch and a 
 No. 1 tip. Tack weld at 1. Then, beginning about 10" from 1 at 2, 
 weld up to 1, from 3 to 2, and from 4 to 3. Use an Airco welding 
 torch with a No. 8 tip and 3/16" or 14" Airco welding rod. 
 
 Operation 2. Let the joint become cold. Then weld from 5 
 to 4, and 6 to 5. 
 
 Operation 3. Preheat as shown at xxxl, to allow for expansion. 
 Weld from 8 to 1, 7 to 8, and 6 to 7, and complete the job by pre- 
 heating at xxx6. 
 
 WELDING ON PATCHES OF FIGURES 31 AND 32: 
 
 Operation 4. Bolt the plate to the mudring. After bevelling 
 the edges, tack weld at 1. Then weld from 2 to 1, 3 to 2 on down to 
 the mudring at 5. A should be done last. 
 
 Operation 5. When the weld is cold, preheat at xxxl, and weld 
 from 6 to 1, 7 to 6 on down to the mudring at A. 
 
 WELDING ON PATCH OF FIGURE 33: 
 
 Operation 6. Preheat along xxxl. Then tack at 1 and weld 
 over about 10" from 2 to 1 and 3 to 2. Let the plate get cold. 
 
 Operation 7. Preheat again at xxxl and weld from 4 to 1. 
 Then preheat at xxxo and weld from 5 to 4. Let the sheet get cold. 
 
 Operation 8. Preheat at xxx3 and weld from 6 to 3. Again 
 preheat at xxx5 and weld from 5 to 6. 
 
 Note : Figure 34 shows the proper way to round the corners of the patches, 
 using a radius of about 54". In preparing all of the joints, use a bevel of about 
 45° and leave the vee open about 3/16" at the bottom, as shown in Figure 35. 
 
 In using the diamond patch of Figure 36, the welding should be done in 
 the same way as that described for the triangular patches. Expansion must be 
 provided for by the proper preheating and reheating at the ends of the line of 
 weld. 
 
 Page Nineteen 
 
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 o U cPogo U o o o 
 o o o o o o 
 
 Fig. 38 
 
 Weld No. 1 
 Patch to Crown She* 
 Weld No. 2 
 
 Weld Flue Fig. 43 
 
 Sheet to Patch 
 
 Fig. 44 
 
 Page Twenty 
 
AIRCO WELDING OF 
 PATCHES ON FLUE SHEETS 
 
 THE TRIANGULAR SHAPED PATCH should be used for flue 
 sheets wherever practicable. The method of applying the 
 patches may be described as follows, the welding being done 
 on the water side of the firebox : 
 
 WELDING ON PATCH OF FIGURE 37: 
 
 Operation 1. Cut the flue sheet as shown in the drawing, using 
 an Airco cutting torch with a No. 1 tip. 
 
 Operation 2. Weld the bridges at 1, Figure 37. Then weld 
 from 2 back to 1 and from 3 to 1. Use an Airco welding torch with 
 a No. 8 tip and 3/16" or y±' Airco welding rod. 
 
 Operation 3. Weld the knuckle at 6 and then from 10 to 6. Then 
 weld the knuckle at 7 and from 11 to 7. 
 
 Operation 4. Complete the job by welding to the flange at 12 
 and 13. 
 
 WELDING ON PATCH OF FIGURE 38, 
 
 This is for a deep job and requires less welding to the flange : 
 
 Operation 5. Prepare the sheet as described for Figure 37. 
 Weld the bridges at 1 and from 2 to 1. Then weld from 3 to 1, 4 to 2, 
 5 to 3 and so on until knuckles are welded at 8 and 9. 
 
 Operation 6. Weld the patch to the flange at 10 and 11. 
 
 WELDING ON PATCH OF FIGURE 39: 
 
 Operation 7. Weld successively bridges 1, 2, 3, 4, 5 and 6. 
 Preheat at ends of rows, and weld bridges 7, 8, 9 and so on until all are 
 welded. All welds should be butt-jointed as shown in Figure 40. 
 
