CHAPTER XII
CARBON BURNING
(=155=) Those who are familiar with gasoline engines will know that after being used for some time, the impurities in the lubrication oil and in the gasoline, which is continually being burned, will form around the top of the piston and cylinder head in the motor. When enough has been deposited and a few high points become overheated through long running, there will be a metallic knock distinctly heard when an extra strain is being exerted by the motor. This layer of impurities is called carbon and its presence means loss of power. Owing to the construction of most cylinder blocks, it is a very difficult matter to reach this portion of the block without dismantling. This requires skilled labor and means much delay. A method of removing this carbon by the oxygen process has been devised, which will save much time and trouble.
[Illustration: FIG. 86.--Removing Carbon from U. S. Army Truck, by the Oxygen Process, at the Ordnance Welding School.]
[Illustration: FIG. 87.--Carbon Burning Apparatus. The Small Copper Tube _A_ is Flexible and can be Bent in any Shape Desired.]
(=156=) To remove carbon from a gasoline engine, first shut off the gasoline in the line and allow the engine to run until all gas has been removed from the carburetor. This is merely a safety measure. If a vacuum feed is used, the vacuum tank is drained, as it would require much time for the engine to consume this amount of gas. The hood of the car is then removed and all parts of the motor on the side where the burning is to be done are covered with asbestos paper or by a heavy piece of canvas which has previously been dampened. This is to keep the sparks from dropping into the apron or oily parts of the machine. Remove the spark plugs and see from the condition of these spark plugs whether the cylinder is dry or oily. An oily cylinder will burn out much more rapidly than when dry. This can be detected very easily from the condition of the spark plugs. It is recommended that only the spark plugs be removed as the removal of the bonnet or any larger portion will require much more oxygen and will not produce as satisfactory results as when the oxygen is introduced through a small opening.
(=157=) Place the carbon removing apparatus, which consists of the oxygen drum, regulator, a length of hose and carbon burning torch, the latter being made up principally of a shut-off valve and a long length of small copper tubing as shown at _A_ in Fig. 87. Turn on not over twenty-five pounds oxygen pressure as far as the torch, and the apparatus is then ready to use. With the torch inserted through the spark plug hole in number one cylinder, that is, the one nearest the radiator, guide the rise of the piston until it is at the top of the stroke. This means that both intake and exhaust valves are closed. On automobiles where a self starter is used, it will be necessary to use a crank for turning over the motor. With the piston at the top of the stroke and both valves closed, there is only a small portion of the cylinder head to be worked upon and this is the part which has the carbon deposit upon it. All machined surfaces and valve seats are fully protected and will not be subjected to any exposure during the burning. If the cylinder seems very dry, a teaspoon of alcohol or kerosene may be sprayed into it through the spark plug port, to facilitate the clearing of the carbon. If the cylinder is somewhat oily, this is not necessary. A match or burning taper is then held over the hole and a stream of oxygen will carry the flame down into the cylinder and ignite the carbon. As soon as this occurs, a small cracking noise can be heard and the carbon will run around the inside of the cylinder in a heated condition. The part around the valves should be cleaned off first, before going to the inner chamber, as this process does not seem to work very well if performed the other way. A roaring noise will be in evidence and the popping of the carbon from the surface as it frees itself may frighten the operator when attempting his first job, but there is absolutely no danger.
(=158=) It must be remembered that oxygen itself does not burn, but merely assists the other inflammable material in burning, therefore it is only the carbon which is contained in the cylinder that in this case does the burning. As soon as this is all consumed, there will be nothing else to burn and the sparks will die of their own accord. When this occurs, the operator will shut off his torch, blow the cylinder out with compressed air and replace the spark plug and then proceed with the next cylinder, which he will treat in the same manner. He must be sure, however, that the piston in cylinder number two, or whatever cylinder he is working on, is moved to the top of its stroke and that both valves in that particular cylinder are closed before he starts his burning. After all cylinders have been treated like number one and the spark plugs are in position, the gasoline is turned on (if the vacuum tank has been drained, it is best to fill this), and the motor started, with the exhaust “cut off” open, in order that any loose particles of carbon may be blown out.
(=159=) While this process is in very common use, and seems to be very simple, there are many who go through the steps without obtaining satisfactory results. It is considered best, if possible, in attempting carbon burning for the first time, to try it on some motor which is about to be overhauled, in order that the results may be studied so that the operator will not go blindly on, without showing some improvement. Many times only the high points are burned out, which will free the motor temporarily of some of its knocks, but within a week or so they will become evident again. He who will become proficient in learning carbon burning should apply himself and study his results.
(=160=) There are those who consider carbon burning injurious to the motor on account of the high temperature flame which they think is introduced. But it is ignorance as to the working principle of this process that makes them think this. When it is considered that a gasoline motor depends upon a rapid succession of internal explosions for its power, the folly of condemning a process of this nature, where absolutely no actual flame is used, will be seen. It is only the incandescent particles of carbon flying about that give any heat at all. After a cylinder has been burned or decarbonized, the hand can be placed upon it immediately, without any fear of being burned. Those motors equipped with aluminum pistons may be handled in the same way as those of cast iron, and when properly used this method of decarbonization is very satisfactory.
(=161=) Many times it is asked how often carbon burning is to be recommended. This will all depend upon the type of motor, its condition, and to some extent, upon the lubricating oil and gasoline used, as well as the mileage of the car. If a machine is being run continually, it may be necessary to have the carbon removed about every two months, but conditions will tend to lengthen or shorten this time as the case may be. When the knocks are in evidence, and the loss of power is noticed, it is time for the carbon to be removed, and whether this is one month or two it is an error to continue running the car which is filled with carbon. Invariably the carbon burner is asked by his customer whether carbon burning will regrind valves; this and many other questions can be intelligently answered and explained to the questioner’s satisfaction if a careful study of the process is made.
[Illustration:
(_Courtesy of the British Oxygen Co._)
FIG. 88.--Photograph Showing Square Piece Cut Out of a Steel Block 9 Inches Thick.]
[Illustration:
(_Courtesy of the Davis-Bournonville Co._)
FIG. 89.--This is an Electrically Driven Oxy-acetylene Cutting Machine for Making Duplicate Cuts on Steel from a Drawing. Dies and many Irregular Forms may be Produced at Low Cost by it.]
[Illustration:
(_Courtesy of the Davis-Bournonville Co._)
FIG. 90.--This Shows a Motor-driven Oxy-acetylene Device Particularly Adapted to Cutting Plates or Sheets into Round, Oval, or Irregular Forms with either Straight or Beveled Edges.]
CONCLUSION
(=162=) In drawing this elementary course in oxy-acetylene welding to a close, the author wishes to again call attention to the fact that this course is merely to be considered as a foundation upon which to build. An effort has been made to confine the student’s line of thought exclusively to the actual welding of the various metals and an intimate knowledge of the tools necessary to accomplish this. Technical terms have been avoided as much as possible, and history, as well as the generation of the various gases, have been considered only of secondary importance and have been purposely omitted. Many repetitions have been made to place emphasis upon certain points and methods. It is hoped that the student who pursues this course if he has been restricted to the use of only one apparatus will realize that there are many such on the market, each one of which may have its advantages, but if the general rules, as outlined, are followed, he will not have much difficulty or be covered with confusion if called upon to operate different makes of apparatus for the first time. If he sees that there is gas pressure on his lines, he should not hesitate, thereby showing his ignorance of that particular type of apparatus, rather let him turn on one valve, and direct the stream of gas toward his nostrils. He can then readily determine whether it is the fuel gas or not and knowing that oxygen will not burn he can turn his fuel gas on and proceed without showing any concern. It might be said that confidence in one’s self is the keynote of success, and this is imperative to make an expert welder, but to the man who studies the flame action on his metals and appreciates the apparatus to the fullest extent, there is a very bright future.
