Gas Welding, 3-24. Military Curriculum Materials for Vocational and Technical Education

DOCUMENT RESUME

ED 221 681 CE 033 687

TITLE SteelWorker--Gas Welding, 3-24. Military Curriculum Materials for Vocational and Technical Education. INSTITUTION Naval Construction Tratping Center, Port Hueneme, Calif.; Ohio State Univ., Columbus. National Center for Research in Vocational Education. SPONS AGENCY Office of Education (DHEW), Washington, D.C. PUB.DATE 78 NOTE 364p4

EDRS PRICE MF01/PC15 Plus Postage. DESCRIPTORS Behavioral Objectives; Blueprints; Course Descriptions; Curriculum Guides; Learning Activities; Lesson Plans; *Metal Working; Postsecondary Education; Secondary Education; Skilled Occupations; Textbooks; *Trade and Industrial Education; *Welding IDENTIFIERS *Brazing; Military Curriculum Project; *Soldering

ABSTRACT This teacher guide, student materials, and text for a secondary-postsecondary level course tor steelworker gaswelding and cutting comprise one of a number ofmilitary-developed curriculum packages selected for adaptation to vocationalinstruction and curriculum development in a civilian setting. The purpose statedfor the course is to provide students with competencyin blueprint reading, welding, brazing, and soldering. Some previousexperience with welding and cutting is required before enrollment ispermitted. The course contains 56 hours of classroom and shopinstruction divided into three phases: (1) blueprint reading,welding electrodes, rods, welding aids, annealing, hardening, andtempering; (2) gas welding piim (vertical and horizontal positions), generalbrazing, and soldering; and (3) silver brazing. Theinstructor guide provides an introduction to the course;outline of instruction; outline of training activities; and lists of texts, references, tools, equipment, material, training aids, training aidsequipment, and master schedule. The outline ofinstruction contains the lesson plan along with teachet and student activities. Studentjob sheets and information sheets are provided. Text materials Coverblueprint reading, layout and fabrication, and soldering. Sixmilitary manuals, one commercial text, and threefilms are suggested as texts, references, or support material. (YLB)

Reproductions supplied by EDR5 are the best that can be made from the original document. ********************************************************************** MILITARYCURRICULUM%TiRIALS

The military-developed curriculummaterials in this course package were selectedl by theNational Center for Research in Vocational Education Military CurriculmnProject for dissemination to the six regional CurriculumCoordination Centers and other instructional materials agencies.The purpose of disseminating these courses was to make curriculummaterials developed by the military more accessible tovocational educators in the civilian setting)

The oourse materials were acquired,evaluated by project staff and practitioners in the field,and:prepared for rilitaxy dissemination.Materials which were specific to the were deleted, copyrightedmaterials were either mated or qppro- val for their use was obtained. The% course packages contain curriculum resource materials which can beadapted to support vocational instruction and curriculum development.

s Military Curriculum St Materials for The National Center Vocational and Mission Statement Technical Education .r.r...-.7-1,111- 1.17:7el .4 olfrrtnt7; ; r mg y. 01.0 .

The National Center for Research In Information and Fieki? Vocational Education's mission is to incre,ase Services Division the ability of diverse agencies, institutions, and organizations to solve educational prob-

, lems relating to individual career planning, preparation, and progression. The National The ationnt Center for fiesearch Center fulfills its mission by: in Vocationnl Education

Generating knowledge through research

Developing educational programs and products

Evaluating individual program needs and outcomes

Installing educational programs and products

Operating information systems and services

Conducting leadership development and I training programs

FOR FURTHER INFORMATION ABOUT Military Curriculum Materials WRITE OR CALL Program Information Office The National Center for Research in Vocational Education The Ohio State Univirsity 1960 Kenny Road, Columbus, Ohio 43210 Telephone: 614/486,3655 or Toll Pres BOO/ 8404016 within the continental U.S. (except Ohlo) 5 Military Curriculum Materials What Materials How Can These Materials Be Obtained? Dissemination Is . Are Available? 4. 1.11 .4... . . ' "'174'1. ". gaual.4,4141.1,61,044.G."44,1,.. 4':ex f ,1 4.1 1.4.4444.444'...141.1.1.41../

Center One hundred twenty courses onmicrofiche Contact the CUrriculum Coordination an activity toincrease the accessib;iity of in your region for information onobtaining military.developed curriculum materials to (thirteen in paper form) and descriptionsof each have been provided to thevocational materials.(e.g., availability and cost). They vocational and technical educators. refer Curriculum Coordination Centers andother will respond to your request directly or you to an instructionalmaterials agency This project, funded by the U.S. Office of instructional materials agencies for disserni- closer to you. Education, includes the identification and nation..' acauisition of curriculum materials in print materialsinclude programmed form from the Coast Guard, Air Force, Course cummuum commirvyroiJ caivirEfIS Army, Marine Corps and Navy. instruction, curriculum outlines, instructor guides, student worbooks apdtechnical EAST CENTRAL NORTHWEST Access to military curriculum .'",naterials is manuals. Rebecca S. Douglass William Daniels provided through a "Joint Memorandum of The 120 courses represent ihefollowing Director Dilector Understanding" between the U.S. Office of Building 17 sixteen vocational subject areas: 100 North First Street Education and the Department of Defense. Springfield, IL 62777 Airdustrial Park Olympia, WA 98504 Agriculture Food Service 217/782.0759 The acquiFpd materials are reviewed by staff 206/753.0879 and subj6ct matter spectalists, and courses Aviation Health Building & Heating & Air deemed applicable to vocational and tech- MIDWEST SZUTHEAST nical education are selected for dissemination. Construction Conditioning Jan Shill, Ph.D. Trades Machine Shop Robert Patton Management & Director Director The National Center for Rsearch in' Clerical Mississippi State University Occupations Supervision 1515 West Sixth Ave. Vocational Education is the U.S. Office of Stillwater, OK 74704 Drawer DX representative to Communications Meteorology & Education's designated 405/377.2000 Mississippi State, MS 39762 ticquire the materials and conduct the project Ong Navigation Pho tography 601/325.2510 activitiPs. Electronics Engine Mechanics Public Service NORTHEAST WESTERN Project Staff: Lawrence F. H. Zane,Ph.D. The number of courses and the subject areas Joseph F. Kelly, Ph.D. Director Wesley E. Budke, Ph.D., Director represented 'kill expand as additional mate- D irector 1776 University Ave. National Center Clearinghouse rink with application to vocationaland 225 West State'Street Trenton, NJ 08025 Honolulu, HI 96822 Shirley A. Chase, Ph.D. technical education are identified and selected 609/292.6562 808/948.7834 Project Director for dissemination. 7

6 1, ....."

Classroom Course 3-24 r-

STEELWORKER GAS WELDING AND CUTTING Table of Contents

Course Description Page 1

Steeelworker 615.2 Gas WeldinAnd Cuttin - Pa6 3 . Instructor Guides And Supporting Material \ Blue rint Reading And Sketchin

Chapter 1 - Blue Prints Page 159

Chapter 5 - Sheet Metal Layout Page 172 And Fabrication

'Chapter 6 - Plate And Pipe Layout Page 181 And Fabrication

Chapter 13 - Soldering Page 204

Chapter 18 - Reinforcing Steel Page 213

A.,,

2 c - 5 AA STEELWOR KEil, GAS WELDING AND CUTTING' Classroom Course.

I I. A...4

.. ./...... _...... ___ r. D.O.T. No.: 4 Dr/eloped by: a 680.231 United States Navy, i Occupational Area: Building and Construction Development and Review Dates Target Audircas: 44, No date Grades 10-edult

./ ( Print Pages: . -3 125 Cost: $2.50 Availability: 14, Military Curriculum Project. The Canter for Vocational Education. 1960 Kenny .Rd.. Columbus, OH 43210

I. x .i it i . .4"...I s .i 3 t ... :2 li 3* 2 .t ti 2 1 < CZ o- CContents: Phase 1 1.1:1 Blueprint Reading 1.1.2 Welding Electrodes, Rods and * Welding Aids \

1.2.1 Annealing, Hardening and * MOO Tempering Phase 2 2.1.1 Gas Welding Pipes, Vertical * Position 2.1.2 Evaluation of G.z Wording * Pipe.Vertical

2.1.3 Welding Pipe, Horizontal- * 4, Position

2.1.4 Evaluation of Gas Welding. * Horizontal . * 2.2.1 General Blazing * 2.2.2 Soldering Phase 3 * 3.1.1 Silver Brazing (steel) *

3.1.2 Silver Brazing (brass) --411.- N I.' * se 3.1.3 Silver Brazing (stainless)

...MOM%

* Materials are recommended but not Provided.

, Expires July 1, 1978 irio ljettiVinilrelyvtntd 1 !./ 1 lb* 1 fr

A ,

Course Description. welding consumables; defining will be competent in reading simpleblueprints from shopwork; identifying After completing this short course:students techniques in preparation of welding pipe invertical fixed position and hardening, and tempering:using correct and knowing purposes for annealing, silver brazing. Some previous experiencewith welding and cutting is horizontal fixed position; performinggeneral brazing end soldering; and doing sroom and shop instructiondivided into three phases. requiredior this purse. This course containsfifty-six hours of-c Plop instruction. Phase 1 contains two units totaling tenhours of classroom and nine hours of

ti Unit 1

shop) 1.1.1 Blueprint Reading (2 hours classroom, 7 hours (5 hours classroom) 1.1.2 Welding Electrodes, Rods and Welding Akis i Unit 2 catsroom, 2 hours shoP) 1.2.1 Annealing, Hardening and Tempering (3 hours of shop instruction: Phase 2 containx two units totaling threehours classroom, and twenty-three hours

Unit 1 (1 hour claisroom, 5 hours shop) 2.1.1 Gas Welding Pipes, Vertical Position hours shop) 2.1.2 _ Evaluation of Gas Welding PipeVertical (2 (5 hours shop) 2.1.3 Gas Welding Pipe, Horizontal Position (2 hours shop) 2.1.4 Evaluation of Gas Welding Pipe-Horizontal ,. Unit 2

shop) 2.2.1 General Brazing (1 hour classroom, 5 hours thop) 2.2.2 Soldering (1 hOur classroom, 4 hours instruction: Phase 3 contains one unit with one hourof classroom and ten hours of shop

Unit 1

3 hours shop) 3.1.1 Silver Brazing (steel) (1 hour classroom, 3.1.2 Silver Brazing (brass) (3 hours shop) 3.1,3 Silver Brazing (stainless) (4 hoursshop) outline of instruction; an student materials. The instructor guidecontains an introduction to the course; an The course contains both instructor and the master schedule. references, tools, equipment, materials,training aids, training aids equipment and oistfirie of training objectives; and lists of texts, student activities. Student job sheets andinformation sheets are also provided. The outline of instruction containsthelessch plan along with teacher and Raiding and Sketching, NAVP6 RS 10077.0and Steelworker taken from two Navy munials, Blueprint The text ;tutorials provicied for this course are also suggested. Five military rnznuals aresuggested for use as military manual and one commercial text are 342, NA VPERS 10653. One additional references. The following films are listed as supportmaterial but are not provided:

MN37 Behind the Shop Drawing MN-4831-1 The Use of Soldering Coppers MC-679A Engineering Drawing-Orthographic Projection

VIOTIIIMMII4Nivi2riall! .0

TITLE: Stoolworker- GAS Cutting and Welding II.

Couroo Number; Special Technical Training Course 615.2

Course Length: 56 periods - 51 tours contact tim4

Taught!. at: Naval Schools Conspruction, Port Hueneme, Naval Schools Construotiop, Davisville, Rhode Island; Construction Training Unit, Gulfport, Mies. eissippi.

Class capacity: Max 10 Min 6

0 Instructor Requirements per class : 2

Course Cirriculum Model Manager: Naval Schools, Construction, Port Hueneme, Calif.,93043

Quota Management Authority: School at which tiiiight

Quota Control: School at which taught

Approval/Implementation Date: When approved by the Chief of Naval Technical Training.

4. TAMA Or CONTENTS

Gown Pap

Table of Contents

Course Data Page

How to Use Instructors Guides

Outline of Training Objectives

Training Objectives

Annex I Bibliography 7

Annex II Equipment Requirements List 8

Annek III Instructional Materials 9-10

Annex IV Mester Schedule 11-12 COURSE DATA PAGE

the knowledge and skill Coorst:, hiatilon: Totrain aciedted steeiWorkers in Program for frxtors dained by thePersonnel Readiness and Capability ilteelworkers skill.

Por.,naneL and RatingEligible: 03 throu0 E6

Obi!gotod oervico: Nona

NOBC/NEC Earned: None

PhysvIll Requirements: Nospecial requirements

ecurity clearance Required:None

Prerequisite Training and/or BasicBattery Test score required: GasCutting/ Welding I 615.1

Wasted Training: MaintenanceWelding

Follow on training: AxeMading-atructural 1- 610.1

performance will be evaluated on a VALIATION: Unless otherwise specified, CO/NO GO basis.

iii 14 now TUaLimaNgszialivs Instructor Guidon aro provided for (inch topic and include supporting instructional materials and aids idontifiud by the topic number And preceded by a letter code designation. The letter code key is as follows:

AS - Assignment Sheet JS - Job Sheet IS - Information Sheet CN - Class Mites OS - Operation Sheet T Test TT - Final Test TR - Transperencies DS - Diagram Sheet PS - Problem Sheet PT - Pretest PE - Performance Evaluation wS - Work Sheet G - General (give a definition of item)

A coaplete listing af all supporting materials and aids is documented with full descriptive titles in Annex.

Thv instructor guides ar intended to be used as nmster lesson plans !muloct to personalization icry the individual instructor. In all cases, it L!, ,,xpected that the instructor will study the references in prepartation

;*oz amotating the guide. It is also expected that each nstructor will develop an anpropriated introduction for each topic that will (1) create interest, (2) show the value of the topic to the student, (3) relate the topic to previous and future topics in the course, and (4) communicate the lertl;n1. objectives to the student. Well prepared introductions will then p ovid(- the important motivationalconditioning to establish readiness and eLject for learning appropriate to each topic.

The first page of each instructor guide Lontains the following functional Information:

1. Topic of lesson 2. Time in periods 3. References A. Instructional Aids 5. Instruction Aids 6. Objectives 7. Topic criterion test (as applicable) 3. Homework assignment (when applicable) 9. Tools and materials

The pages following page 1 of each instructor guide provide in a three- column Lomat: the teachin/learning procedures for conducting the lesson. The la: hand column includes tLe outline of instructional content required by the objectives: the center column includes recommended instructor activities or mutuouology, the right hand column contains recommended student learning activities.

iv Wtic Cho methodology and studont learning activities documented in each iguAructor 3uide have been tested and proven to be effective for the leAd school, those schools implementing this curriculum arc ncouraged to ,..xcrniso creativity in designing learning exercises and conceiving methods and techniques to meet course objectives.

r-- OUTLINE OF TRAINING 011,11=,ES 00,E4OORKER scum.

srEct&L TECHNICAL TRAINING GAB CUTTING/WEIDING II

PHASE 1 Class Pract Total UNIT 1

1.1.1 Llueprint Rending 2 7 9

1.1.2 Welding ElectrodeS, Roda and WeldingAids 5 5

UNIT 2

1.2.1 Annealing, Hardening and Tmpering 3 2 5

PHASE 2 UNIT 1

, 2.'.1 Gas Welding Pipes, VerticalPosition L 5 6 2.1.2 Evaluation of Gas Welding Pipe -Vertical 2 2 2.1.3 Gas Welding Pipe, HorizontalPosition 5 5 2,1.4 Evaluation of Gas WeldingPipe-Horizontal 2 2

UNIT 2

6 2.2.1 General Brazing 1 5 4 5 2.2.2 Sold,!ring 1

PHASE 3 UNIT 1

1.1.1 Silver Brazing (steel) 1 3 4 1.1.2 Silver Brazing (brass) 3 3 3.1.3 Silver Brazing (stainless) 4 4

Total Pcrids, Class 14 22%

Total Periods, Practial 42 787.

Total Periods, Course 56

TotnL Weaks for Course 2

1 /0

TRAINING OBJECTIVES MAUI UNIT 1

Upon completion of this unitthe student will have: Read simple prints for shop work: identified title boxand read notes and specification as found on simple prints: All must be within100% accuracy. Identified the welding consumables in the Mobile Construction BattalionTable of Allowance, namely arn welding electrodes, gaswelding rods, wearfaeing electrodes and welding aids: stated their primary uoe andsecondary use when applicable without error,

1.1.1. Topic: Blueprint Reading Upon completion of this topic thestudent will have:

A. Read simple prints for shopwork; Identified title box and read notes and specifications asfound on simple printa. All must be within 1007. accuracy.

1.1.2 Topic: Welding Electrodes,Rods and Welding Aids: Upon completion of this topicthe student will have:

A. Identified the weldingconsumablies in the Mobile Construction Battalion Table of Allowance,namely arc welding electrodes, gas welding rods, wearfacing electrodesand welding aids: Stated their primary use and secondary usewhen applicable without error.

UNIT 2

Upon completion of thisunit the student will have: Defined the term annenl and listed four purposeeof the process; Defined hardening in terma of work, flame and canehardening; stated the definition of temperini,, and its purpose.All will be without error.

1.2.1 Toplc: Annealing,Hardening and Tempering Upon completion of this topicthe student will have:

A. Defined the term anneal andlist four purposes of the process B. Defined hardening in termsof work, flame and case hardening. C. Stated the definitionof tempering and its purpose. D. All the above will bedone without error.

PHASE 2

UNIT 1

Upon completion of thisunit the student will have: Performed correct techniques for welding pipe as togage setting, type of flame,speed specified of travel manipulation oftorch and correct welding rod. Perform

2 // degree of cleaning of completed weld. Demonstrate proper pipe preparation by beveling, cleaning, aligning, spacing and tack welding priop to welding. Gas weld with a 1/8" triple deoxidized rod V butt joints in the vertical and horizontal fixed positions a 2" mild steel pipe. In doing this he will apply all pertinent safety precautiono asetripulated in IS - 1.1.1.1 and identify and apply the correct procedures and methods of correcting faults. Evaluation will be baned on the Qualification Test for AR-3 level of American Welding Society, otandard for Qualification of Welding Procedures and Welders of Piping and tubing, AIM d10. 9-72 condensed in standard SIT-F1-1 attached to this unit. The final weld must meet the minimum requirements established for gaswelding pipe in the vertical and horizontal fixed non-restricted position, listed in STT-FT-1.

2.1.1 Topic: Gas Welding Pipe, Vertical Position Upon completion of this topic the student will have:

A. Performed correct techniques for welding pipe as to gage setting, type of flame, speed of travel, manipulation of torch and correct welding rod. Performed specified degree of cleaning of campleted weld. B. eemonstrated proper pipe preparation by beveling, cleaning, aligning, npacing and tack welding, prior to welding. C.nn weld with a 1/8" triple deoxidized rod a V-butt joint in the vertical fixed position a 2" mild oteel pipe. In doing this ha will apply all pertinent safety precautions as tipulate in IS-1.1.1.1. and identify and apply the correct procedures and methods of eer- recting faults. Evaluation will be based on the Qualification Test for AR-3 level of American Welding Society, Standard for Qualification of Welding Procedures and Welders for Piping and tubing, AWSD10.9-72 condensed in standard .SI2,FT-1 attached to this unit.

2.1.2 Topic: Practical Evaluation in Gas Welding Pipe, Vertical fixed position. Upon completion of this topic the studeet will have:

A A. Performed correct techniques for welding pipe as to gage setting, type of flame, speed of travel, manipulation to torch and correct welding rod. Perform specified degree of cleaning of completed weld.

B.Demonhratedproper pipe preparation by beveling, cleaning, aligning, spacing and tack welding prior to welding. C. Gas welded a 1/8" triple deoxidized rod a V-butt joint in the vertical fixed position a 2" mild steel pipe. In doing this he will apply all pertinent safety precautions as stipulated in IS-1.1.1.1 and identify and apply the correct procedurea and methodo of correcting faults. Evaluation will be bailed on the Qualification Test for Qualification scsWelding Procedures and Welders for Piping and Tebing, AWS D-10. 9-72 condensed in standard STT-PT-1 attached to this unit. The final weld must meet the mintmum requirements established for gas welding pipe in the vtrtical fixed non-lestricted position.

3 2.1.3 Topic: Gas Wolding Pipe,Uorizoatal Fixed Position Upon completion oi thin topic the studentwill have:

A. Performed correct t';ochniques forwelding pipe aa to gage settl.ng, type of flame, speed oftravel, manipulation of torch and correct welding red. Perform npocified degree of cleaning ofcompleted wnld. B. Demonstrate proper pipepreparation by beveling, cleaning, aligning spacing, and torch welding, prior to welding.

C. Gas we/d with a 1/8" tripledeoxidized rod, a V-butt joint in the horizontal fixed position a 2" mildsteelloipe. In doing this he will apply all pertinent saffity precautions asstipulated in IS.1.1:1.1 and indentify and apply tha correct procedures andmethods of correcting faults. Evaluation will be based on theQualification Test for AR-3 level of American WeldingSociety, Standard for Qualification of Welding Procedures and Welders for Piping and Pubing, AWS-D-10-9-72 condensed in standard STT.FT-1 attached to this unit.

2.1.4 Topic: Practical Evaluatioa in Gas WeldingPipe, Horizontal FiLed Position Upon completion of this topic the student willbe able to:

A. Perform correct techniques for weldingpipe as to gage setting, type of flame, speed of travel,manipulation of torch and correct welding rod. Perform specified degree of cleaning ofcompleted weld. B. Damonstrate proper pipe preparationby beveling, cleaning, aligning, spacing and 'tack welding, prior to welding. C. Gas weld with a 1/8" triple doxidiztd rod a V-buttjoint in the horizontal fixed position a 2" mild steel pipe. Indoing this he will apply all pertinent safety precautions asstipulated in I3.1.1.1.1 and identify and apply the correct proceduresand methods of correctin3 faults. Evaluation will be based on the Qualification Testfor AR-3 level of American Welding Society standard forQualification Test for AR-3 level of American WeldingSociety standard for Qualification of Welding Procedures and Welders forPiping and Tubing, AWS D-10.9-72 condensed in standard STT-FT-1attached to the unit. The final weld must meet the minimum requirementsestablished for gas welding pipe in the horizontal fixed non restrictedposition.

UNIT 2

Upon completion of this unit the student willhave: Bronzed welded a eingel vce butt joint of mildsteel 3/16" x 4" x 6" with an Oxy-gas torch in the flat position. Bronze welded to a tee joint of mild steel3/16" x 4" x 6" with an Oxy-gas torch in the flat position. Bronzewelded a lap joint of mild steel 3/16" x 4" x 6" with an Oxy-gas torch in theflat position The above shall be done in accordancewithsTT -FT-1 Selected propersoldering copper, flux am: solder for the metal to be soldered. Solder sheet metal by preparing the metal and soldering coppers prior to soldering common metals used in the sheet metal shop. All nafety precautions and practicen must be observed. Completed pro- jeer:: mat not. exceed n tolerance of 1/8" plus or minua on any given mensurement.

2.2.1 General Brazing Upon completion of this topic the etudent will have:

A. Bronze welded a single vee butt joint of mild steel 3/16" x 4" x 6" with an Oxy-gas torch in the flat position. B. Broaze weldod a tee joint of mild steel 3/16" x 4" x 6" with an Oxy-gas torch in a flat position. C. Bronzed welded a lap loint of mild 8teel'3/16" x 4" x 6" with an Oxy-gas torch in the flat position. D. 711v above shall be done in accordance with STT-FT-1.

2.2.2Topic: Soldering Upen completion of this topic the student will have:

A. Selected proper soldering copper, flux, and solder for the metal to be soldered. 8:Solder sheet metal by preparing the metal and soldering coppers prior to soldering common metals used in the sheet metal shop. C. All safety piecautions and practices must be obaerved. Completed projects must not exceed a tolerance of 1/8" inch plus or minus on any given measurement.

PHASE 3 UNIT 1

Upon completion of this unit the student will have: Silver brazed a square butt jopet of 1/8" x 1" x 2" mild steel with an Oxy-gas torch in the flat po6ition. Silver brazed a tee joint of 1/8" x 1" x 2" mild steel with an Oxy-gas torch in the flat position. Silver brazed a lap joint of 1/8" x 1" x 2" mil steel with an Oxy-gas torch in the flat position. Silver brazed a square butt joint of 1/16" x 1" x 2" brass with an Oxy-gas torch in the flat and vertical position. Silver brazed a tee joint of 1/16" x 1" x 2" brasa with an Oxy-gas torch in the flat position and vertical position. Silver brazed a 1/4" lap joint of 1/16" x 1" x 2" brass with an Oxy-gas torch in the flat and vertical position. Silver brazed a tee joint of stainless steel 1/16" x 1" x 2" with an Oxy-gas torch in the fiat and vertical posiiton. Silver brazed a k" lap joint of stainless steel 1/16" x 1" x 2" with an Oxy-gass torch in the flat and vertical position. The above shall be done with a joint tolerance of .0015 to .003 and with no build up.

3 a41.1 Topic: Myer BrazingSroel Upon iomplotion oithin topic the ntudent will be able to:

A. Silver btazo a nqunru butt jointof 1/8" x 1" x 2" mild steel with an oxy-gas torch in the flat position. B. Silver braze a tee joint of1/8" x 1" x 2" mild steel with an oxy-gas torch in the flatposition. C. Silver braze i lap joint of1/8" x 1" x 2" mild steel with an oxy-gas torch it the flat position. D. The abovt shall be done with a jointtolerance of .0015 to .003 with no build up.

1.1.2 Topic: Silver Brazing Brass , Upon completion of this topic the student will beable to:

A. Silver braze a square butt joint of1/16" x 1" x 2" brass with an oxy-gas torch in the flat and verticalposition. B. Silver braze a tee joint of1/16" x 1" x 2" brass with an exy-gas torch in the flat and vertical position. C. Silver braze a " lap joint of1/16" x 1" x 2" braas with an oxy-gas tor h in the flat andvertical position. D. The above s done with a joint tolerance of .0015 to .003 and with no build ups.

3.1.3 Topic: Silver Brazing Stainless Upon completion of this topic the student will beable to:

A. Silver braze a tee joint ofstainless steel 1/16" x 1" x 2" with an oxy-gas torch*p the flat and vertical position. B. Silver braze a k" lapjoint of stainless steel 1/16" x 1" x 2" with an oxy-gas torch in the flat and verticalposition.

C. The above shallbe done with a joInt toler .0015 to .003 and with not huild up. ANNEX 1

BIBLIOGRAPHY

UXTS le Steelworker 3 St 2 NAVPERS - 10653E Operator's Manual Weldl.ng Theory and Application TM-9-237 WelainkEncyclopedia, 16th Edition, Monticello Books, Mbrton Grove, Illinois, 60053 The Welding Mhterials Manual NAVFAC P-433.

REFEMNCES:

Naval Construction force Safety Mhnual CgMCBPAC/COMCB/LANT INST 5100.1 American Welding Society, Standard for Qualification of Welding Procedures and Welders for Piping and TUbing ANS-D-10.9-72 is \ "Brazing Manual" American Welding Society Construction Prjat Reading in 1 the frbld, TM-704, chapter 2. ....4.m.VI Blueprint Reading and sketching NAVPERS 10077C Blueprint 'lading, NAVSCON 064-231

7 ANNEX II

EQUIPMENT REQUIREMENTS LIST

required, cost: $438.00 Oxy-Mapp Cutting andWelding Unit, FSN:NA, 10 units

Appropriate testing equipment tocheck quality of welds. $478.00 Pedestal Grinder FSN:3415-204-0035, 2 units required, cost: 4. Pipe Beveling Machine FSN:NA, 1unit required cost: $500.00

8 *

ANNEX III /7

INS5RDCTIONAb MATERIALS

Film:

MN-37- Behind the Shop Drawing (16 min) MN-7831-I The Use of Soldering Coppers (8 min) MC-6797A Engineering Drawing - Orthogragphic Projection (18 uin) MN-9753 "On Solder" (25 min) obsolete

Information Sheet:

Safety Prcautionu Gas Welding and Brazing Testing Standards

Models:

Samples of pipes beveled, spaced and tacked Samples of pipes showing bead placement X-Rays showing defects in welds and good wtlds Samples of soldered, brazed and silver brazed joints.

Instructor Aids:

16 rxi Projector

1.. Soldering Coppers 2. Chipping hammer 3. Pliers, 8" 4. Glovna 5. Spark lighter 6. Tip cleaners 7. Gloves 8. Coggles 9. Wire brush

Materials:

1. Pencils 2. Paper 3. Sheet metal (18 ga) 4. Solder (50/50) 5. Rags 6. Fluxes: a. Brazing b. Silver brazing c. Soldering 7. Pipe, Mild steel (2") 8. Oxygen 5. Mapp gas 10. Triple deoridized Gas Welding rod 1/8"

9 ir Materla7::1 cont. .

1 P. nronze rod (flux coated 1/8") 12. Silver, brazing alloy 1/16"

13. Chalk . . 14. Steel Hate 3116" 15. Brass 1/16" 16. Stainless 1/16" 17. Steel Plate 1/8" 18. Samples of electrodes and rods that are in the T.O.A.,

(.1

10 2(3 Mtn IV

MANTIot SCDE1)11LE GAS COTT wc/nunNG II STEELWORKER SCHOOL

FIRST40

12u,tiLya. gatI24 Tcplc B,012,

1 Blueprint Reading 5/1 2 Blueprint Rtading 5/1 3 Blueprint Reeding 5/1 4 Blueprint Reading 5/1 5 Blueprint Rtading 5/1 6 Blueprint Reading 5/1 BlueprIt Reading 5/1

8 Blueprint Reading 5/1 9 Blueprint Reading 5 /1 10 Welding Electrodes, Rods and Welding Aids 11 Welding Electrodes, Rods and Welding Aids 12' Welding Electrodes, Rods nd Welding Aida 13 Welding Electrodes, Rods and Welding Aids 14 Welding Electrodes, Rods and Welding Aids.