 WELDING CRACKED BRIDGES OF FIGURE 42: 
 
 Operation 8. Preheat bridges marked x at 1 and 2. Weld at 
 these points, and reheat at x. 
 
 WELDING ON PATCHES OF FIGURES 43 AND 44: 
 
 Operation 9. Weld patch to crown sheet. Then weld flue sheet 
 to patch as shown at 2 and 3 of Figure 41. 
 
 Operation 10. Weld flue sheet to crown sheet at 6 and 7 of 
 Figure 43, using butt joint 8 and 9, Figure 41. 
 
 Operation 11. Weld to the flange at 12 and 13. 
 
 Operation 12. A patch may be welded to the crown sheet as 
 shown in Figure 44. 
 
 Page Twenty-one 
 
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 91 'O O p O O O OO O 
 
 ' n n n n r\ n n n n n, t 
 
 Fig. 46 
 
 Fig. 49 
 
 Fig. 47 
 
 Fig. 48 
 
 Pa<7£ Twenty-two 
 
AIRCO WELDING OF 
 PATCHES ON MUDRING 
 
 THE FOLLOWING THREE methods of patching mudrings 
 have proved to be the most serviceable. The beveling should be 
 done with an Airco cutting torch set with a No. 1 tip and the 
 welding with an Airco welding torch and No. 8 tip. Use 3/16" or l /^" 
 Airco welding rod. Leave out rivets adjacent to the weld. 
 
 WELDING ON PATCH OF FIGURE 45: 
 
 Operation 1. Weld from A to 1. Then weld from 2 to 1, and 
 from 3 to 2. 
 
 Operation 2. Weld patch to flange at 3, Figure 45, as shown in 
 detail at c and d, Figure 49. Then weld from 4 to 3 and on to B. 
 
 WELDING ON PATCH OF FIGURE 46 : 
 
 Operation 3. Weld from A to 1 on the mudring. Then back 
 weld from 2 to 1, and allow weld to cool before welding from 3 to 2 
 and so along to 10. Complete the weld at B. 
 
 WELDING ON PATCH OF FIGURE 47: 
 
 Operation 4. Remove the rivets adjacent to the weld on the mud- 
 ring and side sheets, also remove the staybolts that would be affected 
 by the heat. Start to weld at A. Then weld from 2 to 1, a distance 
 of about 10" apart, and let the metal cool. Weld from 3 to 2, also 
 welding to flange near 3. Then from 4 to 3 and B last. 
 
 All weld joints should be beveled at 45° and opened 3/16" at the 
 bottom, as shown in Figure 48. 
 
 Page Twenty-three 
 
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 Page Twenty-four 
 
I 
 
 AIRCO WELDING OF 
 DOOR COLLARS 
 
 N WELDING LOCOMOTIVE door collars the door sheet should 
 be made large enough to include a row of staybolts within its 
 area, as shown in Figure 50. 
 
 Operation 1. Bolt the patch in place by screwing in some of the 
 staybolts 
 
 Operation 2. Bevel the edges of the weld joint at 45° on the in- 
 side of the firebox, using an Airco cutting torch with a No. 1 tip. 
 
 Operation 3. Tack weld for about an inch at 1 and 5, Figure 50, 
 using an Airco welding torch with a No. 8 tip, and 3/16" or %" Airco 
 welding rod. Advance about 10" to 2 and back weld to 1. Weld from 
 3 to 2, 4 to 3 and 5 to 4. 
 
 Operation 4. Now weld from 8 to 1, 7 to 8, 6 to 7 and 5 to 6. 
 Figure 51 gives an end sectional view of the welded joint of a 
 door collar. 
 
 Page Twenty-five 
 
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 Fig. 53 
 
 Lap Weld 
 
 Fig. 54 
 
 Butt Weld 
 
 Fig. 52 
 
 Page Twenty-six 
 
I 
 
 AIRCO WELDING OF 
 DOOR HOLES 
 
 N THE WELDING of door holes for locomotive fireboxes the 
 butt weld of Figure 52 should be used. The work should be 
 done as follows : 
 
 Operation 1. Bevel the edges to 45° with an Airco Cutting 
 torch and a No. 1 tip, and leave bottom of weld open about 3/16 inch. 
 
