IM556
AC-235 May, 2004
WELDING POWER SOURCE Return To Main Index
by
Contents Page
Safety Precautions ...............................................................................................2
Installation and Operating Instructions
for AC-235 ...................................................................................................7
Includes safety, installation, operating instructions
and parts lists.
Learning to Weld ...............................................................................................11
Using the Carbon Arc Torch..............................................................................18
Includes for heating metal, welding aluminum or
brazing with an arc torch.
Selecting Electrodes ..........................................................................................23
Brief descriptions of the types and operating
data for all Lincoln electrodes.
Welding Books and Teaching Aids ...................................................................25
Copyright © 2004 Lincoln Global Inc.
â? World's Leader in Welding and Cutting Products â?
â? Sales and Service through Subsidiaries and Distributors Worldwide â?
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
SAFETY
WARNING ARC WELDING can be hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you pur-
chase a copy of âSafety in Welding & Cutting - ANSI Standard Z49.1â? from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of âArc Welding Safetyâ? booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PER-
FORMED ONLY BY QUALIFIED INDIVIDUALS.
ARC RAYS can burn.
ELECTRIC SHOCK can kill.
1.a. The electrode and work (or ground) circuits 2.a. Use a shield with the proper filter and cover
are electrically âhotâ? when the welder is on. plates to protect your eyes from sparks and
Do not touch these âhotâ? parts with your bare the rays of the arc when welding or observing
skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens
gloves to insulate hands. should conform to ANSI Z87. I standards.
2.b. Use suitable clothing made from durable flame-resistant
1.b. Insulate yourself from work and ground using dry insulation.
material to protect your skin and that of your helpers from
Make certain the insulation is large enough to cover your full
the arc rays.
area of physical contact with work and ground.
2.c. Protect other nearby personnel with suitable, non-flammable
In addition to the normal safety precautions, if welding
screening and/or warn them not to watch the arc nor expose
must be performed under electrically hazardous
themselves to the arc rays or to hot spatter or metal.
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
FUMES AND GASES
kneeling or Iying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
can be dangerous.
the following equipment:
3.a. Welding may produce fumes and gases
â? Semiautomatic DC Constant Voltage (Wire) Welder.
hazardous to health. Avoid breathing these
â? DC Manual (Stick) Welder.
fumes and gases.When welding, keep
â? AC Welder with Reduced Voltage Control.
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
1.c. In semiautomatic or automatic wire welding, the electrode,
fumes and gases away from the breathing zone. When
electrode reel, welding head, nozzle or semiautomatic
welding with electrodes which require special
welding gun are also electrically âhotâ?.
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
1.d. Always be sure the work cable makes a good electrical
cadmium plated steel and other metals or coatings
connection with the metal being welded. The connection
which produce highly toxic fumes, keep exposure as
should be as close as possible to the area being welded.
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
1.e. Ground the work or metal to be welded to a good electrical
confined spaces or in some circumstances, outdoors, a
(earth) ground.
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
1.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
3.b. Do not weld in locations near chlorinated hydrocarbon vapors
damaged insulation.
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
1.g. Never dip the electrode in water for cooling.
form phosgene, a highly toxic gas, and other irritating
products.
1.h. Never simultaneously touch electrically âhotâ? parts of
electrode holders connected to two welders because voltage
3.c. Shielding gases used for arc welding can displace air and
between the two can be the total of the open circuit voltage
cause injury or death. Always use enough ventilation,
of both welders.
especially in confined areas, to insure breathing air is safe.
1.i. When working above floor level, use a safety belt to protect
3.d. Read and understand the manufacturerâs instructions for this
yourself from a fall should you get a shock.
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
1.j. Also see Items 4.c. and 6.
employerâs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.e. Also see item 7b.
â?2â?
Apr. â?93
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
4.a. Remove fire hazards from the welding area.
5.a. Use only compressed gas cylinders
If this is not possible, cover them to prevent
containing the correct shielding gas for the
the welding sparks from starting a fire.
process used and properly operating
Remember that welding sparks and hot
regulators designed for the gas and
materials from welding can easily go through small cracks
pressure used. All hoses, fittings, etc. should be suitable for
and openings to adjacent areas. Avoid welding near
the application and maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available.
5.b. Always keep cylinders in an upright position securely
4.b. Where compressed gases are to be used at the job site,
chained to an undercarriage or fixed support.
special precautions should be used to prevent hazardous
situations. Refer to âSafety in Welding and Cuttingâ? (ANSI
5.c. Cylinders should be located:
Standard Z49.1) and the operating information for the
â? Away from areas where they may be struck or subjected to
equipment being used.
physical damage.
4.c. When not welding, make certain no part of the electrode
â? A safe distance from arc welding or cutting operations and
circuit is touching the work or ground. Accidental contact can
any other source of heat, sparks, or flame.
cause overheating and create a fire hazard.
5.d. Never allow the electrode, electrode holder or any other
4.d. Do not heat, cut or weld tanks, drums or containers until the
electrically âhotâ? parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
5.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have
when opening the cylinder valve.
been âcleanedâ?. For information, purchase âRecommended
Safe Practices for the Preparation for Welding and Cutting of
5.f. Valve protection caps should always be in place and hand
Containers and Piping That Have Held Hazardous
tight except when the cylinder is in use or connected for
Substancesâ?, AWS F4.1 from the American Welding Society
use.
(see address above).
5.g. Read and follow the instructions on compressed gas
4.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
âPrecautions for Safe Handling of Compressed Gases in
Cylinders,â? available from the Compressed Gas Association
4.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a
welding area.
powered equipment.
6.a. Turn off input power using the disconnect
4.g. Connect the work cable to the work as close to the welding
switch at the fuse box before working on
area as practical. Work cables connected to the building
the equipment.
framework or other locations away from the welding area
increase the possibility of the welding current passing
6.b. Install equipment in accordance with the U.S. National
through lifting chains, crane cables or other alternate circuits.
Electrical Code, all local codes and the manufacturerâs
This can create fire hazards or overheat lifting chains or
recommendations.
cables until they fail.
6.c. Ground the equipment in accordance with the U.S. National
4.h. Also see item 7c.
Electrical Code and the manufacturerâs recommendations.
â?3â? Mar. â?93
SAFETY
ELECTRIC AND MAGNETIC
FOR ENGINE
powered equipment. FIELDS
may be dangerous
7.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
8.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
7.b. Operate engines in open, well-ventilated
welding machines
areas or vent the engine exhaust fumes
outdoors.
8.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
____________________________________________________
8.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
7.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
8d. All welders should use the following procedures in order to
Stop the engine and allow it to cool before
minimize exposure to EMF fields from the welding circuit:
refueling to prevent spilled fuel from
vaporizing on contact with hot engine parts
8.d.1. Route the electrode and work cables together - Secure
and igniting. Do not spill fuel when filling
them with tape when possible.
tank. If fuel is spilled, wipe it up and do not
start engine until fumes have been
8.d.2. Never coil the electrode lead around your body.
eliminated.
8.d.3. Do not place your body between the electrode and
____________________________________________________
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
7.d. Keep all equipment safety guards, covers
8.d.4. Connect the work cable to the workpiece as close as
and devices in position and in good repair.
possible to the area being welded.
Keep hands, hair, clothing and tools away
from V-belts, gears, fans and all other
8.d.5. Do not work next to welding power source.
moving parts when starting, operating or
repairing equipment.
____________________________________________________
7.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
7.f. Do not put your hands near the engine fan. Do not
attempt to override the governor or idler by pushing on
the throttle control rods while the engine is running.
7.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
___________________________________________________
7.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
â?4â? Mar. â?93
SAFETY
zones oĂč lâon pique le laitier.
PRĂCAUTIONS DE SĂRETĂ
6. Eloigner les matériaux inflammables ou les recouvrir afin de
Pour votre propre protection lire et observer toutes les instructions
prĂ©venir tout risque dâincendie dĂ» aux Ă©tincelles.