THIRD DAY 1.2.1 15 Annealing, Hardening & Tampering 5/1 1.2.1 16 Annealing, Hardening & Tampertng 5/1 1.2.1 17 Annealing, Hardening & Tampering 5/1 10 Annealing, lw.rdening & Tampering 5/1 1.2,1 19 Annealing, Hardening & Tampering 5/1 2.1.1 20 Gas Welding Pipe, Vertical Position 5/1 2.1.1 21 Gas Welding Pipe, Vertical Position 5/1

FOURTH JAY 2.1.1 22 Gas Welding Pipe,Vertical Position 2.1.1 23 Gas Welding Pipe,Verti.;a1 Position 2.1.1 24 Gas Welding Pipe,Vertical Position 2.1.1 25 Gas Welding Pipe,Vertical Position 2.1.2 26 Evaluation of GasWelding Pipe, Vertical Position 2.1.2 27 Evaluation tf GasWelding Pipe, Vertical Position 2:1.3 28 Gas Welding Pipe,Horizontal Position 5/1 e:1

SECOND WEE:::

Ratio Topic No TYpc Pertod Topic

FIRST DAY 5/1 2.1.3 S 1 Gas Welding Pipe, Uorizontal Position 5/1 2.1.3 S 2 Gas Welding Pipe, Horizontal Position 5/1 2.1.3 S 3 Gas Welding Pipe, Horizontal Position 5/1 2.L.3 S 4 Gas Welding Pipe, Horizontal Position 2.1.4 S 5 Evaluationof Gas Welding Pipe, Horizontal Position 5/1 2.1.0 5 6 Evaluation of Gas Welding Pipe, Horizontal Position 5/1 5/1 !.2.1 S 7 General Brazing

!1ECDND DAY 511 .1.2.1 S 8 General Brazing 5/1 2.7.. S 9 General Brazing 5/1 2.2.* S 10 General Brazing 5/1 2.7.1 5 11 General Brazing 5/1 2.2.1 S 12 General Brazing 5/1 2.2.2 0 13 Soldering 5/1 2.2.1 S 14 Soldering

ThIRD DAY 5/1 2.2.2 5 15 Soldering 5/1 2.2.2 5 lb Soldering 5/1 2.2.2 S 17 Soldering 5/1 1.1.1 C 18 Silver Brazing steel 5/1 3.1.1 S. 19 Silver Brazing steel 5/1 ;.1.1 S 20 , Silver Brazing steel 5/1 1.1.1 S 21 Silver Brazing steel

roURTH DAY Silver BrazIng Brass 5/1 1. .7 5 22 5/1 .1.2 S 23 Silver Brazing Brass 5/1 ;.1.2 S 24 Silver Brazing Brass 5/1 1.i.1 S 25 Silver Brazing Stainless 5/1 .1.:. S 26 'ailver Brazing, Stainless 5/1 3.... S 27 Silver Brazing Stainless 571 %1.3 S 28 Silver Brazing Stainless

2.13 STT-615.2-8W-IS4.1.1,1 45Z/I

NAVAL SCHOOLS CONSTRUCTION PORT HUENEME, CA 93043

STEELWORKER dT SCHOOL TRAINING 'COURSE '-!1-"P

INPORNATION MET

RAPE7Y PRECAUTIONS

INTRODUCTION: This information sheet is designed toprovide information an safety precautions and properactions in case of fire.

SUBJECT NATTER:

1. Alcoholic liquors or narcotics shall not betransported to the school or working area, and no manshall go to work while under the influence of liquor or narcotics.

2. Fighting, wrestling, or throwing of objectsand horseplay is positively prohibited.

3. Strict attention to duty is the first requirement ofsafety. You are warned against permitting your attention to bedistracted from your work as this is the cause of manyinjuries. "Keep your mind on your work and safety on your mind".

4. Do not talk to or distract the attention ofmachine and equipment operators while the machines or vehicles are inoperation.

5 .0bey warning signs and tags. Their purposeis to point out hazards. To disregard them ie to diliberately invite injury.

6. No one is permitted to ride onfenders, running boards, or bus steps; nor to ride standing ontruck bodies.

7. Employees riding on trucks or othervehicles most keep arms and legs inside the body of the vehicle at all times.Sitting on side boards is prohibitpd.

S. No one is permitted to get on or off amoving vehicle.

9. Never try to operate any equipmentunless you are familiar with its operation and have been authorized todo so.

10. Report to your supervisor any defects in equipment or anyother condition which might cause an accident.

11. Remember that at all times some of yourco-workers on the job are inexperienced and may not know when or where danger exists.Warn any man when danger is near. He mayknow all about it; if so no harm is done.

( 1 of 3 ) STT415-2- SW- IS. 1.1.1.1

12. Be constantly aware and stay clear of moving equipment and material

13. You are in danger when you are in a posiiton between a moving piece of equipment or load of material and a stationary object.

14. Do not use a box, chair, barrell, or other makeshift in place of a ladder.

15. Leaning tools or materials against walls, columns, or machines is an unsafe practice.

16. Cleaning, oiling, repairing, or adjusting machinery or equipment while it is in motion may cause serious injury and is prohibited.

17. Always use all safeguards provided. See that'all guardo or other protective devices.are in place before Beginning work.

10. Any extension lamp, pawer tool, welding cable, etc. with frayed insulation, loose connection, or damaged plug should be repaired or repladed imamdiately.

19. Do not touch, handle or tamper with any electrical equipment, air, water, gas, oil, or steam line, or machinery which does not come within your regular duties unless you have received permission and instructions from your supervisor.

20. Do not throw any switch, turn any air, water, steam or oil valve, or start any machine withoue first making certain that everything is in the clear and that no worker will be injursd by such action.

21. In doing work entailing possible eye injury, protect the eyes by wearing the proper type of safety goggles provided for chip purpose

22. Every precaution must be taken to prevent fires. Extinguish all lighted matches, cigarettes or cigars before throwing them away.

23. Throw waste paper, oily rags, and other refuse in containers provided for that purpose.

24. Keep aisles, stairways, exits, and fire equipment clear of obstruction at all times.

25. In case of fire turn in the alarm and return to the scene of the fire to help in extinguishing it.

( 2 of 3 ) STT-615.2*8W.48. 1.1.1.1

JUNE 1974

OXY-MAPP WELDING PHASE

YOU WILL:

1. Observe all safety rules.

2. Wear gloves while welding and burning

3. Wear the welding goggles provided.

4. Use pliers to pick up hot metal.

5. Use safety shields while grinding.

6. Properly stow tools and equipment.

7. Replace oxy-mapp bottles when found empty.

8. Clean your booth and area.

9. Use only materials designated by the instructor.

10. Take breaks on east side of building. yOU WILL NOT:

1. Wear gloves whild grinding.

2. Use goggles while grinding.

3. Put fire bricks or plates in drawers.

4. Misuse welding equipment.

5. Weld on face of platen

6. Waste plates or welding rod.

7. Weld anything other than that specified by the inotructor.

8. Bend platee unless instructed to do no by the instructor.

9. Leave a mess for someone else to clean.

10. Throw trash in metal dumpnters.

11. Play or fool in shops or with another mane tools and equipment

12. Bring any type of food or beverage into the shopu.

13. Go th the exchange ou gedunk break.

14. Leave the area without instructors approval.

( 3 of 3 )

'3 i STEELWORKER smolt' STT GAS WELDING AND BRAZINGPRACTICAL TESTING STANDARDS mild steel welding rod, OBJECTIVES: I. Unlng a 118" triple deoxidized the student will oxy-MAPPweld, in the flat position, a butt joint, a lap joint, and a cornerjoint. Base metal will be 10 g. a. Mild steel. Welds are to be made using the forehand method.

2. Using a 1/8" brass brazingrod and sufficient flux, the student will oxy-MAPP torch braze inthe flat position, a butt joint, a lapjoint, and a corner joint. Base metal will be 10 g.a. mild steel. All brazing is to be done by the forehand method.

actually To ensure impartial grading aninstructor other than the person Insiructing the class willperform the grading.

STT-FT (l of 4)

3,c? [NSTRUCTOR'S GUIDE FOR GRADING

OXY-MAPP GAS WELDING AND BRAZING PRACTICALTEST

four:L" sections as illustrated: 1. With soapstone, divide the test plate into

SECTION #1

11 .01.1111

SECTION #2

oviftliam

SECTION #3

SECTION #4

GRADING

2. Weld or Braze

A. Appearance (1) The ripples formed by the depositedfiller metal must present a uniform appearance. For each section that does not have auniform ripple appearance, up to two points may besubtracted. Maximum loss is two points per section maximum loss per plateis eight points. (2) The build up of filler metal must notexceed 1/8" in height from the face of the plate. For each section that the filler buildupexceeds 1/8" up to two points may be subtracted. Maximum loss is two points

per section. Maximum loss per plate is eight points. (3) The width of the welded/brazed area must notexceed 5/8". For each section that the welded/brazed area exceeds5/8", up to two points may be subtracted. Maximum loss is two points per section.Maximum loss per plate is eight points.

STT-FT (2 of 4)

33 B. UNDERCUT melted into the basemetal (1) For each sectionthat an undercut is two points maybe and left unfilledby the filler metai, up to points per sectionyMaximum subtracted. Maximum loan is two loss per plate in eightpoints.

C. OVERLAP of the filler metalis beyond (1) For each sectionthat the protrusion be subtracted. the bond of the fillermetal, up to two points may Maximum loss per plateis Maximum loss is twopoints per section.

eight points.

D. PENETRATION the surface of theplates (1) The root filler meLalmust extend below the root filler metal being welded/brazed. For each section that be sub- does not extend below thesurface, up to two points may section. Maximum loss tracted. Maximum loss is two points per per plate is eightpoints. metal extends below the (2) For each sectionthat the root filler be subtracted. surface in excess of1/8", up to two points may Maximum loss perplate Maximum loss is twopoints per section.

is eight points.

3. Guided Bend Test

A. Butt Joint-Face Bend bent facing down on the (1) With the face ofthe ftrst section to be bend the section bending guide, pressurewill be applied so as to Welding in Building in a "v"shape as stated in the code for Construction, AWS DI.0-69. Points may be deducted asfollows: metal 1/8" to 1/2"= 2points If the filler metalseparates from base = 4 points If If ft If " 1/2" to 1" ft If If II ft " 1" to 11/2" = 6 points = 8 points If If 1 t ft " 11/2" to 2"

B. Butt Joint-Root Bend facing down on the (1) With the root of thesecond section to be bent the section in bending guide, pressure willbe applied so as to bend Building Constructien, "U" shape as stated inthe code for Welding in AWS DI.0-69.

STT-FT (3 of 4)

3.i Points may be deducted as follows:

If the filler metal separates from base metal1/8" to 1/2' = 2 points tt 11 tt It tt It It " 1/2" co 1" = 4 points It tt It tt tt It " 1" to 1 1/2" = 6 points

It tt II 11 It tt " 1 1/2" to 2" = 8 points

C. Lap Joint-Face Bend (1) The grading instructor will decide which side of Lap joint is to be

used for the face bend test. (a) With the selected side to be bent facing down on the bending guide, with lap joint between bending guide shoulders, pressure will be applied so as to bend the section in a "U" shapa as stated in the Code for Welding in Building Construction, AWS DI. 0-69. Points may be deducted as follows: If the filler metal separates from base metal 1/8" to 1/2" = 4 points

It tt 11 It 11 It tt " 1/2" to 1" = 8 points ft Of If If " 1" to 1 1/2" = 12 points

It tt It 11 tt It tt " 1 1/2" to 2" = 16 points

D. Corner Joint (1) With the legs of thetest specimen facing down on a hard flat surface a force shall be applied until rupture occurs orspecimen flattens upon itself. The force may be applied by any convenient means.

STT-FT (4 of 4)

3 5 STI-615-2-SW->IG 1.1.1 gi

NAVAL SCHOOLS, CONSTRUCTION PORT HUENEME, CALIFORNIA 93043 STEELWORKER STT SCHOOL TRAINING COURSE 615-2

Classification: Unclasiified

Topic: Blueprint Reading Terminal Objective: 1.1

Average Time:Class: 2 periods ?tact ; 7 periods Instructional Materials: A. References

1. TM5-704- Construction Print Reading in the Field Chapter 2 Enabling Objectives: Upon completion of this topic the student will be able to: A. Read simple prints for shop work: Identify title 2. NAVPERE 10077-C Blueprint Reading and Sketching, Chapter 1, pages 1-13 box and read and specifications as found on simple pri 0A s: all must be with 100% accuracy. B. Programmed Instruction

1. Blueprint Reading, NAVSCON 064-231 Criterion Tests: The student willread simple prints C. film for shop work. Identify title bo4rapd read notes and specifications as found on simple prints. All 1. MN-37 - Behind the Shop Drawing (10 min) must be done with 100% accuracy.

2. 14C-6797A - Engineering Drawing, Othographic Projection (18 min) Homework: Reading Assignment: NAVPERS 10653-E Steelworker 3 & 2, Chapter 5, pages 51-59 D. Transparencies

1. None

E. Instructional Aids: 4

1. 16 MN movie projector 3 7 3 ( 1 of 15 ) .4.

STT-615-2-2- SW 1G 1.1.1

F. Tools:

1. None

G. Equipment

1. None'

H. Materials:

1. Penci1s

2. Paper

30 WIT - 615 2- SW 1.1.1 40 amErmiainym immumaxx

Introduce self anti topic. t. Introduction to the Lesson .

A. Establish contact.

1. Minds

2. Teple:Basic Blueprint Reading

B. Establish readiness . Motivate 'student.

1. Purpose

2. Assignment

C. Establish effect 3. Bring out need and value Imatertal being presented.

1- Value

a. Pass course.

b. Perform better on the job.

e. Get advanced.

d. Be a better steelworker

1. Overview: 4. State learntng objec- ttves. 1. State objectives

a. State information 2. Notes and materials necessary to gutde student. 3, Questions

4, Testaale 4

40 ( 3 of 15 ) BIT415-2-8 IC. 1.1.167

INSTRUCTOR ACTIVITY STUDENT ACTIVITY OUTLINE OF INSTRUCTION 5. Ohm film 1411.-37,Behind 1. Watd) fiIm. II. Presentation the shop Drawing.

A. Purpose andmakeup of prints.

1. Convey ideas anddetails

2. Copy of adrawing.

a. Blueprint(white on blue)

b. Black and white(black on white) blue on white) c. ()maids(black, maroon, purple, or

d. Van Dykes (white ondark brown).

gray). e. Negativephosphates (white on

3. Lines

4. Dimensions . Take motes 5. Notes

B. Basic tines

1. Object

d. Visibleoutlineof object.

b. Thick andsolid.

2. Hidden

a. Biddenoutline of object

b. Medium andbroken

4 ( 4 of 15 ) STT-6 5-2-SW- OUTLINE OF INSTRUCTION IC. 1.1.1302 INSTRUCDOR ACTIVITY 3. Center STUDENT ACTIVITY

a. Center of circles, arc, radii,and aymmetrical objects.

b. F!ne and broken (alternatinglong and ehort)

c. Add in dimensioning.

4. Extension 6. Use chalkboardas nac (weary to intenaify a. Extension of outline ' learning. b. F le and solid

c. Used Fith dimeneion lines

d. Starts 1/16" fromobject line.

5, Dimenoion line

a. Locatae dimensiona.

b. Fine and eolid lines.

c. Touchee extension lines witharrowheade.

d. Broken only for dimeneions.

(1) Usually atcenter

(2) Stagger dimensions(one above ether)

6. Leader

a. Pointe to location

b. Fine and solid witharrowhead at one end. 45

( 5 or 15 ) 4 STT-61 -2-SWIGO 1.1.1573 OUTLINE OF INSTRUCTION INSTRUCTOR ACTIVITY STUDENTACTIVITY c. Used to locate notes, specs, of sizes

7. Cutting plane

a. Indicates imaginary cut

b. Heavy and broken.

c. Alternating long and two short dashes.

d. Arrowheads at 900 on each end.

e. Shows cross-sectional areas.

8. Short break

a. Indicates section removed.

b. Heavy end irregular (freehand).

c. Small % of abject removed.

9. Long break 7. Questions to class at 3. Answer questions as random. asked by instructor. a. Indicates section removed.

b. Light ruled with fret:Laud zig zags.

c. Great % of objecl: removed.

10. Phantom or alternate position

a. Used to show secondary position

b. Medium alternating long with two short dashes. Exercise on identification of linen. 41

4 G ( 6 of 15 ) i STT-615 2- SW- IG 1.1.1:3v OUTLIVE OF INSTRUCTION INSTRUCTOR ACTIVITY STUDENT ACTIVITY C. Views (Orthographic Projection

1. Front

a. Most details

b. Length and height. -I c. Lower 16ft corner of print.

2. Top

a. Length and width

b. Above and in line with front view

3. Right side

a. Width and height

b. To the right and in line with front view. tt

4. Back and left

a. Cenerallly not needed.

b. Occupy relative positions if used.

5. Auxiliary

a. Cutting plane

(1) Shows inside 4;) (2) Shows cross section.

( 7 of 15 ) 4:3 STT-615-2SW I.G. 1.1.1 OUTLINE OF INSTRUCTION INSTRUCTOR ACTIVITY STUDENT ACTIVITY

b. Inlined plane

(1) Shows sloped surfaces 8. Show film MC.- 6797A 4. Watch film "Engineering Drawing" (2) Projected parallel to sloped surface. Orthographic Projection

D. Notes

1. Notes

a. Apply generally to object

IOW b. Tells what but not how.

c. May include sizes.

4 2. Specifications

a. Gives specifics 5. Take notes

b. Process (how or when to do).

c. Material

d. Number or amount

3. Location

a. Near view concerned (leader) C.

b. In open area

c. Title block

E. Title block

1. Lower right-hand corner

2. Name or part.

( 8 of 15 ) STT-6

OUTLINE 0? INSTRUCTION INSTRUCTOR ACTIVITY

3. thither of drawing

4. Material

5. Nuniber required.

6. Ordeenumber

7. Date

8. Originator

9. Revisions

10. Scale

F. Bills of materials

1. Type of stock

2. Shape of stock

3. Size

4. Amount (total for order).

G. Dimensioning

1. Purpose

a. Size'

b. Location

2. Types

a. Fractional

b. Decimal

c. Degrees ( 9 of 15 ) STT-615-2-SW- IG. 1.1.1

OUTLIVS 01 INSTRUCTION IhGTRUCTOR Arm VITY ELII.L.NilATIVL3TT

H. Seale (to reduce of expand for clarity)

1. Types

qe. Full (1 =I 1 )

b. 112 .3 1 (1 2)

c. 1/4 gt 1 (1 =3 4)

d. 4 TA 1

e. 2 1

2. Calculating from scale

a. Pull - no calculating

b. 1/2 1 size times 2. 6. Take notes

c. 1/4 1 size times 4

d. 4 1 size divided by 4

e. 2 1 size divided by 2

3 gxamples (drawings to object) 9. Questiong to class at 7. Answer questions as 'random asked by instructor. R. P" (0 114 1 scale 32"

b. 13" @ 1/2 3 scale 25"

c. 12" 4 =.1 scale 3"

d. 13" @ 2 ri1 scale 6-1/2"

)

( 10 of 15 ) STT-615- - SW- IX. 1.1.13,50-

OUTLINE OF INSTRUCTION INSTRUCTOR ACTIVITY smENTAcrivrry

4. Exarv1es (object todrawing).

A. 0" @ k 1 scale - 2"

b. 13" @ 1 scale 6-1/2"

c. 12" @ 4 vt 1 scale =,40"

d. 13" @ 2 tm 1 scale =g 26"

7 Tolerances

1. Allowance

a. Amount oversize

b. Amount undersize

c. Hay be fraction,decimal or degree

2. Plus, Minus, or both

J. Sets of drawlfts.

I. Master print

a. Shows entirejob

b. May be several sheets

c. Will have severalviews of elevation

d. Will have general information.

2. Assembly prints

a. Sometimes callederection print

b. Shows how to assemble

c. Same number as masterprint. ( 11 of 15 )

t)i) STT-615-2-SW I. 1.1.1 39 OUTLINE 07 INSTRUCTION INSTRUCTOR ACTIVITY STUDENT ACTIVITY

3. Subasammibly prints

a. Shows how one partjoins another

b. Same number as master print

4. Detailed prints

a. Shows enlarged nectionof an individual part.

b. Shows haw made

c. Same number as master print

d. Sectional drawings (small parts). 10. Hand out Welding symbol instruction aheet. o+. K. Welding symbola 11. Hand out Programmed Instruction Blueprint Rea( (I. Application ing, NAVSCON 064-231 A. Students will complete ProgrammedInstruction "Blueprint Reading NAVSCON 064-231, with 1007. accuracy. 12. Instruct students to 8. Complete programmed complete programmed Instr.,instruction, ask instruc- uction, assist atudenta tor for assistance when when necessary necessary.

13. Collect completed pro grammed instructiona.

B. Questions to class at random 9. Answer questions an naked by inatructor. II. Summary:

A. Purpose and makeup

1. Convey ideas

2. Copy of drawing

( 12 of 15 ) STT-615-2 I.G. 14111e/O

OUTLINE OF INSTRUCTION 13TRUCTOR ACTIVITY STUDENT ACTIVITY

3. Lines

4. Dimensions

5, Notes

B. Basic lines

I. Object

2. Hidden

3. Center

4. Extension

5. Dimension

6. Leader

7. Cutting piano

8. Short break

9. Long break

10. Phantom or alternate potation.

C. Views

1. Front

2. Top

3. Right side

4. Back and left

5. AMxiliarY 6 : ( 13 of 15 ) STT 615-2-S I.G. 1.1.1 OWLINE 0? INSTRUCTION INSTRUCTOR ACTIVITY STUDENT ACTIVITY

D. Notes andspecifications

1. Notes

2. Specifications

3. Location

E. Title block

1. Location

2. Part

3. Number of drawing

4. Material

5. Quantity

6. Order number

7. Date

8. Originator

9. Revisions

10. Scale

F. Bill of material

1. Type

2. Shape

3. Size

4. Amount (total)

( 14 of 15 ) STT-615-2-SW- I.G. 1.1.1 1-7/ OUTLINE 0? INTTRUCTION DSTRUCTOR ACTIVITY STUDENT ACTIVITY

G. Dimensioning

1. Purpose

2. Types

H. Scale

1. Types

2. Calculationg

3. Examples (drawing to object).

4. Examples (object to drawing).

I. Tolerances

1. Allowance

2. Plus, minus, or both

J. Sets of drawings.

1. Master

2. Assembly

3. Sub-assembly

4. Detail

/III. TEST

A. Written test

1. 8 of 10 questions to be answered correctly

63 ( 15 of 15 ) 11

STT-615-514-1S-1.1.1.1

...... t...._,Av

PIPPINCCULAN Lt4 / 1) < AL,NAYt ONAwN TO LIFT NANO > ' ' mAtO4tit .0f FINIsHING LOCATION Of tPKWOIID *NOLL FINISH mom Rvoil4 Lao war operoNG FLOW, 31144101. MU (ERCEPT rotmu\ 'MILO SWIM oft *AT) Ca CCM.' C// - NtirtteNCt

. OW *HAN 6...i 3PSOFICATON RETIEENct Om 21 Na7 USED 6 g a WI -p

OCHNICTING I / I 1 / ill I StrEPINGE UP* TO .ONT ,Ot To WIWI TO U L._ 1 ..] cnoCA/CO. SOC of Jam' e-../ SPICIIILATION TO *HANNOV* -Post! REFERENCE TR) 01 AMON ON WM) SCR MAASS Ato COPOSITS VOL IS LENGTH Of %IUD OS or OTSCII (Off PAS) WC. INOISUCHT3 Cf Now CLINTINVOU3 WeL03. 03 Pub-wrio via*. (0,07 Fog ricsarAscE wturAu.-)Acuta *nos) .- --, whom PITCHOfNON- RtirtnENct Loa Fra CONTINUOUS WILDS SHOW*40 RILL) LccATER

Standard Location of Information on Welding Symbols

RC ANP GAS WELCING SYNTOLS ,perst OF WELO WELD ....------GROOVE Ft MOALL FLUSH READ'ILIA ,wELO ARC v REVEL u _ J tLuT _illouND ...--% ts, \/VY1-1 K7 0 A.Rchv(ut NEAR) OTHER (OR FAR) BOTH SiDES E. OF jipINT SIDE or JOINT Of JOINT ri0,vrtt. NOTE ,....:4CLuoto ANGLE -7IZU WCLO ALL 06 \ImEllEmENT AROU % IZE 1 SIZEN,1 40'4' i ENGIN 3 Vie. AI 5 ., st ., i n \ 007 SEE \OrrSE7ir PITCH Or rLUSN-% OPENING SIZE OPENING NOTE STAGGERED INCREMENTS t TNE See Or THE JOINT TO WHICH THE ARROW POINTS Is THE ARROW (on NEAR) SIDE. 2. 603.H.3I0E5 Amos or sAMC TYPE Ant or SAME SIZE UNLESS OTHERWISE SHOWN 3 SYMEOLS APPLY BETWEEN ABRUPT CHANGES IN DIRECTION OF JOINT OA AS DIMENSIONED XCEPT wHEAE ALL AROUND SYLIROL IS USED) 4 ALL WELDS ARE CON INUOUS ANO or USER'S STANOARO PROPORTIONS. UNLESS OTHERWISE SHowN. S. TAIL OF ARROW USED POP SPECIfILATION PErEPENLE (TAIL NAT BE OMITTED WHEN REFERENCE NO7 USED) 6- DimENSIONS Or WELD SIZES. INCREMENT tENGTHs AN0 sPAG:Ncs IN INCHES

Legend for Use on Drawings Specifytng Arc and Gas Welding

1 t; SIT-615. -2-SW-IG 1.1.2

NAVAL SCHOOLS, CONSTRUCTION PORT HUENEME, CALIFORNIA 93043 SIVELWCRRER SIT SCHOOL TRIAINIGN COURSE,A15-2

C1655ific"1": Unclassified

Terminal Objective: 1.1 TnPiel Welding Electrodes, Rods and Welding Aids.

Average Time: Class: 5 periods Enabling Objectives: Upon completion of this topic the student will have: Instroct tonal Materials: I. Identified the welding consumables in the Nbbile A. Training Aids Construction Battalion Table of Allowance, Namely are welding electrodes. Gas welding ro0s, B. Publications wearfacing electrodes and welding aids. Stated their primary use ant: secondary use when appli- 1. Texts cable without error.

As Operator's Manual WeldingTheory And Application Criterion Test: 1149-217, pages 69-74 The student will identify the welding 'consumables in the Mobile Construction Battalion Table of b. The Welding Materiala Manual Navfac P-413 Allowance, namely arc welding electrodes, gas welding rods, wearfacing electrodes, and welding aids. e. Welding Encyclopedia16th edition State their prhnary use and secondary use when applicable without error. 7, References None

Homework: V. Fivirment end 14Rterin1n Reading Assignment: 1 MAion. Pqnipment None 1. Operators Manual Welding Theory and application, Toola! WOW TM9-217 Chapter 2, pages 5-12 STT-615-2-SW-10 1.1.2 45/-- 3. Materials:

a. Gas welding rode

b. Arc welding rode

e. Wearfacing rode

d. Holding and heat-resisting compound

e. Surface hardening-case compound

f. Helicular Metal o. InstructorPrepared Materials: (Local) None

( 2 of 26 ) ic_Il2 STT-615-2 SLIUSSUMAIMUSI isL,..'Inktmak.Kaym amumulx

I. Introduce self and topic. I. Introduction to the Lesson

A. Establish contact.

I. Names

Z. Topic: Welding Electrodes, Rods and Welding Aids. Motivate student. B. Establish readiness 2.

1. Purpose

2. Assignment

C. Establish effect 3. Bring out need and value material being presented.

1- Value

A. rASS course.

b. Perform better on the lob.

C. Get advanced.

d. Be a better cteelworker

0. Overview: . State learning obiec- tives. 1. Welding Consumables

a. State information a. Identification and materials nifcessary to gu!de student. b. Primary use

e. Secondary use

a. Characteristics

k 3 of 26 ) STT-615-2-Sh IG. 1.1.2

OUTLINE OF INSTRUCTION INSTRUCPOR ACTIVITY STUDENT ACTIVITY

II. PRESENTATION

A. Welding Consumables:

Note: Use Section 1 of the "Welding MaterialsManual" in 1. Take notes the instruction of this topic.

1. Arc welding electrodes

a. AWS E6011 2. Student exam T11- (1) Primary use 5. Pass out semplcs of E6011 Electrode electrode (a) Mild steel 6. Questions te students (b) Galvanized steel radum te check comp- rehension. (2) Secondary use

(a) Cutting rod

(b) Buildup prior to wearfaeing.

(3) Characteristics

(a) Deep penetration

(b) Light slag

(e) Fast freezing deposit

(d) Tensile strength 62000 to 72000 PSI.

( 4 ef 26 ) STT-615-2-SW-IG. 1.1.2

INSTRUCTOR At.,fIVITY STUDENT ACTIVITY ouTure 0? INSTRUCTION 7. Pass out samplesof 3. Student exam E6012 b. AWS E6012 E6012 Electrode Electrode

(1) Primary use

(a) Mild steel

(b) Rusty steel

(d) Thin sections

(2) Secondary use

(a) Build up prior towearfacing

(3) Characteristics

(a) Shallow penetration

(b) Can use high amperage.

(d) Vertical downwelding

(e) Tensile strength67,000 to 80,000 PSI. E7018 8. Pass out samplesof 4. Student exam c. AWS E7018 E7018 Electrode electrode

(1) Primary use steel (a) For high qualityX-ray welds on mild

(b) Low alloystructural steels

1. Cor-Ten

2. Mayari R

3 Lukens 45 and 50 of 26 ) 1.. ( 5 1.-- I k) STT-615-2SW-IG .1.2 4ir OUTLINE 0? INSTRUCTION INSTRUCTOR ACTIVITY STUDENT ACTIVITY

4. Yoloy

(2) Secondary use

(a) Build up prior to wearfacing

3. Characteristics

a. Soft quiet arc

b. Low spatter

c. Tensile strength70.000 to 78,000 PSI. 9. P038 out samples of AWS 5.Student exam E11018 d. AWS E11018 E11018 Electrode Electrode

(1) Primary use

(a) For high quality X-raywelds on low alloy highstrength steels.

1. T-1

2. Hy 80

3. Hy 90

4. Hy 100

5. SSS 100

6. Jolloy 90

7. Jolloy 100

(2) Secondary use

(a) Build up prior to wearfacing

( 6 of 26) STT-615-2-SW- IG 1.1 2

INSTRUCTOR ACTIVITY STUDENT ACTIVrTY OUTLINE 0? INSTRUCTION

(3) Chaxacteristics

(a) Fast, efficientmetal transfer. properties (b) Excellenttensile and impact 110.000 to 114,000PSI. (c) Tensile strength 10. Pass out sampleof 6. Student exam welding e. AWS/ASTHE70 S-3 (M1G) MIG vielding wire wire

(1) Primary use

(a) M1G welding low tomedium carbon steel.

(2) Secondary use

(a) Build up prior towearfacing

(3) Characteristics

(a) Requirements

1. Work must beclean

2. MUst haveclean, dry shielding gas.

3. Wire must beclean and dry

4. Tensilestrength 78,000 PSI B-4043 11. Pass out samplesof I. Student exam arc-flux coated f. Aluminumelectrode (E4043) E-4043 Electrode electrode

(1) Primary use plate, (a) Metal arc weldingof weldable extruded, sheet, and sand anddie-cast aluminum.

( 7 of 26 ) STT-615-2SW-TG.1.1.2

1NEMIC1'OR ACTIVITY STUDENT ACTIVITY OUTIAWS 0? IF3TRU1'ON

(2) Retendery olse

ft,r% (n) gen 1,43 ttse*A with tr,01, Tio weiti w14a1ile grAesof nlsymiwwin,

tVf ellaretekerielt lea (a) Mint t 11

Teoetie qktontab 21000rni 17, rflan flog enmple of MOO. Stndent NIG (PI116) Alnkinnm MO 01,1141111m weidilen Vire. Ainminnm welding wire

(I) PtImmtv noe

Ain.anorm bindinp mnIft

()) gprovo4nry mqo

1016,10(11,10A6, ($11 Vnt woldinp 11140%14 VISA.

Clit ItO npriiO4 with oso, totph * TIO,

11) Iiisitneloktott len tA) Pvptirslm010

Vot14 triwei110 1 lit

2 Mot hAvec1pon, 4.1 ohlolAtop pAa

lu.1. dtv ). 144,e ..,1,411.0 rIOOVI VonrIlo folvoopth 40100rot

3, Vit 01001,,71,0on rnI

t STT-615-2-SW- IC Jj.l.2

INSTRUCTOR ACTIVITY STUDENT ACTIVITY OUTLINE OF INSTRUCTION 13. Pass out sample of J9. Student exam at E-312.11 and tool steels(AUT1 E312-16) b. High alloy E-112-11 electrode I electrode

(1) Primary use steels (a) Medium, highcarbon, alloy and tool

(b) Stainless steels

(cl Manganese steele

(2) Secondary use

(a) All steel-beaealloys except cast iron.