[Illustration: FIG. 91.--Quick, Permanent Repairs are Made on Large Supply Trucks in the U. S. Army by its Corps of Trained Welders. This View Shows an Individual Welding Unit in Operation at the U. S. Army (Ordnance) Welding School.]
[Illustration:
(_Courtesy of Ben K. Smith, U. S. Welding Co._)
FIG. 92.--This Cylinder did not Require to be Bored or have any other Machine Work Performed, but was Placed in Service Directly after Welding and has been Serving for over Three Years.]
(=163=) The welder who desires the best results should procure the best apparatus possible to fill his requirements. The cost of such is only of secondary importance, the hazard attached to cheaply constructed apparatus and the loss of gas, time and the execution of faulty work and the depreciation of the welder’s reputation, are matters of vital importance. The supplies too, such as filler-rods and the like, should be obtained only from reliable welding companies who have their own shops in which they may test them. It is false economy indeed, to attempt to save a few cents on filling materials, for many dollars’ worth of time and gas may be lost on account of the failure of the metal added.
(=164=) There are a few illustrations set forth herein, to show what has been accomplished in the way of machine construction used in adapting the oxy-acetylene process to the requirements of various manufacturers. These will tend to show to some extent what the future has in store for this wonderful process.
(=165=) It has been rightly stated that oxy-acetylene welding is yet in its infancy. The torches, regulators and in fact all parts of the apparatus are constantly being improved. The process of cutting cast iron must still be solved, so it will again be stated that it behooves those who are interested in this work to apply themselves to the great future in store for them.
GLOSSARY
DEFINITIONS OF TERMS AND WORDS APPLIED TO OXY-ACETYLENE WELDING AND CUTTING
ACETONE. A liquid which is capable of absorbing twenty-five times its volume of acetylene gas under normal temperature and pressure. Employed as a solvent in the acetylene cylinder.
ACETYLENE. An inflammable gas used for welding and cutting.
ACETYLENE CYLINDER. A steel tank filled with porous material and acetone, in which acetylene gas is stored.
ADAPTER. A brass fitting used to connect regulators to different cylinders.
ALIGNMENT. State of being in line.
ALLOY. Metal which is added to another metal. A mixture of two or more entirely different metals.
ANGLE IRON. A steel bar, the cross-section of which forms an angle of 90 degrees.
ASBESTOS. A fibrous material not affected by fire. Usually supplied in sheets or shredded.
AUTOGENOUS WELDING. The process of uniting two pieces of metal together by fusing without additional metal being added, and without the aid of hammering.
BABBITTED. Lined with Babbitt metal. Generally found in bearings.
BACK FIRE. The popping out of the torch flame, due to a slight explosion of the mixed gas between the torch tip and the mixing chamber.
BEARING. Support or wearing surface for a revolving shaft.
BEVEL. To cut or form at an angle.
BEVELED EDGE. An edge cut or formed at an angle.
BLOWHOLE. A hole or cavity formed by trapped gas in metal.
BLOWPIPE. A torch which mixes and burns gases producing high-temperature flames. The term TORCH is given preference in oxy-acetylene welding and cutting.
BRAZING. Uniting metals with brass or bronze by means of heat.
BRAZING WIRE. A filler-rod of brass or bronze used in brazing.
BUTT JOINT. A joint made by butting two edges together.
CAP. A metal cover used to protect cylinder valves.
CARBON BLOCKS. Carbon in block form. Used to assist in building up parts that are to be added. They may be ground to any shape desired.
CARBON RODS. Carbon in rod form. Employed to save holes around which the metal is melted.
CARBONIZING FLAME. A flame with an excess of acetylene gas.
CONTRACTION. The shrinkage of metal due to cooling.
CROSS-BAR. Hand screw for adjusting the passage of gas through the regulator.
CUTTING JET. Central jet of oxygen issuing from tip of cutting torch.
CUTTING TORCH. A torch with one or more heating jets and an oxygen jet, used for cutting metals in the oxy-acetylene process.
CYLINDER. A tank containing gas under pressure.
DUCTILE. That property which permits metal being formed or drawn into different shapes without breaking.
EXPANSION. Increase in size due to heating.
FILLER-ROD. A rod or wire used to supply additional metal to the weld.
FILLET WELD. A weld made in a corner.
FLAME PROPAGATION. The rate at which a flame will travel.
FLASH BACK. The burning back of the gases to the mixing chamber or possibly farther.
FLUX. Chemical powder used to dissolve the oxides and clean the metal when welding.
GAS. Erroneously applied to acetylene gas alone. Both oxygen and acetylene are in the form of gas.
GAUGE. An instrument for measuring pressures of gases.
GENERATOR. A device for manufacturing gas. Usually specified as acetylene generator or oxygen generator.
GRAIN. The arrangement of the molecules or crystals which make up a metal.
HORIZONTAL WELDING. Welding in a level position.
I-BEAM. A steel bar with the cross-section of an I. Sometimes called EYE BEAM.
LINE. Hose or pipe carrying gas.
MANIFOLD. A header with outlets or branches by which several cylinders of gas may be used in batteries.
MONEL METAL. An alloy of copper and nickel.
NIPPLE. A short piece of pipe.
OVERHEAD WELDING. Welding with the torch overhead.
OXIDATION. A combination with oxygen.
OXIDE. A coating or scale formed by oxygen combining with metal.
OXIDIZING FLAME. A flame with an excess of oxygen gas.
OXYGEN. A non-inflammable gas used in oxy-acetylene welding and cutting.
OXYGEN CYLINDER. A steel tank for storing and shipping oxygen. Available for commercial work in 100, 200, and 250 cubic-foot sizes. The oxygen is compressed as free gas to 1800 pounds pressure at 68 degrees Fahrenheit.
PEENING. Stretching the surface of cold metal by use of the hammer.
PENETRATION. A thorough welding completely through the joint of the pieces or parts being fused.
PREHEATING. The heating of a metal part previous to welding. Generally used to prevent strains or distortion from contraction and expansion; also to save gas.
POOL. A small body of molten metal formed by the torch flame.
PUDDLE STICK. A steel rod flattened at one end, used to break up oxides, remove dirt and build up additional metal. Particularly helpful in welding cast aluminum.
PUDDLING. The manipulation of the filler-rod or the puddle-stick in such a manner as to break up oxides, remove dirt, and aid in securing a good fusion of the metal.
REDUCING FLAME. (See Carbonizing Flame.)
REDUCING VALVE. (See Regulator.)
REGULATOR. A device for reducing and maintaining a uniform pressure of gas from cylinders, generators or shop lines.
SCALE. A coating of oxide on fused iron or steel that breaks off as the metal cools.
SCALING POWDER. A name given flux.
SLAG. The oxidized metal and scale blown out when cutting.