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
7. Quand on ne soude pas, poser la pince à une endroit isolé de
antes:
la masse. Un court-circuit accidental peut provoquer un Ă©chauf-
fement et un risque dâincendie.
SĂ»retĂ© Pour Soudage A LâArc
1. Protegez-vous contre la secousse Ă©lectrique:
8. Sâassurer que la masse est connectĂ©e le plus prĂ©s possible de
a. Les circuits Ă lâĂ©lectrode et Ă la piĂ©ce sont sous tension la zone de travail quâil est pratique de le faire. Si on place la
quand la machine Ă souder est en marche. Eviter toujours masse sur la charpente de la construction ou dâautres endroits
tout contact entre les parties sous tension et la peau nue ou éloignés de la zone de travail, on augmente le risque de voir
les vétements mouillés. Porter des gants secs et sans trous passer le courant de soudage par les chaines de levage, cùbles
pour isoler les mains. de grue, ou autres circuits. Cela peut provoquer des risques
b. Faire trĂ©s attention de bien sâisoler de la masse quand on dâincendie ou dâechauffement des chaines et des cĂąbles jusquâĂ?
soude dans des endroits humides, ou sur un plancher met- ce quâils se rompent.
allique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande 9. Assurer une ventilation suffisante dans la zone de soudage.
partie du corps peut ĂȘtre en contact avec la masse. Ceci est particuliĂ©rement important pour le soudage de tĂŽles
c. Maintenir le porte-électrode, la pince de masse, le cùble de galvanisées plombées, ou cadmiées ou tout autre métal qui pro-
soudage et la machine à souder en bon et sûr état defonc- duit des fumeés toxiques.
tionnement.
d.Ne jamais plonger le porte-Ă©lectrode dans lâeau pour le 10. Ne pas souder en prĂ©sence de vapeurs de chlore provenant
refroidir. dâopĂ©rations de dĂ©graissage, nettoyage ou pistolage. La
e. Ne jamais toucher simultanĂ©ment les parties sous tension chaleur ou les rayons de lâarc peuvent rĂ©agir avec les vapeurs
des porte-électrodes connectés à deux machines à souder du solvant pour produire du phosgéne (gas fortement toxique)
parce que la tension entre les deux pinces peut ĂȘtre le total ou autres produits irritants.
de la tension Ă vide des deux machines.
f. Si on utilise la machine à souder comme une source de 11. Pour obtenir de plus amples renseignements sur la sûreté, voir
courant pour soudage semi-automatique, ces precautions le code âCode for safety in welding and cuttingâ? CSA Standard
pour le porte-Ă©lectrode sâapplicuent aussi au pistolet de W 117.2-1974.
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le cĂąble-Ă©lectrode autour de nâimporte quelle partie du
corps.
PRĂCAUTIONS DE SĂRETĂ POUR
3. Un coup dâarc peut ĂȘtre plus sĂ©vĂšre quâun coup de soliel, donc:
LES MACHINES Ă SOUDER Ă
TRANSFORMATEUR ET Ă
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
quâun verre blanc afin de se protĂ©ger les yeux du rayon-
REDRESSEUR
nement de lâarc et des projections quand on soude ou quand
on regarde lâarc.
1. Relier Ă la terre le chassis du poste conformement au code de
b. Porter des vĂȘtements convenables afin de protĂ©ger la peau
lâĂ©lectricitĂ© et aux recommendations du fabricant. Le dispositif
de soudeur et des aides contre le rayonnement de lâarc.
de montage ou la piece Ă souder doit ĂȘtre branchĂ© Ă une bonne
mise Ă la terre.
c. ProtĂ©ger lâautre personnel travaillant Ă proximitĂ© au soudage
Ă lâaide dâĂ©crans appropriĂ©s et non-inflammables.
2. Autant que possible, Iâinstallation et lâentretien du poste seront
4. Des gouttes de laitier en fusion sont Ă©mises de lâarc de effectuĂ©s par un Ă©lectricien qualifiĂ©.
soudage. Se protĂ©ger avec des vĂȘtements de protection libres
de lâhuile, tels que les gants en cuir, chemise Ă©paisse, pantalons 3. Avant de faires des travaux Ă lâinterieur de poste, la debrancher
sans revers, et chaussures montantes. Ă lâinterrupteur Ă la boite de fusibles.
5. Toujours porter des lunettes de sécurité dans la zone de 4. Garder tous les couvercles et dispositifs de sûreté à leur place.
soudage. Utiliser des lunettes avec Ă©crans lateraux dans les
â?5â? Mar. â?93
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product âąâ?ąâ??
as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the time
the shipment is received.
Please record your equipment identification information below for future reference. This information can be found
on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
â? For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
â? For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose âQuick Linksâ? and then
âProduct Registrationâ?. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
â?6â?
OPERATING INSTRUCTIONS
WARNING
CONNECT TO A SYSTEM GROUNDING
âąHave an electrician install and service this equipment. WIRE. SEE THE UNITED STATES
NATIONAL ELECTRICAL CODE
âąTurn the input power off at the fuse box before work- AND/OR LOCAL CODES FOR OTHER
DETAILS AND MEANS FOR PROPER
ing on equipment.
GROUNDING.
âąDo not touch electrically hot parts.
} CONNECT TO HOT WIRES OF
A THREE-WIRE, SINGLE
Input Power and Grounding Connections PHASE SYSTEM OR TO ONE
PHASE OF A TWO OR THREE
PHASE SYSTEM.
Before starting the installation, check with the power com-
pany to be sure your power supply is adequate for the volt-
age, amperes, phase and frequency specified on the welder
nameplate. Also, be sure the planned installation will meet
Attaching Electrode Cable to Holder
the United States National Electrical Code and local code
requirements. This welder may be operated from a single
WARNING
phase line or from one phase of a two or three phase line.
All models designed to operate on less than 250 volt input Before attaching the electrode cable to the electrode
lines are shipped with the input cable connected to the holder or the work cable to clamp, be certain the welder
welder. is turned off or the input power is disconnected.
Place the welder so there is free circulation of air in through
the louvers in the back and sides of the case and out of the 1. Loosen locking screw and slide handle off holder. Place
bottom on all four sides. Mount a NEMA Type 6-50R handle over electrode cable.
receptacle in a suitable location. Be sure it can be reached
2. Remove insulation from electrode cable 1â? ± 1/16â?
by the plug on the input cable attached to the welder.
(25.4mm ± 1.6mm) from end.
WARNING 3. Back out cable connecting screw until end is flush with
inside surface of jaw body.
These installation instructions apply to the input wiring
4. Remove cable connecting clamp from holder jaws. Place
and overload protection installed to supply one AC-235
clamp over bare end of electrode cable and insert into
and comply with the United States National Electrical
holder with clamp centered against connecting screw.
Code as it applies to electric welders. Other equipment
should not be connected to this supply without consult-
ing the input power requirements for that equipment,
the United States National Electrical Code, and all local
codes.
Using the following instructions, have a qualified electri-
cian connect this receptacle (NEMA 6-50R Type) to the
power lines at the fuse box. Three #10 or larger copper
wires are required if conduit is used. For long cable runs
over 100', #8 or larger wire in conduit will be needed to
prevent excessive voltage drops. Fuse the two hot lines
with 50 ampere super lag type fuses as shown in the fol-
lowing diagram. The center contact in the receptacle is for
the grounding connection. A green wire in the input cable
5. Tighten cable connecting screw securely against clamp.
connects this contact to the frame of the welder. This
insures proper grounding of the welder frame when the
welder plug is inserted into the receptacle. If a separate dis-
connect switch is used, it should have two poles for the two
hot lines and both should be fused for 50 amperes.
â?7â?