(h) Build up prior towearfacing

(3) Characteristics via torch. (a) Dare rod ean beapplied with AAA Or

(b) Tensile strength120,000 rsI. 14. PARA Mitt simpleof 10. Student exam, nickel I. Cast iton-are(nickel boos) nickel hasp electrode bane electrode

(1) Primary use

(a) Toin cant ironoectiono.

(h) Where highmachinenhlilitv is Isquiled

()) SAcOutiAry URA

(A) For weldingdiaimiler mAiRIR monol, ateitIlson (b) CAil he used towid And retwet allevp.

(e) Van he uAPta. with TIO

( of 26 ) t b STT-616-2-SW-I4 1.1.2

P".1110UPOR ACTIVITY STUDENT ACTIVITY OUTLINE 0?InTRUCTION

(3) Characteristics

(a) Highly ductile andmachinable.

(b) Excellent forout-of-position work.

(d) Tensile strength50,000 rsi 15. Pass out sample of 11. Student exam nickel- j. Cast iron-arc(nickel-iron base) nickel-iron base elec iron base electrode trode (1) Primary use

(a) Repair all cast iron(heavy and restrained)

liquid (b) Use where 4eld issubject to air, gas or pressure.

(2) Secondary use

(a) Joining cast iron tosteel

th) Build up prior toveartacirtg on cast iron

(11 Characteristics

(a) Weld metal is nothot short

(h) Tensile strength55,000 - f)),000 l*S1 Bra- 16. Pass out qample ofArc.1 12. Student exam Arc k. Arc brt.2in9 Brazing Electrode 2ing Electrode.

(1) Primary uNe and (a) High strength joints oncast iton, stool copper alloys.

s:t ( 10 ot 26) STT-615-2-814 IG. 1.1.2

INSTRUCTOR ACTIVITY STUDENT ACTIVITY OUTLINE 0? INSTRUCTION

(2) Secondary use nickel alloys. (a) Joiningstainless, nickel and

(b) Overlay forfrictional wear.

(3) Cbaracteristics

Crack resistant

(b) Rapid depositionrate to 230 BUN. (c) Hardness: 130BUN - Work hardens

(d) Tensile strength:90.000 PSI Elec- 7. Pass out sampleof 13. Exam Chamfering 1. Chamferingrod chamfering electrode trade.

(1) Primmry use

(a) Chamfering

(b) Grooving

(2) Secondary use

(a) Piercing

(b) Heating

(d) Sear oil-soakedcast iron

(I) Characteristics work (a) Rod must be keptin contact with

( 11 of 26) STT-61 2-SW- IG 1.1.2

DSTRUCTOR ACTIVITY STUDENT ACTIVITY OUTLINE OFINSTRUCTION 18. Pass out sample of 14. Exam. Carbon electrodt m. Carbonelectrodes carbon electrode

(I) Primary use

(a) Carbon arc forbrazing

(b) Heating

(2) Secondary use

(a) Plug for protectingthreads

(b) Case hardening

(3) Characteristics carbon diox- (a) Rod produces acarbon monoxide and protection. ide giving theweld metal some rod 19. Pass out sampleof ga 15. Exam. Gas welding 2. Cas weldingrods welding rod

a. Bare mildsteel rod

(1) Primary use TIG) (a) Low and mediumcarbon steel (ter(11 or

(2) Secondary use electrode (a) For fast build upfeed this rod into arc stremm stand (b) Feed into arc streamof wearfacing rod to better impact iron or stain- (c) Feed ontokerfwhen cutting cast less with torch ( 12 of 26 ) STT-615-2-SW-IC 1.1.2 c1.6

INSTRUCTOR ACTIVITY STUDENT ACTIVITY OUTLINE 0?INSTRUCTION

(3) Characteristics

(a) Tripledeoxidized Acetylene gas. (b) May be usedwith Mapp or

strength 62,000PSI (c) Tensile rod 20. Pass outsample of 16. Exam. Cast iron ir b. Cast ironrod (flux-coated) (flux coated) cast rod. (1) Primary use

iron wheredeposit must have same (a) For gray cast Exhause manifol properties of basemetal. Example:

(2) Secondary use it will make a (a) If no wearfacingrod is availahle hard deposit ifapplied with arc.

(3) Characteristics and heat. (a) Resistant tobending, corrosion 4 (b) Color matchingto cast iron,

(c) Machinable(cool slowly). 14000 to 1600°F (d) Bondingtemperature cooled) (e) Hardness:200 BUN (slow PSI (f) Tensilestrength: 4',000

9,2 ( 13 of 26 ) STT-615-1-SW-IG 1.1.2 INSTaUCTOR ACTIVITY STUDENT ACTIVITY OUTLINE OFINSTRUCTION 17. Exam. Generalbrazing 21. Pass out sampleof (flux coated) rod c. Generalbrazing rods (flux coated) general brazing rod. (1).Pr1mary use

(a) Steel

(b) Cast iron

(d) Bronze

(e) Dissimilarmetal combination

(2) Secondary use law) (a) Some nickelalloys (keep heat r"- (b) Frictional wearoverlay

(3) Chara4eristics

(a) Low fuming

(b) Does not requirefusion

(c) Tensilestrength: 60,000PSI 18. Exam. Highstrength 22. Pass outsample of brazing rods (fluxcoated) brazing rod. d. High strength high strengthbrazing rod. (1) Primary use

(a) Carbon steels

(b) Alloy steels

( 14 of 26 ) STT-615-2-SW-IG1.1.2 INSTRUCTOR ACTIVITY STUDENT ACTIVITY OUTLINE 0? INSTRUCTION

(2) Secondary use

(a) Brass

(b) Bronze

(d) Frictional wearoverlay

(3) Characteristics 1400 -1600°F. (a) Bonding temperature

(b) Bead forming orthin flowing PSI (c) Tensilestrength: 100,000 of 23. Show contentsof silo19. Observe contents flux) silver brazing kits. e. Silverbrazing kits (with brazing kits.

(1) Primary use except the (a) All ferrous andnon-ferrous metals white metals.Example:

1 Instrumeqtation

2 Tubing

3 Controls

4 Switches

5Food vessels

6 Laboratoryapparatus

7Hospital equipment

( 15 of 26) G STT 615- -SW-: IG 1.1.2

INBTRUCTOR ACTIVITY STUDENT ACTIVITY OUTLINE 07 INSTRUCTION

(2) Secondary use espiec- (a) Large work wherealignment is to:portant, ially on brasses, andclose-fitting joints can b maintained.

(3) Characteristice

(a) Thin flowing

(b) Temperature:1145°-1205° P

(c) Tensile strength: 85,000PSI 4. Pass out sample of95/ 20. Exam. Sample of 95/5 9515) f. Solder (tin-antimony solder, solder.

(1) Primary use

(a) For joints requiringelevated temperature

(b) Re2tigeration joints

(2) Secondary use

(a) Food containers (bestsolder is 967. tin - 47. silver)

(3) Characteristics

(a) Do not use on aluminum,zinc or zinc-coated metals (galvanizediron).

(b) Melting temperature(solidus 62° F) Flow temperature (liquidus464 F)

( 16 of 26 ) STT-615-2-SW- 1G 1.1.2

METRUCTOR AcTurry STUDENT ACTIVITY OUTLINE 0? INSTRUCTION

5. Pass out sample of 50/ 21. Exam. Sample of 50/ g. Solder(tin-lead'50/50) 50 solder. 50 solder. --a) Primary use

(a) Radiator cores

(b) Heating units

(2) Secondary uses

(a) Electrical connections

(b) Wiping and sc.atingsolder

(3) Characteristics

(a) Relatively narrow pasty range

(b) Good wetting properties

(d) Flow temperature(liquidus 4210 0 22. EXAM. Sample of 40/60 40/60 - acid core) 26. Pass out sample of 40 h. Solder (tin-lead 60 solder solder. (1) Primary use

(a) Sheetmetal wrk flux needed) (b) General small metalwrk (no extra

(2) Secondary uses

(a) Can be used on similarwork as 50/50 but is mor econiamical.

( 17 ef 26 ) 9J SIT-615-2-SW- IG 1.14 b/ INSTRUCTOR ACTIVITY STUDENT ACTIVITY OUTLINE 0? INSTRUCTION

(3) Characteristics (solidus le F) (a) Melting temperature F) Plow temperature(liquidus 455 23. Exmm. Sample of60/4C, 27. Pass outsample of 60/ core) solder i. Solder (tinlead 60/40 rosin 40 solder

(I) Primary use

(a) Electrical work

(2) Secondary use

(a) Sheetmetal(Use an acid flux o (3) Characteristics

(a) Low temperature Wang temperature(Solidus 361° F)

(Liquidus 374° F) Flow temperature

(b)Narrowpasty range

(c) Flux haslow-corrosive nature 24. Exam. Sample of96/4 28. Pass out sampleof 96/4) solbr. J Solder (tin-silver 9614 solder

(1) Primary use highest electricalconduc- (a)Electrical work (has tivity of all thesoldera.)

(b) Food and beverageequipment

(d) Joining disimiliarmetals

( 18 of 26 ) STT -615-2-SW IG. 1.1.2 ovnate 07 INSTRUCTION INSTRUCTOR ACTIVITY STUDENT ACTIVITY

(2) Secondary use

(a) Refrigeration

(b) May be used in place of all the other solders but is the most expensive.

(3) Characteristics

(a) Cadmium and lead-free

(b) Retains brightfinish

(d) High strength

(e) Good corrosion resistance

(0 Temperature (solidus and liquidus4300 F)

(g) Tensile strength 15,000 PSI

(h) Shear strength 11,200 PSI

3. Wearfacing electrodes 29. Pass out sample of ?50 Exam. Sample of manganese electrode manganese electrode a. Manganeseelectrodes

(1) Primary use

(a) Severe impact and compression

(b) Building up andjoinireanganese.

( 19 of 26 ) 1u3 SIT-615-2-SW- IC 1.1.2

I1ZTRUCTOR ACTIVITY STUDENTACTIVITP OUTLINE 0? INSTRUCTION

(2) Secondary use

(a) joining steel tosteel

(b) Joining cast iron wearfacing rod, Lae thi (c) When out of interWediate Yod.

(3) Mearacteristics A

(a) Rardness: As depositedRB 80-90 Work hardened RC 45-50

(b) Tensile strength:115,000 PSI 30. Pass out sampleoi-N- 26. Exam. Sample of build b. Build up electrde build.up electrode up electrode

(1) Primary use

(a) Build up of wornsteel parts

(2) Secondary use

(a) Joining of steel

(3) Characteristics pounding. (a) Resistant to heavyshock loading and

(b) Resistant todeformation. 4_ (c) Machinable

(d) Rardnens: RC 30

( 20 of 26 ) STT-615-2-SW- IC 1.1.2

INSTRUCTOR ACTIVITY STUDENTACTIVIT13 OUTLINE CI? INSTRUCTION

12)_Secondary_ use

(a) Joining steel tosteel

(b) Joining,cast iron wearfacing rod, use thi (c) When out of intermediate rod.,

(3) Characteristics

(a) Hardness: As depositedRB 80-90 Work hardened RC 45-50

(b) Tensilestrength: 115,000 PSI build 30. Pass out sample of 26. Exam. Sample of b. Build,up electrode build up electrode up electrode

(1) Primary use

(a) Build up of wornsteel parts

(2) Secondary use

(a)Joining'of eteel

(3) Characteristics

(a) Resistant to hhavyshock loading and pounding.

(b) Resistant todeformation.

( 20 of.26 ) ' STT-615-2-SW- IC 12,1t. OUTLINE 0? INSTRUCTION INSTRUCTOR ACTIVITY STUDENTAaranY

(2) Characteristics

(a) Will not increase dimension of part.

(b) Ftee of poisonious compounds such as cyanide.

34. Pass out sample of b. HoldIng and heat-resisting compound 30. Exam. Sample of hold- holding and heat-resis ing and heat-resistir (1) Primary use ting compound compound,

(a) Bolding irregular shapes or parts during welding brazing of soldering.

(b) Protectpthreads and flammable materials from heat o flame arc or spatter.

(2) Charact sties

(a) Can be used over many times by mixing with a small amount of water.

(b) Easily removed from holes or threads

(c) Will not melt, burn, crack, expand or contract when heated. 31. Examine contents of c. Molecular metal 36. Show contents of molecular metal kit. molecular metal kit. (1) Primary use

(a) Leaking pipes, tanks, radiators, refrigeration, sumps, gas mains, pumps, valves, etc.

(2) Secondary use

(a) Joining metals to glass, wood, concrete, stone and other substrates.

--"( 22 of 26 ) S7T-615-2-SW- .2

ouTun 0?IN5TR5CTION INSTRUCTOR ACTIVITY STUDENT ACTIVITY 4,

(3) Characteristics

(a) Grade #1: Aspatula grade used for emergency repairs. Grade #2: Abrushable, fluid material used for coating. Grade #3: Aspatula grade paste used for permanent repairs

III. Application

A. Questions and Discussions:

1. Name five of the seven electrodes and rods for welding36. Ask questions to chec32. Answer questions. of steel students comprehensio

ANS: 6011, 6012, 7018, 11018, 312-16 Stainless, E-7063 MIG. triple deoxidized rod.

H 2. ow many brazing rods are there in the T.O.A. and whic one is the lowest temperature?

ANS: Four; silver brazing, general brazing, hi-strength

, brazing and arc brazing. Silver brazing is the lowest temperature.

3. What should be used to seal a leak in a gas tank?

ANS; Molicular metal

4. Name the wearfacing electrodes in the T.O.A.

ANS: Build up, manganese, intermediate wearfacing and high abrasion resistant.

5. Which solder should be used on food containers

ANS: 96/4 tin-silver

( 23 of 26 ) 11 2 1 1 i STT-615-2-SW- IG

OUTLINE 0? INSTRUCTION INSTRUCDOR ACTIVITY STUDENT ACTIVITY

6. What should be used to harden thethreads on a bolt?

ANS: Csse4ardening compound

7. What welding uaterialshould be used to join am extension on a drill bit?

ANS: Hi-strength brazing rod

8. What material should be used toweld a manifold?

ANS: Cast iron gas (flux-coated)

9. What steel welding rod can beused,for cutting?

ANS: 6011

10. What kind of flux core soldershould be used on electrical work?

ANS: Rosin core.

IV.SUMNARY

A. Welding Consumables

1. Arc welding electrodes

a. Steel

(1) 6011

(2) 6012

(3) 7018

(4) 11018

(5) 870S3 (NIG)

(6) 312-16 (Stainless) ( 24 of 26 ) 113 STT-615-2-SW- IG 1.1.2

OUTLINE 0? IESTRUMION INSTRUCTOR ACTIVITY STUDENTACTIVItidC( b. Aluminum

(1) 4043 (Stick)

(2) 5356 (HIC)

c. Cast iron

(1) Nickel base

(2) Nickel-iron base

d. Brazing

(1) Arc brazing

a. Chamfering

(1) Chmnfar rod

f. Carbon

(1) Carbon electrode

2. Gas welding rods

a. Mild steel

(1) Triple deoxidized rod

b. Cast iron

(1) Cast iron (flux-coated)

c. Brazing

(1) General brazing

(2) High-strength brazing

(3) Silver brazing ( 25 of 26) 113 STT-615-2-SW IG

INSTRUCTOR ACTIVITY STUDENT ACTIVIN/ OUTLINE OF INSTRUCTION

d. Solder

(1) Tin - Antimony 95/5

(2) Tin - Lead 50/50

(3) Tin - Lead 40/60 - Acid core

(4) Tin - Lead 60140 - RosinCore(

(5) Tin - Silver 96/4

3. Wearfacing electrodes

a. Manganese

b. Build up

c. Intermediatewearfacing

d. High abrasion wearfacing

4. Welding aids 0

a. Case-hardeningcompound

b. Holding and heat-resistingcompound

c. Molecularmetal

V. TEST: None 37. Post assignment on 33. Copy assignment VI. ASSIGNMENT: chalkboard A. Operator'sManual Welding Theory and Application", TM9-237, Chapter 2, pages 5 through 12. 113

( 26 of 26 ) 11 _ STT-615-2..$14- IC 1.2.1 76

NAVAL SCROOLEAi2ONSTRUCTION PORT HUENEME, CALIFORNIA 93043 STEELWORKER SIT SCHOOL TRAINING COURSE 615-2

Classification: Unclassified

Terminal Objective: 1.2. Topic:Annealing, Hardening and Tempering Upon ccupletion of this topic Average Time:Class: 3 perinde Enabling Objective: Pract: 2 periods the atudent will have. 1. Defined the term anneal and list four purposes of Instructional Materials: the process. A. Training Aids:None 2. Defined hardening in terms of work, flame and case 3. PUblicatiens: hardening. 3. Stated the definition of temperin andit's pur- 1. Text pose. All will be without error. a. lOperatorts ManualWelding Theory and Application" TM9-237 pages 14-18. Criterion Test: The student will define the termannea4 and list b. Weiding Encyclopedia" 16thedition pages 11-15, 11-16. four purposes of the process. Define h dening in terms of work, flame and casehandening State the 2. Reference: None definition of tempering and it's purpos All will be without error. C. Equipeent and Materials: Homework: None 1. Oxy-liapp Welding Outfit

Material (Local); None D. Instructor Preparirad Homework: STT-615-2-Sw 1G- 1.21 IttlaSALIMISSILI! MU cm lummAcTurrt - Introduce self and topic I. Introduction to the Lesson . .1 A.Establish contact.

2. Topic:Annealing,Hardening and Tempering

B. Establish readiness . Motivate student.

1. Purpose

2. Assignment

C. Establish effect 3. Bring out need and value of material being presented. I. Value

a. Pass course.

b. Perform better on the job.

c. Get advanced.

d. Be a,better steelworker

D. Overview: ". State learning obiec- tives. 1. Annealing a. State information 2. Hardening and materials necessary to guide student. 3. Tempering

12i 12) ( 2 of 10 STT-615-2-SW- IG. 1.2.1

INSTRUCTOR ACTIVITY STUDENT'ACTIVITY/2"-- OUTLINE 0? INSTRUCTION 5. Draw diagrams on chalk1. Take notes II. PRESENTATION board of different she pets of-castings-and-ex-2._Ask_questinns A. Amnealing plain how stress forms due to different cooli . 1.Remove-streSses rates. a. Castings 6. Draw on chalkboatd Ma (1) Castings with original residual stresses. grams of welded castin and how contractional (a) Castings with thick and thin sections stress forms.

(2) Previously welded castings - prior to rewelding. 7. Urse slide on stress strainoliagram to illustrate strain relatio b. Weldments %ships. (1) Enabling greater load before deforming or cracki 6. Draw diagram on chalkboard on how stress NDTE: Make use of the stress-strain diagram toillustrate combtned residual and welding stressess. goes to top of weld an wten machined off will cause distortion unles c. Machining weldments stress is relieved. (1) Weldments can distort while being machinedunless first stress relieved after welding.

d. Procedure

(1).Uniform heating

(2) Allow one hour soaking time for each one inch o thickness.

2. Induce softness

a. Machinablility

(1) Cast iron (welding forms iron carbides).

(2) Medium and high-carbon steel

( 3 of 10 ) (3 ) Tool steel 124 123 STT-615-2-.SW- N.T1.).2h2 ( IhSTRUCTOR ACTIVITY STUDENT ACTIVITY4-'' OUTLINE 0? IhSTRUMION

b. Remove work hardening

(1) Parts subject to stress andvibration.

Example: Brake lines and copper fuellines work harden

at bends. nr.

3. Alters ductility

a. Annealing returnsductile requirements.

(1) Increases ability to be drawnOr stretched.

4. Alters toughness_

a. Enables weldments towithstand greater bhock.

(1) Will resist fracture after permanentdeformation has begun.

5. Alters electrical conductivity

a. Work-hardened copper oraluminum offers greater elec- tical resistance.

6. Refines crystalline sEructures

a. Refining fromcoarse-grain structure improves physical properties.

7. Removes gases

a. Annealing permitsslow gas release fram castings.

8. Changes microstructure

a. Slow coolingproduces spheroidized carbide.

(.4 of 10 ) STT-615-2-SW

INSTRUCTOR ACIIVITY STUDENT OUTLINE OF INSTRUCTION ADMIT(

B. ESIdening

1. Work hardening

a. Methods

(1)-Peening-,,hincering 9. Bend wire to illustrat (2) Bending how it work hardens (a) Example: Bend a copper or steelwire until it work hardens.

Note; The wire will become hot atthe point of bend indicating the friction of the grainsagainst each other.

Use the stress-strain diagram toshow area of work hardening:Which causes increasedhardness and strength.

(3) Drawing

(a) Example: Reducing wird rod ortubing size by drawing through a die.

(4) Cold rolling

(a) Sheet, plate, stc.

( 5 of 10 ) STT-615-2-SW- IG. 1.2.1

INSTRUCTOR ACTIVITY STUDENT OUTLINZ 0? INSTRUCTION ACI2

2. Flame hardening

4. Definition:Heating the surface of a ferrous material to a high temperaturefollowed by a rapid quench.

b. Advantages

(1) Hardness limited to a thin casing.

(a) Core retains ductility, toughness and resistant to impact.

(2) Machined surface retains dimension.

(3) Large objects can be flame-hardened.

(4) Flame hardened areas nay be made as mmall,or as large,as desired.

(5) Adaptable to a variety of shapes and sizes

(6) Limited time required.

(7) Almost entirely free of distortion.

c. Quenching solutions

(1) Water

(2) Brine

(3) Oil

(4) Air 130

1.2) ( 6 of 10 ) STT-615-2-SW. IC 1.2 1

arum INSTRUC'TIQN trr INSTRUCTOR ACTIVITY STUDENT ACTIVI11Q Y

3. Case hsrdening'(wth torch)

a.Definition: Carburizing and subsequent hardening by suitable hsat treatment all or part of the surface por- ' tions of an iron..barealloy.

b. Advantages

(1) Hardness limited to a thin casing

(a) Core retains ductility, toughness and resistance to impact.

(2) Machined surface retains dimension

(31)Mildsteel may be hardened

(4) Limited tine required

(5) Selective case lardening

(6) Case hardening material is safe to use because it is cyniLi free.

c. Quenching solutions

(1) Clean cold water

d. Examples of items to case hdrden

(1) Chisels and punches. (use mild steel)

(2) Threads on bolts, nuts, etc.

(3) Pins

13,1)

( 7 of 10 ) TT-615-2-SW- IG." "-- INSTRUCTOR ACTIVITY STUDENT ACTIVI OUTLINE 0? INSTRUCTION

C. Tempering ( Drawing )

1. Definition: The reheating ofiron-base alloys after hardening to some temperature below the critical rangefollowe by any desired rate of cooling.

2. Advantages NE- a. Imparts toughness tothe steel.

Note: In the hardened condition steels tend tobe brittle and have law resistance to shock, but if reheated (tempered) they are softened somewhat and toughened. The higher the tempering temperature, the greaterthe toughness and the lower the hardness

III. APPLICATION 10. Ask questions 3. Answer questions A. Questions and Discussion

1. Name four purposes for annealing.

ANS: a. Remove stresses

b. Induce softness

c. Alter ductility

d. Alter toughness

e. Alter alctricalconductivity

f. Refine ciystalline structure //1 g. Remove gases framcastings

h. Change microstructure

( 8 of 10 ) STT-615-2SW- IC 112.1 OUI/INE OP :NSTRUCTION INSTRUCTOR ACTIVITi STUDENTACTIVITY7

2. What are the ;pee ways to harden al in the field?

ANS: a. Work hardening

b. Flame hardening

c. Case hardening.(with hardeingcompound)

3. Umpering impacts what property to hardened steel? .

ANS:Toughness

4. flaw can metal be hardened without hgat?

ANS: a. Wafk hardened

(1) Peening - hammering

(2) Pending

(3) Drawing

(4) Cold-rolling

5. What is the main advantage of case hardening?

ANS:The surface obtains a high hardness but the core retain ductility, toughness and resistance to impact.

IV. SUMMARY

A. Annealing

1. Ranove stresses

2. Induce softness

3. Alter toughness

( 9 of 10 ) 13G 133 e9 INSTRUCTOR ACTIVITY STUDENT ACTIVI OUTLINE 0? DABTRUCTION

4. Alter ductilitY

5. Alter electtical conductivity

6. Refine crystalline structure

7. Remove gases

8.*Change macrostructure

B. Hardening

1.. Work hardening

2. Flame hardening

3. Case hardening

C. Tempering

1. Toughness

V. TEST 11. In shop demonstrate annealing, hardening, A. Annealing and tempering.

B. Hardening and Tempering 12. Supervise student pra - 4. Practice under instr- tice and test. uctors supervision. C. Case Hardening 5. Take test VI. ASSIGNMENT: None STT -615 -2 -SW - IG. 2.1.1 80

NAVAL.SCH,XIS, CONSTRUCTION -PORT HUENEXE,-CALIFORNIA 93043 STEELWORKER STT SCHOOL TRAINING COURSE 615-2 GAS CUTTING/WELDING II

Classifixstion: Unclassified Terminal Cbjective: 2.1 Topic: Gas Welding Pipe, Vertical Position Enabling Objective: Upon completion ofhis topic A-rage Time: Class: 1 period the student will be able to: Ptact: 5 periods A. Perform correct techniques'for weld g pipe Instructional Materials: as to gage setting, type of flame, p4 of trav419, A. Text: manipulation of torch and correct wediitg rod. Per- -form-specilie°ree=of-cleaning-o 1. Steelworker 454'2, NAVPERS-10653-E.,Chapter 6. cotPletedwe1d B. Demonstrate proper pipe prepare on bi%beveling, B. References: cleaning, aligning, spacing and tack weld*, prior to welding. 1. American Welding Society, standard for qualification C. Gas weld with a 1/8" triple deoxidized rod a \ of welding procedures and welders for piping and V-butt joint in the vertical position, (fixed) a tubing AU'S D-10, 9-72. 2" mild steel pipe. In doing this he will apply all pertinent safety precations as stipulated in IS- 2. Operator's Mhnual Welding Theory and Application 1.1.1.1 and identify and apply the correct procedure TH9-237. and methods of correcting faults. Evaluation will be based on the Qualification Test for AR-3 level, 3. The Welding Encyclopedia, 16th Edition . of American Welding Society, standard for Qualifi- cation of Welding Procedures and Welders for Piping C. Instructional Material and Tubing, AWS D10. 9-72 condensed in standard STT-FT-1 attached to this unit. 1. Safety for welders (informationsheet) IS-1.1.1,-1 Criterion Test: 2. Samples of pipes beveled, spaced and tacked. Evaluation will be based on the students abiIi*v 3. Samples of pipes showing bead placement. to pass the visual andguided-bend test as stipulated above. 4. X-Rays showing defects in welds and good welds. Homework: None

1.1 0 13 (,) ( 1 of 5 ) STT-615-2-SW- IC. 2.1.1

D.Instructor Aids: Noma

E. Tools

1. Chipping hammer

2. Pliers, 8"

3. Gloves

4. Spark lighter

5, Tip cleaner

F. Equipment:

1. Oxy-Happ Cutting and Welding Unit

2. Bench grinder

3. Pipe beveling machine

G. Materials:

1. Paper, lined scratch pad.

2. Pencils

3. Pipe, mild steel 2"

4. Oxygen

5. Mapp Gas

6. Triple Deoxidized Rod (steel gasrod)

1.1

14i ( 2 of 5 ) STT-615-2-SW 1G- 2.1.1 g1;1

OVniple Of INSTROCTIO, INSTRUCTOR =IVRY 1 3TUDINT 4CTIVITI

Introduction to the Lesson 1. Introduce self and topic.

-EstablLsh contact.

1. Nsmes

2. Topic: Pipe Welding (Vertical)

B. Establish readiness 2. Motivate student.

1. Purpose

2. Assignment

C. Establish effect 3. Bring out need and value of material being presented. " Value

a. Pass courses

r,1 b. Perform better on the job.

C. Get,advanced.

d. Be a better steelworker

D. Overview: A. State learning objectives. 1. Gas weld a V-butt joint in the vertical fixed position (Practice) a. State information and materials necessary to guide student.

( 3 of 5 ) 1 .4 ti STT-615-2-SW- IC. 2.1.1 OUTLIFE 0? :NSTRUCTION INSTRUCTOR ACTIVITY STUDENT AcrIvrrx

I/. PRESRMATION.

A. Techniques of Pipe Welding (vertical fixed position)

1. Adjust gages for beveling pipe

a. Happ

b. Oxygen

(1) Determined by

(a) Size and thickness of pipe.

2. Bevel pipe

3. Remove scale

4. Align pipe

a. Spacing

5. Tack Pipe

a. Four tacks

(1) Don't stop or start a weld on tacks

6. Position pipe in vertical fixed posiiton

7. Complete other side of pipe 5. Demonstrate welding 1. Practice gas welding a 2" pipe in the ver- a 2" vertical fixed 8. Do not stir puddle with rod tical fixed position. pipe.

9. Do not agitate puddle with flame

10. Clean scale from weld 1 C3 jOUTLIn 0.? INSTRUCTION INSTRUCTOR ACTIVITY

B. Faults in gas welding 6. Explain reasons for faults in welding. 1. Porosity

2. Undercut

3. Overlap

4. Poor fusion

5. Incomplete penetration

6. Warpage

III. APPLICATION:

A. Insert questions to check students conprehension.

IV. SUMARY:

A. Single V-butt vertical fixed pipe weld.

V. TEST: None

1 4 ( 5 of 5 ) STT-615-2-SW- IG 2.1.2 7r-

NAVAL SCHOOLS, CONSTRUCTION PORT HUENEME, CALIFORNIA 93043 STEELWORKER STT SCHOOL TRAINING COURSE 615-2 GAS CUTTINGNELDING II

Classification: Unclassified

Topic:Practical Evaluation in Gas Welding Pipe,Vertical Teminal Cbjective: 2.1 Fixed Position. Average Time: Class: 0 periods Enabling Objective: Upon completion of this topic Pract: 2 periods the student will be able to: Instructional nacerials: A. Perform correct techniques 'for welding pipe as to gage setting, type of flame, speed of travel, A. Text: None manipulation of torch and correct welding rod. Per- form specified degree of cleaning of completed weld. B. References: None B. Demonstrate proper pipe preparation by beveling, C. Tools: cleaning, aligning, spacing and torchwelding, prior to welding. 1. Chipping hammer C. Gas weld with a 1/8" triple deoxidizedroda V- butt joint in the vertical fixed position a 2" 2. Plers 8" mdld steel pipe. In doing this he will apply all pertinent safety precatuions as stipulated in IS- 3. Gloves 1.1.1.1 and identify and apply the correct procedure and methods of correcting faults. Evaluationwill 4. Spark lighter be based on the Qualification Test for AR-3 level of American Welding Society standard for Qualifi- 5. Tip clelners cation of Welding procedures and Welders for Piping and Tubing, AWS D10. 9-72 condensed in standard D. Equipment: STT-FT-1 attached to this unit. The final weld must 1. Oxy-Mapp cutting & welding unit meet dhe minimum requirements established for gas welding pipe in the vertical fixed non-restricted pcsition 2. Bench grinder

3. Pipe beveling machine Criterion Test: Evaluation will be based on the students ability to pass the visual and guided-bend test as stipulated above. Homework: None 1 4 ( 1 of 4 ) 1 '6 ti STT-615 -2SW - 1G. 2.1.27'

E. Materials:

1. Pipe, mild steel 2"

2. Oxygen

3. Mapp Gas

4. Triple deoxidized Rod (steel Gas rod)

1. 5 2 r ( 2 of 4 ) STT-615-2-SW

otrOM cisTkiketio4 ...... /LINS1111291...EILYAII I

1. Introduce self and topic. f I. Introduction to the Lesson 1

A. Establish contact.

1. Name:

2. Topic:Elpe Welding (Vertical) Evaluation

B. Establish readiness 2. Motivate student.

1. Purpose

2. Assignment

C. Establish effect 3. Bring out need and value of material being presented. 1- Value

a. Pass course.

b. Perform better on the job.

c. Get advanced.

d. Be a better steelworker

D. Overview: I 4. State learning oblee- 1. Gas weld a V-butt joint in the vertical tives. fixed position for evaluation a. State information and materials necessary to guide student.