SOLDERING. Uniting metals by fusing with a different metal which has a much lower melting-point than the pieces to be joined. The use of a lead, tin and zinc alloy is called _soft soldering_. _Hard soldering_ is similar to _brazing_.
TACKING. Fusing pieces together at one or more places.
TIP. A copper or brass nozzle for a welding or cutting torch.
V. Angle or groove between two beveled edges prepared for welding.
V-BLOCK. Block cut out in the shape of a V, or angle iron, used in lining up shafts.
VALVE. A device for shutting off the passage of gas.
VERTICAL WELDING. Welding as applied to an upright position.
WELDING ROD. Material used to supply additional metal to the weld. (See Filler-rod.)
LECTURES
NOTE.--In order to determine whether the student is obtaining the information desired it is sometimes thought fitting to give written examinations. These serve as an index as to what the student has learned and what he has not. They also let the instructor know whether he is making every point clear in his training.
The following questions fit in with each chapter or part thereof and are merely a suggestion for the instructor who has no course of training outlined. With one or two exceptions all answers to these questions may be found within the manual. There are a few misleading questions purposely inserted to see if the student is thinking for himself.
LECTURE NUMBER ONE
Subject--APPARATUS
1. Name the different classes into which oxy-acetylene welding apparatus may be divided and explain the principles upon which this classification depends.
2. Illustrate by line sketches the various locations of the mixing chambers for the oxygen and acetylene gases in welding torches.
3. (_a_) Where is the logical location for the mixing chamber in welding torches employed in automobile and tractor repair work?
(_b_) Give reasons for so thinking.
4. How is the torch and the welding tips treated after repeated “flash-backs” have taken place?
5. Describe briefly the working principles of a regulator and illustrate with a simple sketch.
6. Explain the difference between high and low-pressure regulators.
7. (_a_) Can acetylene regulators be interchanged with oxygen regulators with perfect safety? Explain why.
(_b_) How is it possible, in majority of cases, to distinguish in a very simple manner, between oxygen and acetylene regulators, when no gauges are attached?
(_c_) Why does this difference exist?
8. (_a_) Why should all tension upon diaphragm springs be removed before admitting gas under pressure to the regulator?
(_b_) Can a regulator which has been abused in this manner be repaired?
(_c_) What can be employed as a fitting substitute for gallilith?
9. Explain why the high-pressure gauge on the acetylene regulator cannot be used as an index to the contents of the attached cylinder of gas in exactly the same manner as the oxygen high-pressure gauge.
10. Why is glycerine used as a substitute for oil when regrinding torch valve-seats with emery powder, and with lead-oxide in the caulking of leaky joints along the line?
LECTURE NUMBER TWO
Subject--OPERATION
1. (_a_) Under what pressure is oxygen gas received in the cylinders used commercially?
(_b_) Does this pressure vary to any great extent with changes in temperature?
2. (_a_) Under what pressure is acetylene gas received in the cylinders used commercially?
(_b_) Does this pressure vary to any great extent with changes in temperature?
3. (_a_) In setting-up apparatus for the first time, or in attaching regulators to new cylinders, what precaution should be observed regarding cross-bar on regulators before the gas is turned on?
(_b_) Where should the operator stand when turning on the gas?
4. (_a_) How much pressure should be placed on the oxygen hose, when the torch-valves are closed, before starting to operate with a medium-sized tip?
(_b_) How much pressure should be placed on the acetylene hose, when the torch-valves are closed, before starting to operate with a medium-sized tip?
5. (_a_) After both the oxygen and acetylene gases are in the line hoses as far as the torch, which valve on the torch is opened first in order to light?
(_b_) What would happen if the other torch-valve were opened first?
(_c_) What would likely occur if both valves were opened before torch was lighted?
6. (_a_) How is it possible, when lighting torch, to determine whether enough pressure is on the acetylene line without looking at gauge?
(_b_) How is it possible, in the case of oxygen pressure?
7. (_a_) What is meant by a neutral flame?
(_b_) How hot is a neutral oxy-acetylene flame?
(_c_) Is the temperature of a neutral flame the same whether large or small tip is used?
8. (_a_) If too much acetylene gas is used, how will the flame be affected?
(_b_) What action will this have on the weld?
9. (_a_) If too much oxygen gas is used, how will the flame be affected?
(_b_) What action will this have on the weld?
10. (_a_) Explain briefly how apparatus is shut-off, when not to be used for several hours or more.
(_b_) Why should particular care be taken to see that acetylene cylinders are tightly closed when empty?
(_c_) What action does oxygen have on oils and greases?
LECTURE NUMBER THREE
Subject--WELDING OF CAST IRON
(_Part One_)
1. (_a_) How is it possible to distinguish cast iron from such metals as malleable iron?
(_b_) From semi-cast iron?
(_c_) From cast steel?
2. (_a_) What kind metal is used in making “filler-rod” used in the welding of cast iron?
(_b_) What general rule can be laid down as to the relation of the metal in the “filler-rod” to the metal to be welded?
3. (_a_) What are the characteristics of good cast iron “filler-rods”?
(_b_) Can piston rings and other small scraps of cast iron be used successfully as “filler-rods”? Explain why.
4. (_a_) What is the purpose of a flux?
(_b_) Is a flux used in the welding of cast iron?
5. (_a_) Name one formula for making a cast-iron flux?
(_b_) How often is the flux applied, and by what means?
(_c_) In what condition are fluxes kept when not in use?
6. (_a_) How should the flame be held in the welding of all cast iron?
(_b_) When and how is the “filler-rod” added to the weld?
7. (_a_) Name the one principal cause of blow-holes and hard spots in the weld.
(_b_) Mention some of the others.
8. (_a_) When is it advisable to grind, or “V” out, the ends of the pieces to be welded?
(_b_) When is it not advisable?
9. (_a_) Does the application of heat cause contraction or expansion in metals?
(_b_) Are there any excepts to this rule? Name one.
10. (_a_) Were two cast-iron bars measuring 2 × 12 inches and ¹⁄₂-inch thick, to be welded, end to end, what precaution should be observed in laying out, if the finished job is to measure just 24 inches long?
(_b_) In what respect would this problem differ were the bars only 6 inches originally and the finished job to measure 12 inches overall?
(_c_) Is the action of the metal in the weld a constant, or a variable quantity depending upon the length of the bar in this problem?
LECTURE NUMBER FOUR
Subject--WELDING OF CAST IRON
(_Part Two_)
11. (_a_) How could a spoke, broken midway between the hub and rim, of a 24-inch, 4-spoke wheel (otherwise intact) be welded without preheating? (Use a sketch if necessary to make method clear.)
(_b_) If a wheel of like size were broken only in the rim, midway between spokes, explain procedure in welding without preheating.
(_c_) Same sized wheel, broken only in hub;--can weld be made without preheating? Give reasons for so thinking.
(_d_) Were breaks (_a_), (_b_) and (_c_) all present in same wheel, with rim fracture on opposite side of adjoining spoke from break in hub, should welding be started at rim or hub? Why?
12. (_a_) In the building up of broken or missing teeth in cast-iron gears, what procedure is necessary when no carbon blocks are available for forms?
(_b_) If certain carbon centers from dry cell batteries are obtainable how should they be treated before allowing molten metal to come in direct contact with them?
(_c_) What very important point must be uppermost in mind when dental work on gears is being done?
(_d_) Explain precautions taken in allowing work of this nature to cool.