6. Slide handle into position and secure by turning the lock- Duty Cycle
ing screw in until it is tight. The threaded end of the
The AC-235 is rated for 20% duty cycle on all switch posi-
screw will then pass against the inside of the handle and
tions except maximum (235 amps). At 235 amps the duty
the head of the screw will be completely inside the han-
cycle is 18%. A 20% duty cycle means that the arc can be
dle.
drawn for 2 minutes out of each ten minute period. An 18%
duty cycle means that the arc can be drawn for 1.8 minutes
out of each ten minute period. If the welding time is longer
than this for several successive ten minute periods, the
windings may overheat and be damaged. Be sure to leave
the unit âonâ? for each 10 minute period to let the fan motor
run for adequate cooling. Overheating reduces welder life.
Important Safety Note: Make sure insulation is secure and
that screws are tight and cannot be touched. If screw can
Electrode Selection Guide
be touched, DO NOT USE HOLDER, contact your dis-
tributor.
See Chart on Welder and at the end of this manual
Arc Torch (Optional Accessory)
Attaching Work Cable to Clamp
The arc torch (see page 18) is especially suited for use on
Insert work cable through strain relief hole in work clamp these welders for brazing, welding non-ferrous metals and
and fasten securely with bolt and nut provided. preheating before bending and forming.
MAINTENANCE
Electrode and Work Cable Replacement
Substitution of cables with larger sizes requiring connec- Routine preventative maintenance is not required. See your
tions to be made internally is not recommended. local Lincoln Electric Authorized Field Service Shop for
Connections for additional lengths or larger sizes should be necessary repairs.
properly made externally. Lincoln Electric QD (Quick
Disconnect) connectors are available for this purpose.
If either cable requires replacement for other reasons, they
should be replaced with the appropriate Lincoln partsâ?
and only by qualified personnel.
Welding Current Selection
Each position on the current selector switch is marked with
the output amperes for that setting. Turn the switch to the
current required for each application.
There is a slight amount of play in each switch position. It
is good practice to move the switch back and forth once
within this play after switching to a new position. This wip-
ing action keeps the contacts free from dirt and oxides.
CAUTION
Do not turn the selector switch while welding as this will
damage the contacts.
â?8â?
NOTES
â?9 â?
How To Use Parts List
1. Refer to the drawing below.
2. Find the part on the drawing.
3. Using the item number from the drawing find the part name and description in the table.
4. Get the welder code number found on the nameplate.
5. Order the part from The Lincoln Electric Company, or from a Lincoln Field Service Shop. Be sure to give the Parts
List number, item number, part name and description, number required, the welder name, model number and code
number.
Parts List P-275 (AC-235)
10
2
4
11
3
7
56
1
8
12
13
22
15
14
21 18 19
16 20
17
15A
Item Description Item Description
1A Fan Motor
1B Fan Blade 16 Work Clamp
2 Case OPTIONAL UNDERCARRIAGE KIT INCLUDES:
3 Nameplate 17 Wheel
4 Warning Decal 18 Washer
5 Selector Switch 19 Axle
6 Switch Handle 20 Front Foot
7 Output Lead Clamp 21 Push Nut
8 Line Switch
INPUT CABLE
10 Lower Back Panel 22 Input Cable
11 Upper Back Panel
ACCESSORIES
12 Electrode Cable
13 Electrode Holder
14 Work Cable
15 Head Shield
15A Welding Gloves
â? 10 â?
LEARNING TO WELD
The serviceability of a product or structure utilizing this type of information is and must
be the sole responsibility of the builder/user. Many variables beyond the control of The
Lincoln Electric Company affect the results obtained in applying this type of information.
These variables include, but are not limited to, welding procedure, plate chemistry and
temperature, weldment design, fabrication methods and service requirements.
No one can learn to weld simply by reading about it. Skill
comes only with practice. The following pages will help
the inexperienced welder to understand welding and
develop his skill. For more detailed information order
a copy of âNew Lessons in Arc Weldingâ? listed on page
25.
The Arc-Welding Circuit
The operatorâs knowledge of arc welding must go beyond
FIGURE 1âThe welding circuit for shielded metal arc
the arc itself. He must know how to control the arc, and this
welding.
requires a knowledge of the welding circuit and the equip-
ment that provides the electric current used in the arc.
The electric arc is made between the work and the tip end
Figure 1 is a diagram of the welding circuit. The circuit
of a small metal wire, the electrode, which is clamped in a
begins where the electrode cable is attached to the welding
holder and the holder is held by the welder. A gap is made
machine and ends where the work cable is attached to the
in the welding circuit (see Figure 1) by holding the tip of
welding machine. Current flows through the electrode
the electrode 1/16-1/8â? away from the work or base metal
cable to the electrode holder, through the holder to the elec-
being welded. The electric arc is established in this gap and
trode and across the arc. On the work side of the arc, the
is held and moved along the joint to be welded, melting the
current flows through base metal to the work cable and
metal as it is moved.
back to the welding machine. The circuit must be complete
for the current to flow. To weld, the work clamp must be Arc welding is a manual skill requiring a steady hand, good
tightly connected to clean base metal. Remove paint, rust, physical condition, and good eyesight. The operator con-
etc. as necessary to get a good connection. Connect the trols the welding arc and, therefore, the quality of the weld
work clamp as close as possible to the area you wish to made .
weld. Avoid allowing the welding circuit to pass through
What Happens in the Arc?
hinges, bearings, electronic components or similar devices
that can be damaged.
Figure 2 illustrates the action that takes place in the electric
This arc-welding circuit has a voltage output of up to 79 arc. It closely resembles what is actually seen during weld-
volts which can shock. ing.
The âarc streamââ?? is seen in the middle of the picture. This
WARNING is the electric arc created by the electric current flowing
through the space between the end of the electrode and the
ELECTRIC SHOCK can kill.
work. The temperature of this arc is about 6000°F.
Carefully review the ARC WELDING SAFETY
(3315°C), which is more than enough to melt metal. The
PRECAUTIONS at the beginning of this
arc is very bright, as well as hot, and cannot be looked at
manual.
with the naked eye without risking painful injury. The very
dark lens, specifically designed for arc welding, must be
used with the hand or face shield whenever viewing the arc.
The arc melts the base metal and actually digs into it, much
as the water through a nozzle on a garden hose digs into the
earth. The molten metal forms a molten pool or crater and
tends to flow away from the arc. As it moves away from the
arc, it cools and solidifies. A slag forms on top of the weld
to protect it during cooling.
â?11 â?
If you are using a hand shield, hold the electrode holder in
your right hand and the hand shield in your left. (For weld-
ing left-handed it is the opposite.)
FIGURE 2âThe welding arc.
The function of the covered electrode is much more than
simply to carry current to the arc. The electrode is com-
posed of a core of metal wire around which has been
extruded and baked a chemical covering. The core wire
Whenever possible, weld from left to right (if right-hand-
melts in the arc and tiny droplets of molten metal shoot
ed). This enables you to see clearly what you are doing.
across the arc into the molten pool. The electrode provides
additional filler metal for the joint to fill the groove or gap Hold the electrode at a slight angle as shown.
between the two pieces of the base metal. The covering also
melts or burns in the arc. It has several functions. It makes
the arc steadier, provides a shield of smoke-like gas around 2. The Correct Way to Strike an Arc
the arc to keep oxygen and nitrogen in the air away from
Be sure the work clamp makes good electrical contact to
the molten metal, and provides a flux for the molten pool.
the work.
The flux picks up impurities and forms the protective slag.
The principal differences between various types of elec- Lower your headshield or hold the hand shield in front of
trodes are in their coatings. By varying the coating, it is your face. Scratch the electrode slowly over the metal and
possible to greatly alter the operating characteristics of you will see sparks flying. While scratching, lift the elec-
electrodes. By understanding the differences in the various trode 1/8" (3.2mm) and the arc is established.
coatings, you will gain a better understanding of selecting
NOTE: If you stop moving the electrode while scratching,
the best electrode for the job you have at hand. In selecting
an electrode you should consider: the electrode will stick.