15J ( 3 of 4) STT-615-2-514- IG. 2.1.2

INSTRt.:CTOR ACTIVITY Sr'."..)EN: ACTT VITr 0i2TIR.E OF .:.7371.;.(rICN srII 5. Stress the importance II. PRESENTATION of neatness. A. Practical evaluation forvertical fixed position pipe 6. For testing, a complet welding. test piece can only be evaluated. 1. Introduce test

a. Nature of test 7. Have test pipe cut, beveled and letter stamped prior to prac- b. Purpose of test. tical test thme. -.2. Directions for Test 8. Stress that pipe will a. Project to becompleted not be turned for welding during test. b. Time alloted . Make a single V-butt vertical fixed pipe c. Eow graded weld for evaluation. (1) Appearance

(2) Undercut

(3) Overlap

(4, Guided-Bend Test

3. Evaluating the completed weld.

( 6 of4) STT-615-2-SW- IG 2.1.31,451

NAVAL SCHOOLS, CONSTRUCTION PORT HUENEME, CALIFORNIA93043 STEELWORKER STT SCHOOL TRAINING CJRSE 615-2 GAS CUTTING/WELDING II

Classification: Unclassified

Topic:Gas Welding Pipe, Horizontalfixed position. Terminal CbActive: 2.1

Average Time: Class: 0 periods Enabling ObjeCtive:Upon completion of this topic Pract: 5 periods the student will be able to: Instructional Materials:None A. Perform correct techniques for welding pipe as A. Text:None to gage setting, type of flame, speed of travel, manipulation of torch and correct welding rod. Per- form specified degree of cleaning of completed weld. B. References:None B. Demonstrate proper pipe preparation by beveling, C. Instructor Aids: None cleaning, aligning, spacing and tack welding, prior to welding. D. Tools: C. Gas weld, with a 1/8" triple deoxidized rod, a 1. Chipping hammer V-butt joint in the horizontal fixed position a 2" mild steel pipe. In doing this he will apply all pertinent safety precautions as stipulated in IS- 2. Pliers 8" 1.1.1.1. and identify and apply the correct proce- 3. Gloves dures and methods of correcting faults. Evaluation will be based on the Qualification Test for AR-3 level of American Welding Society, Standard for 4. Spark lighter Qualification of Welding Procedures and Welders for Piping and Tubing, AWS D1O. 9-72 condensed in stand- 5. Tip cleaners ard STT FT-1 attached to this unit. E. Equipment: Criterion Test: 1. Oxy-Mapp Cutting and Welding Unit Evaluation will be based on the students ability to pass the visual and guided-bend test as stipulated 2. Bench Grinder above. Homework: None 3. Pipe Beveling Machine 130IV' r..1

( 1 oi 5 ) 1.57 STT-615-2 -SW 10. 2.1.3 lee)

P. Materials:

1. Pipe, mild steel 2"

2. Oxygen

3. 14app Gas

4. Triple Deoxidized Rod (steel gas rod)

( 2 of 5 ) STT-611-2-SW IG- 2.1;3 ouv144 Mting114141 IMBREITLEMSEI f. Introduction to the Lesson . Introduce self and topic.

A. Establish contact.

1. Names

2. Topic: Pipe welding (Horizontal)

B. Eatablish readiness . Motivate student.

1. Purpose

2. Assignment

C. Establish effect 3. Bring out need and value of material being presented. Value

a. Pass course.

b. Perform better on the job.

C. Get advanced.

d. Be a bettersteelworker

D. Overview: 4, State learning objectives. 1. Gas weld a V-butt joint in the horizontal a. State information fixed position (practice) and materials necessary to guide student.

( 3 f 5 ) STT-615-2 -SW - IG. 2.1.3

OUTLINE 0? INSTRUCTION IIZTRUCTOR ACTIVITY 'STUDENTACTIVITYP--

chl II. PRESENTATION 5.BeVel pipe ahead on pip beveling machine but A. Techniques of pipe welding (horizontal fixed position) permit student to oper ate machine after dem- 1. Adjust gages for beveling pipe. onstration.

a. Elapp

b. Oxygen

(1) Determined byt

(a) Size and thickness of pipe

2. Bevel pipe

3. Remova scale

4. Align pipe 6. Stress the hmportance 1. Remove scale of proper alignment. a. spacing 2. Align pipe 7. Demonstrate tacking of a. spacing 5. Tack pipe pipe. a. Four smell tacks 3. Tack Pipe a. Four tacke 4. Position pipe (1) Dont stop or start welds on tacks

6. Position pipe in vertical fiued position

7. Start weld at 7 o'clock and weld toward 6 o'clock on the vosition of the pipe and weld 1/2" pas 12 o'clock Then finish weld by starting at 7 o'clock and finish weld.

( 4 of 5 ) 163 STT-615-2-SW- IG 2.1 3

INSTRUCTOR ACTIVITY STUDENT ACTIVIT UTLINE 0? INSTRUCTION .Practice gas welding 8. DO not stir puddle withrod 2" vertical fixed pipe

9. Do not agitate puddlewith flame

10. Clean scale from weld. 8. Explain reasons for B. Faults in gas welding faults in welding.

1. Porosity

2. Undercut

3. Overlap

4. Poor fusion

5. Incomplete penetration

6, Warpage

III. AM/CATION:

A. Insert questions to checkstudent cmmyrehension

rv. SUNMARY:

A. Single V-butt horizontalfixed pipe weld

V. TEST: NONE

( 5 of 5 ) STT-615-2-SW- IG. 2.14 9

NAVAL SCHOOLS, CONSTRUCTION PORT HUENEME, CALIFORNIA 93043 STEELWORKER SIT SCHOOL TRAINING COURSE 615-2 GAS CUTTING/WELDING II

Classification: Unclassified

Topic: Practical Evaluation in Gas Welding Pipe, Horizontal Terminal Cbjective: 2.1 Fixed Position. Average :ime: Class: 0 periods Enabling Objective: Upon completion of this topic Pract: 2 periods the student will be able to : InstrJctional naterials: None A. Perform correct techniques for welding pipe as to A. TEXT: None gage setting, type of flame, speed of travel, manipulation of torch and correct welding rod. Perform B. References:None specified degree of cleaning of completed weld. B. Demonstrate proper pipe preparation by beveling, C. Instructional Aids:None cleaning, aligning, spacing and tack welding, prior to welding. DTools: C. Gas weld with a 1/8" triple deoxidized rod a V- 1. Chipping hammer butt joint in the horizontal fixed position a 2" mild steel pipe. In doing this he will apply all 2. Pliers pertinent safety precautions as stipulated in IS- 1.1.1.1 and identify and apply the correct procedures 3. Gloves and methods of correcting faults. Evaluation will be based on the Qualification Test for AR-3 level of 4. Spark lighter American Welding Society Standard for Qualification of Welding Procedures and Welders for Piping and 5. Tip cleaners Tubing, AWS D10. 9-72 condensed in standard STT-FT-1 attached to this unit. The final weld must meet the E. Equipment: minimum requirements established for gas welding pipe in the horizontal fixed non-restricted position 1. Oxy-Mapp Cutting and Welding Unit Criterion Test: 2. Bench Grinder Evaluation will be based on the students ability to pass the visual and guided-hend test as stipulated 3. ?i'Re beveling machine. above.

None 1Homework:

1 t5 ( 1 of 4 ) STT-615-2-SW- 1G. 2.1.4

F. Materials:

1. Pipe, ndld steel 2"

2. Oxygen

3. Mhpp Gas

4. Triple deoxidized rod (steel gas rod)

( 2of 4 ) STT -615 SW 2.1.4 sq° saLiburamax.on rmsn et jnM111021M..[

1. Introduce self and topic. ; 1. Introduction to the Lesson

A. Establish contact.

1. Hamel

2. Topic: Pipe Welding (Horizontal) Evalua- tion. B. Establish readiness 2. Motivate student.

. Purpose

2. Assignment

C. Establish effect 3. Bring out need and value of material being presented.

1- Value

a. Pass course.

b. Perform better on the Job.

c. Get advanced.

d. Be a bettersteelworker

D. Overview: ". State learning obiec- tives. 1. Gas weld a V-butt joint in the horizontal a. State information fixed position for evaluation. and materials necessary to guide student.

( 3 of 4 STT-615-2-SW- IG. 2.1.4 INSTRUOTCR AC.TIVIn C? INS:14:_,CTTCN STU)EhTACTIVITY9

II. PRESENTATION 5. Stress the importance of neatness A. Practical evaluation for horizontal fixed position pipe welding. 6. For testing, a complet ed test piece can only 1. Introduce test be evaluated.

a. Nature of test 7. Have test pipe cut belved and ltter stamp b. Purpose of test prior to practical tes time. 2. Directions for Test 8. Stress that pipe will a. Project to be completed not be fumed for welding during test. b. Time alloted 1. Nake a simple Vybutt c. Haw graded horizontal fixed pipe weld for evaluation. (1) Appearance

(2) Undercut

(3) Overlap

(4; Guided-Bend test

3. Evaluating the completed weld

.1 ?3 ( 4 of 4 ) STT -615 -2 -SW - IG. 2.2.1 F,ir

NAVAL SCHOOLS, CONSTRUCTION PORT HUENEME, CALIFORNIA 93043 STEELWORKER STT salon TRAINING COURSE 615-2 fr

Classification:Unclassified

Topic: General Brazing Terminal Objective: 2.2

Average Time: class: 1 period Enabling Objective:Upon completion of this topic Pract: 5 periods the student will be able to: Instructional Materials: A. Bronze weld a single vee butt joint of mild steel A. Training Aids: MICA 3/16" x 4" with an Oxy-gas torch in the flat positia B. Bronze weld a tee joint of mild steel 3/16" x 4" B. Publications: with an Oxy-gas torch in the flat position. 1. Texts: None C. Bronze weld a lap joint of mild steel 3/16" x 4" teth an Oxy-gas torch in the flat position. 2. References: D. The above shall be done in accordance with a. "Brazing Manual" AmericanWelding Society FWC-FT-1.

C. Equipment and Materials: Criterion Test: The student will bronze weld a single vee butt joint 1. Major equipment of mild steel 3/16"r 4" with an OXY-gas torch in the flat position. Bronze weld a lap joing of mild a. Gas Welding Equipnent steel 3/16" x 4" with any Oxy-gas torch in the flat position. Bronze weld a lap joint of inild steel 2. Tools 3/16" x with an oxy-gas torch in the flat position. All will be in accordance with SWC-FT-1. a. Gloves Homework: None b. Goggles

c. Pliers

d. Slag hammer

e. Spark lighter 1:?)3

f. Tip cleaners ( 1 of 11 ) 1j STT-615-2-SW- IC.. 2.2.1

g. Wire bruah

3, Hateriz4ls

s. Brazing flux

b. Bronze Rod (flux coated)

c, Chalk I d. Happ gas

0. Oxygen

f. Steel plate (zaild).3/16" x 4"

D. Instructor prepaired materials (Local)None

1 '? ( 2 of 11 ) IG-2.2.1

joisErza kNSTRUGTO2, AGT1.11n7 AllIABLAETIALE

I. IntroductCbn to the Lesson . Introduce seif and topic.

A. Establish contact.

1. Hanes

2. ,Toplc: General Brazing

B. Establish readiness . Motivate student.

1. Purpose

2. Assignment

C. Establish effect 3. Bring out need and value of material being presented. I. Value

s. Pass course.

b. Perform better on the !ob.

c. Get advanced.

d. Be a better steelworker

D. Overview: State learning oblec- 1. General Brazing (Mild ateel) tives.

a. Simple Vee butt a. State information and materials necessary to b. Tee joint guide student.

c. Lap joint

, ( 3 of 11) SW-615-2-SW- IG 2.&1

OUTLINE 0? INSTRUCTION IN5TBUCTOR ACTIVITY STUDENT ACTIVITc

II. PRESENTATION

A. General Brazing (mild steel) 3/16" x 4" x 6" 5. Draw diagrams on the / Take notes chalkboard of the thre 1. Single-vee butt pypes of joints and th configuration of the a. Preparation bronze deposits.

(1) Sample plates 3/16" x 4" x C"(300 bevel)

(2) Grind or file joint area. (Do not wire brush)

421 Alignment of beveled joint. (1/16" root 'Opening)

b. Tacking

(1) Place a mmall tack weld at each end of joint. (Get good penetration)

c. Fluxing

(1) Apply flux over entire joint area.

d. Preheat

(1) Preheat entire joint area.

Note: Proper preheat is obtained when flux remmins liquid when torch is removed from plate-keep flame off of flux. 6

It5 ( 4 of 11 ) 1 TT-615-2-SW- IG. 2.2.1

OUTIINE 0? :NS!RUCTION INSTRUCTOR ACTIVITY STUDENT ACTIVITY

e. Bronze welding

(1) First pass

(a) Camplete penetration

(b) Tin bevel ahead of bead

(2) Second pass

(a) Tin ahead of bead

(b) Proper fusion into first pass

f. Post heat

(1) Bring test plates to uniform temperature

g. Cleaning

(1) Quench after plate temperature drops below7000 F

(2) Completely remove all flux by chipping and wire brushins.

Note: Protect hands and eyes when cleaning off flux - 6. Stress safety it will cut like glass.

( 5 of 11)

e STT-615-2-SW- IG._

OUTLIVE 0? INSTRUUTION INSTRUCTOR ACTIVITY STUDENT ACTIfITY

2. Tee joint 1

a. Preparation

(1) Sample plates 3/16" x 4" x 6" (no bevel).

(2) Grind or file joint area. (Do not wire brush)

(3) Alignment of tee joint. (no gap)

b. Tacking

(1) Place a mmall tack weld at each end edge of vertical plate

c. Fluxing

(1) Apply flux over entire joint area. (Note - mwke sure flux penetrates joint).

d. Preheat

(1) Preheat entire joint area.

Note: Proper preheat is obtained when flux remains liquid whnn tarch is removed fram plat42 - keep flame off of flux.

e. Bronze welding

(1) First pass

(a) Camplete penetration of tee joint 7. Stress the importance of good tinning of (b) Tin joint ahead of bead joint.

( 6 of 11 ) STT-615-2-SW-IG. 2.2.1

OUTLINE 0? WSTRUCTION INSTRUCTOR ACTIVITY STUDENT ACTIVITY (2) Second pass /or (a) Tin ahead of bead

(b) Proper fusion into first pass

Note: Bronze weld is to be made only on one side of tee joint for test specimen .

f. Post heat

(1) Bring test plates'to uniform temperature.

g. Cleaning

(1) Quench after plate temperatuae drops below 7000 F.

(2) Completely remove all flux by chipping and wire brushing

Note: Protect hands and eyes when cleaning off flux - it will cut like glass.

3. Lap joint

a. Preparation

(1) Sanple plates 3/16" x 4" x 6" (no bevel)

(2) Grind or file L int area. ) Do not wire brush)

(3) Alignment of lap joint (5/16" lap - no gap)

.1$ I ( 7 of 11 ) OUTLIVE 0? DGTRUCTION IVBTRUCTOB ACTIVITY

b. Tacking

(1) Place a small tack weld at each end on edge of lap joint.

c. Fluxing

(1) Apply flux over entire joint area.

Note: Mae sure flux penetrates joint.

d. Preheat

(1) Preheat entire Joint area

Note: Proper preheat is obtained when flux remains liquid when torch is removed from plate. Keep flame off of flux.

e. Bronze welding

(1) First pass

(a) Penetrate brazing material into lap joint

(b) Tin ahead of bead

(2) Second pass

(a) Tin ahead of bead

(b) Proper fusion into first pass

Note: Bronze 'weld ia to be made only on one side of tee Joins for test specimen.

( 8 of 1.L) ,STT-615-2-SW- IG. 2.2.1

OUTLINE G? INSTRUCTION INSTRUCTOR AcrIvrry STUDENT

f. Post heat

(1) Bring test,plates to uniform temperature.

g. Cleaning "%trait.

(1) Quench after plate temperature dnops below 7000 F.

(2) Completely remove all flux by chipping and wire brushing.

Note: Protect hands and eyes when cleaning off flux - it will cut like glass. Insure that there is pro= per ventilation for the flux and zinc fumes and that the student does not position his face directly over the work..

III. APPLICATION:

A. Questions and Discussion

1. Why is preparation of a joint to be brazed, not wire brush

ANS: Wire brushing may deposit foreign matter, such as grease, on the weld area and not remove the mill scale.

2. Why is a stronger joint obtained by first grinding or M- ing a joint?

ANS: Filing and especially grinding will leave grooves for th filler metal to lock into.

3. In preheating why should the flame be kept off the flux?

ANS: The flame could burn the flux.

4. Why is uniform poseheat necessary? 192 ANS: To prevent residual stresses 19k 5. Why is brazing flux more hazardous to remove than slag?

( 9 of 11 ) ANS: It will cut lf'n glass. STT-615-2-SW- IG. 2.2.1

OUTLIVE 0? INSTRUCTION INSTRUCTOR ACTIVITY STUDENT ACTIVITY

IV. SUNMARY: /b7

A. General Brazing (nild'steel) 3/16" x 4"

1.'Single-vee butt

a. Preparation

b. Tacking

c. Fluxing

d. Preheat

e. Bronze welding

f. Post heat

g. Cleaning

2. Tee joint

a. Preparation

b. Tacking

c. Fluxing

d. Preheat

e. Bronze welding

f. Post heat

g. Cleaning

( 10 of 11 ) 190 STT-615-2-S1- IG. 2.2.1 OUTLUE C.? :NSTRUCTION INSTRUCTOR ACTIVITY STUDENT ACTIVITY

3. Lap joint

a. Preparation

b. Tacking

C.F1.41.44A

d. Preheat

e. Bronze welding

f. Post heat

g. Cleaning 7. Student ct e 2. Practice brzing at brazing at individua individta pace under V. TEST: pace under supervision superv on of the of instructor. ins ructor. A. Practical Test (General Brazing- Mild Steel)

1. Single-Ime butt

2. Tee joint

3. Lap joint

VI. ASSIGNMENT

A. "Operator's Manual Welding Theory and Application" TM9- 8. Past assignment on chal 237, Chapter 2, Pages 6 through 12. board.

196

19:5 ( 11 of 11 ) STT-615-2-SW-IG. 2.2.2.

NAVAL SCHOOL$, CONSTRUCTION PORT HUENEME, CALIFORNIA93043 STEELWORKER SIT SCHOOL ThIAING COURSE 615-2

Classification: Unclassified

Topic: Soft Soldering Terminal Objective:2..2

Average Time:Class: 1 period Enabling Objective:Upon completion of this topic Pract: 4 periods the student will be able to: Reference: A. Naval Construction Force Safety MAnual COMCBPAC/ A. Select proper solderingcopper, flux and solder COMCBLANT INST. 5100.1 for the metal to be soldered.

Text:A. NANTERS 10653-E Steelworker 3&2pp. 284-292 B. Solder sheet metal by preparing themetal and soldering coppers prior to solderingcommon metals Instructional Nhterials: used in the sheet metal shop. C. All safety precautions and practices A. Films: must be observed. Completed projects mustnot exceed a tolerance of 1/8 inch plus or minus on any givenmeasure- 1. }V-7831-IcheUse of Soldering Coppers (8 min.) ment.

2. 11N-9753 On Solder" (25 min) obsolete Criterion Test: When shown the various types of soldering coppers the student will identify each B. Transperencies: None by it's correct name and characteristic; Select proper flux and solder for the metal to be soldered; C. Actual finished samples of various projects. Soldered sheet metal by preparing metal andsolderin coppers prior to soldering metals used in the sheet Instructional Aids: metal shop. All safety precatutions andpractices must be observed. Completed projects mmst A. 16 NM movie projector not exceed a tolerance of 1/8 inch plus or minus on any given measurement, and conform to standards as_stipulated Toolsq in SWC-FT-1

A. Soldering coppers Homework:

A. Reading assignment NAVPERS 10653-ESteelworker 3&2 Pages 372-385

(1 of 10 ) ,

) lquipment:

A. Shears

B. Brake.

Materials:

A. Sheet metal o B. Solder

C. Rags

D. Fluxes

19 0 ( 2 of 10 ) STT-6 5-2-SW !G-2.212' ()tamp oy issrpqmoN INSTRIKTOR ACTIVVY

y, I. Introduction to the Lesson . Introduce self and topic.

A. Establish contact.

1. Names

2. Topic: Soft Soldering and metal layout

A B. Establish readiness . Motivate student.

1. Purpose

2. Assignmant

C. Establish effect 3. Bring out'need and value

of material being presented.I' 1. Value

a. Pass courae.

b. Perform trtter on the job.

c. Get advanced.

d. Be a bettersteelworker

D. Overview: s 4. State learning objectives. 1. Objectives )a. State information 2. Notes and:msterials necessary to guide student. 3. Questions 4

4* Testable

2112

( 3 of 10.) TT-615-2-SW- IC. 2.2.2

OUTLINE 0? INSTRUCTION INSTRUCTOR ACTIVITY STUDENT ACTIV1

U. PRESENTATION

A. Soldering equipment.

1. Soldering coppers (irons)

a, Made of copper far high heat conductivity

b. Supplied in pairs.

(1) One to use and one being preheated

(2) A four pound copper is actually two-two pound coppers.

c. Supplied in various formsand shapes for specified jobs

(1) Pointed - fOr general work

(2) Stub - for gweating seams that requires con- centrated heat

(3) Bottom - for bottom of pails, pans, etc., in restricted space.

2. Electric irons

'a. Best for shop work . Show film MN-7831-1 2. Watch film "The use of soldering b. Supplied in various forms and shapes for specific coppers". jobs. . Discuss key point of Discuss film ct Designated by watts. movie

203 rio ( 4 of 10 ) 204 OUTLINE 0? :NSTRUCTION INSTRUCTOR ACTIVITY

B. Fluxes

1. Corrosive

a. Zinc chloride

-, (1) Obtatned by cutting raw hydrochloric (muriatic) acid

(2) Break down oxides on the metal

(3) Forme protective coating on metal to prevent oxidation.

(4) Nelts at about 354° F which is slightly below melti point of most soft solders.

(5) Used on galvanized steel or zinc.

b. Ammonium chloride (Sal Ammoniac). 8. Random questioning to class to check compre (1) Seldom used as a flux by itself because'of high hension. corrosive action.

(2) Fumes are toxic and should not be breathed.

(3) Used for:

(a) Tinning flux for soldering coppers.

(b) Iron an4 steel

(4) Comes in cake or powder form

c. Hydrochloric acid (1) Used raw or cut with water.

( 5 of 10 ) 2 STT-615-2-SW- IG. 2.2.2

OUTLINE 0? 1:3TRUCTION INSTRUCTOR ACTIVITY STUDENT ACTIVITY./ NOTE: Alwasy pour acid into water - Never water into acid. /1V

(2) Dee on galvanized surfaces 0.

(3) Combined with acetic acid or various other elements for anxiAg stainless steel, mone1 and other high nickel alloys.

d. Phosphoric acid

(1) Excellent flux for stainless steels and other nicke alloys.

e. Stearin&

(1) Deed on special alloys and metals

(a) Aluminum

(b) Stainless steel

NOTE: All corrosive fluxes must be removed after soldering due to high corrosive actions of the flux.

2. Non-corrosive fluxes

a. Rosin

(1) Effective only on light, very clean work, copper or copper allays, or pretinned ferrous metals

(2) Net suited for heavy work requiring more heat

la) Because it carbonizes at a low temperature

(3) Does not remove oxidation already present

(4) Does prevent heat oxidation during soldering

(5) Deed mostly on electrical work or any work that flux cannot be removed after soldering. ( 6 of 10 ) ISTT-615-2-SW- IG. 2.2.2

OUTLINE OF INSTRUCTION INSTRUCTOR ACTIVITY STUDENT ACTIVITY

b. Tallow

(1) Not used as a flux since discovery of more effective methods

(2) Used on fusion welding and soldering of lead

C. Composition of soft solders

1. Alloys of lead, tin and antimony

a. About 50% tin ,507. lead with very small amount of antimony is the most common

b. Melting point about 3610 to 596° F

c. Available in three grades

(1) Grade 1 - fine solder

(a) Over 55% tin

(b) Melting point approximately 365° F

NOTE: When a tin lead alloy is referred to as 50-50 40-60, or 60-40, etc., the tin is always indicate first and lead second.

(2) Grade 2 - medium solder

(a) 50-50 solder - 50% tin, 507. lead (b) Melting point approximately 450° F. 210 (c) Used on electrical work, not as good as Grade 1.

( 7 of 10 ) 20 3 SRR-615-2-SW- IC. 2.2.2

OUTLIVE 0? 2NSTRUCTION INSTRUCTOR ACTIVITY STUDENT ACTIVITY (3) Grade 3 - common solder llb (a) Over 557. lead

(b) Melting point approximately 500° F.

NOTE: When antimony content is 0.5% or less in a solder it may be used, except in very,special cases, for the same applications as the straight tin lead solders.

D. Soft Solders (available shapes).

1. Wire - can be with or without acid or rosin core.

2. Bar - has no core

E. Application of soft sJ1ders

1. Base metals

a. Mist be clean

b. Must be tinned (thin coating of solder on tip)

c. Must be proper tepperature

,(1) Too much heat will cause excessive oxidation of base metal.also burns tinning off soldering coppers

3. Use the proper flux. Most metals require a different flux.

4. When using a torch

a. Heat the base metal, never the solder

(1) Heat from the base metal will melt the solder 2 1 2 11 (.8Of 10 ) STT-615-2-SW- IG. 2.2.2 OUTLIVE 0? IlW111,ClION 'IMT13UC1'OR ACTIVITY STUDENT ACTIVITY

APPLICATION 117

A. Student under supervision will layout and favricate the various projects assigned by the instructor. 9. Assign projects to stu4. Layout and fabricate dents and supervise wo various soldered joint perforned by students, under supervision of the inscructor. 10. Stress importance of good housekeeping B. Prior to completion of application clean up workarea.

TV. SUMMARY

A. Soldering equipment

1. Soldering coppers

2. Electric irons

B. Fluxes

1. Corrosive

a. Zinc chloride

b. Ammonium chloride (Sal Anmoniac)

c. Hydrochloric acid

d. Phosphoric acid

e. Stearine.

2. Non-Corrosive

a. Rosin

b. Tallow 21.;

( 9 of 10 ) STT-615 -2 -SW- IG 2.2,2

CAMINS C? INSTRUCTION IMTRUCrOR AGTI VITY STUDENT ACTIVITY

C. &ompesition of soft solders

1. Alloys of tin and lead

2. Alloys of lead, tin and antimony

3. Miscellaneous types of solder

D. Soft solder (availabel shapes)

1. Wire

2. Bar

H. Application of soft solders

1. Base metal preparation

*2. Soldering coppers

3. Proper flux

4. Use of torch

P. Sheetmetal layout - practical

1. Equipment

V. TEST

A. Practical- shee.t metal soldered joints

B. Written at end of unit

216

21 j (10 of 10 ) STT-615-27SW- 1G. 3.1.1. il?

of NAVAL SCHOOLS, CONSTRUCTION

- PORT HUENEME, CALIFORNIA 93043 STEELWORKER=SIT SCHOOL TRAINING COURSE 615-2

Classification: Unclassified

Silver Brazing (Steel) Terminal Objective:3.1 AvINze Time: Class: 1 period Enabling Objective: Upon completion of this topic Pract: 3 periods the student will:be able to: Instructional Materials: . Silver Braze a square butt joint of 1/8" x'1" x2" A. Training Aids: None mild steel with an Oxy-gas torch in the flat position,

. B.Silver Braze a tee jointOf 1/8"x 1" x 2" mild B. Publications: steel With an oxy-gas torch in the flat position.

1. Test: None C. SilverBragea lap joint of 1/8" x 1" x 2" mild steel wig' an oxy-gas torch in the flat position. 2. Refczences: . D. The above shall be done with a joint of .0015 to .003 with no build up. a. "Brazing Manual"American Welding Society Criterion Test: C. Equipment and Materials: The student will Silver Brazea square butt joint of 1/8" x 1" mild steel with an oxy-gas torch in that i 1. Major Equipment flat posiiton, Silver Braze a tee joint of 1/8" x 110 1" mgd steel with an Oxy-gas torch in.tha flatpos.. a. Gas welding equip ent ition, Silver Brazea lap joint 1/8" x 1" mild steel with an oxy-gas torch in the flat Position. Ths above shall be done with a joint of .0015 to .003 with no 2. Tools: build up.

a.. Gloves Homework: Reading Assignment: "Operators Manual Welding Theory b. Goggles and application TM9-237 Chapter 3 pages 19-22 .

c. Pliers

d. Slag Hammer

218 21 ( 1 of 15 ) 0

e. Spark lighter

f. Tip cleaners

g. Wire brush

3. Materials

a. Chalk

b. Flux, Silver Braze

c. Mapp gas

d. Oxygen

d. Silver brazing alloy (Codmium free) 1/16"

f. Steel strip (mild) 1/8" x 1"

D. Instructor prepaired materials (Local) None

220 21.0 ( 2 of 15 ) Stt-615:-2-W 1 G- 3.1.1 ptalliaLariNECSEUSE MEI1EVRADIEE3IE1 =DmACTIMI

I. Introduction to the_lesson . Introduce self and topic.

A. Establish contact.

I. Names

2. Topic:Silver Brazing (Steel)

B. Estaillish readiness . Motivate student.

I. Purpose

2. Assignment

C. Establish effect 3. Bring out need and value of material being presented. 1. Value I

a. Pass course.

b. Perform better on the lob.

c. Get advanced.

d LI: a better steelworker

O. Overview: #4. State learning obiec- tives. 1. Silver Brazing (steel) 1/8" x 1"x 2"

a. Square butt a. State information and materials necessary to guide student. b. Tee joint

(1) Flat

(2) Vertical

( 3 of 15') STT-615-2 -SW - IG. 3.1.1

OUTLINE 0? INSTRUCTION INSTRUCTOR ACTIVITY STUDENT ACTIVITY

c. Lap joint

(1) Flat ,

(2) Vertical

II. PRESENTATION

A. Silver Brazing (Steel) 1/8" x 1" x 2" 5. Draw diagram on the Take notes chalkboard of the thre

1. Square-butt joint (flat) types of joints and th.. disposition of the all a. Preparation in the joints. 2. Ask qUestions when in (1) Sample strips.1/8"Xl"x 2" doubts

(a) No bevel - only remove sharp top corner edge of both kitting sides of strips with a file. This 4 will permit alloy to Penetrate into closefitting joint instead of spreading over top sides of strips.