13. (_a_) Realizing that hard spots occur in most welds executed by the new welder and having learned the cause of their presence and how to overcome them, would it not be possible to utilize this process for hardening parts which were subject to much wear and little strain? Explain procedure.
(_b_) Why is it necessary to preheat such pieces as the following before the weld is attempted; broken water-jackets on gas-engine cylinders, usually brought about by freezing, and holes or cracks in crank cases, caused by the loosening of a connection rod; when lugs on the same cylinder, the arms on the same crank case can be welded without preheating, and ofttimes without even dismantling the motor?
LECTURE NUMBER FIVE
Subject--WELDING OF CAST IRON
(_Part Three_)
14. Describe fully the manner in which two cast-iron bars measuring 1 × 6 inches and 24 inches long, are welded end to end, citing preparations, precautions, and the procedure and materials necessary to execute and carry the weld through to a cool state.
NOTE.--Both gases are in the line hoses as far as the welding torch.
LECTURE NUMBER SIX
Subject--WELDING OF CAST IRON
(_Part Four_)
15. (_a_) Are water jackets on cast-iron cylinder blocks welded in a cold, or a preheated condition?
(_b_) Is this true under all conditions?
(_c_) If a crack were found in the combustion head of a cylinder block and the entire water jacket and cylinder were cast in one, how should this job be prepared in order to make a successful weld?
(_d_) In welding a broken lug on the base of a cylinder block how should lug appear after weld is cold?
LECTURE NUMBER SEVEN
Subject--EQUIPMENT
1. Describe the operation, step by step, taken to set up an oxy-acetylene welding plant, from the assembling of the parts, right through, until a neutral welding flame is obtained. (If a sketch, with the gas cylinders and parts numbered 1, 2, 3, etc., will assist in making description clear, it may be used.)
2. (_a_) Is it desirable to have a planed metal, or a brick-top table for welding purposes?
(_b_) Explain why.
3. Outline and describe briefly, a simple method of building a popular type of welding table.
4. (_a_) What is the name and style of bricks used in the welding shop?
(_b_) Name at least three purposes for which these bricks are used.
5. (_a_) Why does an emery wheel play such an important part in the oxy-acetylene welding industry?
(_b_) Why is it desirable to have a flexible shaft attachment for the emery wheel, if possible?
(_c_) Name some of the important things a flexible shaft attachment is used for in the preparation and finishing of welds.
6. (_a_) In what kind of containers is retort cement purchased in the commercial world?
(_b_) Where is retort cement used in the welding shop?
(_c_) How does it differ from the ordinary clay or putty?
7. (_a_) Why should a blacksmith forge be added to the welding shop equipment if one is obtainable?
(_b_) What two important tasks is a forge used for in the welding shop?
8. (_a_) It is essential that several pails of water be located throughout the shop; why should this be necessary?
(_b_) Mention a few instances where water is required in the welding shop.
9. Explain fully why great care should be exercised in ventilating a shop where commercial welding is being done.
10. (_a_) Describe one simple method of constructing a flux box.
(_b_) What advantages has this type of container?
LECTURE NUMBER EIGHT
Subject--REPAIRS
1. What is the best method of locating a leak in either the oxygen or acetylene lines?
2. If a leak were found in a ground seat, how could it be stopped if the nut on the coupling had been screwed up as far as possible?
3. Name one method of attaching connections to hoses so that they will not blow off or pull off when pressure is applied.
4. How could either an oxygen or acetylene hose that had been burned or otherwise injured, be repaired to withstand the gas pressure?
5. How could regulator be operated if the cross-bar for applying pressure upon the diaphragm springs were lost?
6. (_a_) What procedure would be necessary to make connection if cylinder were supplied with an adaptor which would not fit the regulator connection and it could not be coupled up directly?
(_b_) Realizing that all cylinder connections about a regulator are generally supplied with a ¹⁄₄-inch taper pipe thread, why do all manufacturers solder them in?
7. Explain why oxygen high-pressure gauges are constructed with a loose back and a solid front.
8. (_a_) Where is the first place to seek trouble in a gauge if it leaks?
(_b_) Can such leaks be repaired?
(_c_) Describe method.
9. If either a high-or low-pressure gauge were injured beyond the repair state how could welding plant be kept in operation without it?
10. (_a_) What would be the trouble, in shutting off a welding plant, if there were a reading on the high-pressure gauge and none on the low-pressure gauge, after permitting gas to escape from the hose?
(_b_) How could the reading on this gauge be brought back to zero?
LECTURE NUMBER NINE
Subject--STEEL WELDING
(_Part One_)
1. (_a_) Is the welding of steel more or less difficult than cast iron?
(_b_) Explain why.
2. (_a_) Why is the choice of the welding tip so important when working on steel?
(_b_) What will result if the tip is too large?
(_c_) If too small?
3. (_a_) Why is the choice of a “filler-rod” of a correct size so important for steel welding?
(_b_) What will happen if the “filler-rod” is too large?
(_c_) If too small?
4. (_a_) What kind of a “filler-rod” is used in welding steel?
(_b_) Give a general rule covering relation of “filler-rod” to the metal being welded in all cases, but one or two.
(_c_) Name one exception.
5. (_a_) Is a flux (or scaling powder) necessary in welding steel?
(_b_) Explain why.
6. (_a_) How is the flame adjusted for steel welding?
(_b_) What kind of a flame is generally used in finishing steel work?
(_c_) Why is this done?
7. (_a_) How is the flame held when executing a steel weld?
(_b_) How is the “filler-rod” held when making a steel weld?
8. (_a_) Is it necessary to “V” out on steel the same as on cast iron?
(_b_) Explain why.
9. (_a_) Is a steel weld as strong as the original metal if not built up?
(_b_) Explain why.
10. (_a_) Is the same provision made for expansion and contraction on steel as on cast iron?
(_b_) Give reasons for so thinking.
LECTURE NUMBER TEN
Subject--STEEL WELDING
(_Part Two_)
11. (_a_) What is meant by a “crater” in steel welding?
(_b_) How are they removed from the weld?
12. (_a_) What are some methods and marks of distinguishing steel from other metals?
(_b_) How is cast steel distinguished from cast iron?
13. (_a_) Name some of the qualifications of a good “filler-rod” for mild steel welding.
(_b_) In what manner does the “filler-rod” differ for the alloyed and high-carbon steels?
14. (_a_) In bringing the neutral flame in contact with the metal on a steel weld, should the cone bend and spread on the surface, or just lick it?
(_b_) Explain why.
15. (_a_) What is the principal cause for hard spots in steel welds?
(_b_) What causes some of the others?
16. (_a_) Is it rolled steel or cast steel that does not expand when heated?
(_b_) Name one other metal that does not expand when heated.
17. (_a_) Why are welds more difficult on sheet iron and steel than on some of the heavier pieces?
(_b_) What can be used as a “filler-rod” on sheet metal work?
18. (_a_) What difficulty is generally encountered, when making a long weld like on a steel tank?
(_b_) How can this be overcome?
(_c_) Why do the open ends on sheet steel welds overlap in welding when same class of work on cast iron separates?
19. (_a_) What causes steel welds to carbonize?
(_b_) What usually causes a burnt steel weld?
20. Describe fully how a broken automobile frame can be welded and re-enforced to make it stronger than originally.
LECTURE NUMBER ELEVEN
Subject--STEEL WELDING
(_Part Three_)
21. (_a_) What kind of a “filler-rod” is used in welding cast steel?