NOTE: Most beginners try to strike the arc by a fast jab-
1. The type of deposit you want, e.g. mild steel, stainless,
low alloy, hardfacing. bing motion down on the plate. Result: They either stick or
their motion is so fast that they break the arc immediately.
2. The thickness of the plate you want to weld.
3. The position it must be welded in (downhand, out of
3. The Correct Arc Length
position).
The arc length is the distance from the tip of the electrode
4. The surface condition of the metal to be welded.
core wire to the base metal.
5. Your ability to handle and obtain the desired electrode.
Once the arc has been established, maintaining the correct
Four simple manipulations are of prime importance. arc length becomes extremely important. The arc should be
Without complete mastery of these four, further welding is short, approximately 1/16 to 1/8" (1.6 to 3.2mm) long. As
more or less futile. With complete mastery of the four, the electrode burns off the electrode must be fed to the
welding will be easy. work to maintain correct arc length.
The easiest way to tell whether the arc has the correct
length is by listening to its sound. A nice, short arc has a
1. The Correct Welding Position
distinctive, âcracklingâ? sound, very much like eggs frying
Beginners will find it easier to learn how to control the in a pan. The incorrect, long arc has a hollow, blowing or
welding arc using the two-handed technique shown below. hissing sound.
This requires the use of a headshield.
a. Hold the electrode holder in your right hand.
b. Touch your left hand to the underside of your right.
c. Put the left elbow against your left side.
(For welding left-handed it is the opposite.)
â? 12 â?
4. Run beads on a flat plate. Run them parallel to the top
4. The Correct Welding Speed
edge (the edge farthest away from you). This gives you
The important thing to watch while welding is the puddle practice in running straight welds, and also, it gives you
of molten metal right behind the arc. Do NOT watch the an easy way to check your progress. The 10th weld will
arc itself. It is the appearance of the puddle and the ridge look considerably better than the first weld. By con-
where the molten puddle solidifies that indicate correct stantly checking on your mistakes and your progress,
welding speed. The ridge should be approximately 3/8" welding will soon be a matter of routine.
(9.5mm) behind the electrode.
Common Metals
Most metals found around the farm or small shop are low
carbon steel, sometimes referred to as mild steel. Typical
items made with this type of steel include most sheet metal,
plate, pipe and rolled shapes such as channels, angle irons
and âIââ?? beams. This type of steel can usually be easily
Most beginners tend to weld too fast, resulting in a thin,
welded without special precautions. Some steel, however,
uneven, âwormyâ? looking bead. They are not watching the
contains higher carbon. Typical applications include wear
molten metal.
plates, axles, connecting rods, shafts, plowshares and
scraper blades. These higher carbon steels can be welded
IMPORTANT: For general welding it is not necessary to
successfully in most cases; however, care must be taken to
weave the arc; neither forwards and backwards nor side-
follow proper procedures, including preheating the metal to
ways. Weld along at a steady pace. You will find it easier.
be welded and, in some cases, carefully controlling the
temperature during and after the welding process. For fur-
NOTE: When welding on thin plate, you will find that you
ther information on identifying various types of steels and
will have to increase the welding speed, whereas when
other metals, and for proper procedures for welding them,
welding on heavy plate, it is necessary to go more slowly
we again suggest you purchase a copy of âNew Lessons in
in order to get good penetration.
Arc Weldingâ? (see page 25).
Regardless of the type of metal being welded, it is impor-
Practice
tant in order to get a quality weld that it be free of oil, paint,
rust or other contaminants.
The best way of getting practice in the four skills that
enable you to maintain:
Types of Welds
1 Correct Welding Position
2. Correct Way To Strike An Arc Five types of welding joints are: Butt Welds, Fillet Welds,
3. Correct Arc Length Lap Welds, Edge Welds and Corner Welds.
4. Correct Welding Speed
is to spend a little more time on the following exercise.
Use the following:
Mild Steel Plate ......................3/16" (4.8mm) or heavier
Electrode ............................1/8" (3.2mm) Fleetweld 180
Current Setting..........................................105 Amps AC
Do the following:
Of these, the Butt Weld and Fillet Weld are the two most
1. Learn to strike the arc by scratching the electrode over
common welds.
the plate. Be sure the angle of the electrode is correct. If
you have a headshield use both hands.
Butt Weld
2. When you can strike an arc without sticking, practice the
Butt Welds are the most widely used welds. Place two
correct arc length. Learn to distinguish it by its sound.
plates side by side, leaving 1/16â? (1.6mm) (for thin metal)
to 1/8â? (3.2mm) (for heavy metal) space between them in
3. When you are sure that you can hold a short, crackling
order to get deep penetration .
arc, start moving. Look at the molten puddle constantly,
and look for the ridge where the metal solidifies.
â? 13 â?
Tack the plates at both ends, otherwise the heat will cause
the plates to move apart. (See drawing):
Fillet Welds
Now weld the two plates together. Weld from left to right
When welding fillet welds, it is very important to hold the
(if right-handed). Point the electrode down in the crack
electrode at a 45° angle between the two sides, or the metal
between the two plates, keeping the electrode slightly tilted
will not distribute itself evenly.
in the direction of travel.
To make it easy to get the 45° angle, it is best to put the
electrode in the holder at a 45° angle, as shown:
Watch the molten metal to be sure it distributes itself even-
ly on both edges and in between the plates.
Penetration
Unless a weld penetrates close to 100%, a butt weld will be
weaker than the material welded together.
Multiple Pass Welds
(12.7 mm)
Make multiple pass horizontal fillets as shown in the
sketch. Put the first bead in the corner with fairly high cur-
rent. Hold the electrode angle needed to deposit the filler
beads as shown putting the final bead against the vertical
plate.
In this example, the total weld is only 1/2 (12.7mm)the
thickness of the material; thus the weld is only approxi-
mately half as strong as the metal.
In this example, the joint has been flame beveled or ground
prior to welding so that 100% penetration could be
achieved. The weld, if properly made, is as strong or Welding in the Vertical Position
stronger than the original metal.
Welding in the vertical position can be done either vertical-
up or vertical-down. Vertical-up is used whenever a large,
strong weld is desired. Vertical-down is used primarily on
sheet metal for fast, low penetrating welds.
Vertical-Up Welding
The problem, when welding vertical-up, is to put the
molten metal where it is wanted and make it stay there. If
too much molten metal is deposited, gravity will pull it
downwards and make it âdrip.ââ?? Therefore a certain tech-
â? 14 â?
nique has to be followed: 1. Use 1/8 (3.2mm) or 3/32" (2.4mm) Fleetweld 180 electrode.
2. On thin metal, use 60-75 amps. (14 ga 75 amps â? 16 ga
60 amps.)
3. Hold the electrode in a 30-45° angle with the tip of the
electrode pointing upwards.
4. Hold a VERY SHORT arc, but do not let the electrode
touch the metal.
5. An up and down whipping motion
will help prevent burn-through on
very thin plate.
1. Use 1/8" (3.2mm) at 90-105 amps or 3/32" (2.4mm) at 6. Watch the molten metal carefully.
60 amps FleetweldÂź 180 electrode.
The important thing is to continue lowering the entire arm
2. When welding, the electrode should be kept horizontal as the weld is made so the angle of the electrode does not
or pointing slightly upwards. (See drawing.) change. Move the electrode so fast that the slag does not
catch up with the arc. Vertical-down welding gives thin,
3. The arc is struck and metal deposited at the bottom of
shallow welds. It should not be used on heavy material
the two pieces to be welded together.
where large welds are required.