(2) Grind, file or sana paper joint area. (Do not use a wire brush)

Note: Do not use aluminum-oxide emery paper.

b. Positioning

(1) Alignment of joint ( no gap) hold strips in place by use of fire bricks, etc. - do not tack.

c. Fluxing

(1) Apply flux over entire joint area.

223 ( 4 of 15 ) STT-615-2-SW-IG. 3.1.3

OUTLIVE 012 INSTRUCTION INSTRUCTOR ACTIVITY STUDENT ACTITY

d. Preheat

(1) Preheat entire joint area.

Note: Proper preheat is obtained if flux remains liquid when torch is removed from plate. Keep flame Off of flux.

e. Brazing

(1) Peed brazing alloy into joint until alloy no longer disappears from top edge. Complete penetration must be obtained.

Vote: Ifalloy smokes, too much heat is being applied.

(2) No build-up bead is required

f. Post heat

(1) Bring test strips to uniform temperature

g. Cleaning

(1) Queoch after test strips temperature drops below 700 F.

(2) Completely remove all flux by chipping and wire , brushing.

Note: Protect hands and eyes when cleaning off flux - 6. Stress safety it will cut like glass

( 5 of 15 ) STT-615 -2-SW - IG. 3.1.1

OUTLINE 0? INSTRUCTION INVITUCTOR ACTIVITY . STUDENT ACTIVITY ii /141;?/ 2. Tee jant (flat)

a. Preparation

'(l),Sample strips 1/8" x 1" x 2"

(2) Grind, fileor sandpaper joint area. (Do not use a wire brush)

Note: Do not use aluminum-oxide emery paper.

b. Positioning

(1) Alignment of joint (no gap). Hold vertical strip in

. place by the use of a steel strip or rod (touching top edge of vertical strip and bench top) - Do not tack.

c. Fluxing

(1) Apply flux over entire joint area.

d. Preheat

(1) P.eheat entire joint area.

Note: Proper preheat is obtained if flux remains liquid when torch is removed from strips. Keep flame off of flux.

e. Brazing

(1) Feed brazing alloy into joint until alloy no longer disappears from fillet. Complete penetration must be obtained.

Vote: If alloy smokes, too much heat is being applied

(2) Throat of fillet build-up must not exceed 1/32"

( 6 of 15') 227 TT -615 -2-SW-IG. 3.1.1 OUTLIVE OF INSTRUCTION I ?STRUcroR A CTI VIT Y STUDENT ACTIVITY

f. Post heat /c4S-

(1) Bring test strips to uniform temperature

g. Cleaning

(1) Quengh after test strips tepperature drops below 700 F.

(2) Completely remove all flux by chipping and mire brushing.

Note: Protect hands and eyes when cleaning off flux - it will cut like glass.

3. Tee joint (vertical)

a. Preparation

'(1) Sample strips 1/8"x 1" x 2"

(2) Grind, file or sandpaper joint area. (Do not use a 4 wire brush)

r Note: Do not use aluminum-oxide emery paper.

b. Positioning

(1) Alignment of joint (no gap). Hold strips in place by the use of fire bricks - Do not tack.

c. Fluxing

(1) Apply flux over entire joint area 23 ) 2) ( 7 of 1 5 ) 4" STT-615-2-SW- IG. 3.1.1

OUTLINE OFINSTRUCTION INSTRUCTOR ACTIVITY STUDENT ACTIVITY'

d. Preheat

(1) Preheat entire joint area.

Note: Proper preheat is obtained if flux remains liquid when torchjs removed from strips- Keep flame of of flux.

e. Brazing

(1) Feed brazing alloy,from top end bf joint and permit capillary and gravity action to fill the joint down vertical. Feed the alloy until it no longer disappeas from fillet.

Note: Ifalloy smokes, too much heat is being applied.

(2) Throat of fillet build-up must not exceed 1/32"

f. Post heat

(1) Bring tast strips to uniform temperature.

8. Cleaning

(1) Quench after test strips temperature drops below 700 Y.

(2) Completely remove all flux by chipping and wire brushing.

Note: Protect hands and eyes when cleaning off flux- it will cut like glass.

23'1

( 8 of 15 ) 23.1. STT-615-2-SW IG. 3.1.1

OUTLINE 0? INSTRUCTION INSTRUCrOR ACTIVITY STUDENT ACTIVITY /427 4. tap joint (flat)

a. Preparation--

.(1) Sample strips 1/8" x 1" x 2"

(2) Grind, file or sandpaper joint area. (Do not use a wire brush).

Note: Do not,use aluminum-oxide emery paper.

b. Positioning

(1) Alignment of joint (no gap) Lap strips 1/4". Suppor top strip on its free end by a 1/8" scrap strip and hold down with a fire brick. (Do not tack)

c. Fluxing

(1) Apply flux over entire joint area, including betwee lap joint.

d. Preheat

(1) Preheat entire joint area.

Note: Proper preheat is obtained if flux remains liquid when torch is removed from strips. Keep flame off of flux.

e. Brazing

(1) Feed brazing alloy into joint until alloy no longer disappears. Complete penetration mmst be obtained.

Note: Ifalloy smokes, too much heat is being applied

(2) Throat of fillet buildup must not exceed 1/32"

( 9 of 15 ) 23J S Tr -615-2 -SW- 1G . 3 . 1 .1

OUTLINE 0? INSTRUCTION INSTRUCTOR ACTIVITY STUDENT A MI VITY/-

f. Post heat

(-1)-8ring-test-a trip s-to-untform

g. Cleaning

(1) Quench after test strips temperture drops below 700° F.

(2) Completely remove all flux by chipping and wire brushing.

Note: Protect hands and eyes when cleaning off flux - it will cut like glass

5. Lap joint (vertical)

a. eparation

(1) Sample strips 1/8" x 1" x 2"

(2) Grind, file or sandpaper joint area. (Do not use wire brush)

Vote: Do not use aluminum-oxide emery paper

b. Positioning

(1) Alignment of joint (no gap). Hold strips in place by the use of fire bricks. Lap strips 1/4" (Do not tack)

c. Fling

(1) Apply flux over entire joint area, including betweer lap joint.

2'1i; 23;; ( 10 of 15 ) OUTLIVE OP DWRUCTION INSTRUCTOR ACTIVITY

d. Preheat

(1) Ptabeat entire joint area

Note: Ptoper preheat is obtained if flux remains liquid when torch is removed. Beep flame off of flux.

e. Brazing

(1) Feed brazing alloy from top end of joint and permit capillary and gravity action to fill the joint down vertical. Feed the alloy until it no longer disappears from fillet.

Note: If alloysmokes, too much heat is being applied

(2) Throat of fillet build-up must not exceed 1/32"

f. Post heat

(1) Bring test strips to uniform temperature

g. Cleaning

(1) Quench after test strips temperature drops below 700° F.

(2) Completely remove all flux by chipping and wire brushing.

Note: Protect hands and eyes when cleaning off flux - it will cut like glass.

Insure that there is proper ventilation for the flux and metallic fumes and that the student does not posiiton his face directly over the work

Silver brazing alloy is thinflowing and only the joint tolerance of .0015 to .003 should be filled with little or no build-up

(11 of 15 ) 2A ,OUTLIVE OF :NSTRUCTION INSTRUCTOR ACTIVITY

III. APPLICATION

A. Questions and Discussion

1. What is the most desirable joint tolerance for a silver brazed joint?

.0015 to .003

2. How can it be dateimined when the joint is completely filled with alloy?

ANS: The alloy being fed into the joint will no longer disappear.

3. How can it be determined when the joint has reached the proper temperature for brazing.

ANS: The flux will remain liquid from the heat of the bas metal.

4. Why shouldn't aluminum-oxide emery paper be used to prepare a joint for brazing?

ANS: The aluminum-oxide will remain on the part to be brazed and prevent the flow of the allay.

IV: SUIVARY

A. Silver Brazing )steel) 1/8" x 1" x 2"

1. Square butt (flat)

a. Preparation

b. Positioning

c. Fluxing

d. Preheat

e. Brazing ( 12 of 15 ) TT-615-2-SW IG. 3.1.1. GeTLI:71. CF :ESIRUCTION INsTaucroa ACTIVITY STUDENT ACTIVITY 1

f. Post heat /3/

g. Cleaning

2. Tee joint (flat)

a. Preparation

b. Positioning

c. Fluxing

d. Preheat

e. Brazing

f. Post heat

g. Cleaning

3. Tee joint (vertical)

a. Preparation

b. Positioning

c. Fluxing

CI. Preheat

e. Brazing

f. Post heat

g. Cleaning 242

( 13 of 15 ) STT-615-2-SW- IG. 3.1.1

OUTLIVE OF INSTRUCTION INSTRUCTOR ACTIVITY STUDENT AcTIvrrY , 4. Lap joint (flat) /.3- a. Preparation

b. Positioning

c. Fluxing

d. Preheat

a. Brazing

f. Post heat

g. Cleaning

5. Lap joint (vertical)

a. Preparation

b. Positioning

c. Fluxing

d. Preheat

e. Brazing

f. Post heat

g. Cleaning 7. Students will practice2. Practice silver brazing Silver brazing at an at individual pace un- V. TEST: individual pace under der supervision of the supervision of the instructor. A. Practical Test (Silver Brazing Steel) instructor.

1. Sq utt joint

2. Tee joint

3. Lap joint 244 ( 14 of 15 ) 2 43 STT-615-2-SV- IG. 3.1.1

OLTLIVE 0? INSTRUCTION IMTRUCTOR ACTIVITY STUDENT ACTIVITY VI. ASSIGMENT 133

A. "Operator's Manual Welding Theory and Application" TM9-23-8. post asaignment on the Chapter 3. pages 19 through 22. chalkboard

( 15 of 15 ) SIT-615-2-SW- IG. 3.1.2/3q

NAVAL SCHOOLS, CONSTRUCTION PORT HUENEME, CALIFORNIA 93043

STEELWORKER S$T SCHOOL TRAINING COURSE 615-2

" Classificacionainclassified

Terminal Objective: 3.1 Topic: Silver Brazing (Brass) Enabling Objective: Upon completion of this topic Average Time: Pract: 3 periods the student will be able to: Instruc-ional Materials: A. Silver Braze a square butt joint of 1/16" x 1" A. Training Aids: None x 2" brass with an oxy-gas tarch in the flat and vertical position. B. Publications: B. Silver braze a tee joint of 1/16" x 1" x 2" with an oxy-gas torch in the flat and vertical position. 1. Texts: None C. Silver braze a 1/4" lap joint of 1/16" x 1" x 2" 2. References: brass with an oxy-gas torch in the flat and vertical posiiton. a. "Brazing Manual" American Welding Society D. The Above shall be done with a joint of .0015 to .003 and with no build up. C. Equipment and Materials: Critericn Test: The student will silver braze a 1. Major Equipment square butt joint of 1/16" x 1" x 2" brass with an oxy-gas torch in the flat and vertical position, a. Gas welding equipment Silver braze a tee joint of 1/16" x 1" x 2" brass with an oxy-gas torch in the flat and vertical pos- 2. Tools ition, Silver braze a 1/4" lap joint of 1/16" x 1" x 2" brass with an oxy-gas torch in the flat and a. Glaves vertical position, All shall be done with a joint of .0015 to .003 and with no build up. b. Goggles Hamework: Reading Assignment c. Pliers 1. "The Welding Encyclopedism 16th edition pages d. Slag hammers C-32, P-40 and- P-41.

2 4 ( 1 of 13 ) 2 4 STT-615-2-SR_IG. 3.1.2

OUTLM C? :NSTRUCTION INSTRUCTOR ACTIVITY STUDENT.ACTIVITY

e. Spark lighter /3%C

f. Tip cleaners

g. Wire brush

3. Haterials

a. Flux, Silver Brazing

b. Nhpp gas

c. Oxygen

d. Silver Brazing alloy (Cadmium free)

e. Brass strip 1/16" x 1" x 2"

D. Instructor Prepared Material (local): None

25,) ( 2 of 13 ) 3.1.2 muzinisism rusTRucToll APTIMY STUDENT ?mum,/

1 I. Introduction to the Lesson 1. Introduce self and topic.

A..' Establish contact.

I. Names

2. Topic: Silver Brazing (Brass)

B. Establish readiness 2. Motivate student.

1. Purpose

2. Assignment

C. Establish effect 3. Bring out need and value of material being presented. 1. Value

a. Pass course:

b. Perform better on thejob.

c. Get advanced.

d. Be a better Steelworker

D. Overview: State learning objec- 1. Silver Brazing (Brass) tives.

a. Square butt joint (flat) a. State information and materials necessary to b. Tee joint guide student. (1) Flat position (2) Vertical position c. Lap joint (1) Flat position (2) Vertical positien

( 3 of13.) 25A. STT-615-2-SW- IC. 3.1.2

OUTLIFE C? INSTRUCTION INSTRUCTOR Am V1TY STUDENT ACTIVITY

II. PRESENTATION /3 7

A. Silver Brazing (brass)

1. Square-butt joint

a. Preparation

(1) Sample strips 1/16" x 1" x 2" Stress removing sharp edges from brass strips b. Posiitoning 2. Ask questions when in doubt. (1) Alignment of joint (no gap). Hold strips in place by use of fire bricks, etc. - Do not tack

c. Fluxing

(1) Apply flux over entire joint area

d. Preheat

(1) Preheat entire joint area

Note: Proper preheat is obtained if flux remains liquid when torch is removed from plate - keep flame off of flux.

e. Brazing

(1) Feed brang alloy into joint until alloy no longer dispears from top edge. Complete penetration must be obtained.

.,t Note: If alloy smokes, too much heat is being applied

(2) No buildup bead is required.

f. Post heat 25.;

(1) Bring test strips to uniform temperature. ( 4 of 13 OUT1IVE 0?:NSTRUCTION II4STRUCTOR ACTIVITY

g. Cleaning

(1) Quench after test strips temperature drops below 700 F.

(2) Completly remove all flux by :hipping and wire brushing.

Note: Protect hands and eyes when cleaning off flux - 6. Stress the importance it will cut like glass. of sharp flux particle

2. Tee joint (flat)

a. Preparation

(1) Sample strips 1/16" x 1" x 2"

(2) Grind, file or sandpaper joint area. (Do not use a wire brush)

Note: Do not use aluminum-oxide emery paper.

b. Positioning

(1) Alignment of joint (no gap) Hold vertical strip in place by the use of a steel strip or rod (touching top edge of vertical strip and bench top). Do not tack.

c. Fluxing

(1) Apply flux over entire joint area.

d. Preheat

(1) Preheat entire joint area.

Note: Proper preheat is obtained if flux remains liquid when torch is removed from strips - Keep flmme off of flux.

( 5 of 13 ) STT-615-2-SW- IG. 3.1.2 OUTLINE OF :NSTRLCrION ItSTRUcroR AanVITY STUDENT ACTIVITY

e. Brazing

(1) Feed brazing alloy into joint until alloy no longer disappears from fillet. Complete penetration must be obtained.

Note: If alloy smokes, too umch heat is being applied.

(2) Throat of fillet must not exceed 1/32"

f. Post heat

(1) Bring test strips to uniform temperature.

g. Cleaning

(1) Queuch after test strips temperature drops below 700 F.

(2) Completely remove all flux by chipping and wire brushing.

Note: Protect hands and eyes when cleaning off flux - it will cut like glass.

3: Tee joint (vertical)

a. Preparation

(1) Sample strips 1/16" x 1" x 2"

/ (2) Grind, fileor sandpaper joint area. (Do not use a wire brush)

Note: Do not use aluminum-oxide emery paper.

b. Positioning

(1) Alignment of joint (no gapl. Hold strips in place by the use of fire bricks - Do not tack 2 ''"r ( 6 of 13 ) ,...1 2'3 STT-615-2-SW- IC. 3.1.2 OUT7I1.7. Cl :NSTRUCTION INBTRucroRACTIVITY STUDENT ACTIVITY/VO

c. Fluaring

(1) Apply flux over entire joint area.

d. Preheat

(1) Preheat entire joint area.

Note: Proper preheat is obtained if flux remains liquid when torch is removed frcm strips. Keep flame off of flux.

e. Brazing 7. Stress why alloy must be fed from top in a (1) Fe:d brazing alloy fram top end of joint and permit vertical joilt. capillary and gravity action to fill the joint down vertical. Feed the alloy until it no longer disappears fram fillet.

Note: If alloy smokes, too much hAat is being applied.

(2) Throat of fillet buildup must not exceed 1/32"

f. Post heat

(1) Bring test strips to uniform tenperature

g. Cleaning

(1) Quench after test strips temperature drops below 700 F.

(2) Completely remove all flux by chipping and wire brushing

Nota: Protect hands and eyes when c4aning off flux - it will cut like glass. 2

12) ( 7 of 13 ) TT-615-2-SW- IG. 3.1.2 OUTLIE 0? INSTRUCTION INSTRUCTOR ACTIVITY STUDENT ACTIVITY /5// 4. Lap joint (flat)

a. Preparation

(1) Sample strips 1/16" x 1" x 2"

(2) Grind, file or sandpaper joint area. (Do not use a wire brush)

Note: Do not use aluminum-oxide emery paper.

b. Positioning

(1) Alignment of joint (no gap). Lap strips 1/4". Suppor top strip on its free end by a 1/16" scrap strip and hold down with a fire brick, (Do not tack)

c. Fluxing

(1) Apply flux over entire joint area, including between lap joint.

d. Preheat

(1) Preheat entire joint area.

Note: Proper preheat is obtained if flux remains liquid when torch is removed from strips - Keep flame off of flux.

e. Brazing

(1) Feed brazing alloy into joint until alloy no longer disappears. Complete penetration must be obtained.

Note: If alloy smokes, too much heat is being applied

(2) Throat of fillet buildup must not exceed 1/32"

21' ( 8 of 13 )

2 L OUTLINS 0? INRUCTION INSTRUCTOR AcrIVITY

f. Post beat

(1) Bring test strips to uniform temperature

g. Cleaning

(1) Quegch,after test strips temperature drops belaw 700 F.

(2) Completely reuove all flux by chipping and wire brushing

Note: Protect hands and eyes when cleaning off flux - It will cut like glass.

5. Lap joint (vertical)

a. Preparation

(1) Sample strips 1/16" x 1" x 2" 8. Explain why a wire brush, and aluminum (2) Grind, file or sandpaper joint area.(Do not use oxide paper should not wire brush) not be used.

Note: Do not use aluminum-oxide euery paper.

b. Positioning

(1) Alignment of joint (no gap). Hold strips in place by the use of fire bricks. Lap strips 1/4". (Do not tack).

C. Fluxing

(1) Apply flux over entire joint area, including between lap joints.

d. Preheat

(1) Preheat entire joint area ( 9 of 13 ) 263 STT-615-2-SW- 10. 3.1.2 owmui GF INSTRUCTION INSTRUCTOR ACTIVITY STUDENT AcrIvrry /4/3 Note: Proper preheat is obtained if flux remains liquid when torch is removed 7 Keep flame off of flux.

e. Brazing

(1) Feed brazing allay from top end of joint and permit capillary and gravity action to fill the joint down

. vertical. Feed the alloy until it no longer disappears from fillet.

Note: If alloy smokes, too much heat is being applied

(2) Throat of fillet buildup must not exceed 1/32"

f. Post heat

(1) Bring test strips to uniform temperature

(2) Completely remove allflux by chipping and wire brushing.

Note: Protect hands and eyes when cleaning off flux- It will cut like glass

Insure that there is proper ventilation for the flux and metallic fumes and that the student does not position his face directly over the work.

Note: Silver brazing alloy is thinflowing and only the joint tolerance of .0015 to .003 should be filled with little or no buildup

( 10 of 13 ) SW-615-2-SW- IG. 3.1.2 .

OUTLINE 0? LYSTRUCTION INSTRUCTOR ACTIVITY STUDENT ACTIVIT1, //1

III. APPLICATION:

A. Questions and Discussion

1. Is silver alloy thin-flowing or bead -formdng

ANS: Thin-flowing

2. How can a lap joint be set up to retain close-joint tolerance during brazing?

ANS: Support the free end of the top strip with a piece of scrap metal equal to the thickness of the bottom strip.

3. Immediately after brazing, what should be done to the test strips?

AM: Post heat uniformily

4. Why should the joint be completely fluxed prior to brazing?

ANS: Unfluxed areas will oxidize.

rv. SUMNARY:

A. Silver Brazing (brass) 1/16" x 1" x 2"

1. Square butt (flat)

a. Preparation

b. Positioning

c. Fluxing

d. Preheat

e. Brazing

( 11 of 13 ) TT-615-2-SW- 1G. 3.1.2 CL71.1Y.F. C? Ir..)raucTION INSTOCTOR ACTIVITY STUDEPTAarIvITACJ

f. Post heat

g. Cleaaing

2. 'lee joint (flat)

a. Preparation

b. Positioning

c. Fluxing

d. Preheat

e. Brazing

f. Post heat

g. Cleaning

3. Tee joint (vertical)

a. Preparation

b. Positioning

c. Fluxing

d. Preheat

e. Brazing

f. Post heat

g. Cleaning

4. Lap joint (vertical)

a. Preparation

b. Positioning ( 12 of 13 ) 2/) STT-615-2-SW- IG. 3.1.2 OUTLIbE 0? "INSTRUCTION .INSTRUCPOR ACTIVITY STUDENT AanVITY/Vb

c. Fluxing

d. Preheat

3. Practice silver braz- , e. Brazing ing brass joints.

f. Post heat

g. Cleaning

V. TEST; 4. Practical Test

A. Practical Test (SilverBrazing Brass) a. Butt joint (flat)

1. Butt joint (flat) b. Tee joint (flat)

2. Tee joint (flat) c. Tee joint (vertical:

3. Tee joint (vertical) d. Lap joint (flat)

4. Lap joint (flat) e. Lap joint (vertical: 5. Lap joint (vertical)

B. Witten Test

1. Annealing, hardening andtempering

2. Welding equipment applications

3. Correct welding rod selection

VI. ASSIGNMENT

A. "Me Welding Encyclopedia", 16thedition, Pages C-32, P-40 and P-41. 272,

21- ( 13 of 13 ) STT-615-2-SW- IG. 3.1.3 /V7

NAiAL SCHOOLS, CONSTRUCTION PORT HUENEME, CALIFORNIA93043 SMLWORKER SIT SCHOOL TRAINING COURSE 615-2

CIAsqificstion: UncJdsified

Topic: Silvox Brazins Stainless Terminal Objective: 3.1

Average Time: Pract: 4 periods Enabling Objective: Upon completion of this topic the student will be able to: Instructional Materials: A. Silver braze a tee joint of Stainless Steel 1/16" x 1" x 2" with an oxy-gas byrch in the flat and ver- A. Training Aids:None tical position. B. Publications E. Silver braze a 1/4" lap joint of Stainless Steel 1/16" x 1" x 2" with an oxy-ga3 torch in the flat 1. Text: Hone and vertical posiiton. C. The above shall be done with a joint of..0015 2. Reference:

to .003 and with no buildup. , a. "Brazing Manual" Anerican Welding Society Criterion Test: C. Equipment and materials: The student will silver braze a tee joint of Stain- less Steel 1/16" x 1" x 2" with an oxy-gas torch 1. Major equipmnt in the flat and vertical posiiton. Silver Braze a 1/4" lap joint of Stainless Steel 1116" x 1" x 2" a. Gas welding equipment with an dxy-gas torch in the flat and vertical position. The above shall be done with a joint of 2. Toole: .0015 to .003 and with no build up.

a. Glovls Homework:Reading assignment

b. Goggles 1. "Tbe Welding Encyclopedia" 16th edition, pages H-16 - 11-17 C. Plieys

d. Slag hahmer 2%

( 1 of 12 ) SST-615-2-SW- IC. 3.1.3

e. Spark lighter

f. Tip cleaners

g. Wire brush

3. Materials

a. Flux

b. Mapp gas

c. Oxygen

d. Silver brazing alley (cadmimm free) 1/16"

e. Stainless Steel strip 1116" x1"

D. Instructor Prepared Materials (Local)

None

, ( 2 of 12 ) 2 ? 5 0 STT-61 -2-SW IG.3.1.3.

INSTRUCTOR t1LCTIVXTY 7

I. Introduction to the Lesson . Introdure self and topic.

A. Establish contact.

1. Names

2. Topic:Silver Brazing Stainless

B. Establish readiness . Motivate student.

1. Purpose

2, Assignment

C. Establish effect 3. Bring out need and value of material being presented. 1. Value

a. Pass course.

b. Perform better on the job.

c. Get advanced.

d. Be a bettersteelTorker

D. Overview: 1.. State learning objec- 1. Silver Brazing (Stainless)1/16" x 1" x 2" tives. a. Tee joint a. State information (1) flat and materials necessary to gu;de student. (2) Vertical b. Lap joint (1) flat (2) Vertical

( 3 of 12 ) TT-615-2-SW- IG. 3.1.3

OUTIINE 0? IN57RUCTION INSTRUCDOR ACTIVITY STUDENTACTIV452)

II. PRESENTATION 5. Draw on the chalkboard 1. Take notes diagrans of the tee A. Silver Brazing (stainless) and lap joints and the method of applying and 1. Tee joint (flat) drawing the alloy thro gh the joints. a. Prepartion

(1) Sample strips 1/16" x 1" x 2"

(2) Grind, file or sandpaper joint area. (Do not use a wire brush)

Note: Do not use aluminum-oxide emery paper.

b. Positioning 6. /nsura the students un2. Ask question when in derstand the importanc doubt (1) Alignment of joint (no gap). Hold vertical stri of perfect alignment. in place by the use of a steel strip or rod (touching top edge of vertical strip and bench top) - Do no tack.

c. Fluxing

(1) Apply flux over entire joint area

d. Preheat

(1) Preheat entire joint area.

Note: Proper preheat is obtained if flux reoaina liquid when torch is removed from strips - keep flame off lf flux

2 )

( 4 of 12 ) 2"? STT-615-2-VW- IG. 3.1.3 OUTLINE c? LN5TKCTION INSThUCTOR ACTIVITY STUDENTACTIVITY/51

e. Brazing

(1) Feed brazing alloy into joint until alloy no longer disappears from fillet. Complete penetration uust be obtained.

Note: If alloy smokes, too much heat is being applied.

(2) Throat of fillet buildup must not exceed 1/32"

f. Post heat

(I) Bring test stripe to uniform temperature.

g. Cleaning

(1) Quench after test strips temperature drops below 700 F.

(2) Completely remove all flux by chipping and Rire brushing.

Note: protect hands and eyes when cleaning off flux - it will cut like glass.

2. Tee joirt (vertical)

a. Preparation

(1) Bawls strips 1/16" x 1" x 2"

(2) Grind, file or sandpaper joint area. (Do not use a wire brush)

Note: Do not use aluminum-oxide caery paper.

b. Positioning

(1) Alignment of joint (no gap). Hold strips in place 2 by the use of fire bricks - Do not tack

( 5 of 12 ) OUTLICi. 0? :-..16TRUCrION

c. fluxing

(1) Apply flux over entire joint area

d. Preheat

(1) Preheat entire joint area

Note: Ptoper preheat is obtained if flux remains liquid when torch is removed from strips - Keep flame off of flux.

e. Brazing

(1) Feed brazing alloy from top end of joint and permit capillary and gravity actian to fill the joint dawn vertical. Feed the alloy until it no longer disappears from fillet

Note: If alloy smokes, too much heat is being applied.

(2) Throat of fillet buildup must notexceed 1/32 "

f. Post heat

(1) Bring test strips to uniform tenperature.

g. Cleaning

(1) Quench after Vast strips temperature drops bplow 700° F.

(2) Campletely remove all flux by chipping and wire brushing.

Note: Protect hands and eyes when cleaning off flux - it will cut like glass.

( 6 of 12 ) 2 '3 STT-615-2-SW- IG. 3.1.3 OUTLIII C? :167:RIXTION INSTRUCTOR ACTIVITY STUDENTAcrurr453

3. Lap joint (fiat)

a. Preparation

(1) Sample strips 1/16" x 1" x 2"

(2) Grind, file or sandpaper joint area. (Do notuse a wire brush)

Note: Do not use aluminum-oxide emery paper.

b. Positioning

(1) Alignment of joint (no gap). Lap strips 1/4". Sup- port top strip on its free end by a 1/16" scrap strip and hold down with a fire brick. (Do not tack

c.FluXing

(1) Apply flux over etetire Joint area) including betwee lap joint,

d. Preheat

(1) Preheat entire joint area.

Note: Proper preheat is obtained if flux renlaine liquid when torah is removed from strips - k=:ep flame off of flux.

e. Brazing

(1) Feed brazing alloy into joint until alloyno longer disappears. Complete penetration must be obtained

Note: If alloy smokes, too'much heat is beingapplied

(2) Throat of fillet buildup must not exceed 1/32"

2k,') ( 7 of 12 ) SIT-615-2-SW- IG.\ 3.1.3

OUTLINE G? :NSTRZiCrION INSTRUCTOR ACTIVITY STUDENT A

f. Post heat

(1) Bring test strips to uniform temperatme

g. Cleaning

(1) Quench after test strips temperature drops below 7000 F.

(2) Completely remove all flux by chipping and wire brushing,

Note: Protect hands and eyes when cleaning off flux - it will cut like glass.

4. Lap joint (vertical)

a. Preparation

(1) Sample strips 1/16" x 1" x 2"

(2) Grind, file'or sandpaper joint area. (Do not use wire brueh)'

Note: Do not use aluminum-oxide emery paper.

b. Positioning

(1) Alignment of joint (no gap). Hold strips in place by the use of fire bricks. Lap strips 1/4". (Do not tack)

c. Fluxing

(1) Apply flux over entire joint area, including between lap joint.

d. Preheat

(1) Preheat entire joint area ( 8 of 12 ) (MUNE 0? :YSTRIJCTION IMSTRUCrOR AcrIVITY

Note: Proper preheat is obtained if flux remains liquid when torch is removed. Keep flame off of flux.

e. Brazing

(1) Feed brazing illpy from top end of joint and permit capillary and gravity action to fill the joint down vertical. Feed the alloy until it no longer disappears,from fillet.

Note: If alloy smokes, too much heat is being applied

(2) Throat of fillet buildup must not exceed 1/32"

f. Post heat

(1) Bring test strips to uniform temperature

g. Cleaning

(1).Quench after test strips temperature drops below 700° F.

(2) Completely remove all flux by chipping and wire brushing.

Note: Protect hands and eyes when cleaning off flux - it will cut like glass.

Insure that there is proper ventilation for the flux and metallic fumes and that the student does not position his face directly over the wri.