 Operation 2. Tack at 1, Figure 53 ; weld from 2 to 1, 3 to 2 and 
 so on to 5, using an Airco welding torch with a No. 8 tip, and 3/16" 
 or %" Airco welding rod. Then weld from 8 to 1, 7 to 8, 6 to 7 and 
 5 to 6. 
 
 A lap weld like that of Figure 54 is sometimes used for welding 
 door holes, but it should not be resorted to if the butt weld of Figure 
 52 can be made. 
 
 Page Twenty-seven 
 
Fig. 60 
 
 Fig. 64 
 
 Page Twenty-eight 
 
AIRCO WELDING OF 
 
 KNUCKLE CRACKS AND PATCHES IN 
 
 DOOR AND FLUE SHEETS 
 
 IN THE FOLLOWING work the welding should be done on the 
 water side of the firebox wherever possible. The bevels should 
 be cut with an Airco cutting torch and a No. 1 tip, and the 
 welding done with an Airco welding torch set with a No. 6 tip. Use 
 Airco 3/16" or y A " welding rod. 
 
 WELDING THE FLUE SHEET KNUCKLE CRACK OF FIGURE 55: 
 
 Operation 1. Preheat at xxxl, and tack weld at 1. Then start 
 at 2 and back weld to 1, from 3 to 2, and 4 to 3. Reheat at xxx4. 
 
 WELDING THE FLUE SHEET KNUCKLE CRACK OF FIGURE 56: 
 
 Operation 2. Weld from flue sheet over knuckle to crown sheet 
 on the water side of the firebox, and complete weld from the inside. 
 This weld should be reinforced about y%" and widened to about 2" 
 at the top of the vee, as shown in Figure 57. 
 
 WELDING THE FLUE SHEET KNUCKLE CRACK OF FIGURE 58: 
 
 Operation 3. Start to weld the flange at A, Figure 58, working 
 on the inside of the firebox. Then weld on the water side from 1 to 
 A, back weld from 2 to 1, 3 to 2 and so on to the flange at B. 
 
 WELDING THE DOOR SHEET KNUCKLE CRACK OF FIGURE 59: 
 
 Operation 4. Working from inside of firebox, weld from 1 to 
 A, back weld from 2 to 1, 3 to 2 and on across to 8 and B. The dis- 
 tance between tack points of weld should be about 10". Figure 60 
 gives the form of vee for the butt weld. 
 
 WELDING THE FLUE SHEET PATCH OF FIGURE 61: 
 
 Operation 5. Weld the flange at A. Then back weld from 2 
 to 1, and on to B. 
 
 WELDING THE FLUE AND SIDE SHEET PATCH OF FIGURE 62: 
 
 Operation 6. Cut the side sheet to outside of the rivet holes, as 
 shown in drawing c. Weld the flange at A, and then back weld down 
 to the flange at C. Now weld from 6 to 5, 7 to 6 and so on to B. 
 
 Xote: The flue sheet weld of Figure 63 should be performed as described 
 for Figure 55. 
 
 Crack C of Figure 64 should be welded the same as that of Figure 55, while 
 Patch D may be welded in place by the method shown in Figure 61. 
 
 Page Twenty-nine 
 
Page Thirty 
 
T 
 
 AIRCO BUILDING-UP OF 
 WORN EDGES OF FIREBOX 
 
 HE EDGES OF fireboxes become worn, and cause leaky joints, 
 from excessive caulking, erosion from escaping steam and cor- 
 rosion. 
 
 The restoration of these edges by building-up may be accom- 
 plished as follows, using an Airco cutting torch with No. 1 tip, an 
 Airco welding torch with a No. 8 tip, and Airco 3/16" or 54" weld- 
 ing rod. 
 
 Operation 1, Figure 65. Brush the rust off the edge of Figure 
 65 and build up from 1 to 2. Light hammering of the weld while 
 red hot will improve the joint. 
 
 Operation 2. Figure 66. A piece rusted out as shown in this 
 figure may be built up by first removing the rivets 1, 2 and 3, and 
 then adding metal from a down to the bottom of the sheet to the mud- 
 ring. 
 