4. Before too much molten metal is deposited, the arc is
SLOWLY moved 1/2-3/4" (12.7-19mm) upwards. This
takes the heat away from the molten puddle, which Overhead Welding
solidifies. (If the arc is not taken away soon enough, too
Various techniques are used for overhead welding.
much metal will be deposited, and it will âdrip.ââ??)
However, in the interest of simplicity for the inexperienced
5. The upward motion of the arc is caused by a very slight welder the following technique will probably take care of
wrist motion. Most definitely, the arm must not move in most of his needs for overhead welding:
and out, as this makes the entire process very complicat-
1. Use 1/8" (3.2mm) at 90-105 amps or 3/32" (2.4mm) at
ed and difficult to learn.
60 amps Fleetweld 180 electrode.
6. If the upward motion of the arc is done correctly with a
2. Put the electrode in the holder so it sticks straight out.
wrist motion, the arc will automatically become a long
arc that deposits little or no metal. (See drawing.) 3. Hold the electrode at an angle approximately 30° off
vertical, both seen from the side and seen from the end.
7. During this entire process the ONLY thing to watch is
the molten metal. As soon as it has solidified, the arc is
SLOWLY brought back, and another few drops of metal
are deposited. DO NOT FOLLOW THE UP AND
DOWN MOVEMENT OF THE ARC WITH THE
EYES. KEEP THEM ON THE MOLTEN METAL.
8. When the arc is brought back to the now solidified pud-
The most important thing is to hold a VERY SHORT arc.
dle, IT MUST BE SHORT, otherwise no metal will be
(A long arc will result in falling molten metal; a short arc
deposited, the puddle will melt again, and it will âdrip.â?
will make the metal stay.)
9. It is important to realize that the entire process consists
If necessary â? and that is dictated by the looks of the
of SLOW, DELIBERATE movements. There are no fast
molten puddle â? a slight back and forth motion along
motions.
the seam with the electrode will help prevent âdripping.â?
Vertical-Down Welding
Vertical-down welds are applied at a fast pace. These welds
are therefore shallow and narrow, and as such are excellent
for sheet metal. Do not use the vertical-down technique on
heavy metal. The welds will not be strong enough.
â?15 â?
Welding Sheet Metal
Welding sheet metal presents an additional problem. The
thinness of the metal makes it very easy to burn through.
Follow these few simple rules:
1. Hold a very short arc. (This prevents burn through, since (12.7 to 19 mm)
beginners seem to hold too long an arc.)
5. Use the back-stepping method. Begin to weld 3"
2. Use 1/8â? (3.2mm) or 3/32" (2.4mm) Fleetweld 180 electrode.
(75mm) from the heel of the share and weld to the heel.
3. Use low amperage. 75 amps for 1/8" (3.2mm) electrode, The second weld will begin 6" (150mm) from the heel,
40-60 amps for 3/32" (2.4mm) electrode. the third weld 9" (225mm) from the heel, etc.
4. Move fast. Donât keep the heat on any given point too
long. Keep going. Whip electrode.
5. Use lap welds whenever possible. This doubles the
thickness of the metal.
Hardfacing
Backstepping greatly reduces the chances for cracking of
There are several kinds of wear. The two most often the share, and it also greatly reduces possible warpage.
encountered are:
NOTE: The entire process is rather fast. Many beginners
1. Metal to Ground Wear. go much to slow when hardfacing plow shares, running the
(Plowshares, bulldozer blades, buckets, cultivator risk of burning through the thin metal.
shares, and other metal parts moving in the soil.)
Hardfacing of Idler and Roller (Metal to Metal Wear)
2. Metal to Metal Wear.
(Trunnions, shafts, rollers and idlers, crane and mine car A very common application of hardfacing for metal to
wheels, etc.) metal wear is the hardfacing of idlers and rollers and the
rails that ride on these rollers and idlers.
Each of these types of wear demands a different kind of
hardsurfacing electrode. The reason for hardfacing these parts is primarily mone-
tary. A few dollars worth of electrode will completely build
When applying the proper electrode, the service life of the
up a roller or idler, and the hard surface will outlast sever-
part will in most cases be more than double. For instance,
al times the normal life or such rollers and idlers.
hardsurfacing of plowshares results in 3-5 times more
acreage plowed. If the following procedure is followed, it is not even neces-
sary to remove the grease bearing while welding. This will
How to Hardface the Sharp Edge (Metal to Ground save a lot of time:
Wear)
1. The roller (or idler) is inserted on a piece of pipe that is
1. Grind the share, approximately one inch (25mm) wide resting on two sawbucks. This enables the operator to
along the edge, so the metal is bright. turn it while welding.
2. Place the share on an incline of approximately 20-30°. 2. Use Jet-LHŸ BU-90 electrodes, 5/32" (4.0mm) at 175
The easiest way to do this is to put one end of the share amps or 3/16" (4.8mm) at 200 amps.
on a brick. (See drawing.)
3. Weld across the wearing surface. Do not weld around.
Most users will want to hardface the underside of the
4. Keep the roller (or idler) cool by quenching with water,
share, but some might find that the wear is on the top
and by stopping the welding periodically. This will pre-
side. The important thing is to hardface the side that
vent shrinking of the roller (or idler) on the grease bear-
wears.
ing.
3. Use 1/8" (3.2mm) Abrasoweldâ? electrode at 90-105 amps.
5. Build-up to dimension. The weld metal deposited by
Strike the arc about one inch (25mm) from the sharp edge.
BU-90 electrode is often so smooth that machining or
4. The bead should be put on with a weaving motion, and grinding is not necessary.
it should be 1/2 to 3/4" (12.7 to 19mm) wide. Do not let
the arc blow over the edge, as that will dull the edge.
(See drawing.)
â? 16 â?
In this way no large amount of heat is put into the mass.
NOTE: The quenching of the roller (or idler) has another
purpose: It increases the hardness â? and thus the service
Most inexperienced welders will probably use the second
life â? of the deposit.
method, because they have no way of preheating large cast-
ings. Smaller castings can easily (and should) be preheated
The hardfacing of the rails is a lot easier:
before welding. A forge, stove, a fire, or the Arc Torch are
1. Place the rails with the side that rides on the rollers and all excellent means of preheating.
idlers upwards.
When using the 1/2" (12.7mm) at a time method, it is rec-
2. Use Jet-LH BU-90 electrodes. Same ampere setting as ommended to start 1/2" (12.7mm) away from the previous
on the idlers and rollers. bead and weld into the previous bead (backstepping).
3. Build-up to size. After welding Cast Iron, protect the casting against fast
cooling. Put it in a sand (or lime) box.
4. Do not quench. This will make the deposit slightly soft-
er than the deposit on the idlers and rollers. That means If sand or lime is not available, cover it with sheet metal or
that the wear will primarily be on the rails, which are a any other non-flammable material that will exclude drafts
lot easier and less time-consuming and cheaper to build- and retain heat.
up.
NOTE: The same electrode â? BU-90 â? will give the
Cast Iron Plate Preparation
operator two desired hardnesses, just by a difference in
cooling rate, making it possible to put the hardest deposit Wherever practical, the joint to be welded should be âveedâ?
on the most expensive parts. out by grinding or filing to give complete penetration. This
is especially important on thick castings where maximum
NOTE: The outside of the rails (the side that comes in con-
strength is required. In some instances a back-up strip may
tact with the ground) should be surfaced with Abrasoweld,
be used and plates may be gapped 1/8" (3.2mm) or more.
since this side has Metal to Ground wear.
On sections where only a sealed joint is required and
strength is not important, the joint may be welded after
Welding Cast Iron slightly veeing out the seam as shown.
When welding on a piece of cold cast iron, the tremendous
heat from the arc will be absorbed and distributed rapidly
into the cold mass. This heating and sudden cooling creates
WHITE, BRITTLE cast iron in the fusion zone.
This is the reason why welds in cast iron break. Actually,
one piece of the broken cast iron has the entire weld on it,
and the other piece has no weld on it.