Silver brazing alloy is thinflawing and only the joint tolerance of .0015 to .003 should be filled with little or no build-up

( 9 of 12 ) STT-615-2-SW- IC. 3.1.3

INSTRUCTOR ACTIVITY STUDENT ACTIVITY OUTLIVE 0? INSTRIXTION

III. APPLICkTION /56

A. Questions and Discussion

1. Where should silver alloy be fed in a verticaljoint?

ANS:Top end of joint

2. What is the maximum throat dimensions on afillet in a silver brazed joint?

AXIS: 1/32"

3. How much should a lap joint be lapped?

ANS: 1/4"

4. Which one of the silver-brazed test strips should be tacked prior to brazing?

ANS: None

IV. SUMMARY:

A. Silver Brazing (Stainless) 1/16" x 1" x 2"

1. Tee joint (flat)

a. Preparation

b. Positioning

c. Fluxing

d. Preheat

e. Brazing

f. Post heat 2q2

Cleaning ( 10 of 12 ) 29ig. STT-615-2-SW- Ia3.1.3

OUTLIa OF IN57RUCTION INSTRUCTOR ACTIVITY STUDENT ACTIVITY

2. Tee joint

a. Preparation

b. Positioning

c. Fluxing

d. Pieheat

a. Brazing

f. Post heat

g. Cleaning

3. Lap joint(flat)

a. Preparation

b. Positioning

c. Fluxing

d. Preheat

e. Brazing

f. Post heat

g. Cleaning.

4. Lap joint (vertical)

a. Preparation

g. Postioning

c. Fluxing

d. Preheat ( 11 of 12 ) 293 ir

8-g TT-615-2-SW-- IC. 3.1.3.

OUTLINE 0? LKSTRUCTION INSTRUCTOR ACTIVITY STUDENT ACTIVITY

e. BraeraN,

f. Post heat

g. Cleaning

Pracdcal Test V. TEST a. Teejoint (flat) A. Practical Test (Silver Brazing Stainless) b.. Tee joint (vertical' i. Tee joint (flat) c. Lap joint (flat) 2. Tee joint (vertical) d. Lap joint (vertical' 3. TAT joint (flat)

, 4. Lap joint (vertical)

VI ASSIGNMENT: 4. Reading assignuent A. "The Welding Encyclopedia", 16th edition, Pages11-16 and M-17.

2(.-13

( 12 of 12 ) 3-01g 15-ei

'CHAPTER)

BLUEPRINTS ,

made Blueprintsare reproduced copies of me- The original drawings for prints are chanick or ot)er types of technical drawings.by drawing directly on, or tracing adrawing on The term "blueprint readInginsJnterpret1ng a translucent tracing paper orcloth, using black the ideas expressed by others on'drawings, waterproof(india)ink or a drawing pencil. blueprints This original drawing is normally referred to as a _whether the drawings aractuai1y "master copy." These copies of the or not. tracing language tracings are rarely, if ever, sent to ashop or Drawing or sketching is thp universal of these trac- used by engikeers, tehnlcian4and skilled crafts- job site. Instead, reproductions us made freehand ingsare made and distributedto person or men. Whether this drawing offices where needed. These tracings canbe or with drawing instrumentsit is needed to if properly convey all the necessaryIi,ormatlon to theused over and over indefinitely handled and stored. individual who will fabricate andassemble the the pre- object whether it be a building,ship, aircraft, From these tracings, mentioned in vious papagraph, blueprints aremade. The term or a mechanical device.If many people are term in involved in the fabrication of thnobject, copies blueprint is a rather loosely used (prints) are made of the origiaaldrawing ordealing with reproductions of orignaldrawings.' One of the first processesdevised to reproduce tracing so that all persons invcilvedwill have the white lines on a same information. Not only aredrawings used as or duplicate tracings produced objects, theyblue background, hence the termblueprints. plans to fabricate and assemble reproduction are also used to illustratehow machines, ship, Today, however, other methods of and'main- have been developed, and theyproduce prints of aircraft, etc., are operated, repaired, different colors. The colors maybe brown, tained. differences lie in This chapter contains generalinformation black, gray, or maroon. The concerning blueprints. After studyingthis chapter the types of paper and the developiug processes you should be able to tellhowblueprints are madeused. is contained A patented paper identified as"BW" paper and reproduced, what information prints with black lines on awhite on a blueprint, andwhere this information Is produce'à the meaningbackground. located. You will be able to state The ammonia process or "OZALIDS"produc- of the various types of lines used onblueprints black, blue, or maroon and list the precautions to beobserved, when es prints with either able to linee on a white background. handling blueprints. You will- also be IrAndyke paper produces a white line on a definethe common types of shipboardblue- they are numbered dark brown background. prints and describe how Other processes that may be usedto re- and filed. produce drawings, usually smalldrawings or sketches, are the offrce type duplicatingmachines, machines, ,and HOW PRINTS ARE MADE such as the mimeograph, ditto the like. One other type ofduplicating process drawings A mechanical drawing is drawnwith Instru- rarely used for reproducing working ruling pens, T-is the photostatic process. Thisin reality is ments such as compasses, in which a large camera squarest; triangles, andfrench curves. Prints a photographic process original drawings reduces or enlarges a tracing ordrawing. The./ (copies) are reproduced from photostat has. white lines on a darkbackground in much the same manner asphotographic prints tracing or are reproduced from negatives. when reproduced directly from a

.2cr? BLUEPRINT READING AND SKETCHING

drawing.If the photostated print is then' re- NUMBER TITLE prodiod, it will have brown lines on a white background. Photostats are generally used py various businessesfor incorporating reduced MIL-STD-18A Structural symbols size drawings into reports or redords. Military drawings and blueprints4re prepared MIL-STD-20 Weiding terms and in accordance with thedefinitely prescribed definitions standards and procedures set forth in Military Standards (MIL-STDS). These MIL-STDS are MIL-STD-21 Welded-Joint designs, listed in the Department of Defense Index of armored-tank type Specifications and Standards, which is issued as of 31 Jgly of each year. Common MIL-F.TDS MIL-S7D-22A Welded joint design concerning engineering drawings and blueprints are listed by number 'and title below, MIL-STD-2F Nomenclature and,symbols Change 1 for ship structure NUMBER TITLE MIL-STD-100'A Engineering drawing PARTS OF A BLUEPRINT practices Military blueprints are prepared as to size, MIL-STD-8C Dimensioning and format, location of, and information included, tolerancing in the various blocks, etc. according to MIL- STD-100A of 1 October 1967. The various parts MIL-STD-9A Screw thread conventions of a blueprint are described briefly in the following and methods of specifying paragraphs. MIL-STD-10A Surface roughness, TITLE BLOCK Change 2 waviness, and lay 1 The title block is located in the lower right-. MIL-STD-12B Abbreviations for use hand corner of all bluep-rints and drawings pre- on drawings pared in accordance with Military Standards. The block contains the drawing number, the name of the MIL-STD-14A Architectural symbols part or assembly that the blueprint represents, and all information required to identify the part 11;:,.-STD-15 Graphic symbols for or assembly. . Part No. 1 electrical and elec- The title block also includes the name and. tronics diagrams part lA address of the Government agency or organization preparing the drawing, the scale, drafting record, MIL-STD-15 Electrical wiring authentication, and the date (fig. 1-1). Part No. 2 equipment symbols for A space within the title block with a diagonal ships plans part-2 or slatit line drawn across it (not shown in fig. 1-1) indicates that the information usually placed MIL-STD-15 Electrical wiring in it is not required or is given elsewhere on Part No. 3 symbols for architec- the drawing. tural and electrical layout drawings, part 3 REVISION BLOCK MIL-STD-16C Electricaiand electronic reference designations The revision block (not shown)is usually located in the upper right-hand corner of the MIL-STD-17B Mechanical Symbols blueprint and is used for the recordingof changes Part 1 (revisions) to the print. All revisions are noted in this block and are dated and identified by a MIL-STD-17B Mechanical symbols for letter, and a brief description of the revision. A Part No. 2 aeronautical, aerospace- revised drawing is shown by the addition of a Change 1 craft, and spacecraft use letter to the original number as shown in figure

2' Chapter 1 BLUEPRINTS icS

Lillie/ '01'.

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NAVAL FACILITIES ENGINEERING COMMAND DES, .E! /1/174,449Y DEPARTMENT OF THE NAVY DR*N. .11 449xtiilsow U.S. NAVAL STAT1ON,WASHINGTON,D.C. CHK. //1457-W/47/04/ ac. 071/Z/a1/774V IN CHNRGE Ar Gle44'r 192.06! 220-3E1

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FEC ORAW1NO NO. APPROV DATE, CODE WENT. NO. SIZE1 . SAVO 4 f ....o. 1 1 6 74 2 0 1 FICEIN CHARGE 8009 ) F 1 A P P R V 0 OATE

I SHEET 1 OF / P U U C WORKS OFFICER SCALE 4* I. SPEc.8Z805/68 Ns82805

45,159(65) Figure 1-1. Blueprint title blocks. (A) Naval Ship Systems Command; (B) Naval Facilities Engineering Command.

1-1A. If the print shown in figure1-1A was 1-1A, and FEC drawing No. fig. 1-1B),which, revision appears in a block in the lowerright corner of again revised, the' letter A in the other places block would be replaced by the letter B. the title block. It may be shown in also; for example, near the topborder line in side at bRAWING NUMBER the upper corner, or on the reverse both endssothatitwill be visible when a drawing is rolled up. (Numberingshipboard All blueprints are identified by adrawing chapter.) number, (NavShip Systems Command No.fig. blueprints is discussed later in this

3 BLUEPRINT READING AND SKETCHING

If a blueprint has more than one sheet, thisbly drawings of aircraft). Parts numbered in information isincluded in the number blockthe title block can be located on the drawing indicating the sheet number and the number of by looking up the numbers in squares along the sheets in the seriqs. For example, note that in lower border. Zone numbers read from right the title blocks shown in figure 1-1, the sheetto left. is sheet 1 of 1. SCALE REFERENCE NUMBERS The scale of the blueprint is indicated in one Reference numbers that appear in the title of the spaces within the title block. It indicates block refer to numbers of other bluprints. Whenthe size of the drawing as compared with the mere than one detail is shown on a drawing, actual size of the part. The scale may be shown a dash and a number are frequently used. Foras 1" = 2", 1" = 12", 1/2" = l', and so on. example, if two parts are shown in one detailIt may also be indicated as full size, onedrawing, both prints would have the same drawinghalf size, one-fourth size, and so on. number, plus a dash and an individual number, such Ifa blueprintindicates that the scale is as, 8117041-1 and 8117041-2. 1" = 2", each line on the print is shown one-half In addition to appearing in the title block, itsactuallength. A scale showing 3" = 1" the dash and number may appear on the face each line on the print is three times its actual of the drawings near the parts they identify. length. Some commercial prints show the drawing and Very small parts are enlarged to show the dash number and point with a leader line to the views clearly, and large objects are normally part; others use a circle, 3/8 inch in diameter reduced in size to fit on a standard size draw- around the dash number, and carry a leader line ing paper. In short, the scale is selected to to the part. fit the object being drawn and space available on a sheet of drawing paper. A dash and number are used to identify modified Remember; NEVER MEASURE A DRAWING. or improved parts, and also to identify right-hand USE DIMENSIONS. Why? Because the print may and left-hand parts. Many aircraft parts on thehave been reduced in size from the original left-hand side of an aircraft are exactly like thedrawing; Or, you might not take the scale of corresponding parts on the right-hand side inthe drawing into consideration. Then, too paper -reverse. The left-hand part is usually shown in the stretches and shrinks as the humidity changes, t dr awing. thus introducing perhaps, the greatest source Above the title block on Some prints you mayof error in actually taking a Ineasurement by see anotation such as "159674 LH shown; laying a rule on the print itself. Play it safe and 159674-1 RH opposite." Both parts carry the READ the dimensions on the drawing; they alwaxs same number. But the part called for is dis- remain the same. tinguished by a dash and number. (LH means Graphical scales are often placed on maps left-hand, and RH means right-hand.) Some com- and plot plans. These scales indicate the num- panies %Ise odd numbers for right-hand partsber of feet or miles represented by an inch. A and even numbers for left-hand parts. fraction is often used, as 1/500, meaning that one unit on the map is equal to 500 like units on the ground. A LARGE-SCALE MAP has a scale ZONE NUMBERS of 1" = 10'; a map with a scale of 1" = 1000' is considered to be a SMALL-SCALE MAP. Zone numbers on blueprints serve the same Various typesand shapesofscalesare purpose as the numbers and letters printed on used in preparing blueprints. Three common borders of maps to help you locate a particular types are shown in figure 1-2. point. To find a particular point, you mentally Architects' scales(fig.1-2A), are divided draw horizontal and vertical lines from these into proportional feet and inches and are gener- letters and numerals, and the point where these ally used in scaling drawings for machine and lines intersect is the particular point sought. structural work. The triangular architects' scale dem will use practically the same system usually contains 11 scales, each subdivided dif- to help you locate parts, sections, and views on ferently. Six scales read from the left end, large blueprinted objects (for example, assem- whilefivescales read from theright end.

4 Chapter IBLUEPRINTS

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ARCHITECTS SCALE

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ENGINEERS' SCALE

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GRAPHIC SCALES

4.16(65)A Fig, re 1-2. Types of scales.

5 Peg BLUEPRINTREADING AND SKETCFUNG 111,1MINi

)01 750 --- -- 20017511111000 371 453 - 119000* 110250 1 MA42 --- 253 37$ --- 100 500 232-11511-- - 10021912.750--- $2 323 t 43 33 4 iono $3. 37 233.130 ns.no 14 750 124 4011---- - 70 000 4 4 082 21 7.003 - 42290 57 525 41 4117 207.301 40 000 200542 31417 - 33 250 I 71 $.- 32 103-- 132475-- 140425 23100-- 73is, 7 73.1125-- 14300 - 055 141127-MEE: I 44.500 144 000 1 33475 .--1211 500 122.343 .. -

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a 65,9 Figure 1-3.Aircraft stations and frames.

6 Chapter 1BLUEPRINTS

Figure 1-2A shows how the 3/16-inch subdivisionA bill of material for an electrical plan is shown of the architects' scale is further subdividedin figure 1-4 into 12 equal parts represenfing 1 inch each, and the 3/32-inch subdivision into 6 equal parts APPLICATION BLOCK representing 2 inches each. The application block (fig. 1-5) is usually Engineers' scales (fig. 1-2B), aredividedinto located near the title block and identifies directly decimal graduations (10, 20, 30, 40, 50, and60 or by reference the larger units ofwhich the divisions to the inch). These scales are usectdetail part of assembly on the drawing forms a for plotting and map draiving and in thegraphic component. The "next assembly" column (fig. solution of problems. 1-5), shows the drawing number or model number Metric scales (fig. 1-2C), are used in con- of the next larger assembly to which the drawing juntion with drawings, snaps, and soforth, made applies. The ' used on" column shows the model in countries using the metric system.This number or equivalent designation of the assembled system is also being used with increasingfre- unit(s) of which the part is a component. quency in the United States. Thescale is divided into centimeters and millimeters.In .conversion, 2.54 cm (centimeters) are equalto 1 inch. FINISH MARKS Graphic Scales (fig. 1-2D), arelines subdi- to convenient Finish marks (V)are used on machine vided into distances corresponding drawings to indicate surfaces thatmustbe finished units of length on the ground orof the object better surface They are placed by machining. Machining provides a represented by the blueprint. appearance and providesthe fit with closely in or near the title block ofthe drawing and duringthe of the draw- matedparts.Inmanufacturing, their relative lengths to the scales finishing process the requiredlimits and tol- ing are not affected if the print isreduced or erances must be observed.MACHINED FIN- enlarged. ISHES should not be confused withfinishes of paint, enamel, grease, chromiumplating, and STATION NUMBERS similar coating.Finish marks are discussed in chapter 6 of this training course. Various systems of station marking areused further on aircraft drawings. Forexample, the center line of the airplane on onedrawing may be taken NOTES AND SPECIFICATIONS as the zero station,and objects to the right or Blueprints contain all the informationabout leftof center along the wings orstabilizers which can be presented graph- may then be located bygiving the number ofail object or part line zero ically(thatis,in drawing). A considerable inches between them and the center be presented this station. On other drawings,the zero station may amount of information can be at the nose of the fuselage, at afirewall, way, but there is moreinformation required by at some other supervisors, contractors,manufacturers, and at the leading edge of a wing, or the graphic location depending on the purpose of the drawing. craftsmen, which is not adaptable to shown form of presentation. Informationof this type Station numbers for a. typioal aircraft are is generally given on thedrawings as notes in figure 1-3. or as a set ofspecifications attached fo be drawings. BILL OF MATERIAL NOTES are generally placed ondrawings to give additional information toclarify the object The bill of material block on ablueprint are used to contains a list of the partsand/or material on the blueprint.Leader lines print concerned. indicate the precise part beingnotated. used on or required by the A SPECIFICATION is a statement ordocu- The block identifiesparts and materials by number, ment containing a description orenumeration of stock number or other appropriate particulars, as the terms of a contract, orde- and also lists the quantityused or required. shown on a blue- The bill of material often contains alist of tails of an object or objects not standard parts, known as a partslist or schedule. print or drawing. such as machine Specifications (specs) describe items sothat Many commonly used items, they may be procured, assembled,and main- bolts, screws, turnbuckles,rivets, pipefittings with the per- and valves have been standardizedbzthe military. tained to function in accordance .14fr BLUEPRINT READING AND SKETCHING at BILL OF MATERIAL

"ANTI" CS 0 ESCRI PTION I ASSEMBLY

if co TR 01. NORTH . Heir 0 R FSN NO. NO. .

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3 IPLUG: ATTACHNTNT 3 WIRE l$ Awl., it$ V. T A 3431-102-309 I 0 I0

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A...... --, 65.10 Figure 1-4.Bill of material. formance requirements; furnish sufficient in-engineering, or help from the preparing organ- formation to permit determination of conformance ization. to the description;and furnish the above in Federal specifications cover the character- sufficient completeness for accwiplishment with- istics of material and supplies used jointly by out the need of research, development, designthe Navy and other Government departments. All Federal specifications used by the Navy Denartment as purchase specifications are listed in the Department of Defense Index of Specifi- cations and Standards.

LEGEND OR SYMBOLS

_NEXT ASS1Y USED ON The legend, if used, is generally placed in the upper right-hand corner of a blueprint below APPLICATION the revision block. The legend is used to explain or define a symbol or special mark placed on 65.11 a blueprint. Figure 1-6 shows a legend for an Figure 1-5. Application block. electrical plan.

8 Chapter 1BLUEPRINTS- /P7

L EGEND t Os FLuOREScENT FIXTURE: 8 DENOTMS 5cD CIRCUIT NUMBER, *50 DE.NoTES TYPE *a- NoMERoN7 ; "2 WIRE IN xi. CONDUIT uNLEs5 oTHRRWISE NOTED, VecoNDulT IN FLOOR 401, bupLEX REcErrAoLe S SWITGII -, 53 5 WAv Writ A N,\ - ---- CONDUIT IN FLooR CONDUIT IN CEILING N, 0 N.1.11 OUTLrr LIOX, II IXTURZ No. II To BE INUTALLEP N 4) Ex a UGHT alF1-001) LISirr Pe rumALARM11 IltID4 I to V. V IRRATIttd rem' 1 ri xTuRe RATE # 9 yq 1,AMTIAQE /o0 GI cae sELOCK00-4ILL-TII,c s a 0 yt4 ER mOSTAT Jo 1 2 IFIFI72 %. JUNCTIONBQX I Win 4./liu5Wir bola e° FAN y TOUAT It 00141 s a 11. MOTOR coNNEcTIoN 0 Ole Tr TELAPtOwe ovra-r 5 -44m.PLUG.1Wmoix.cd.i. 0 SPEc. -, al Ej FIRE Al.Mo4 SwITcli It Me. II CPI. ;NWIsvlioN PoR itu-s 5 7 (SPEC.) 0 NI

NOTE; SEE SPECIFICATIONS FOR DETAILED INFORMATION ON LIGHTING FIXTURSS

MTNRPROWNI., DEIICRINTIONI SYPHIOL invousais oNr000moe Nolama :rot%7,4'...%::,,c, Ig.v: ..w..g.mtavoir FLUORESCENT LIGHT DETAIL LAWRENCE 0. CANNACIE 5440$ Lou *ova , sty. NO SCALE IARCNITECT I1 NAyAL NESVIVEELECTRONICS FACILITY FIXTURE 50, 2 40W RAW/ILLS XENTUCRY AM ELECTRICAL PLAN cmg r,. RISER DIAGRAM . Ida 1. 41.1 __--,-,-'m."' warCIL ------SAT l...... --. i""""G.------:.:6777::::;%M* I 1 Ol C sousne 4=42-1--1--- 1031. ",",11141 FOS CPU 04, ma gam s mc....1-- v .., YIE II ORAWNI4/ fRI. 1111701 *VI 1,...i...,-9

26.6 Figure 1-6. An electricalplan.

-411( 31,15 1 A BLUEPRINT READING AND SKETCHING

MEANING OF LINES meaning, as shown by figure 1-7, Figure 1-8 showe the use of standard lines in a simple In order to be° able to raad blueprints you drawing. must acquire a knowledge, of the use of lines. The alphabet of lines is the common language of the technician and the engineer. SHIPBOARD BLUEPRINTS In drawing an object, a drqftsman not only arranges the different views in a certain man- Various types of blueprints (usually referred ner, but he also uses different types of linesto as plans), are used in the construction, operation to convey information. Line characteristics suchand maintenance of Navy ships. The common types as width, breaks in the line, and zigzags have axe defined below.

LINE STANDARDS NMI CONVENTION DESCRIPTION AND APPLICATION EXAMPLE - HEAW UNBROKEN LINES VISIBL E LINES USED TO INDICATE VISIBLE EDGES OF AN OBJECT -

. i mEDILIIA LINES WI TH SHORT I [ I I EVENLY SPACED DASHES i. HICOEN LINES USED TO INDICATE CONCEALED I L...JEDGES

- _ THIN LINES MADE UP OF LONG AND SHORT DASHES ALTERNATELY SPACED AND CONSISTENT IN CENTER 401%/ LINES LENG TH USED TO INCICATE SYMMETRY %If ---- -.1- ABOUT AN AXIS AND LOCATION OF CENTERS --.. THIN LINES TERMIMATED WITH ARROW HEADS AT EACH END DIMENSION LINES H USED TO INDICATE DISTANCE MEASURED I

THIN UNBROKEN LINES FI-- EXTENSION LINES USED TO INDICATE EXTENT --Ii OF DIMENSIONS I

142.46 Figure 1-7. Line characteristics and conventions for MIL-STD drawings.

, 1 , 3., I,

1111111111111MIli Chapter 1BLUEPRINTS /66,

6 systems, or PRELIMINARY plans are plans submittedwith arrangement of equipment, prior to award components which are notnecessarily subject bids, or other plans, submitted to strict compliance as todetails .provided the of contract. CONTRACT plans are planswhich illustrate required results are accomplished. that are mandatory WORKING plans are thecontractor's con- design features of the ship struction plans which are necessaryfor con- requirements. CONTRACT GUIDANCE plans areplans which struction of the ship. the ship subject CORRECTED plans are workingplans which illustrate design features of have been corrected toillustrate the final ship to development. fabrication, and in- STANDARD plans are plansillustrating ar- and system arrangement, rangement or details ofequipment, system, or stallation. specific requirenients are ONBOARD plans (discussed below) are ades- components for which ignated group of plans illustratingthose feature's mandatory. considered necessary forshipboard reference. TYPE plans areplans illustrating general

EXAMPLE DISCRIPTION ANO APPLICATION NAM2 COIWO4TION V. X 20 THD. THIN LINE TERMINATED WITH ARROW. HEAD OR DOT AT ONE END LEADER USED TO INDICATE A PART. DIMENSICN OR OTHER REFERENCE

MEDIUM SERIES OF ONE LONG DASHAND , TWO SNORT DAOIES EVENLYSPACED -...... / PHANTOM ENDING Kitt LING DASH POSITION OR USED TO INDICATE ALTERNATE DATUM LINE OF PARn, REPEATED DETAILOR TO INDICATE A DATUM PLANE

STITCH MEDIUM LINE OF SNORT DASHESEVENLY SPACED AND LABELED STITCH I I i LINE USED TO INDICATE STITCNING OR SEWING

THIN SOLID RULED LINES WITH FREEHAND vcpzAGs 1/\, - a REAX DRAWING (IANG) .-..49--, USED TO REDUCE SIZE OF REQUIRED TO DELINEATE OBJECTAND REDUCE DETAIL i

THICK SOLID FREE HAND LINES

BREAK (SHORT) 1...... i Ell USED TO INDICATE A SHORTBREAK

OJTTING OR mac SOLID LINES WITH ARROWEAD VIEWING r 1 TO INOICATE DIRECTION INWHICH PLANE SECTION OR PLANE IS VIEWED OR VIEWING L TAK EN PLANE Mr LIg OPTIONAL

... IMP CUTTING THICKSNORT DASHES 7 PLANE FOR ...,. COWPLEX OR USED TO SHOW OFFSET WITHARROW. imi .1 CI; OFF SET I HEADS TO SHOW OIRECTION VIEWED ze, VIEWS .4,...1

142.46 conventions for MIL-STDdrawings Continued. Figure 1-7 Linecharacteristics and

31 170 BLUEPRINT READING AND SKETCHING Al10.11. 4.* PHANTOM LINE ...i:EXTENSION LIRE DIMENSION LINE CENTER LINE EADER LINE

-SECTIONING LINE OF:\

BREAK LINE SECTION-AA A OUTLINE HIDDEN LINE CUTTING PLANE LINE 45.150(65) Figure 1-8. Use of standard lines.

ONBOARD PLANS The code identification number is a federal supply code number which identifies the design Upon completion of a Navy ship, the shipbuilder activity. Code number 80064 (fig. 1-1A) identifies furrdshestheship with copiesofall plans NavShips. (Code number 80091 (fig. 1-1B) iden- considered necessary for operating and maintain- tifies the Naval Facilities Engineering Command.) ing the ship(onboard plans), and a Ship Plan Index The three-digit group number is assigned from (SPI). The SPI lists all plans applicable to the the NavShips Consolidated Index of Drawings, ship concerned except plans for certain mis- Materials, and Services Relatel to Construc- cellaneous itemscoveredbystandardor tion and Conversion, NavShips 0902-002-2000. type plans. This number identifies the equipment or system Onboard plans include only those plans con- (or in some cases the type of plan) concerned. sidered by NavShips or the Supervisor of Ship- The number 800 (fig. 1-1A) identifies the plan building as being necessary far shipboard ref- as a contract plan. erence. The SPI therefore should not be used as The serial or file number is assigned from a checkoff list for the sole purpose of obtaining a a block of numbers provided by the Supervisor completesetof allplans. When experience of Shipbuilding. The revision letter denotes the indicates the need for plans other than those furn- latest revision of the plan as stated previously. ished as onboard plans, or additional copies of onboard plans, they may be obtained from the home yard of the ship concerned or the System di Command concerned. A guide for the selection of onboard plans appears in chapter 9001 of the NavShips Technical Manual. DLG 16303H1844928A

NUMBERING A Shipboard plans are numbered according to MIL-STD-100. The complete plan number consists of five parts; size, code identification number, the system command number (consisting of a DD 880S3801H1257161A three-digit group number, and a serial or file number), and revision letter as shown in figure 1-1A. The size letter (H in fig. 1-1A), indicates the size of the blueprint according to the table of format size in MIL-STD-100. Size letters run from A (for the smallest print) to K (for the 65.161 largest print). Figure 1-9. Shipboard plan numbers.

12 Chapter 1 BLUEPRINTS 171

Figure 1-9 shows shipboard plannumbering HANDLING BLUEPRINTS systems that were used previousto the system (DLG 16 in Blueprints or prints are valuable permanent Just described. In the first block records that can be used over and overagain if fig. 1-9A) is the ship identificationof the lowest to keep these numbered ship for which the plan isapplicable.necessary. However, if you are prints as permanent records,_youmust handle - Thethree-digit group number is takenfrom simple rules to NavShips 0902-002-2000, andidentifies the planthem with care. Here are a fe* as a lighting systemplan. The letter H denotesfollow to preserve these prints: previously. the plan size as explained 1. Keep them out of strong Sunlightthey Figure 1-9B shows the numbering system thatwill fade. was used before the adoption of thethree-digit 2. Don't allow them to become wet orsmudged group system. The system used"S" groupwith oil or grease; these ingredients seldomdry numbers which identified the equipment or system out completely, thereby making theprints prac- concerned. The number S3801 (fig. 1-9B) identifiestically useless. the plan as a ventilation system plan. Plansusing 3. Don't make pencil or orayon notations on this numbering system may ix related tothe a print without properauthority. If you-receive appropriate chapter of the NavShipsTechnical instructions to mark a print, use an appropriate Manual by replacing the S of the "S" group colored pencil and make the markings a perma- number ith the 9 of the NavShips Technictl ment part of the print. Yellow is a goodcolor to Manual chapter number and dropping thelast use on a print with ablue background (blue- digit of the "S" group number. In figure 1-9B, print). for example, thiS would produce the number 4. Keep prints stowed in their properplace 9380. Chapter 9380 of the NavShips Technical so they can be readily locatedthe next time you want to refer to them. !Manual islitled "Ventilation and Heating." Most of the prints that you will handle will be received properly folded. Your main concern willbetorefold them correctly. You may, FILING however, have occasion to receive printsthat folded On most ships, plans arefiled in the engi-have not been folded at all, or have been neering log room. Aboard tendersand repairimproperly. technical library The method of folding prints depends upon ships, they may be filed in the the type and size of the filingcabinet, and the or the microfilmlibrary. The plans arefiled in numerical sequence according tolocation of the identifying marks on theprints. cabinetsin It is preferable to place identifyingmarks at the the three-digit or"S" group number and the vertically (up- file number. When a laterrevision of a plan istop of prints when filing them previous revisionright), and at the bottom right-hand corner,when received, the plan with the In some cases construction is removed from thefile and destroyed, and the filing them flat. current plan filed in its place. prints are stored in rolls.

13 31)3 bt ,3-b2V/72-

CHAPTER 5 ANDFABRICATION SHEETMETALLAYOUT direction tilting the tooldightly in the tasksthe line, For shortlines, use will involve avariety of (See fig. 5-1.) lines, use Your duties tools and theappli-of movement. For longer with layout the steel scaleas a guide.straightedge. When requiring" skill techniques. Thischapter or a basic layout acircumference rule twopoints,prick cation of methods ofmeasuring, marking, to draw aline between will describe We you have fr om one prickpunch mark and joiningsheet metal. punch eachpoint. Start the line cutting, forming, handtools toward thecerter. Complete discuas the useof various and scribe prick punchmark in will also in theseoperations by scribingfrom the other and powertools requiredapplicable to shopwork. direction. and safetyprecautions the opposite 3TEEL SQUAREis a desirable The FLAT perpendicular orparallel TOOLS tool forconstructing paral- USTNG LAYOUT method oflayout known as lines. In the flat steel squareis used lel linedevelopment, theparallel to eachother essentially aprocess lines that are. This The LAYOUTof metal is cutting, to construct the baseline. material for perpendicular to clamp of measuringand marking is veryimportant as well asillustrated infigure 5-2. Just drilling, orwelding. Accuracyinfluence on the procedure is firmly tc thebaseline. Slidethe work, becauseit has an the straightedge the straightedge,and in layout fabrication,assembly, andbody of thesquare along ease ofsubsequent measurements lines throughthe desired operations. Usingwrong draw perpendicular joint result in apart beingfabricated might easily overall job, thuswasting points. which doesn'tfit in the instances, you and material.In many both time blueprints andsketches as your will depend on for thefabrication job guide tomeasurementsability to readand work being laidout. Hence, is importantto from blueprintsand sketches need basic in layoutwork. If you your successblueprints, youwill find chapters information on Readinz andSketchin% 1 and 8of Blueprint reference. 10077-C, anexcellent used NayPers ea the nameimplies, are Layout tools, jobs on metal.Some of for layingout fabrication which you may use commonlayout tools fol- the more simple layoutduties are as in performing combination square,pro- lows: flatsteel square, and trammel tractor, prickpunch, dividers, pOints. scribed with aSCRATCH Linesfrequently are orSTRAIGHT- AWL, using aSTEEL SCALE hold the best resultsin scribing, EDGE. For firmly in place,and set scale orstraightedge close to theedge of 11.202X. the point ofthe scriber as scriber out- Scribing a line. possible bytilting the Figuro 5-1. the scale as on the pointand draw ward. Thenexsrt pressure 51 173 STEELWORKER 3 & 2

WON

"\*

MEEEME222E222MEMEMEMEEEEM.