 Operation 3, Figure 67. In welding sheets to a mudring build 
 up the joint of the two sheets for about 5" above the bottom. Bevel 
 the bottom of the sheets as shown in Figures 68 and 69. 
 
 Page Thirty-one 
 

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 Fig. 71 
 
 Page Thirty-two 
 
AIRCO WELDING OF 
 FULL-WELDED HALF DOOR SHEETS 
 
 THERE ARE TWO methods used to weld in half door sheets of 
 fireboxes. That shown in Figure 70 is sometimes resorted to 
 to save time. It is not the best way to do the work, however. 
 This method leaves the old rivetted flange on the side sheets. The 
 welding is done by starting at 1, back welding from 2 up to 1, and so 
 on around, ending at B on the mudring. 
 
 The most serviceable way to do the work is as shown in Figure 71. 
 
 Operation 1. The side sheet should be cut to the inner edge of 
 the rivet holes, fitting the door sheet to the edge of the side sheet. Use 
 an Airco cutting torch with a No. 1 tip, and bevel the joints as shown 
 in sketch at left of Figure 70. 
 
 Operation 2. Screw in the second row of staybolt holes, and 
 bolt the door sheet to the mudring. 
 
 Operation 3. Using a No. 8 tip in the Airco welding torch and 
 3/16" or *4" Airco welding rod, start to weld at 1, Figure 71. Then 
 weld the door sheet to the side sheet by welding from a point about 
 10" down at 2 up to 1, from 3 to 2 and ending at A on the mudring. 
 
 Operation 4. Back weld 10" from 6 to 1, from 7 to 6 and on 
 around to B at the mudring. The sketch at the left of Figure 71 
 shows the style of joint between the door sheet and the side sheet. 
 
 Page Thirty-three 
 
Weld Na9] 
 Fig. 75 
 
 Fig. 72 A 
 
 Page Thirty-jour 
 
AIRCO WELDING OF 
 HALF DOOR SHEETS RIVETTED TO SIDE 
 
 SHEETS 
 
 IN PREPARING TO weld half door sheets above or below the 
 doorhole, the sheet should be cut not nearer the doorhole than 
 between the first and second rows of staybolts as shown in 
 Figures 72 and 72A. All the staybolts, except those adjacent to the 
 weld, may be screwed in place. The door sheet should be rivetted to 
 the side sheet and mudring before welding. The cutting should be 
 done with an Airco cutting torch and No. 1 tip, the weld vee being 
 formed as shown in Figure 73. 
 
 Operation 1. Weld the flange at 1, Figures 72 and 74, using an 
 Airco welding torch with a No. 8 tip and 3/16" or %" Airco welding 
 rod. Then at a distance of about 10" from 1 back weld from 2 to 1, 
 from 3 to 2 and continue to 8. Figure 75 gives details of the end 
 of the weld. 
 
 Page Thirty-five 
 
Page Thirty-six 
 
SPECIAL AIRCO WELDING 
 
 STEEL BEAMS 
 
 IN WELDING STEEL beams, like those of Figures 76 and 77, 
 bevel the web at 45° on one side if less than V as shown at A, 
 and the flange at D. If over 1", use the double bevel of Figure 
 78. Make a hole at the junction of the flange and the web at b. 
 This will make it possible to get a strong weld at this point. 
 Start to weld the flange at a, and weld the web last. 
 
 VARIOUS KINDS OF CRACKS 
 
 FIGURE SEVENTY-NINE SHOWS the method to use in weld- 
 ing cracks where expansion must be carefully considered. The 
 best practice is to tack and back weld. The back weld jumps 
 should be about 6" for Ya" plate, 10" for #" plate and 12" for y 2 " 
 plate. Bevel at 45°, and leave bottom of vee open about Y%" . Preheat 
 one end of the crack as shown at xxa. If the crack is in a vertical 
 position tack weld at the top at 1, then back weld upward from 2 to 1, 
 and 3 to 2. Complete the weld by reheating it red hot at xxb. The 
 weld should be made about 2" wide at the top, and be reinforced about 
 Y" thicker than the original metal. 
 
