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There are three most important set of operations for repair welding: Preparation for welding Repair welding Postweld operations This article introduces actions and procedures for repair welding and surfacing.
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There are three most important set of operations for repair welding: Preparation for welding Repair welding Postweld operation This article introduces actions and procedures for repair welding and surfacing. Preparation for Welding A large number of factors should be considered and decisions made before starting to weld. Safety. The repair welding location or area must be surveyed and all safety considerations satisfied. This can include the posting of the area required by certain regulations, removal of all combustible materials from the area, the draining of fuel tanks of construction equipment, aircraft, boats, trucks, etc. Other precautions include the elimination of toxic materials such as thick coats of lead paint, plastic coverings of metals, etc. Cleaning. The immediate work area must be clean from all contaminants and this includes removal of dirt, grease, oil, rust, paint, plastic coverings, etc., from the surface of the parts being welded. The method of cleaning depends on the material to be removed and the location of the work piece. For most construction and production equipment, steam cleaning is recommended. When this is not possible solvent cleaning can be used. Blast cleaning with abrasives is also used. For small parts pickling or solvent dip cleaning can be used and, finally, power tool cleaning with brushes, grinding wheels, disc grinding, etc., can be employed. The time spent cleaning a weld repair area will pay off in the long run. Disassembly. Except for the simplest repair jobs disassembly may be required. This can be related to items mentioned above but also applies to lubrication lines, instrument tubing, wiring, etc. Sometimes it is necessary to disassemble major components such as machinery from machinery frames, etc. Protection of adjacent machinery and machined surfaces. When repair welding is done on machinery many parts that are not removed should be protected from weld spatter, flame cutting sparks, and other foreign material generated by the repair process. Sheet metal guards or baffles are used to protect adjacent machinery. For machined surfaces, asbestos cloth can be employed. It is wise to secure protective material with wire, clamps, or other temporary bracing. Machined surfaces within five feet of the welding operation should be protected. Bracing and clamping. On complex repair jobs bracing or clamping may be required. This is because of the heavy weight of parts or the fact that loads may be exerted on the part being weld repaired. If main structural members are to be cut the load must be carried by temporary braces. The braces can be temporarily welded to the structure being repaired. Lay out repair work. In most repair jobs it is necessary to remove metal so that a fullpenetration weld can be made. A layout should be made to show the metal that is to be removed by cutting or gouging to prepare the part for welding. The minimum amount of metal should be removed to obtain a full-penetration weld. The layout should be selected so that welding can be balanced, if possible, and that the bulk of the welding can be made from the more comfortable welding position. Preheating. The preheating and flame cutting or gouging are parts of the preparation for welding but can be considered part of the welding operation. When flame cutting or gouging is required, preheating should be the same as when welding. It might not be quite as important since stresses are much smaller; however, the thermal shock on the metal can occur in gouging as well as in welding. Cutting and gouging. The oxygen fuel gas-cutting torch is most often used for this application. Special gouging tips are available and they should be selected based on the particular geometry of the joint preparation. It is possible, by closely watching the cut surface, to find and follow cracks during the flame gouging operation. The edges of the cracks will show since they become slightly hotter. The air carbon arc cutting and gouging process is also widely used for weld repair preparation. Proper power sources and carbons should be selected for the volume of metal to be removed. The technique should be selected to avoid
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Rebuilding and overlaying Rebuilding and overlaying with weld metal or spray metal are both considered surfacing operations. Surfacing is the deposition of filler metal on a base metal to obtain desired dimensions or properties. Overlay is considered to be a weld or spray metal deposit that has specific properties sometimes unlike the original surface properties. Rebuilding is used to bring parts back to their original dimensions and properties, such as the rebuilding of worn shafts, repair of parts that were machined undersize, etc. Overlay surfacing is used to return the part to original dimensions but with weld metal having particular properties to reduce wear, erosion, corrosion, etc. Rebuilding and overlay, or the all-embracing term, surfacing, can be done by many of the welding processes and by the thermal spraying processes. The selection of the process is based on the same factors that are used to select a welding process for fabricating or repairing. There are some situations in which the thermal spray processes should be selected. The thermal spray processes do not introduce as much heat into the work as the welding processes. Where this is an important requirement, the thermal spray method should be used. It is possible to thermal spray certain materials that cannot be deposited with the welding processes. This applies particularly to the ceramic sprayed coatings or other nonmetallic materials. Selection of the welding process
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The selection of the welding process and the welding procedure and technique is as
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