Cutting Do not exceed the Duty Cycle â? See
page 8)
The arc welder and the electrode can be used for cutting
steel and cast iron. Follow this procedure:
1. Use 1/8:â? (3.2mm) or 5/32" (4.0mm) Fleetweld 180 electrode.
In order to overcome this, the welding operator has two
2. Set welder on maximum (235 amps).
choices:
3. Hold long arc on edge of metal, melting it.
1. He can preheat the entire casting to 500-1200°F. (260-
649°C). If the cast iron is hot before welding, there will 4. Push the arc through the molten metal, forcing it to fall
be no sudden chilling which creates brittle white cast away.
iron. The entire casting will cool slowly.
5. Raise the electrode, and start over again.
2. He can weld 1/2" (12.7mm) at a time, and not weld at that spot
The important thing is to continue this up-and-down, saw-
again until the weld is completely cool to the touch.
ing motion, melting the metal and pushing it away.
â?17 â?
If a lot of cutting is to be done, USING THE CARBON ARC TORCH
soak each electrode in water
. . . Welding Aluminum and Copper Alloys
for a minute or two. It keeps
. . . Brazing and Soldering
them cooler, and the electrodes
. . . Heating, Bending and Straightening
last longer.
WARNING Jaw Assembly
T9984
ELECTRIC SHOCK can kill. (2 Required)
When soaking electrode keep your gloves and
Complete Arc Torch
clothing dry. Never dip an electrode holder in
K1876-1
water..
Piercing Holes
Thumb Screw
1. Welder setting: Maximum T9078
(Part of T9984)
Use 235
(235 amps).
amperes
2. Electrode: 1/8â? (3.2mm) or
5/32" (4.0mm) Fleetweld 180.
Ground Clip
3. Hold the electrode with a T10379-1
long arc perpendicular
over the spot where the
hole is to be made.
4. When the metal is molten, Required Equipment
push the electrode through
1. A Lincoln Carbon Arc Torch L-2645; Its rating is 100
the molten puddle.
amperes.
5. Give the molten metal a chance to fall through the hole.
2. 1/4, 5/16 or 3/8â? (6.4, 7.9, or 9.5mm) carbons: Use only
6. Circle with a long arc around the edge of the hole until copper coated and cored carbons to avoid overheating
the desired diameter hole has been made. the holder and provide even burning of the carbons.
If the electrode is pushed through too soon it will stick in 3. Any AC or DC welder: Carbons burn much faster on DC
the puddle. Be sure the metal is molten before pushing than they do on AC. Also the carbon connected to the
through . positive DC output should be larger than the carbon con-
nected to the negative DC output so both carbons
NOTE: On heavy metal (5/16" (7.9mm) or thicker), posi-
burnoff at about the same rate.
tion the plate to be pierced vertically, and the electrode hor-
izontally. This allows the molten metal to drip away freely
as you are boring through.
Torch Connections
Insert the straight ferrule on the end of one arc torch lead
into the standard electrode holder. Attach the spring clip on
the end of the other lead to either the work clamp or the
welding table where the work lead is clamped. If connect-
ed to the table, insulate the work from the table. See draw-
ing below.
CAUTION: INSULATION IS REQUIRED
IN THESE TWO AREAS.
â? 18 â?
WARNING
ARC RAYS can burn.
The carbon arc torch rays will cause severe
arc burns to exposed skin. Therefore, a pair of
work gloves, long sleeved shirt or sleevelets,
and an apron are recommended.
Use an arc welding headshield or hand shield with a No. 11 2.00"
or No. 12 lens. Oxyacetylene goggles are not sufficient eye
and face protection.
When adjusting the length of carbons, be sure the welder is 0.06"
turned off. An arc flash while making this adjustment can
burn hands or eyes.
When laying the torch down, avoid touching the carbons to
the grounded bench or work. This is best done by turning Use the thumb control on the arc torch to rotate the carbons until
the welder off. As an alternative, either set the torch on an they touch. Start the arc by reversing the thumb control setting
insulated surface or lay it on its side with the leads hanging to spread the carbons 1/16 to 3/16" (1.6 to 4.8mm) apart. As the
down over the bench so the handle rests on the bench top. carbons burn away use the thumb control to maintain the
desired arc. When the proper arc can no longer be maintained,
DO NOT EXCEED THE OUTPUT DUTY CYCLE OF
turn the welder off and readjust the carbon stickout.
THE WELDER. Exceeding this duty cycle in successive
10 minute periods can overheat the welder and damage the A wide, soft, quiet flame gives the best results for most
windings. (See page 8.) jobs. When the carbon tips are too close together a small
flame accompanied by a hissing or crackling sound results.
The shape of a good flame is illustrated below. The flame
Heat Settings
fans out to form a âfish tailâ? shape with inner and outer
Recommended current settings for different material thick- cone. To heat a crack or a corner, position the flame as illus-
nesses and carbon sizes are given in the table. Generally, use trated.
only enough current to cause the filler metal to flow freely on
the work. Do not use currents so high that the copper coating
burns away more than 1/2ââ?? (12.7mm) above the arc.
Set the carbons to extend about 2â? (50mm) beyond the copper jaws.
WARNING
Be sure the welder is turned off when making this
adjustment.
Thickness of Approximate Current Carbon
Base Metal Setting (AC) Diameter
Heat intensity is controlled by changing the current setting,
1/32"(0.8) 30-50 amps 1/4"(6.4)
by moving the carbons closer together or farther apart, or
1/16"(1.6) 50-60 amps 1/4"(6.4)
by changing the distance between the flame and work.
1/8"(3.2) 70-80 amps 5/16"(7.9)
1/4"(6.4) 90-100 amps 3/8"(9.5) When the work sets on a metal table, the table absorbs
some of the heat. To avoid high heat loss, the part can be set
on thin metal strips or some insulation.
After adjusting the welder current and setting the carbon
stickout, start the welder and you are ready to go. Removal of Nuts and Bolts: Apply heat with the arc torch
for a few seconds and nuts can be easily turned off.
â? 19 â?
Welding Procedures
Heating Heavy Parts
1. Use the recommended AC currents and carbon sizes list-
Heavy metal can be heated more rapidly by connecting the
ed in the Table on page 19. A headshield is required.
work lead to the work so the arc is between the carbons and
the work as well as between the two carbons. To do this,
2. Use a l/8" (3.2mm) âAluminweldâ? coated electrode as a
connect the lead carbon (the carbon which leads the direc-
filler rod. Hold it in the left hand (for right-handed people).
tion of travel) to the electrode holder. Connect both the trail
carbon and the work cable to the work or to the welding 3. Hold the arc torch in your right hand and start the arc by
table. With this connection, raising the torch reduces the shorting the carbons together and adjusting them to a
amount of the arc going to the work thus reducing the heat- 1/16" (1.6mm) gap.
ing. The arc between the carbons and work tends to pit the
4. Hold the arc torch as shown here. Hold your eyes right
surface of the work.
over the arc torch looking in between the two carbons.
5. Play the arc 3" to 4" (75 to 100mm) up and down the
joint at the start. This preheat helps to give a smoother
bead and an easier start when the filler rod is applied.
6. Move the torch to the beginning of the joint (right-hand-
ed people should begin at the right and move left).
7. Place the tip of the electrode in the arc. If the coating
Welding Aluminum Alloys With The melts off and flows easily into the joint, the metal is hot
Arc Torch enough to start welding.
The need to repair aluminum parts continues to grow. 8. Let a droplet of the filler rod melt and fuse into the
These repairs can be simply made with an AC welder using joints.
Aluminweld DC coated electrodes as a filler rod and The
9. Watch the molten puddle. Add more filler metal by mov-
Carbon Arc Torch. The arc torch preheats the aluminum
ing the end of the rod in and out of the arc as the right
plate, assuring good fusion.
hand moves the arc torch slowly along the joint.