Figure ,5-2.Drawing perpendicular parallel lines. 11.204X

Before using the flat steel square, or at least at periodic intervals, see that you check it for accuracy as shown in figure 5-3. When the square is off, your work will be proportion- ately off, no matter how careful you are.

r-OOUBLE THE ERROR r"--1

11.205 BOON( Figure 5-4. Using combination square.

(see fig. 5-5). Set the vertex of your protractor TO NG tJ,E on the mark, and then scribe a V at the desired angle (in this case 700). Scribe the line between the vertex and the point located by the V, and you have constructed an angle of 70°. 11.203X When you locate a point and mark it with the Figure 5-3.Checking the square. PRICK PUNCH, be sure to use very light taps with a small ballpeen hammer. The smaller the mark you make (so long as it is visible),, the The COMBINATION SQUARE can be used to more useful and accurate that mark becomes. draw a similar set of lines, as illustrated in You will use DIVIDERS to scribe arcs and figure 5-4. An edge of the metal upon which you circles, to transfer measurements from a scale are working is used as thebaseline, as you will to your layout, and to transfer measurements note in the illustration. One edge of the head offrom one part of the layout to another. Careful the combination square is 90° and the other edgesetting of the dividers is of prime importance. is 45°. When you transfer a measurement from a scale Combination squares are delicate instruments to the work, set one point of the dividers on the and will be of little value if you permit them to mark and accurately adjust the other leg to the receive rough handling. Stow your squares prop- desired length as illustrated in figure 5-6. erly when you have finished using them. Keep To scribe a circle, or an arc, grasp the di- them ()lean and in tiptop shape, and you will be viders between the fingers and the thumb as illus- :able to construot 90° angles, 45° angles, andtrated in figure 5-7. Place the point of one leg parallel lines without error. on the center, and swing the arc. Exert enough : To construct angles other than 450 or 90°, pressure to hold the point on center, slightly you will need a PROTRACTOR. Mark the vertexinclining the dividers in the direction in which of the angle on your baseline with a prick punch they are being rotated.

52 FABRICATION Chapter 5SHEETMETALLAYOUT AND

11.206X angle with Figure5-5.Constructing an the protractor.

11.208X circle Figure 5-7.Scribing an arc or a with dividers.

,r4r TRA.MMEL POINT'S ser POR A irRAOIUS 4111"1"11.1ftliftlimeikeatete 11.207 L1111%. Setting the dividers. 4".14 . Figure 5-6. TRAMMIR.

with a radiuslarger than To seri'.a circle 1.1.209X the tool toselect i; theTRAMMEL your dividers, the points, Setting trammelpoints. POINTS. Thetechnique of ad Figure 5-8. in figure 5-8,is 4AI z left-hand as indicatedmark, slide theright-hind point to point on one tighten thethumbscrew. the desireddistance, and scribed in the same The arc, orcircle, is then manner aswith thedividers.

MAKING SIMPLELAYOUTS is a pattern ona flatsheet A STRETCHOUT If a flat sheetis 11.210X which has notbeen formed. it may be and cylindrical the correctshape and ,size, Figure 5-9.Forming square laid out to object. Figure shapes from flatpatterns. formed into athree-dimensional formed three-dimensionalobjects being 5-9 shows When jobs arelaid out, allow- from flat patterns. must be added. how they weremade. Somehave ances foredges and seamssheet metal jobat them and seewelded. Others areriveted end MAKING A D117.13PAN is a 'had the seams the fastestand to have if youare assigned as welded seam is that you are sure of the steelsoldered. The and soldered in the sheetmetal section easiest to lvout, but the riveted sheet a striker boxes, will beused seam is byfar the betterof the two in shop. Someof these pans, orshops. Take alook around themachinery in your 53 )Ge '

STEELWORKER 3 & 2 metal work. The various methods of seaming are discussed later in this chapter. Br Jak out your layout tools. Select a piece of sheet metal or template paper aboat 1 foot square. Lay out-a pan, or -box, similarto that shown in figure 5-10. Make the sides about 1 1/2 inches in height, and the bottom about 9 inches square. Don't forget the tab for riveting. The angle on the tab is 45'. (See the flaps marked "T" in fig. 5-11). If this angle were not cut, you wouki have difficulty forming the side of the box. When you have the drip pan, or box, laid out, form the pan by breaking (bending) the Odes up 90'. If you have made all of your measurements accurately, and have made your breaks on the line, the upper edge will be even all around, like the one shown in figure 5-11. 11.212 Figure 5-11. Layout of box.

H L + 2H STRETCH OUT 11.211X 9 Figure 5-10.-Dimenaions for a box or drip pan layout.

THE STRETPHOUt OF A OYLINDRICALJOB TT'Cr will be rectangular in shape, as shown in figure' 5-12. SYne dimension of, the rectangle will be the height of the cylinder, and the other dimension 11.213X will be the circuraference of the cylinder. When Figure 5-12. Stretchout of a cylinder. you're given measurements for a cylindrical job, however, you mq be given the diameter rathez than the circumference of the cylinder. You'll'3.1416 (or you can use 3.14 or 3 1/7, depending have to find the circumference yourself. on how accurate you wish to be), and the answer One method of determining circumference is will give you one dimension for the, stretohout, by computation or with a circumference rule.To find out what part of an inch the decimal Le, You remember that the circurnferenceof a multiply that number by the denominator of the tolerance required. Suppose your circumference circle is equal to 3.1416 times the diameter came oat to '9.678" and the tolerance is/16". (C=IrD)..By the use of this formula you can find the length of the stretchout of any cylin-The 9 is in 'inches and the .678 is.a decimal drical object. Just multiply thó diameter byfraction of an inch. Now multiply .678 by 16

313 1740, ANDFABRICATION AnTALLAYOUT Chapter5SHEET JOB THECYLINDRICALwith AVA TION OF run nols-a-flat-sided_gtsuctureis shownin figUre that you'llends. Such-a shape III rounded for thisshape, find 5-14. thestretchout circle ofthe 4Net4IleTN5 To figure of acompleted formed by circumference would be the of such acircle as Then addtwice diameter of theshape. figure 5-14. the twocarved ends partW in the un- of thestraightforfiguring the length equation symbol tr isalways 11.214X Use thefollowingal)+2W. The a let D=5and W=6. rule. knowndimensions:example; about 5-13.Circumference Here isan 27.7080, or Figure 3.1416. 5 + (2x6) = be thelength Now,3.1416 x other will rounded offto 11. inches,and the which is 16 and 27 3/4 you aremaking. get 10.848, put thisover of theshape that and youcome upwith 11, of the Since you an inch.The length FORLAYOUTS have11/16th of dimension. USINGGEOMETRY you cylinder isthe other - OR RIGHTANGLE desired determiningcircumference._ A 900 square. method cf rule. Theupper CONSTRUCTINGhave atrue steel Another circumference in difficult ifyou square, orthat is by useof the rule isgraduated is not have no still need a circumference aregularlayout that you off. You edge ofthe manner as shown But supposesquarewhich is ycurdividers, inches inthe game graduated as youhave a Break out the loweredge is you the for thelayout. Draw abaseline scale, but loweredge gives right angleand astraightedge. 5-15. Setthe 5-13. The of anycirclewithin ascriber, in figure .in figure circumference in figure onelabeled AB thanone-half AB; approximate will notice like the greater like those of therule. Youlower edgedirectly for adistance scribe arcs the range on the 9 3/8dividersA as acenter, changing thesetting 5-13 thatthe readingmark is alittle over then' with Now,without and scribe 3-inch circumference labeled Cand D. center, below the would bethe would. dividers, useB as a Draw aline Thisreading of 3inches and df the at Cand D. and inches. adiameter for acylinder ot another setof arcs arc's intersect of acircle with stretchout pointswhere the to lineAli, length of a for thestretch-threugh the perpendicularswill also be, the Thedimensions the height will haveerected angles. You thatdiameter. then, are you right two equal cylindricalobject, Don't for- four 90° or AB into out of a thecircumference. forming divided line cylinder and allow forthe seams. havebisected or AT A of the have to ANGLE get thatyou'll parts. ARIGHTdividers is atrick CONSTRUCTINGwith apair of GIVENPOINT

B 4.ROLL .... .-1- A ...KOLL.1 .1 STRETCHOLOT

11.216 L a 90°angle by Trc 4N2vii Constructing Figure 5-15.bisecting aline. 11.215X cylintier. 5-14.Variationof a Figure 56

31'r , 171 ' STBELWORKER 3 & 2 .that you'll find quite useful in making layouts'. Figure 546 is &nil tlistra_tlethoci_for constructing a 'fight angleat a given point. Suppose that you. have. line XY with A as a point at which you need to erectaperpendicular to form a right angle. Select any convenient point which falls somewhere within the proposed 900 angle. In figure 5-16 that point is C. Using C 90' 90' as the center of a circle, .with a radius equal to CA, scribe_* semicircular arc as shown in figure 5-16. Lay a straightedge along the points B and C and draw a line which will intersect the other end of the arc at D. Now, draw aoline connecting the points .D and A and you have constructed a 90° angle. This method may be used to form 90 corners in stretchouts that are square or rectangular, like a drip pan or a box. LAYING OUT DRIP PAN WITH A PAIR OF DIVIDERS is no more difficult than erecting a perpendicular. You'll need dividers, scriber, straightedge, and a sheet of template paper. You know the dimensions, the length, width, and height or depth to which the pan must be made. Draw a baseline (see fig. 5-17). Select a point onthis line for one corner of the drip-pan layout. Erect a perpendicular through this point forming a 90° angle. Next, measure off on the baseline the required length of the pan. At this point erect another perpendicular. You now have three sides of the stretchout, Using the required length of the pan for the other dimensions, draw -the fourth side parallel to the baseline, connecting the two perpendiculars that you have erected. Now, set the dividers for marking off the depth of the drip pan. You can use a steel scale to measure off the correct radius on the dividers. Using each corner for a point, swing a wide arc 11.218X Figure 5-17. Laying out a drip pan with dividers.

like the one shown in the second step in figure 5-17. Extend the end and side lines as shown in the last step in figure 5-1'7, and complete the stretchout by connecting the arcs with a scriber and straightedge. The next step is to lay out tabs like those shown in figure 5-11. Their size is determined by the diameter of the rivet, which 11.217 in turn is determined by the thickness of the sheet. Figure 5-16. Constructing a 90° angle at All that remains to be done now is to transfer a given point, the pattern to the sheet, cut the metal, and form it.

31 Chapter 5SHEET METAL LAYOUT ANDFABRICATION

You have seen how a pan can belaid oat without the use of a steelsquarely the use of geomet- tructionsYeu_bisected_a_line,_erected a perpendicular from a givenpoint on a line, and drew parallel lines by geometricconstruction. You'll find that these and othergeometrical principles may be used to do a lotof layout problero 5 rapidly and accurately. BISLCTING AN ARC is anothergeometric constr:mtion with which you should befamiliar. Angle ABC (see fig. 5-18) isgiven. With B as a center, draw an arc cutting the sidesof the angle at D and E. With D and E ascenters, and with a radius greater thanhalf of arc DE, draw arcs intersecting at F. A line drawn from Bthrough the point F bisects the angle ABC. Two methods ased to DIVIDE A LINEINTO A GIVEN NUMBER OF EQUALPARTS are illustrated in figure 5-19. When themethod shown in view A is to be used youwill need a straight- method, draw edge and dividers. In using this 11.220(127E) line AB to the desired length.With the dividers to divide set at any given radius, usepoint A as center Figure 5-19. Two methods used and scribe an arc abovethe line. Using the a line into equal parts. same .radius and B ascenter, scribe an arc below the line as shown. Frompoint A, draw a B of figure straight line tangent to the arc whichis below When the method shown in view B. With the 5-19 is used to divide a line into agiven number point B. Do the same from point of equal parts, you will needonly a scale. In dividers set id atkv given distance, startat point at right angles A and step off the requirednumber of spacesusing this method, draw a line this case, to one end of the base line.Place the scale at along line AD using tick marksin such an angle that the numberof spaces re- 6. Number the tick marks as shown.Do the iame covered from point B along line BC.With the straight- quired will divide evenly into the space point A, 5 to 1, by the scale. In the illustration(view B, fig. edge, draw lines from point 6 to 5-19) the baseline is 2 1/2" andis to be di- 4 to 2, 3 to 3, 2 to 4, 3. to 5, and11 to 6. You have scale so t! .` six equal parts. vided into six spaces. Place the now divided line AB into the 3" will cover 2 1/2" onthe baxclir.c. 3" divided by 6 spaces =1/2", draw linqs from the ,1/2" spaces on the scaleperpendicular to the baseline. Incidentally, you mayeven use a full 6 inches in the scale byincreasing its angle of slope from, the baseline anddropping perpendiculars from the full-inch graduationto the baseline. TO DIVIDE OR STEP OFFTHE CIRCUM- FERENCE OF A CIRCLE into sixapproximately equal parts, just set the dividersfor the radius of the circle and select a pointof the circumference for a beginning point. In figure5-20, point A is selected for a beginning point. With A as acenter, swing an arc through thecircumference of the circle like the one shown at B inthe illustration. Use B, then, as a point, andswing an arc through the circumference at C.Continue to step off 11.219 divided the circle Figure 5-18. Bisecting anangle. in this manner until you have

:31 a% 17q STEELWORKER 3 ta 2 into six equal parts. If thepoints of intersection between the arcs and thecircumference are connected as shown in figure 5-20,the lines will intersect P:t the center of thecircle, forming angles of 60'. If you need an angle of 30°, all youhave to do is to bisect one of these 60°angles, by the method described earlier in this chapter.Bisect the 30' angle and you haveIt15° angle. You can construct a 45° angle in the samemanner by bisecting a 90° angle. In all probability,you'll have a protractor to lay out these andother angles. But just in case you don't happento have a steel square or protractor, it's agood idea to know how to construct angles ofvarious sizes and to erect perpendiculars. LAYING OUT A SQUARE ORRECTANGULAR cifelp into six ELBOW WITH A PAIR OF DIVIDERSis another Figure 5-20. Dividing a geometric construction. equal parts. 11.221 job in which you will use

THROAT RADIUS

Figure 5-21. Layout of square orrectangular elbow. 11.222X 58 ...... "'"...."""C"

Chapter 5SHEET METAL LAYOUT AND FABRICATION

Take a look at figure 5-21. View A in the illustration shows you what the completed job should look like. Now, to make your layout for this job, draw the baseline OZ shown in view B of the illustration. Set the dividers for a distance equal to the width of the cheek. This distance forms the throat radius. This rule will not always apply, as it must often be governed by the amount of space available to make the turn with the elbow. Now, with 0 as a center, scribe the arc YU. To get the heel radius, add the width of the cheek 11.223X tothe throat radius. Using 0 as a center, Figure 5-22.Single-hem edge. scribe the arc ZTa These layouts, when cut, will form the cheeks, or sides, of the elbow. The next operation is to lay out the heel and throat pieces. These are the other two of the four sides of the elbow, the throat being the inside piece, and the heel the outside piece. Set the dividers at exactly 1 inch, and step off the heel and throat arcs as shown in view C, figure 5-21. If, there is a distance of less than 1 inch left at the end of the arc, measure it with another pair of dividers or a scale. To make the stretchout of the heel and throat, lay 11.224X out one piece of metal equal to the height of Figure 5-23. Double-hem edge. the elbow (see view A, fig. 5-21) and equal in length to the number of steps takem with the dividers, plus the fraction of an inch left over. One stretchout will be the heel and the other the throat,. You can assemble this elbow by welding, in which case you won't need to allow for tabs. But welding will cause a .Xhin section to warp, so you may need to use one of the other standard methods for joining this type of work.

ALLOWING FOR EDGES 11.225X Thus far your practice jobs have been laid Figure 5-24.Wired edge. out to be formed with the edges left as they are. Very few of your jobs in the shop will actually be fabricated in this manner. Edges are formed tosmooth edge is desired inside as well as out- improve the appearance of the work, strengthenside. The allowance for the double-hem edge is the piece, or to eliminate the raw edge. These twice the width of the hem. edges may be formed from the metal itself by inserting wire, or by attaching a band or angle A WIRED EDGE (fig. 5-24) will often be iron. The kind of edge that you will use on any specifiedin plans. Objects such as ice-cube job will be determined by the purpose, size, ortrays, funnels, garbage pails, and other articles strength of the edge needed. formed from sheet metal are manufactured with wired edges to strengthen and stiffen jobs and THE SINGLE-HEM EDGE is illustrated in eliminate sharp edges. The allowance for awired figure 5-22. This edge can be made in any width. edge is 2 1/2 times the diameter of the wire In general, the heavier the metal, the wider theused. For example, if you are using wire which hem is made. The allowance for the hem is edualhas a diameter of 1/8 inch, multiply 1/8 by to its width (W in fig. 5-22). 2 1/2 and your answer will be 5/16 inch, which THE DOUBLE-HEM EDGE (fig. 5-23) is used you will allow when laying out sheet metal for where additional strength is needed, or when a making the wired edge.

\3 ....iu.7' 3-0V/21

CHAPTER 6 PLATE AND PIPE LAYOUT ANDFABRICATION

In addition to sheet metal, Steelworkers alsoas a combinatkon punch, shear,and coper. This are required to layout and fabricate plate metal. machine has several attachments, including de- Plate layout procedures are essentially the samevices for slitting, notching, and coping. With as those for sheet metal, which were coveredthis machine (as, in fact, with all machinesused in the preceding chapter. There, are, however,for working metal) you must be careful notto some aspects of plate metal fabricationwhich exceed the rated capacity specified by the man- merit a separate discussion. Plate metal isufacturer. generally much thicker than sheet metal and is, therefore, more difficult to work and form. The first part of this chapter will, therefore, FORMING PLATE be devoted to examining the techniques necessary to cut, form, and join plate metal. The machines used for bending plate are Steelworkers must also be able to layoutsimilar to the machines used for bending sheet and fabricate piping or pipingsyetems, such as but are designed to take greater thicknesses might be used in a tank farm project. Theof metal. Most machines used for plate work remaining portions of the chapter will discuss are power driven. Figure6-3 shows a large procedures for cutting, bending, and joining pipe, slip-roll forming machine used for bendingplate. and layout operations peculiar to the fabrication of piping systems. Specific torch cutting and welding techniques carried out in the various stages of both plate and pipe fabrication will be covered in greater detail in later chapters on welding.

FABRICATING PLATE Some aspects of plate fabrication whichdiffer from the procedures previously described in ahaPter 5 for sheet fabrication are discussed in the following sections. CUTTING PLATE Perhaps the most common method of cutting plate is to use the gas (either oxyacetylene or OXY- MAPP gas) cutting torch, as deicribed in chapter 9 of this training manual. However, plate may also be cut with various tools and machines. Some power saws may be used to cut plate. The heavy-duty slitting shear shown in figure 6-1 is useful for cutting' Very heavy sheet, light plate, strap iron, and flat bar stock. The power- 11.300 driven machine shown in figure 6-2 is known Figure 6-1.Heavy-duty slitting shear.

31;) STEELWORKER 3 & 2

ADJUSTABLE ADJUSTMENT FOR BAR TAKE-UP OR MOTOR CUTTER RETURN SPRING

ADJUSTABLE TAKEUP 5 PIECE BARCUTTER KNWES HAND WHEEL CONTROL ANGLE STRIPPER FOR FULL-FLOATING FOR 90" CUTS PUNCH UPPER BLADE FOR COPER UPPER NOTCHING BLADE 3 PIECE 2 PIECE NOTCHER COPER DIE DIE ....----- ADJUSTABLE ADJUSTABLE DEPTH GAGE DEPTH GAGE HAND CONTROL FOR ENGAGING BAR STRIPPER FOR .-----w CUTTER SLITTING MITERING AN131.1,ES SHEAR AND COPER ----STRIPPER FOR.ROUND AND SQUARE BARS. ALWAYS IN POSITION SUPPORT FOR MITERING ANGLES SPIRAL GEARS FOR STRIPPER ADJUSTMENT ;1., ADJUSTMENT SCREWS FOR 4,2-.. --HAND CRANK FOR CENTERING DIE-BLOCK STRIPPER ADJUSTMENT SINGLE SCREW HOLDING/ lv SHEAR BLADE'S WITH DIE-BLOCK, ALLOWING FOR FOUR CUTTING EDGES QUICK CHANGES OF BLOCKS e.3

FOOT PEDAL

11.301X Figure 6-2. Combination punch, shear, and coper.

Figure 6-4 shows a power bending brake that One layout problem that is particularly im- can be used for forming plate. portant in plate work should be noted at this Although plate is usually bent on power bend-point. Regardless of the method to be used for ing machines, it can be heated and then ham- bending plate, you must always consider the mered into shape. Also, it is sometimes possible thickness of the plate and provide an adequate to heat small sections of plate or bar stock BEND ALLOWANCE. The amount of material and then bend them on a pipe bending slap.which is actually used in forming the bend is

92 Chapter 6PLATE ANDPIPE LAYOUT ANDyABRICATION Le-3

,".tot%

tt.

11.302 bending plate. Figure 6-3.Slip-rollforming machine for

Terms allowance. The thickerthe Bend Allowance known as the bend calculation of metal, the moreimportant is the In order for youto more thoroughlyunder- In working withthin sheet, and discussion ofbend the bend allowance. disregard) stand the calculation familiar with you can estimate(or sometimes even allowance, youshould become of the material.In working with As you study thefollowing the thickness the mate- the following terms. heavy plate, neglectingthe thickness of terms, referto figure 6-6and locate each serious deviationsfrom specified rial would cause lack ofpart described. dimensions andperhaps even complete fit between componentparts. LegThe longer partof a formed angel, the metal on theinside Bending compressesstretches the metal onthe FlangeThe shorterpart of a formedangle. of the bend, and these two the same length,each is outside of the bend.Halfway between If both parts are lies a space thatneither known as a leg. surfaces or extremes but retains the same shrinks norstretches, Figure 6-5 length. This isthe neutral axis. Mold Line (ML)The line formedby extending illustrates the neutralaxis of a bend. It isalong surfaces of the legand flange band allowance is the outside thisneutralaxis that the so that theyintersect. computed.

93 STEELWORKER 3 i 2

SENDING LEAF

OPERATING LEVER /I , Figure 6-4.Power bending brake forplate work. 11.303X

BEND THICKNESS (I) TANGENT UNE ( BL

LEG

Lzc's,

MOLD LINE IMLI , NEUTRAL AXIS FAO PONT./)1--el R+I I-, SETBACK (MEND) r--BASE WASUREWENT

11.304.2 Figure 6-6.Neutral fods. 11.304.1 Figure 6-6.Bend allowance terms. 94 FABRICATION AND PIPELAYOUT AND .Chapter 6PLATE freAors can bedetermined Usually, eachof these The linet which the or drawingsfrom which you Bend TangentLine (BL) from the blueprints metal starts tobend. are working. following examplesrefer As youstudy the understand where The amountof material 6-7 to helpyou BendAllowanee (BA) to figure figures areobtaindd. consumed inmaking the bend. and how themathematical MEASURED from Remember, bendallowance is the bend. It isalways but bendallowance is Radius (R)The radius of the insideof the bend; axis of themate- the inside ofthe bend unless COM.PUTED alongthe 'neutral measured from 'used. "nberefore,when calculating otherwise stated. rial being add the bendradius to one-half moldbend allowance, to determinethe The amountthat the two of the thicknessof the metal, Setback (SB) overlap whenthey are bent neutral axis. line dimensions 90* bend, radius of the is the produceof the radius around theformed part. In a Bend allowance bend, and thesine Of (radius of thebend plus thickness axis of the the SB R + T of the neutralradians. Theradian relates of the metal). - the bend in generated to thesize of the length of the axe bend allow- Brake or SightLine) the purposeof computing Bend Line(also called formed.angle. For of radians perdegree of line on themetal being ance,the number for bend The layout with the nooseof the cornice 0.017453. Thusthe formula It is set even guide in bendingbend is brake and servesas a allowance is; (Before formingsetbend, it must the work. the material can ba = rXO be deeidedwhich end of conveniently insertedin the brake.) be most meatured, andmarked The bend lineis then !mid tangent Where pencil, from the ba it bendallowance bend with a soft which is to beplaced of theneutral yds of the line closestto the end r = radius the bend inradians brake. Thismeaturement should 9 = size ofthe angle of bend under the the bend. Themetal (fig. 6-7).What is the be equal tothe . ulius of the EXAMPLE I. is to be madein in the brakeso that allowance for a90° bend which isthen inserted will falldlrectly over 1/2 inch thick? nose ofthe brake plate that is 0,750 inches the bend line. 0.50 + 0.250 - 0 =0.017453 x 90 =1.57 radians Flat Theflat portion orflat Flat Portion or not includedinTherefore; 1.57 = 1.178or 1.18inches of a plateis that portion ba = 0.750 x What is thebend the bend. Itis equal tothe base measure- EXAMPLE 2(fig. 6-8). is to be made setback. allowance for a180° bend which ment minus the 1/2-inch stock? Measure- in a length of Measurement (orMold Line 1.0 + 0.250 =1.25 inches Base measurement isthe outside 180 = 3.14radians ment)The base 0 = 0.017463 x dimensions of aformed plate.Base measure- blueprint ordrawing, Therefore; 3.14 = 3.926inches . ment will begiven on the part. ba = 1.25 x or maybe obtainedfrom the original JOINING PLATE angle that isless than 90when Closed AngleAn than 900 plate includeweld- legs, or more The methodsused to join used in measured between measured, and riveting.Tho method when the amountof bend is ing, brazing, the compositionof the depends upon parts, the that is morethan 90°each case size andshape of the OpenAngleAn angle less thanmaterial, the finished object isintended, when measuredbetween legs, or service forwhich the general, amount ofbend is measured. of otherfactors. In 90° when the and the numberpreferred methalof joining-plate. welding is the widely used tojoin plate Computing BendAllowance Riveting was once commonly usedat sections. Althoughit is not that you allowance, twopri- time, it isstill possible In order tocompute bend radius of thethe present join plate byriveting or must beknown; the may berequired to mary facts of angle inthe bend. bend, andthe decree 96 I sin : STEELWORKER 3 & 2

7-[

RADIUS T ) 6"

11.304.3 Figure 6-7.Bend allowance and length computation for a 90° L-shaped bracket:

11 -1-"2 DIA

0.50"DIA 0.50.:DIA-

4" 4"

\2" I.. RADIUS DQTTED LINE = AXIS NEUTRAL AXIS

11.375 Figure 6-8.Computing overal/ length of a U-bolt. 96

394 / a."/ Chapter 6PLATE AND PIPE LAYOUT AND FABRICATION Is that you may have to burn outbal rivets and Table 6-1 gives the rivet sizes commonly.. replace them in riveted structures. Mostrevet-used for riveting plate under ordinaryconditionq ing of plate is done with hot rivets. In general, remember, however, that unusual loadtng or other rivets used for joining plate should be ofthe unusual service conditions will affect the sizeof same material as the Olate. rivets required for the job. Before riveting plate,kclean the adjoining sur- _The selection of rivets for plateWork must faces of the plate. Then bolt the sectionsof be made on the basis of the load on the struc-plate' firmly together, putting the bolts through ture and other service conditions. Determiningsome of the rivet holes. Afterthe riyets have loads, selecting rivet' materials and sizes, and been driven in the other rivet holes, removethe designing riveted joints requires an extensive bolts and put in rivets. knowledge of propertiesof materials and of design standards. As a rule, you will work Small rivets may be driven cold. Large rive from specifications and blueprints or you willmust be heated. Care must be taken to: id be told what size and type of rivets to use andoverheating the rivets. A correctly hea ivet what type of layout to make for the rivet holes. is light red in color when it is taken mthe Figure 6-9 illustrates some types of rivetsfire, and cherry red when it is drivt.FigUre 6-10 shows a rivet set upfEtr driving. The Commonly used for joining plate and structural the shapes. length of the rivets should extend through

RIVET HEADS

COUNTERSUNK, COuNTERsuNK, SUTTON, RAISED FLAT CONED NECK

PAN-HEAD RIVET BEFORE BEING DRIVEN

SUTTON, PAN, , pan, STRAIGHT NECK CONED NECK STRAIGHT NECK

RIVET POINTS

V 421bici AcZ/Man, - , 111W1 ,",TINLIEwPpy , SNAP HAMMERED LIVERFOOL COUNTERSUNK, COUNTERSUNK, FULL RAISED

STRESS MATO COUPLE HERE At SWING STRESS HERE A--PAN HEAD J1111MMICN,A PAYING SURFACES ,77174t::% PULL IN PLAT .1,111.11.e, PULL IN PLATE

HAMMERED POINT SHEARING STRESS HERE ORIVEN RIVET CONNECTINGTwoPLATES

11.305 Figure 6-9. Types of rivets commonly usedfor joining plate and structural shapes.

97 STEELWORKER 3 & 2

.11.392 6-11, and then tamping the joint witha calking tool, as illustrated in figure 6-12. Metal calking able 6-1.-:-Rivet Sizes Required For Various should only be done from the side upon which aiaknesses of Plate, Under Ordinary Conditions, pressure will be exertedas,for example, from the inside of a tank.,

Rivet size Plate thickness CUTTING PIPE (diameter, (inc1,3s) ) Cutting pipe is not much different than &Maw inches) structural shapes, except that you must always keep in mind that the cut will either be radial or miter. 1/ 4 Under 5/64 The gas cutting torch is used to cut pipe 5/64 to 5/32 fitttngs for welding. As we mentioned before, 3/8 procedures relating to the use of -theciatting be 7/32 torch are given in chapter 9. The torch may, 1/2. /3 hand-operated or it may be rnountedonamechan- ical device for more accurate control. 5/8 2 to 5/16 Cutting machines may be used to prepare of templates. These 3/4 5/16 to 1/2 many fittings without the use 7/8 1/2 to 3/4

1 3/4 to 1 SPLITTING TOOL .11M. 1 1/8 1 and over

. \ Immo HOLDM-QN HOT RIVET HAmMEH IVETINO /HAMMER 11.307 =1. / - Figure 6-11, Forming a groove for metal , calking a joint. kg ffr.. Amoy .;11..... UT SOLT in, / 4111i,

WASHERS CALKING TOOL INNER' PLATE OUTER PLATE ,

,!.N. 11.306 ;6903 .N.N. N.N.% Figure 6-10.Rivet set up for driving. metal a distance of 1-1/2 dmes thediameter IOW to have sufficient metal to form the head. A procedure known as METAL CALKING is sometimes used to make riveted jointswater- 11.308 tight. Metal calking eonsists af forming a groove Figure 6-12. Tamping joint with metal calking or furrow with a splittingtool, as shown in figure tool.