(_b_) Is a flux used?
22. (_a_) What kind of a “filler-rod” is employed when welding cast iron to steel?
(_b_) What kind of a flux is used?
23. (_a_) Can springs be successfully welded?
(_b_) State reasons.
24. (_a_) Why are crank-shaft welds so hard to execute successfully?
(_b_) What kind of a “filler-rod” is used for best results on most crank-shafts?
(_c_) What points does the welder consider when deciding whether a weld of this nature is advisable?
25. (_a_) Briefly describe the method of building up crank-shaft bearings that have been worn down.
(_b_) What are some of the precautions taken in work of this kind?
26. (_a_) When automobile propeller shafts and rear axles break, it is generally adjoining the square end. Is it advisable to weld this short piece on?
(_b_) What is the correct procedure in a case of this kind?
27. (_a_) If a case-hardened ring-gear is to have its teeth built up or new ones added, how is it handled after welding?
(_b_) Should all case-hardened work be so treated after welding?
28. (_a_) In welding two pieces of metal, one of which is considerably lighter than the other, how is the flame held in order to bring both pieces to a fusion at the same time?
29. (_a_) If a steel weld were to break in the line of weld, how should it be prepared if it is to be rewelded?
(_b_) Does this procedure apply only to steel?
30. Were a hole 6 inches square in a sheet of steel to be welded up without preheating, what would be the approximate size of the patch necessary and how would it be prepared, in order to take care of the expansion and contraction strains?
LECTURE NUMBER TWELVE
Subject--STEEL WELDING
(_Part Four_)
31. (_a_) Why should a steel weld of any kind be executed as rapidly as possible?
(_b_) What will happen if steel is kept in a heated condition too long?
(_c_) Why should a change be in evidence under these conditions?
32. (_a_) Explain what is meant by a “dished” patch, for boiler or thin armor plate?
(_b_) Draw such a patch.
(_c_) How is a patch of this nature prepared?
33. (_a_) What is meant by a “corrugated” patch for boiler or thin armor plate?
(_b_) Sketch such a patch.
(_c_) How is this kind of a patch prepared?
34. (_a_) What advantages has a “corrugated” patch over one that is “dished”?
(_b_) Where are “corrugated” patches used extensively?
35. (_a_) How are boiler flues prepared for re-tipping?
(_b_) Sketch a simple jig for holding such pieces in place for welding.
36. (_a_) Describe how lengths of various sized pipe can be welded together end to end.
(_b_) What precautions are necessary when executing such welds?
37. (_a_) When welding large steel castings why is it almost always advisable to preheat the work?
(_b_) Why is preheating so necessary on vanadium and other alloyed steels?
38. Why is it desirable to chip out the sand and thin scale formations, in and around blow-holes in steel castings before filling in?
39. (_a_) Why do the majority of good welders bend their steel “filler-rods” at right angles about 6 inches from the end?
(_b_) Why isn’t this being done on cast iron?
40. (_a_) What advantage is there in making a vertical weld from the top down, rather than starting from the bottom and working up?
(_b_) In welding overhead why is it so important that the work be in a molten state before adding the “filler-rod”?
(_c_) In overhead welding, why doesn’t the metal drop when in a molten state?
LECTURE NUMBER THIRTEEN
Subject--OXY-ACETYLENE CUTTING
1. Explain fully which parts of an oxy-acetylene cutting plant are different from a welding unit.
2. (_a_) If there is a difference in either of the regulators, mention which one it is.
(_b_) What is the difference?
(_c_) Why is it necessary?
3. (_a_) Is it possible to weld with a cutting torch?
(_b_) What precaution is necessary if this is done?
(_c_) Why isn’t this process used?
4. Explain how cutting can be done with the welding torch if necessary.
5. (_a_) In cutting by the oxy-acetylene process, which does the cutting, the oxygen jet or the neutral flame?
(_b_) What action has the oxygen jet on the metal?
(_c_) What part does the neutral flame play in cutting?
6. Can oxygen or acetylene under sufficient pressure be made to cut individually? Explain fully.
7. Why is it specially important that armored hose be used on the oxygen line when making heavy cuts?
(Give at least two reasons.)
8. (_a_) How is a cutting torch lighted? Describe in detail.
(_b_) How is cut started on metal?
(_c_) How is torch held in regard to metal being cut?
9. (_a_) Is it possible to successfully cut cast iron?
(_b_) Wrought iron?
(_c_) Cast steel?
(_d_) Rolled steel?
10. (_a_) Cutting can be done under water with ordinary cutting apparatus; why doesn’t the flame go out when submerged?
(_b_) What additional equipment is generally used in underwater cutting?
LECTURE NUMBER FOURTEEN
Subject--BRASS WELDING
1. Explain as fully as possible the chief characteristics of a good “filler-rod” for brass welding.
2. (_a_) Is a flux used in welding brass?
(_b_) What is one way of making a good flux for brass?
3. (_a_) What kind of a flame is used in brass welding?
(_b_) Why?
4. (_a_) In what position is the flame held in welding brass?
(_b_) How should the “filler-rod” be held?
5. (_a_) Is it advisable to “V” out or burn off the ends of brass work to be welded?
(_b_) Explain why.
6. (_a_) What causes the dense white fumes to appear when fusing brass?
(_b_) What is cause of brass welds being porous?
7. Why should brass work not be disturbed when red hot?
8. What is the most difficult part of brass welding as a whole?
9. Why are brass welds generally cooled in water as soon as fusion is completed?
10. Why is it difficult for the beginner to weld heavy pieces of brass?
LECTURE NUMBER FIFTEEN
Subject--WELDING OF MALLEABLE IRON
1. (_a_) Can malleable iron be successfully welded?
(_b_) What is the most successful method of joining two pieces of malleable iron?
2. What are three methods of detecting malleable iron?
3. (_a_) What kind of “filler-rod” is used on malleable iron?
(_b_) Are “filler-rods” of malleable iron satisfactory?
(_c_) What kind of flux is used on malleable iron work?
4. (_a_) How is a malleable iron casting prepared for welding?
(_b_) How hot should work be, previous to adding “filler-rod”?
(_c_) What will occur if too much heat is applied?
5. (_a_) In what respect does the adjustment of the flame differ on malleable iron from that of cast iron and steel?
(_b_) How is the flame held in relation to the work?
(_c_) Does the flame come in direct contact with the “filler-rod”?
6. (_a_) Is more, or less, surface covered by the “filler-rod” on malleable iron than on cast iron?
(_b_) Why?
7. (_a_) How should malleable iron be cooled?
(_b_) Is this the same as in welding brass?
8. On what part of machinery does a welder generally expect to find malleable iron castings?
9. Explain carefully how a malleable iron automobile, axle or transmission, housing that has been cracked or broken, can be re-enforced so that it will be stronger than ever.
10. Describe very briefly how malleable iron is made and in what respect it differs from cast iron when cold, and also when under the influence of the oxy-acetylene flame.
LECTURE NUMBER SIXTEEN
Subject--CARBON BURNING
1. (_a_) Explain what is meant by carbon burning.
(_b_) In what respect is it used extensively?
2. (_a_) Will oxygen gas burn alone or does it merely aid combustion?
(_b_) Will carbon in a free state burn?