Practice
Work Preparation
When you first try to weld with these procedures, you may
Here are recommended edge preparations and types of
have a tendency to burn through. Therefore, a few minutes
joints for different thicknesses of base metal. All welds
practice before working on the parts to be welded is rec-
must be made in the downhand position. Round parts must
ommended. Use scrap material about as thick as the part
be rotated.
you are going to weld. Practice the technique to get the feel
of the arc.
Brazing
The techniques for brazing with an arc torch are very much
like the ones used for gas brazing. Only enough heat is need-
ed to melt the filler metal and to raise the parts to be brazed
to the melting temperature of the filler metal â? usually
slightly over 1,000°F. (538°C). A good brazed joint is
assured when the filler metal flows into the joint and adheres
evenly to the surfaces. Use only enough filler metal to make
a smooth joint. Use standard gas brazing rod and flux .
Heat the end of the brazing rod and dip it into the flux. The
flux will stick to the hot rod. Play the arc back and forth a
short distance along the seam when the right temperature is
reached. Apply flux as needed and melt off brazing rod to
fill the seam. Move along the seam until the job is com-
plete.
â?20 â?
If the part being brazed does not get hot enough, increase These electrodes are used for general purpose all-position
the current or hold the torch closer to the work. Whenever fabrication and repair welding; also the best choice for pipe
possible, have the joint horizontal to secure best flow of welding and sheet metal butt, corner and edge welds. They
molten filler rod. can be used for repair work when dirt, grease, plating or
paint cannot be completely cleaned from the steel.
Soldering Typically used with motions âAââ?? and âBââ?? (below) for the
first pass on vertical-up welds.
The arc torch can be used to solder copper piping and other
copper, tinned and galvanized parts. Best results are High-Deposit Group (E6027, E7024)
obtained with overlapping pieces. Clean the surfaces to be
soldered and cover them with soldering flux to prevent oxi- This group includes the heavy coated, iron powder elec-
dation and to speed soldering. Acid core solder produces trodes with their soft arc and fast deposit rates. These elec-
good results. trodes have a heavy slag and produce exceptionally smooth
beads. They are generally used for production welding
The best soldering can be done on the lowest current tap of where all work can be positioned for downhand welding.
the welder. Use approximately 1/4" (6.4mm) diameter car- Stringer beads, with drag technique, are always preferred
bon and make certain to bring it into firm contact with the over weave passes with these electrodes.
piece to be soldered to avoid arcing. Simply play the arc on
High-Speed Group (E6012, E6013, E7014)
the area to be soldered and feed solder into the joint as it
reaches proper temperature. After the soldering is complet-
This group includes electrodes which have a moderately
ed, the carbon must be removed quickly to prevent arcing.
forceful arc and deposit rates between those of the out-off
Never use so much heat that the solder boils.
position and high-deposit electrodes. They are primarily
general purpose production electrodes especially for down-
Heating, Bending and Straightening
hill fillets and laps or short and irregular welds that change
Choose the carbon size and current setting depending upon direction or position. Also widely used in maintenance and
the thickness of the metal to be heated. Play the arc over the recommended for sheet metal fillet and lap welds. Motion
section to be heated until the desired temperature is âDââ?? (below) is generally used for vertical-up welding, but
reached. For bending this is usually a dull red color on ordi- motions âAâ? and âBâ? are also suitable.
nary mild steels.
Low Hydrogen Group (E7018, E7028)
Do not hold the carbons too close to the work. Arcing the
surface increases the tendency for the base metal to crack These electrodes are generally called âlow hydrogen.â? The
when the bending is done. name comes from the fact that their coating contains little
hydrogen in either moisture or chemical form. Low hydro-
Carbon Arc Torch Maintenance gen electrodes offer these benefits: outstanding crack resis-
tance, lowest porosity on sulphur bearing steels, and capa-
The handle is held together with a screw and spring lock ble of X-ray quality deposits. Thus, they are the first choice
washer to give just the right friction on the electrode shafts. when welding âproblemâ? steels. E7018 can be used in all
If the handle is removed for any reason, the screw at the positions, with Motion âCâ? recommended for the first pass
front of the handle should be turned up snugly and then on vertical-up welds. NEVER use a whipping technique or
backed off 1/2 turn to give the proper friction. a long arc with these electrodes. ALWAYS fill craters by
drawing electrodes away slowly. ALWAYS keep these elec-
Occasionally the screws in the copper jaws will bind, so it
trodes dry. Electrodes not used within a few hours after a
will be advantageous to lubricate the threads with graphite
container is opened must be stored in heat cabinets. LH-73
grease and work the grease well into the threaded jaw.
is recommended with the AC-235. Normally, DC(+) is pre-
ferred for these electrodes.
SELECTING ELECTRODES
Which electrode is best for the particular job . . . how do
you use it? These are important questions because the cost,
quality, and appearance of your work depends on proper
electrode selection and application. MILD STEEL ELEC-
TRODES may be classified into the following groups:
Out-of-Position Group (E6011)
This group includes electrodes which have a snappy, deep
penetrating arc and fast freezing deposits.
â? 21 â?
Motions
Manipulation depends on the joint. Some of the common
motions are shown above.
Motion âAâ? is a straight whipping motion used with fast-
freeze electrodes to make stringer beads in all positions and
on all types of joints. It keeps the molten pool small and lets
it freeze quickly so the weld metal doesnât spill down or
through the joint. Keep arc short when in the crater and
longer during whip out from the crater.
Motion âBâ? is a whipping motion combined with a slight
weave in the crater. It is used with fast-freeze electrodes as
the first pass on vertical fillets and V-butts.
Motion âCâ? is a simple side-to-side weave used with all
types of electrodes to make fill passes on vertical fillets and
V-butts. Also sometimes used with fill-freeze and low
hydrogen electrodes to make the first pass on these joints.
Motion âDâ? is a triangular weave used with fill-freeze and
low hydrogen electrodes to make one pass vertical fillets
and V-butts. It results in a larger weld than Motion âCââ??.
Motion âEâ? is a box weave used with all types of elec-
trodes to make fill passes on vertical fillets and V-butts. It
is similar to Motion âC,ââ?? but with a distinct pause and
slight upward motion at each edge of the weld to assure
complete crater filling and elimination of undercut.
Motion âFâ? is a circular motion used with all types of elec-
trodes to make overhead welds. Sometimes accompanied
by a slight whip after each oscillation in the crater. Always
use a series of stringer beads overhead; do not weave.
Motion âGâ? is a simple side-to-side weave used with all
electrodes on wide fillets or butts in the flat position.
â? 22 â?
NOTE: The AC-235 is an AC welder. DC electrodes have been included in the chart below for referance only.
ELECTRODE IDENTIFICATION AND OPERATION DATA
Electrode
Conforms to Test Polarity Sizes and Current Ranges (Amps.)
Coating Requirements of Electrode (+) = âReverseâ?
Color AWS Class Brand Name 5/64" Size 3/32" Size 1/8" Size 5/32" Size 3/16" Size 7/32" Size 1/4" Size 5/16" Size
(â?) = âStraightâ?