 Page Thirty-seven 
 
PATCHES ON CYLINDRICAL SHELLS 
 
 SKETCHES A AND B of Figure 80 show how patches should be 
 applied to cylindrical shells and tanks. The base of the tri- 
 angular patch should run with the circumference of the shell. 
 A weld like that of Sketch A should be started at 1 and go to 3. 
 and be allowed to cool. Then .from 3 to 5 and cool. Finally from 
 5 to 1. 
 
 The weld of Sketch B should be run from 1 to 3, and allowed 
 to cool. Then from 3 to 5 and cool, and from 5 to 1. 
 
 LOCOMOTIVE FLUES 
 
 TO WELD LOCOMOTIVE flues, first countersink the fluehole 
 about 3/16" deep, as shown in Figure 8E Extend the flue to 
 within %" of the outer surface of the sheet and 1 /16" beyond 
 the bottom of the countersinking. Leave out the copper ferrules, and 
 expand the flues just enough to fill the flueholes. 
 
 Start to weld at the bottom of the hole, and weld around to the 
 top on one side, and then the same way on the other half. Weld the 
 fillet flush with the inside of the flue and the face of the flue sheet. 
 
 Figure 83 shows the order in which the flues should be welded 
 so that unequal expansion may be allowed for. Weld the row of 
 flues 1, 2, 3 and then 4, 5, 6, then 7,8,9 and so on to completion. 
 
 Page Thirty-eight 
 
GENERAL AIRCO WELDING 
 IN THE LOCOMOTIVE SHOP 
 
 WHILE the foregoing pages have been devoted to a descrip- 
 tion of the application of the Airco Process to locomotive 
 firebox repairs, there are many other jobs in the locomotive 
 shop on which the Airco Process can be used successfully, some of 
 which are enumerated below : 
 
 CUTTING 
 Staybolts 
 Rivets 
 
 Miscellaneous sheet steel 
 Miscellaneous angle iron 
 
 WELDING 
 
 Firebox mudrings 
 Stationary boilers 
 Superheater tubes 
 Superheater units 
 Boiler flues 
 Ash pans 
 Petticoat pipes 
 Aprons 
 Oil tanks 
 Angle iron 
 Channel iron 
 
 Page Thirty-nine 
 
AIRCO SERVICE 
 
 THE information contained in thisbooklet cov- 
 ers the welding of locomotive fireboxes. 
 Should you, however, desire special informa- 
 tion not dwelt upon here, or personal help, we 
 would be glad if you would call upon the nearest 
 branch of the Air Reduction Sales Company. 
 Airco Service Stations are located in the following 
 cities : 
 
 Atlanta. Ga. 
 Baltimore, Md. 
 Boston, Mass. 
 Bridgeport, Conn. 
 Bronx, N. Y. 
 Brooklyn, N. Y. 
 Buffalo, N. Y. 
 Camden, N. J. 
 Chicago, 111. 
 Cincinnati, O. 
 Cleveland, O. 
 Coatesville, Pa. 
 Columbus, O. 
 Defiance, O. 
 Des Moines, Iowa. 
 Detroit, Mich. 
 Dorchester, Mass. 
 Duluth, Minn. 
 East St. Louis, 111. 
 Emeryville, Calif. 
 Grand Rapids, Mich. 
 Jersey City, N. J. 
 
 Johnstown, Pa. 
 Kansas City, Mo. 
 Louisville, Ky. 
 Milwaukee, Wis. 
 Minneapolis, Minn. 
 New Haven, Conn. 
 New York City 
 Oklahoma City, Okla. 
 Paters on, N. J. 
 Peoria, 111. 
 Philadelphia, Pa. 
 Pittsburgh, Pa. 
 Richmond, Va. 
 San Francisco, Calif. 
 Seattle, Wash. 
 So. Bethlehem, Pa. 
 So. Boston, Mass. 
 Springfield, O. 
 St. Louis, Mo. 
 Tacoma, Wash. 
 Toledo, O. 
 Warren. O. 
 
 Page Forty 
 
 PRINTED BY 
 WtLBERT GARRISON CO. 
 82 BEEKMAN ST.. NEWYORK