3. (_a_) Why is it advisable to remove only the spark plugs and not the entire valve cap or “bonnet” when burning carbon in a gas engine?
(_b_) Can it be done either way?
4. (_a_) Does it make a difference if the carbon is hard and dry in the cylinder?
(_b_) What will help in such cases?
5. (_a_) If the cylinder is rather oily does this make a difference?
(_b_) Does the presence of oil aid or retard combustion?
6. (_a_) What precautions are necessary before carbon burning is attempted?
(_b_) How is asbestos paper used in carbon burning?
(_c_) Name a good substitute for asbestos paper when carbon burning.
7. (_a_) Is there any danger of warping the valves and overheating the cylinder and piston when burning carbon?
(_b_) What is the effect of carbon burning on aluminum pistons?
8. (_a_) What pressure is used on the oxygen line for carbon burning?
(_b_) Will carbon burning re-grind valves?
9. (_a_) How long should the burning be done?
(_b_) How often is carbon burning recommended for a gas engine?
(_c_) If there are any carbon particles or sand left in the cylinder after burning is done how are they removed?
10. Describe how the carbon is removed from a four-cylinder engine, paying particular attention to details such as lighting, which part of the head the torch is played on first, what does the burning and where the carbon goes.
LECTURE NUMBER SEVENTEEN
Subject--PREHEATING AGENCIES
1. (_a_) What is meant by preheating as applied to the oxy-acetylene welding industry?
(_b_) What are several fuels which can be used very successfully for preheating?
2. Name the three principal reasons why parts to be welded are generally preheated.
3. (_a_) Why is charcoal considered the best preheating agent for general welding?
(_b_) Why should it not be used to any great extent in closed rooms during the winter months?
(_c_) If used during the winter what precautions are observed?
4. (_a_) Mention two materials which are used extensively for building up ovens and doing the preheating.
(_b_) What kind of brick is used?
5. (_a_) How much should cast iron be preheated?
(_b_) Brass or bronze?
(_c_) Aluminum?
6. Sketch and describe how a temporary brick preheating oven should be built, giving all dimensions, such as: length, width and height and reasons for them.
7. Explain how a cylinder block with a broken water jacket is set up for preheating; how oven is built for charcoal fire; how fire is started; how block is protected while welding and how it is returned to a cold state.
8. (_a_) What precautions are necessary in setting up and preheating aluminum?
(_b_) If piece is to be turned while in the fire, what provision is made in building up oven?
9. In which cases is preheating absolutely necessary in order to make a satisfactory weld?
10. (_a_) Give a sketch showing a preheating torch for use on illuminating gas and compressed air, which can be constructed very easily.
(_b_) Why are preheating torches not popular for general welding?
(_c_) Where are they used in numbers?
LECTURE NUMBER EIGHTEEN
Subject--ALUMINUM WELDING
(_Part One_)
1. (_a_) Is the welding of aluminum, more or less difficult than such metals as cast iron and steel?
(_b_) Explain why.
2. (_a_) Name the two methods of making aluminum welds.
(_b_) Can they be combined?
(_c_) Why?
3. (_a_) What kind of a “filler-rod” is used in welding aluminum?
(_b_) Is a flux used? Why?
4. (_a_) Is a cast or drawn “filler-rod” preferred?
(_b_) Name the two important metals which should be present and the percentage of each in the “filler-rod.”
5. (_a_) How should the flame be adjusted for aluminum welding?
(_b_) How is the flame held in relation to the work?
6. (_a_) How is the “filler-rod” added?
(_b_) In what respect does this differ from all other metals?
(_c_) Why can this be done?
7. (_a_) Name the principal characteristics of aluminum with regard to heat.
(_b_) What other metal acts in a similar manner?
8. (_a_) Is it necessary to “V” out aluminum for the same reasons as other metals?
(_b_) Explain why.
9. (_a_) Will an aluminum welding be as strong as the original?
(_b_) Give reasons.
10. (_a_) What kind of a tool is used to aid in making an aluminum weld by most welders?
(_b_) How is such a tool made?
LECTURE NUMBER NINETEEN
Subject--ALUMINUM WELDING
(_Part Two_)
11. (_a_) What kind of files are used to finish aluminum welds?
(_b_) In what respect do they differ from the ordinary kind?
12. (_a_) In which hand is the welding torch held in aluminum work?
(_b_) In which, the “filler-rod”?
(_c_) The puddle stick?
13. (_a_) What materials are used to “back-up” aluminum work for preheating?
(_b_) Describe fully how aluminum is “backed-up” previous to preheating, in order to prevent the collapse of metal while welding.
14. (_a_) How quick does the heavy coating or aluminum oxide form on a clean hot piece of aluminum?
(_b_) Will the metal flow together when this oxide is present?
(_c_) How is it overcome?
15. (_a_) Is it advisable to weld aluminum from one side only or from both sides?
(_b_) Why?
16. In preheating aluminum with charcoal, what precautions are taken in setting up; in starting the fire; during the welding operation, and in cooling the piece?
17. (_a_) Are preheating torches played directly on aluminum work?
(_b_) What kind of an oven is used?
18. (_a_) Is it necessary to heat the whole of an aluminum crank-case if one part has to be preheated?
(_b_) Give reasons.
19. (_a_) Are clamps used to hold parts in place on preheated aluminum?
(_b_) Explain why.
20. When starting to weld a cold piece of aluminum, the flame is brought in contact with the work and held there much longer than on a similar size piece of steel before any apparent change occurs. How is this accounted for, knowing that aluminum has a much lower melting point that steel?
LECTURE NUMBER TWENTY
Subject--ALUMINUM WELDING
(_Part Three_)
21. Explain fully why it is necessary to employ greater speed in the welding of aluminum than on any other metal?
22. (_a_) What is retort cement?
(_b_) How does it differ from ordinary clay?
(_c_) For what purpose is it used in aluminum welding?
23. (_a_) When performing an aluminum weld by the puddle system, is the welder dependent upon the flame, the “filler-rod” or the puddle stick, for the fusion of the metal?
(_b_) Give explanations.
24. (_a_) What method of welding is used when executing a vertical weld on aluminum?
(_b_) Why isn’t the other method used?
(_c_) Is the vertical welding of aluminum to be avoided?
25. (_a_) Can aluminum welds be made overhead?
(_b_) Explain why.
26. (_a_) Is the same method used on aluminum as in cast iron in welding from the closed end, toward the open?
(_b_) Is this procedure necessary on preheated work?
27. (_a_) If a suspension arm, of a “U” type, on an aluminum crank case were to break about 3 or 4 inches from the body of the case, could it be welded in place without dismantling the motor?
(_b_) Explain in detail how such an arm should be welded.
28. Due to the contraction and expansion, it is very difficult to have the bolt hole, in the end of an aluminum suspension arm that has been welded, return exactly to its former position. How is this difficulty provided for?
29. (_a_) Should a section of an aluminum crank case be missing, would it be advisable to build up a new part with the “filler-rod” or to cast a new part in a mold and then weld it in?
(_b_) Under what conditions should the above be done?
30. (_a_) If it were found that an aluminum crank case after being welded, had one corner about ¹⁄₈-inch lower than the rest of the case and it had not affected any of the bearings, could it still be reclaimed?
(_b_) Give procedure.