MILD STEEL
Brick Red E6010 Fleetweld 5P DC(+) 40-75 75-130 90-175 140-225 200-275 220-325 240-400
DC(â?) 80-135 110-180 155-250 225-295 245-325
Tan E6012 Fleetweld 7
AC 90-150 120-200 170-275 250-325 275-360
AC 50-85 75-120 90-160 120-200 150-260 190-300
Gray E6011 Fleetweld 35
DC(+) 40-75 70-110 80-145 110-180 135-235 170-270
AC 80-130 120-160
Red Brown E6011 Fleetweld 35LS
DC(±) 70-120 110-150
AC 50-80 75-105 110-150 160-200 205-260
Gray Tan E6013 Fleetweld 37
DC(±) 45-75 70-95 100-135 145-180 190-235
AC 110-160 150-225 200-280 260-340 280-425
Gray Brown E7014 Fleetweld 47
DC(â?) 100-145 135-200 185-235 235-305 260-380
AC 100-150 150-200 200-260
Gray* E6013 Fleetweld 57
DC(â?) 90-135 135-180 180-235
AC 40-90 60-120 115-150
Brown E6011 Fleetweld 180
DC(±) 40-80 55-110 105-135
AC 65-120 115-175 180-240 240-300 300-380 340-440
Gray E7024 JetweldÂź 1
DC(±) 60-110 100-160 160-215 220-280 270-340 320-400
AC 190-240 250-300 300-380 350-450
Red Brown E6027 Jetweld 2
DC(±) 175-215 230-270 270-340 315-405
AC 65-120 115-175 180-240 240-315 300-380 350-450 380-600
Gray* E7024 Jetweld 3(1)
DC(±) 60-110 100-160 160-215 215-285 270-340 315-405 360-600
DC(+) 70-100 90-150 120-190 170-280 210-330 290-430 375-500
Gray E7018 Jetweld LH-70
AC 80-120 110-170 135-225 200-300 260-380 325-440 400-530
E7018 AC 70-90 95-135 140-200
Gray* Jetweld LH-73
(white numbers) DC(+) 65-85 90-125 130-185
DC(+) 70-110 95-160 120-190 180-270 250-330 300-400
White E7018 Jetweld LH-75
AC 80-110 100-170 135-225 210-290 270-370 325-420
7018 DC(+) 85-110 110-160 130-200 180-270 250-330 300-400
Gray JET-LH 78
(white numbers) AC 120-170 140-230 210-290 270-370 325-420
AC 180-270 240-330 275-410 360-520
Gray Brown E7028 Jetweld LH-3800
DC(+) 170-240 210-300 260-380
LOW ALLOY, HIGH TENSILE STEEL
5/16" Jetweld 3 does not conform to any AWS/ASME classification.
(1)
Pink E7010-A1 Shield ArcÂź 85 DC(+) 50-90 75-130 90-175 140-225
Pink* E7010-A1 Shield-Arc 85P DC(+) 140-225
Tan E7010-G Shield Arc HYP DC(+) 75-130 90-185 140-225 160-250
Gray E8010-G Shield-Arc 70+ DC(+) 75-130 90-185 140-225
DC(+) 90-150 120-180 180-270 250-350
Gray Brown E8018-C1 Jet-LHÂź 8018 C1
AC 110-160 140-200 200-300 300-400
DC(+) 110-150 130-190 180-270 250-330 300-400
Gray Brown E8018-C3 Jet-LH 8018 C3
AC 120-170 140-225 210-290 270-370 325-420
DC(+) 110-150 130-190 180-270
Gray E8018-B2 Jetweld LH-90
AC 120-170 140-225 210-290
DC(+) 70-100 85-155 120-195 160-280 190-310 230-360
Gray E11018-M Jetweld LH-110M
AC 80-110 100-170 135-225 200-310 240-350 290-410
STAINLESS STEEL
Pale Green E308-15 StainweldÂź 308-15 DC(+) 30-70 50-100 75-130 95-165 150-225
Gray E308-16 Stainweld 308-16 DC(+); AC 20-45 30-60 55-95 80-135 115-185 200-275
Gray E308L-16 Stainweld 308L-16 DC(+); AC 30-65 55-100 80-140 115-190
Gray E309-16 Stainweld 309-16 DC(+); AC 30-60 55-95 80-135 115-185 200-275
Gray E310-16 Stainweld 310-16 DC(+); AC 30-65 55-100 80-140 120-185 200-275
Gray E316L-16 Stainweld 316L-16 DC(+); AC 30-65 55-100 80-140 115-190
Pale Green E347-15 Stainweld 347-15 DC(+) 30-70 50-100 75-130 95-165
Gray E347-16 Stainweld 347-16 DC(+); AC 30-60 55-95 80-135 115-185
ALUMINUM
White AluminweldÂź DC(+) 20-55 45-125 60-170 85-235
1/8" Size 5/32" Size 3/16" Size 1/4" Size
CAST IRON
Light Tan ESt FerroweldÂź DC(+); AC 80-100
DC(±) 60-110 100-135
Black ENiCl SoftweldÂź
AC 65-120 110-150
HARDFACING
DC(±) 40-150 75-200 110-250 150-375
Black Wearshield ABR
AC 50-165 80-220 120-275 165-410
Black Faceweld 1 DC(+); AC 60-150
Âź
Black Faceweld 12 DC(+); AC 60-150
DC(±) 145-210 180-280 230-360
Dark Gray Jet-LH BU-90
AC 155-225 200-290 255-375
DC(±) 120-180 160-260 200-350
Dark Gray MangjetÂź
AC 135-230 165-285 220-385
DC(+) 110-275 150-400
Dark Gray WearweldÂź
AC 125-275 200-400
Means registered Trademark of The Lincoln Electric Company.
Âź
The electrodes under the shaded portions of this chart will operate on
the AC-235 Arc Welder. However, the size and current used must be
* Has identification dot on coating.
within the capacity of the welder.
â? 23â?
â? 24 â?
G Do not touch electrically live parts or G Keep flammable materials away. G Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.
G Insulate yourself from work and
ground.
Spanish
G No toque las partes o los electrodos G Mantenga el material combustible G ProtĂ©jase los ojos, los oĂdos y el
AVISO DE bajo carga con la piel o ropa moja- fuera del ĂĄrea de trabajo. cuerpo.
da.
PRECAUCION G Aislese del trabajo y de la tierra.
French G Ne laissez ni la peau ni des vĂȘte- G Gardez Ă lâĂ©cart de tout matĂ©riel G ProtĂ©gez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des piĂšces sous tension.
G Isolez-vous du travail et de la terre.
G BerĂŒhren Sie keine stromfĂŒhrenden
German G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
G Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
G Não toque partes elétricas e elec- G Mantenha inflamåveis bem guarda- G Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENĂĂO da.
G Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURERâS INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO
BE USED AND FOLLOW YOUR EMPLOYERâS SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHĂTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
G Keep your head out of fumes. G Turn power off before servicing. G Do not operate with panel open or
G Use ventilation or exhaust to
WARNING
guards off.
remove fumes from breathing zone.
Spanish
G Los humos fuera de la zona de res- G Desconectar el cable de ali- G No operar con panel abierto o
AVISO DE
piraciĂłn. mentaciĂłn de poder de la mĂĄquina guardas quitadas.
G Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
PRECAUCION
humos. Utilice ventilaciĂłn o
aspiraciĂłn para gases.
French
G DĂ©branchez le courant avant lâentre- G NâopĂ©rez pas avec les panneaux
G Gardez la tĂȘte Ă lâĂ©cart des fumĂ©es.
G Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
ATTENTION
protection enlevés.
teur pour Îter les fumées des zones
de travail.
German
G Strom vor Wartungsarbeiten G Anlage nie ohne SchutzgehÀuse
G Vermeiden Sie das Einatmen von
abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
Schweibrauch!
WARNUNG
G Sorgen Sie fĂŒr gute Be- und nen; Maschine anhalten!) Betrieb setzen!
EntlĂŒftung des Arbeitsplatzes!
Portuguese
G NĂŁo opere com as tampas removidas. G Mantenha-se afastado das partes
G Mantenha seu rosto da fumaça.
G Desligue a corrente antes de fazer
G Use ventilação e exhaustão para moventes.
ATENĂĂO
serviço. G Não opere com os paineis abertos
remover fumo da zona respiratĂłria.
G Não toque as partes elétricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUĂĂES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRĂTICAS DE SEGURANĂA DO EMPREGADOR.
â? World's Leader in Welding and Cutting Products â?
â? Sales and Service through Subsidiaries and Distributors Worldwide â?
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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