INDEX
A
Absorbent, acetone as an, 26, 31 -- asbestos as an, 31 -- charcoal as an, 31 -- mineral wool as, 81
Acetone as an absorbent, 26, 31
Acetylene cylinders, construction of, 31
Acetylene gas, temperature of flame of, 1
Adapter, types of, 46
Aluminum, backing up in welding, 114 -- charcoal in welding, 116 -- contraction and expansion in welding, 116 -- clamps, use of in welding, 115 -- crank cases, welding, 118 -- filler-rods in welding, 112, 115 -- flux method of welding, 109, 111 -- oxidation of bright surfaces in welding, 113 -- preheating in welding, 116, 117 -- preheating, method of, 52 -- puddle and flux systems of welding compared, 111 -- puddle method of welding, 109, 111 -- strains, avoiding internal, 118 -- suspension arm of crank case, repairing, 118 -- tip used in welding, 109 -- welding, 109-117 -- welding from one side, 114
Apparatus, classes of welding, 19 -- desirability of securing the best, 144 -- emery wheel, need of, 41 -- high-pressure welding, 20 -- low-pressure welding, 19 -- medium-pressure welding, 19 -- metal top table, disadvantages of, 39 -- mixing chambers, 21 -- oils and grease to be avoided, 37 -- oxy-acetylene, for cutting, 125 -- regulator, 22 -- -- types of, 24 -- required in welding, 19-26 -- -- replacing lost cross-bar, 46 -- setting up, manner of, 31, 32 -- shop equipment, 39, 43 -- shutting off, procedure in, 35
Apparatus repairs, 44-50 -- -- adapters, types of, 46 -- -- gauges, operation of, 49 -- -- gauges, safety, 47, 48 -- -- hose clamps, 45 -- -- hose, repairing leaky, 45 -- -- leaks, method of locating, 44 -- -- leaky threads, repairing, 44
Asbestos as an absorbent, 31 -- in aluminum welding, 116 -- paper cover protection, 55
Automobile frame, welding, 91
Automobile, propeller shafts, welding, 95
Axles, automobile, welding, 95
B
Blow holes, causes of, 65
Boiler flues retipping, 98, 99
Boiler, “corrugated” patches, 102, 103 -- “dished” patches in repairs to, 101 -- “L” patches in repairing, 103 -- repairing, 99-101
Borax as a brass flux, 107
Brass, alloy of, 106 -- filler-rod in welding, 106 -- flux in welding, 107 -- fumes in welding, 108 -- melting-point, 106
Brass welding, 106-108
Bronze for welding purposes, 123 -- welding malleable iron with, 121
C
Carbon burning, 135-144 -- -- in gasoline engine, 136-139 -- -- theory of, 139
Carbonizing flame, 34
Cast iron, welding of, 58-80 -- -- -- -- blow holes, causes of, 65 -- -- -- -- charcoal as preheating agent, 76 -- -- -- -- combustion head of cylinder, repairing, 78, 79 -- -- -- -- contraction of metals in, prevention of, 71 -- -- -- -- expansion and contraction of metals, 65-67 -- -- -- -- filler rod, 61 -- -- -- -- flux a cleansing agent, 61 -- -- -- -- flux, manner of application of, 62 -- -- -- -- flux, simple substitute for, 61 -- -- -- -- gasoline engine cylinder block, repairing, 75, 76 -- -- -- -- gear wheel teeth, three ways of restoring, broken, 71-74 -- -- -- -- hardening parts by use of carbonizing flame, 74 -- -- -- -- lugs, welding on cylinder block, 80 -- -- -- -- methods of distinguishing metals, 60 -- -- -- -- preparations for, 67 -- -- -- -- procedure in, 63, 64, 67-70 -- -- -- -- successful weld, criterion of, 75 -- -- -- -- tip, size of, 63
Cast steel, procedure in welding of, 88
Charcoal as an absorbent, 31 -- as preheating agent, 76 -- in aluminum welding, 116
Clamps, inadvisable in welding aluminum, 115
Contraction and expansion in aluminum welding, 116 -- -- -- in preheating, 53 -- -- -- in welding steel, 87
Contraction of metal in welding, prevention of, 71
“Corrugated” patch, method of making, 102, 103
Crank cases, aluminum, repairing, 118
Crank shafts, welding methods, 93, 94
Crater, development and removal of, 88
Cross-bar, replacing lost, 46
Cutting by oxy-acetylene process, 6
Cutting with oxy-acetylene, 125-134
Cutting torch, welding torch and, compared, 127
Cylinder block, repairing cast-iron gasoline engine, 75, 76
Cylinder bore, device for polishing, 79, 80
Cylinders, acetone as absorbent in, 26
D
Decarbonization of automobile engines, 136, 139
Demand for oxy-acetylene operators, 17
“Dished” patch in boiler repairs, 101
E
Emery wheel, value of in welding shop, 41
Expansion and contraction of metals, 65-67 -- -- -- in welding, 87
Explosions, precautions against, 37
F
Feather flame, 33, 35
Filler rod, 89 -- -- in brass welding, 106 -- -- in welding malleable iron, 122 -- -- metal in, 61 -- -- used in aluminum welding, 112 -- -- used in welding steel, 82, 91
Fire brick, in aluminum welding, 116 -- -- preheating oven of, 54 -- -- table, 39
Flame, carbonizing, 34 -- feather, 33, 35 -- neutral 33, 35 -- oxidizing, 34 -- torch, cutting under water with, 133 -- varieties of, adjustment of, 32,33
Flashbacks, causes of, 21, 22 -- prevention of, 22
Flux, application, manner of, 62 -- container, 42 -- in brass welding, 107 -- office of, 61 -- substitute, a simple and effective, 61
G
Gasoline engine, carbon, how to remove from, 136-139
Gasoline tanks, necessity for caution in repairing, 103
Gauges, operation of, 49 -- safety, 47, 48
Gear wheel teeth, three ways of restoring broken, 71-74
Glossary, 145-148
Goggles, eye, 35
H
Hardening parts through use of carbonizing flames, 74
Heat in welding malleable iron, 123
High-pressure regulated, 24
Hose, armored, used on oxygen line, 133 -- clamps in repairing, 45 -- leaky, 45
L
“L” patches, 103
Leaks, method of discovering, 44 -- repairing threads, 44
Lectures, 149-166
Low-pressure regulator, 24
Lugs, welding on cylinder block, 80
M
“Maine,” battleship, wreck cut up with oxy-acetylene gas, 6
Malleable iron, bronze, welding with, 121, 123 -- -- clean surface, necessity of in welding, 122 -- -- heat in welding, 123 -- -- melting to be avoided, 121 -- -- preheating unusual, 123 -- -- steel strips in welding, 123 -- -- welding, 120-124
Metals, methods of distinguishing, 60, 87
Mineral wool as an absorbent, 31
Mixing chamber, 21
N
Needle valve, regrinding leaky, 26
Neutral flame, 33, 35
O
Oils and grease, importance of avoiding use of, 37
Operation in oxy-acetylene welding, 27-38
Operator, standing position of, relative to work, 32
Overhead welding, 105
Oxidation of bright surfaces in aluminum, 113
Oxidizing flame, 34
Oxy-acetylene, cutting metals with, 6 -- flame, varieties of adjustment of, 32, 33 -- in airplane construction, 9 -- in automobile manufacture, 10 -- in boiler shops, 10 -- in brass and copper work, 10 -- in commercial welding, 11 -- in electric railways, 11 -- in foundries, 11 -- in lead burning, 12 -- in lumber mills, 12 -- in machine shops, 12 -- in manufacturing, 12 -- in mines, 13 -- in pipe work, 13 -- in plate welding, 13 -- in power plants, 13 -- in railroad work, 13 -- in rolling mills, 14 -- in sheet metal manufacture, 15 -- in shipyards, 15 -- in the forge shop, 11 -- in tractor industry, 16 -- lake boats cut apart by, 8 -- operators, demand for, 17 -- scrap cut up by, 6 -- scrap yards, 15 -- structural steel, 15 -- torch as fire department tool, 7 -- torch can be used under water, 8 -- varied uses of, 9
Oxy-acetylene cutting, 125-134 -- -- apparatus for, 125 -- -- arrangement of oxygen line, 125 -- -- cutting torch, extemporizing a, 132 -- -- flame, cutting under water with, 133 -- -- flickering of oxygen jet, 127 -- -- high-pressure and low-pressure regulators compared, 127 -- -- hose, armored, in, 133 -- -- pressure of acetylene and oxygen, 129 -- -- steel and cast-iron, 131 -- -- torch in preparing steel, 131 -- -- torch, cutting and welding compared, 127 -- -- torch, using cutting, for welding purposes, 133
Oxy-acetylene welding, apparatus required in, 19-26 -- -- a fusing process, 62 -- -- auto-frame repairs, 4 -- -- classes of apparatus, 19 -- -- containers, seamless, made through use of, 3 -- -- definition of, 1 -- -- fire-brick table, 39 -- -- future of, 17 -- -- growth of process, 8 -- -- locomotive frames, 4 -- -- metal-top table, disadvantages of, 39 -- -- mixing chambers, 21 -- -- operation in, 27-38 -- -- principle of, 125 -- -- repairs through, 3, 5 -- -- shop equipment, 39-43 -- -- variety of applications of, 3
Oxygen, cylinders, 27 -- gas, result of too much, 35 -- office of in combustion, 27 -- table of different pressures of, at various temperatures, 29
P
Preheating, aluminum, 117 -- asbestos paper for oven, 55 -- charcoal in, 53 -- extraction and expansion in, 53 -- drafts, protecting work from, in, 54 -- fuels used in, 53 -- in aluminum work, 116 -- ovens, 56 -- reasons for, 51 -- setting up work, 56 -- torch for, burning city gas, 54 -- varied heats for different metals, 52
Preheating agencies, 51-57 -- -- fire-brick oven, 54 -- -- ovens, 55, 56 -- -- torch, burning city gas, 54
Propeller shafts, welding automobile, 95
Puddle method of welding aluminum, 109, 111
R
Regulator, care of, 25 -- construction and action of, 22, 23 -- types of, 24
Ring gears, building teeth on case-hardened, 96
Retort cement, 42
S
Sheet steel and iron, welding, 89
Ships, repairs to seized German by acetylene process, 5
Shop equipment, 39-43 -- -- blacksmith forge, 42 -- -- carbon rods and blocks, 43 -- -- emery wheel, 41 -- -- fire-brick table, 39 -- -- flux container, 42 -- -- retort cement, 42 -- -- ventilation, 43
Sparks, characteristic thrown off by emery wheel, 59
Spring’s, welding, futility of, 92, 93
Steel, automobile frame, welding, 91 -- automobile axles, welding of, 95 -- automobile propeller shafts, welding, 95 -- boiler flues, retipping, 98, 99 -- boiler repairs, 99-101 -- cast, procedure in welding, 88 -- construction and expansion in welding, 87 -- “corrugated” patch, 102, 103 -- crank-shafts, welding of, 93, 94 -- craters, formation of, in welding, 88 -- definition, 81 -- “dished” patch in boiler repairs, 101 -- filler-rod used in welding, 82 -- filler-rod to be used in welding, 97 -- flame control in welding, 81, 82 -- hard spots, formation of in welding, 89 -- heat treatment in welding unequal sized pieces, 97 -- internal strains in welding, 100 -- “L” patches, 103 -- metals, methods of distinguishing in welding, 87 -- methods of welding, 82-86 -- outside appearances in welding, 87 -- overhead welding, 105 -- sheet, welding, 89 -- speed required in welding, 97 -- springs, inadvisability of welding, 92, 93 -- susceptibility of when molten, 97 -- teeth, building up of, 96 -- vertical welding of, 104 -- weld, broken, method of repairing, 96 -- welding, difficulties of, 81, 92
Steel welding, 81-105
T
Table of different pressures of oxygen at various temperatures, 29
Tanks inflammable gases, caution to be used in welding, 103
Teeth, building up of, 96
Temperature of acetylene gas flame, 1
Tip, size of in welding, 63
V
Ventilation, 56, 108 -- importance of in welding shop, 43
Vertical welding, 104
“V-ing” metal in welding, 63
W
Welding, aluminum, 109-117 -- brass, 106-108 -- cast iron, procedure, 67-70 -- malleable iron, 120-124 -- methods of distinguishing between metals, 58 -- sparks in determining kind of metals in, 58
Welding of steel, 81-105 -- -- -- broken weld, manner of repairing, 96 -- -- -- cast, procedure in, 88 -- -- -- contraction and expansion in, 87 -- -- -- crank shafts, 93, 94 -- -- -- craters, formation of in, 88 -- -- -- filler-rod in, 91 -- -- -- hard spots, formation of in, 89 -- -- -- heat treatment in unequal sized pieces, 97 -- -- -- methods of, 82-86 -- -- -- overhead welding, 105 -- -- -- springs, futility of welding, 93 -- -- -- teeth, building up of, 96 -- -- -- vertical welding, 104
[Illustration]
Wiley Special Subject Catalogues
For convenience a list of the Wiley Special Subject Catalogues, envelope size, has been printed. These are arranged in groups--each catalogue having a key symbol. (See special Subject List Below). To obtain any of these catalogues, send a postal using the key symbols of the Catalogues desired.
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MECHANICAL ENGINEERING
=10a= General and Unclassified; Foundry Practice; Shop Practice.
=10b= Gas Power and Internal Combustion Engines; Heating and Ventilation; Refrigeration.
=10c= Machine Design and Mechanism; Power Transmission; Steam Power and Power Plants; Thermodynamics and Heat Power.
=11=--=Mechanics.=
=12=--Medicine. Pharmacy. Medical and Pharmaceutical Chemistry. Sanitary Science and Engineering. Bacteriology and Biology.
MINING ENGINEERING
=13=--General; Assaying; Excavation, Earthwork, Tunneling, Etc.; Explosives; Geology; Metallurgy; Mineralogy; Prospecting; Ventilation.
Transcriber’s Notes
Inconsistencies have not been standardised, except as mentioned below.
Changes made:
Illustrations have been moved out of text paragraphs.
Some obviously missing punctuation has been inserted, some unnecessarily repeated words and unnecessary punctuation have been deleted, some obvious minor typographical errors have been corrected silently.
The paragraph numbers have been standardised to bold face numbers.
Page 37: It is quite necessary that these torch valves closed ... changed to It is quite necessary that these torch valves are closed ....
Page 48: ... remove the guage from the regulator ... changed to ... remove the gauge from the regulator ....
Page 169: (Hose) clamps in reparing ... changed to (Hose) clamps in repairing ....