39- 0 Chapter 6-4-PLATE AND PIPE LAYOUT ANDFABRICATION machines cut and bevel the pipe in oneoperation, PIPE BENDING wall thick- the bevel extending 1or.the full pipe Any piping system of consequencewill have noes. When pipe is cut byhand, beveling is done for such a, as a second operation. bends in it. When fabricating pipe fittings a RADIAL system, bends can be made by avariety of For many types of welded methods, either hot or cold, and eithermanually cut is required prior to beveling.Radial cutting machine. Cold bends simply means that the cutting torchis held soor on a power beading to the interior center-in pipe are usually made on a.bending machine. as to be perpendicular Various types of equipment areavailable, ralitng line at all times. In other words,the gas cutting hydraulically orifice always forms a continuationof a radiusfrom portable handsets to large, with the driven machines which cancold bend pipe up of the pipe, making the cut edge square will be concerned pipe wall at every point. Figure6-13 illustratesto 16-inches in diameter. You radial cutting. Except in the caseof the bluntprimarily, however, with hotbending techniques, bull plug, for which the radial cutprovidesusing a bending slab oremploying a method the proper vee, the radial cut shouldbe followed known as wrinkle bending. by a beveling cut for pipe with3/16 inch or more wall-thickaess. MAKING TEMPLATES In MITER cutting the torchflame ia held le that the entire cut surfaceis in the same bend pipe, you plane. The miter cut is followedby a beveling Whatever method you use to should,ordinarily, have some patternwhich cut, leaving 1/32 to1/16 inch nose at the inner bend. Tem- wall. Figure 6-14 illustrated mitercutting. represents the desired shape of the

Figure 6-13.Radial cutting. 145.179k

plates made from wire orsmall, flexible tubing can be invaluable inpreparing new installations, as well as In repairwork, When properly made, they will provide an exact guideto the bend desired. One of the simple typesof bend template is the centerline template. Acenterline template is made to conform to thebend, or bends, of the pipe to be made. It is used tolay off the bend area on the pip; and as aguide 1/44tAx.ing the pipe or tube bending operation.Figure 6-15 illustrates the use of a centerline template.These timplates are made of wire orrod, and are shaped to establish the centerline of the pipe tobe installed; the ends of the wire are securedto special clamps, called flange spiders.Aclearance disk, 145.180X the pipe, Figure 6-14.-- Miter cutting. which must be the same diameter as

3 9 " STEELWORKER 3 & 2 -

11.344 Figure 6-15.Centerline template. 47

is used if there is any doubt aboutthe clearance around the pipe. ...

HOT BENDING

Hot bends are accomplishedon a bending slab (fig. 6-16). This slab requires littlemaintenance beyond a light coating of machine oilto keep 0 rust in cheek. As a preliminary step in hot bending, pack the pipe with dry sand to preventthe heel or outside of the bend from flattening,If flattening HEAT BAFFLE occurs, it will reduce the cross-sectional areaof the pipe, and restrict the flow offluid through 0 0 the system. Drive a tapered wooden plug intoone end of ...4.-...... PULL the pipe. 'Place the pipe ina vertical position -"" with the plugged enddown and fill it with dry A7 - sand, .leaving just enoughspace at the upper end to take a second plug. Toensure that the sand is tightly packed, tap the pipe continuallywith a wooden or rawhide mallet during thefilling 11.346 operation. A good rule of thumb is totap ONE Figure 6-16. Bending on a slab. HOUR for each inch of pipe diameter.The second plug is identical with the first,except that a small vent hole is drilledthrough itsheat has been obtained, bend the pipe to conform length; this vent permits the escape ofany gases to the wire template. The template is also used (mostly steam) which may form in thepacked to mark the bend area on the pipe. pipe when heat is applied. No matterhow dry the The main problem you will have in bending sand may appear, there is- alwaysa possibility copper tubing and pipe is preventing wrinkles and that some moisture is present. Thismoisture flat spots. Wrinkles are caused bycompression will form steam which will expand andbuild up of the pipe wall at the throat (inside) ofthe bend. pressure in the heated pipe, unless somemeans Flat spots are caused by lack of support forthe af escape is provided. Ifyou do not provide apipe wall, by stretch in the heel (outside) of vent, you will almost certainly blowout one of the bend, or by improper heating. the plugs before you get the pipe bent. If the pipe is properly packed and properly When you have packed the pipe with sand,heated, wrinkles and flat spotscan be prevented the next step is to heat the pipeand make the by bending the pipe in segmentsso that the bend. Mark the bend area of the pipewith chalk 3tretch is spread evenly over the whole bend or soapstone and heat to an even red heat alongarea. When a pipe is bent, the stretch tends to the distance indicated from A to Bin figure 6-17. occur at the middle of the bend. If the bendarea Apply heat to the bend area firston the outside is divided into a number of segmentsand then of the bend and then on the inside.When an even bent in segments, the stretch willoccur at the

100 Chapter 6 PLATE AND PIPE LAYOUT AND FABRICATION

to slip over the end of the packed pipe.Bending pins and holddown clamps (dogs) are used to WOOD PLUG position the bend at the desired location, Be sure to wear asbestos gloves when working----7-- TEMpLATE- on hot bending jobs. Pins, clamps, andbaffles often have to be moved during the bending operation. These items absorb heat radiated from the pipe as well as from the torch flame itself; you cannot safely handle these bending accessories without gloves. Each material has its peculiar traits, and you will need to know about these traits inorder to get satisfactoryresults. The following hints for. bending different materials should prove helpful: WROUGHT IRONThis material becomes brittle when hot, so always use a large bend radius. Apply the torch to the throat of the bend instead of to the heel. BRASSDo not overbend, as brass is likely 11.347 to break when the bend direction is reversed. Figure 6-17. Heating and bending pipe to conform to wire template. COPPERHot bends may be made in copper, although the copper alloys are more adaptable to cold bending. This material is one that is not center of each segment and thus be spread fairly likely to give any trouble. evenly over the whole bend area. Another advantage o bending in segments is that. this is about ALUMINUM Overbending and reverse bend- the only way you can follow a wire templateing do not harm aluminum, but because there accurately. is only a small range between the bending and When bending steel and some other pipingmelting temperatures, you will have to work with materials, you can control wrinkles and flatcare. Keep the heat in the throat at all times. spots by first overbending the pipe slightly andYou will not be able to see any heat color, so then pulling the end back, as shown infigure 6-18. you must depend on "feel" to tell you whenthe Hot bends are made on a bending slab, asheat is right for bending. You can do this by indicated in figure 6-16. The pull to make thekeeping a strain on the pipe while the bend bend is exerted in a direction parallel to thearea is being heated. As soon as the bend starts, surface of the bending slab. Theneceseary lever-flick the flame away from the area. Play it back age for forming the bend is obtained by using and forth to maintain the bending temperature chain-falls. orblock-and-tackle, or by using aand, at the same time, to avoid overheating. length of pipe which has a large enough diameter CARBON-MOLYBDENUM and CHROMIUM- MOLYBDENUM These may be heated for bending,ifnecessary; however, caution must be exercised so as not to overheat the bend area because these types of metals are easily crys- FLATTENING OVERSEND AND AT THROAT 1 PULL' BACK TO tallized when extreme heat is applied. Pipes CAUSED BY 1 ROUND UP made from these materials should be bent cold BENDING. THROAT in manual or power bending machines.

WRINKLE BENDING

11.348 It may seem odd that after describing pre- Figure 6-18.Overbending to correct cautions necessaryto keep a bend freeof flattening of pipe. wrinkles, we next describe a method which

101

3 ') STEELWORKER 3 di 2 deliberately produces Wrinkles as a means of Wrinkle bending has been sucessful on pipe bending the pipe. Nevertheless, you will findof more than 20 inches in diameter. Experience the wrinkle bending techniquea__ simple and._has shown that, for aim inch diameter_pipe and direct method of bending pipe, and perhaps over, more complete and even heating is accom- in Many pipe bending situations, the only con-plished using two weldiag torches rather than venient method. This would particularly be the one. In any event, the heating procedure is the case if no bending slap were available, or ifsame, the torch or torches being used to heat time considerations did not permit the rathera strip approximately two-thirds of the circum- lengthly sand-packing process. ference of the pipe (see fig. 6-20). The heated Basically, wrinkle bending consists of a simple strip need not be very wide (2-3 inches is usually heating operation in which a section of the pipesufficient) since the bend will only be through is heated by a gas welding torch. When the metalabout 12° at most. The heated portion, as we becomes plastic (bright red color) the pipe ishave noted, is the part which will stretch to bent SLIGHTLY, either by hand or by means ofbecome the outside of the bend. The 'portion tackle ..igged for that purpose. The heated por- which is not heated directly will compress slightly and pucker to form tha wrinkle. tion, which stretches, forms the heel (outside) The technique most often used to bend the of the bend, while the wrinkle is formed at thepipe, once it has been heated, is simple end throat (inside) of the bend due to compreasiori. straightforward. The pipe is merely rolled over It ought to be understood that the pipe should(heated portion on underside) and one end lifted not be bent through very large angles (12° beingup hi hand (or by tackle), while the other end considered the mmdmum for one wrinkle) in is held firmly on the ground. order to avoid the danger of the pipe buckling, Tbe procedure in making s, large bend is to make several wrinkles, one at a time. If, for LAYOUT OPERATIONS -maniple, you want to produce a bend of 90°, a minimum of eight separate wrinkles could La& of templates, charts, and mathematical be made. Figure 6-19 shows a 90° bend madeformulas need not hinder you in pipe layout. with 10 separate wrinkles. In emergencies, welded pipe of equal diameter can be laid out in the field quickly and easily. By using the methods described here and a few simpletools, you canlay out branches and

HEATED PORTION OF PIPE 2/3 OF CIRCUMFERENCE/

127.149 127.150 Figure 6-19.-90° bend made with 10 separate Figure 6-20. Part of pipe heated prior to wrinkles. wrinkle bending.

102 30 Chapter 6 PLATE AND PIPE LAYOUT ANDFABRICATION 3

Y-connections as well as turnsof any angle,into 90-degree segments orquarter a. The framing radius, and number of segments.- square,spiritlevel, and soapstone are used in the following manner. The few simple tools required areboth roll; readily available and familiar to theSteelworker Block the pipe so it cannot move or through alaost tab,- use. A framing square,then place the inside angle of the squareagainst a bevel protractor with a12-inch blade, athe pipe and level one leg. One point onthe cen- wrap-around (or tape), terline is then under the scale at adistance of spirit level, a spring steel pipe from the a center punch, a hammer,and soapstone willhalf the outside diameter of the of cardboard orinside angle af the square (see fig.6-21).. Re- meet all needs. (A stiff strip peating at another part of the pipewill locate. sheet tin about 3 inches widealso makes a By this good wrap-around.) For purposesof our dis-two points, and hence the centerline. cussion, the long part of the framing squaresame method the quarterpoints also my be and the shortlocated. This operation is a mustprior to is referred to as the BLADE method. part as the TONGUE. any layout with the field 'Two methods of pipe layout arecommonly If you are using a long pieceof piPe and used; they are the one-shot methodand theare going to cut bothends, in adation to the ship method. The ONE-SHOT methodis usedsquare, you will need apiece of carptnter's in the field. With thismethod, you will usechalk-line with a plumb bob on eachend and handtools and make your layout onthe pipe to two 24- or 36-inch Mt steel rules(depending be cut. As you can *mil), see,the one-shoton the diameter of thepipe) to locate top and only use itbottom centerlines. Figure 6-22 shows a.plumb method is so named because you bob and rules being used tolocate top and once. will make tem- bottom centerlines. In the SHOP METHOD you Another one-shot method ofquartering pipe plates for pieces that are going to beduplicated it around in quantity. As an example, ajob order comesis to take a strip af paper and wrap into the ship for 26 pieces of6-inch pipe, allthe pipe and tear or cut the partthat overlaps. it wouldThe ends should touch. Removethe paper from cut at the same degree. Obviously, illustrated in be very tizne-consumizig to usethe one-shotthe pipe and fold it in half, as method; hence, the shop method isused forview A, figure 6-23. Then doublethe strip once again,as shown in view B.This will divide laying out. Patterns can bemade of template parts. Place the strip paper or thin-gagesheet metal. An advantageyour strip into four equal templates is that whenof paper around the pipe. At the creasemarks of thin-gage sheet metal and where the ends meet, markthe pipe with you have finished withthem, they can be stored quartered. in an appropriate place inthe toolroom forsoapstone and your pipe will be later use. Bear in mind that all pipe turns aremeasured TEMPLATE FOR TWO-PIECE TURN by the number of degrees bywhich they turn with square aside from the course set by the adjacentstraight The fact that a length of pipe section. The angle is measuredbetween the ends can be fabricated by wrapping arectangular centerline of the intersecting sectionsof pipe. Branch connections are measuredin angle of turn away from the mainline. For example, LEVEL a 60-degree branch is socalled because the angle between the centerlineof the main pipe and the centerline of thebranch connection FRAMING measures 60 degrees. Turns aredesignated SQUARE by the number of degrees bywhich they deviate from a straight line. QUARTERING THE PIPE In laying out any joint,the first step is to establish reference points or linesfrom which markings can be 145.186X additional measurements or quarter made. This is done by locating acenterline and Figure 6-21. Locating top and side dividing the outside circumferenceof the pipe points.

103

3 '3 STEELWORKER 3 &

If the templet developed in view C, figure 6-24 is wrapped around the pipe with the base line square with the pipe, the curved linea-b-c-d- e-f-etc. will locate the position for cutting to inakea gO-degiléb, 1Wo-piace turh.' "DrAW a circle (view A, fig. 6-24) equal to the outside diameter of the pipe and divide half of it into equal sections. The more sections, the more accurate the final result will be. Perpendicular to the centerline, and bisected by it, draw line AI equal to the 0,D. (view B, fig. 6-24) and to this line construct the template angle (TA) equal to one-half of the angle of turn, or in this case 45 degrees. Dray/ lines parallel to the centerline from points a, b, c, etc. on the circle and mark the points where these lines intersect line ai with corresponding letters. As an extension of AI, but a little distance from it, draw a straight line equal to the pipecircumference, or that of the circle in view Afigure 6-24. This line (view C, fig. 6-24) should then be divided into twice as many equal spaces as the semi- circle a-b-c-etc. and lettered as shown. Per- pendiculars should then be erected from these 145.187X points. Their intersections with lines drawnfrom Figure 6-22.Locating top and bottom the points on ai in view B, figure 6-24 parallel centerlines. to the base line in view C, figure 6-24 determine the curve of the template. SIMPLE MITER TURN After quartering the pipe, proceed to make a simple miter turn. Locatethe center of the A cut (see point c in fig. 6-25) in the general location where the cut is to be made. Use a 127.151 spring steel wrap-around to make line ab com- Figure 6-23. Folding strip of paper for use pletely around the pipe, at right angles to the in quartering pipe. center and quarter lines, thus establishing a base line for further layout work. When measuring, treat the surface of the section of plate into a cylindrical form makes pipeasifit were a flat surface. Use a flat available a method (known as parrallel forms) steel rule or tape, which will lie against the of developing pipe surfaces, and hence developing surface without kinks, even though it is forced the linesof intersection between pipe walls.to follow the contour of the pipe. These angles Based on this principle, wrap-around templates can also be checked for accuracyby sighting can be made for marking all mannerof pipe with the square. fittings, for cutting preparatory to welding. Use the protractor and square to determine The development of a template is done inthe proper amount of cut-back for the desired practice by dividing the circumference (in the angle of the miter turn. Start with the protrac- end view) of the pipe into a certain number of tor scale set at zero, so that the flat surface equal sections, which are then projected on toof the protractor and the blade are parallel. the side view of the desired pipe section.The You can now set the protractor for thenumber lengths of the various segments which make up of degrees desired. After you have the correct the pipe wall may then be laid out, evenly spaced, setting,lock the blade. Place the protractor on a base line which is ineffect the unwrapped on the square with the bottomblade on the out- circumference. This is shown in figure 6-24. side diameter of the pipe. Now read up to the

104 Chapter 6PLATE AND PIPE LAYOUT AND FABRICATION /9 5- t

I IN THIS CASE OF! A 90 DEG. TU' r"' T 1 = T = 900 I TEMPLATE ANGLE VIEW A I (T.A.) = 1/2 ANGLE OF TURN (T)

Il..* 0.0. --i..1 A a b c d rg hi hg VIEW C

\ 145.188X Figure 6-24. Principles of template layout.

NO. OF DEGREES

145.189 Figure 6-25.Simple miter turn. OD OF PIPE 145.190 cut-back on the vertical blade and take one-hall. Figure 6.-26. Finding the cut-back. You must be sure that the flat surface of the protractorisflush againstthe blade of the square (see fig. 6-26). The outside radius of the measure off the same distance along the bottom pipe should have been determined during the quarter line. Make punch marks with the center quartering operation. punch on each side of the line, along the side After you have obtained the cut-back measure- quarter lines. These marks will make it easy ment, mark one-half off along the centerline toalign the pipe for welding after the joint on topofthepipe. From the opposite sideis cut. Use the spring steel wrap-around and

105

33:3 .1 STEELWORKER 3 & 2 pull the loop to the cut-back point; then, draw and branch of equal diameter, draw the side and a chalk line over the top half ofthe pipe through end view as shown in figure 6-28, views A and B. the first cut-back point. A word of caution is: In making the template for the branch in do not- allow- the- wrap-around to-twist or kink,figure 6-28, view A, draw. lines 1 - 5 at-45_ and hold the chalk at a right angle to it while degrees tothe centerline. Lay off distance marking the pipe. Now roll the pipe one-half1-P equal to twice the thickness of the pipe turn and mark a chalk line in the same waywall and draw the smooth curve S-P-S.Now, around the bottom half of the pipe. project point P from view A to view B and draw the lines P-t radially. At a distance above pointt equal to the thickness of the header TWO-PIECE TURN wall, draw a-t horizontally, and vertical lines If a template is not available, dimensions and a-a and t-t. With lowerpoints a as centers markings for the cut necessary for a two-piece and a radius equal to one-half the header O.D., welded turn ofany angle between 1 and 90 swing arcs m-n; then with e as a center swing degrees may be determined by maldng a full- arcs r-s. Using the intersectionsof these arcs sized drawing as shown in figure 8-27. as centers, and with the sameradius, draw the Draw the centerlines intersecting at b bycurved lines a-b-c-d-e and e-d-c-b-a. using the angle of turn T and then draw the Divide the outside circumference of the branch outlines of the pipes by using the centerlines top into equal parts and draw the vertical lines and the diameter D. These will intersect atb-b, c-c, etc. Also, draw the horizontalbase a and c. By laying the pipe overthe drawing line a-a. so that point b will coincide withthat deter- Lay off the unwrapped circumference as mined by construction details, the line a-b-c-bshown in view D (fig. 6-28) and divide each may be drawn in preparation for mitercutting half of it into the same number of equal parts and beveling. as the branch semicircumference.Plotting in After being prepared for welding, one sectionview D the distances a-a, b-b, etc., from view of pipe should be rotated through 180 degreesB, which give the distances from baseline to form the desired angle, and then shouldbe to the branch curve of intersection,determines tack-welded. Spacing should be slightly greater the location of the branch template. at the inside of the turn. To make the template for the hole in the header, divide the circumference of the header WELDED TEE into equal parts, as at points 1, 2, 3, etc.,and To layout the template for cutting thebranchproject these points across to view A (fig. 6-28) and header for a 90-degree tee withheader as shown. As in view C, layoff the line 1-6-1 equal to one-half the circumference of the header, and divide it into the same number of equal parts as was don) on the header. Locatepoint P, a distance from 1 in view C equal to 1-P in view B. With this point P and the distances 5-5,4-4, etc.,in view A, plotted as shown in view C, the curve of the template is located.

BRANCH CONNECTION Branch to header connections, as shown in figure 6-29, at any angle of 45 to 90 degrees can be fabricated In equaldiameter pipe by the following procedures. (Note that angles less than45 degrees can be made, but practical limitation is imposed by difficulty of welding T = ANGLE OF TURN the crotch section.) D = OUTSIDE DIA. OF PIPE First quarter both sections of pipe asbefore. Then locate the centerline of intersection (point B) 145.191 on the header and draw line GFaround the pipe Figure 6-27. To locate cut on pipe for any at this point. Set the diameter FG on the blade angle two-picce turn. of the square. Set and lock the protractor at

106

3 :3 ig7 LAYOUT ANDFABRICATION Chapter 6PLATEAND PIPE

VIEWS SHOWINGSECTIONS OF PIPEAFTER CUT ON PATTERNLINE. RADIAL. N Ki ALL CUTS VI EWS SHOWINGSECTIONS OF PIPE AFTERBEVEL AND WELD HAVEBEEN MADE.

a _m411411111 d c Circumference L. Edge oftempl3te-7

3.45.192X Figure6-28.-900 tee.

107 Jig STEELWORKER 3 & 2 cut-back measurement. With the same settings, and with the square upside dowtr \as compared with before, locate point I the same was you located point IL thii-prot-Fact-or to oiie-liàfthèiiiithF of degrees of turn away from the heade(in the example 1/2 of 60° = 30). With the 131e set to the diameter, the second portion, HC, the second cut-back measurement will be Indio on the tongue. The second cut-back measureme is the total distance FC. Connect points C an B and connect C with the point, which corresponds to B, on the quarter line on the opposite side of the header. This outlines the second cut and completes the marking of the header. Use the same two cut-back measurements to lay out the end of the branch: branch cut-back 145.193 distance DA is equal to header cut-back distance Figure 6-29. Br anch connections. FA; branch cut-back distance EC is equal to header out-back distance FC. U the branchendis square, make cut-back measurements from tt rather one-fourth the number of degrees of turn away than marking in a circumferential line. Make from the header (in the example 1/4 of 600 = 15°). all cuts as bedore, level and join the branch With the bladealono; FG, the first cut-back and header by welding. measurement, FA, will be indicated on the tongue of the square. Measure off this distance along WELDED TEE (BRANCH SMALLER the centerline of the header from line FG and THAN TIIE HEADER) mark point A. As described before, join point A with the points of intersection of line FG and One of the best types of joint for a 90-degree the two side quarter lines, to outline the firstbranch connection where the branch is smaller cut. thhn the header is obtained by inserting the smaller With the same protractor setting, flip the branch pipe through the wall down to the inner square and mark point H; the distance FH is surface of the header, so that the outside surface equal to FA; FH is the first portion of the second of the branch intersects the inside surface of

BRANCH 4" IN DIAMETER AND LESS 145.194X Figure 6-30. Method where line of cut is first marked on main,

108

336 /9 LAYOUT ANDFABRICATION_ Chapter 6PLATEAND PIPE

BRANCH 6" OR MOREIN DIAMETER 145.195X method. first marked onbranch with this Figure 6-31.Line of cut is

LINE OF RADIAL CUT (450 SETTING)

1 STRAIGHT EDGE (800 SETTING) 145.196X 400 branch for Figure 6-32.Marking out on eccentric branchconnection. (SS° SETTING) header is at all points.When the the header this type ofintersection pre- properly beveled,desirable vee forwelding. sents & very dimensions In casetemplates ortemplate available, the lineof cut on bothheader are not by othermethods, 145.197 and branch canbe looated Three-piece Yconnection, of templatesis recommended. Figure 6-33. but the use the squareend of the In thefirst method, position be placed inthe correct marked branch should line ofintersection A new lineof cut is then against theheader and the wall thickness. through thepoints "b", flat soapstonepencil, as shown smooth curve marked with a as a first line at thetop of theheader. 6-30. case, tapering to the joint shouldthen in figure cutting isemployed in this Following radialcutting, the Since radial wall shouldintersect and since theouter branch "b" should be beveled. cut on thebranch, the header wall,the point To locatethe line of until even the inner the branoh adistance be slippedinto the hole be located onboth sides of branch should to slightly morethan the header from "&" equal 109 ,, STEELWORKER 342

a similer procedure is followed as shownin figure 6=32. TEREE-PIECE Y_CONNECTION The entire procedure for fabrication of an equal diameter, three-piece Y connection ,is, based on individual operations already described. As the first step, quarter the end of the three pieces di pipe and apply circumferential lines. When the three pieces are welded together to form the Y there will be three centerlines radiat- ing from a common point. The open angle between each pair of adjacent 145.198 centerlines must be decided, for each of these Figure 6-34. True Y. angles will be the angle of one of the brsnches of the Y. As shown in figure 6-33, these open angles determine the angle of adjoining sides of with point "b". A soapstone pencil may thenadjacent branches. Thus, half of the number of be used to mark the line for radial cutting.degrees between centerlines "B" and "G" are No beveling is necessary. included in each of the adjoining cut-backs be- A second method for larger diameter pipe tween these two branches. The same is true with is shown in figure 6-31. Mter centerlines haverespept to the other angles and out-backs be- been drawn, the branch should be placed againsttween oenterlines "B" aid "A". Moreover, each the header as shown. By means of a straight-piece of pipe must have a combination of two edge, *the distance between "a" and the headerangles cut on the end. wall is determined, and this measurement above To determine the amount of.cut-back to form the header transferred to the branch wall asan angle of the "Y", lay the protractorat one- represented by the curved line "a-b-c". After half the open angle between adjacent branch cen- this line is radially cut, the branch may be usedterlines. Place the protractor on the square, to locate the line of cut on the header, allowing crossing the outside radius measurement of the for the intersection of the outer branch wallpipe on the tongue of the square, and read the and inner header wall as before. This line shouldcut-back distance of the blade of the square. be radially cut, followed by beveling. Mark off this distance on one side quarter line In making an eccentric branch connection,on each of the two pieces that are to bejoined. the extreme case of which is where the side ofThen mark the cut-back lines. Repeat this pro- the branch is even with the aide of the header,cedure for the other two angles of the "Y",

127.268 Table 6-2.-Computations and Measurements for a "Y"Connection.

ACB ACG BCG

Open angle between centerlines 90 deg. 110 deg. 160 deg. Protractor setting (half of each angle) 46 deg. 55 deg. 80 deg. Cut-backs 6" 4 1/8" 1 1/16" Centerlines A Paired cut-back measurements fe6" ab as 1 1/16" ab es 1 1/16'; (inches) cdni4 1/8" fe =16" ccili 4 1/8"

110

3 3 -1:Chapter6PLATE AND PIPE LAYOUT AND FABRICATION Of

TEMPLATE FOR TWO BRANCH LINES

...... ,'""1,...... 1...... J..""....C...... L...... )

b1 C1 d el 11 el c al 1 1 1 1 1 b1alil OUTSIDE CIRCUMFERENCE TEMPLATE FOR MAIN LINE PIPE

145.199X Figure 6-35.Template for true Y branches and main of equal diameter.

111

3 3 ;) STEELWORKER 3 & 2

taking care to combine the cut-backs on each a. full-sized drawing of the intersection as shown pipe end. Three settings of the protractor deter-in figure 6-34 should be made. The intersection mine all cut-backs. Of the centerlines of the three pipes will locate An alternate method for determining eachpoint "b", and lines from "b" to the intersec- cut-back ia to treat two adjacent branches astions of the pipe walls will locate points tt, c, a simple miter turn. Subtract the number of and d. From these points the pipe mw be marked degrees ct open angle between centerlines fromfor cutting. Miter cutting, followed by suitable 180 degrees and set the protractor at one-half; beveling,is necessary in preparing the pipe cross the outside radius measurement on the for welding. tongue. Mark 'one side of each adjoining pipe section. Repeat for the other two branches. Take TEMPLATE LAYOUT FOR TRUE care to combine the proper cut-backs on each Y BRANCHES AND MAIN LINES pipe end. Set the protractor for each open angle of the "Y" connection. In laying out a template for a . true Y, a The computations and measurements for the drawing oftheintersection should be made, Ikrout shown in figure 6-33 are shown in tableas shown in view A, figure 6-35. After drawing 4 6-2. The pipe is 12-inches in diameter, and as thelinesof intersection, the same essential a radius of 6 inches. methods as for other templates are followed. Note that here it is suggested the equally divided LAYOUT OF TRUE Y semicircumferencesaremoreconveniently ..In laying out pipe for the fabrication of aplaced directly on the base line. The distances tr-us Y without the use of templates or tables,from the base line to the line of intersection

BASE LINE 01 TAB TAB I EXTERNAL CIRCUMFERENCE

145.200X Figure 6-36. Orange peel head.

112 Chapter 6PLATE AND PIPE LAYOUT AND FABRICATION 2 63

H . W1. 1/2 W .4; 4

W2. 7/8 W 1-* 17CI67R6F SEGMENTS

1.2.843.-3

W SHOULD BE 5 OR MORE. IF 415 USED,IT LOOKS BOXED. 11.201 Figure 6-37,-- A field method of making an orangepeel. plotted on the unwrapped base Une determinex-x in 'view A and draw thelines a-o, etc., in this view. the template. Now divide x-o-x into equal partsinthis case, six. Then draw the lines x1 -x1 and x2 -x2. ORANGE PEEL HEAD These represent the concentric circles in view A number of different typesof heads areB. In laying out the template, thedistances a-b, used in welded piping construction. Here, web-c, ,a2-1:02 , etc., axe taken from view B, are interested in one generaltype; the ORANGE while the distances x-o, x-xL , x-x2 ,b-bt , etc., PEEL, since it will often concern youin your are taken from view A. (Itis not actually nec- work. A main advantage of the orange peelis essary to draw views, A and B sinceall the values resisting internalcan be determined bysimple computation.) All that it has high strength in beveling pressure. cutting should be radial followed by a If templates or tables are not availablefor cut. making an orange peel head, a reasonably accu- A one-shot field method ofmaking an orange followingpeel is shown in figure 6-37. Thismethod can rate marking can be secured by the only one procedure for laying out a template.. be used when you are going to make The number of arms to make an orange peel orange peel. Incidentally, thetabs shown in fig- head should be the minimum( number which can ure 6-37will help to line up yotir template be bent over easily to form the head. Whilefive better. arms and welds areredommended as the minimum number for any pipe,this numter should be increased for larger sizes of pipe.Diviting SAFETY the circumference by five is a good methodfor The primarysafety concern in plate and deciding the number of arms, provided, of course, do with the there are at least five. pipe fabricating operations has to To lay out the template, !draw the sideand use Of cutting andwelding torches and related end views as shown in figure 6-36. Dividethe equipment. Specific safety precautions appro- pipe circumference in view into the samepriate tothe operations covered in this chapter number of equal parts as it planned to have will, therefore, be discussed in theforthcoming welds, and draw the .raditil lines o-a, o-b, etc.chapters on cutting and welding equipmentand Project the points a, b, etc., \on thebase line techniques.

113

3 4 3 -ay ?0Y.

CHAPTER 1 3

SOLDERING

then supply the heatrequired to heat the sur- Soldering is a processwhich joins metals solder. However, the alloys (commonly faces and thus melt the by melting nonferrous filler heating devices are sometimesused for the di- known as solders) on thesurfaces to be joined. surfaces to be joined; in this True solders, called SOFTSOLDEFtS, always rect heating of the 800° F, and belowcase, the solder ismelted 174 the heat from the have melting points below heated surfaces. the melting points of themetals to be joined. source of heat soft soldering If you use a welding torch as a Since the temperatures used for for soldering, use it carefully.A welding torch are always below_800° F, and the temperatures above 800° F, soft gives out much moreheat than is actually re- used for weldi* are always quired for soldering. If youoverheat the solder- soldering is not classified as awelding process. to retin them and per- valuable adjunct ing coppers, you will have Soldering is, nevertheless, a haps reforge them.Excessive heat may also to welding because it is asimple and fast means being joined and may soldered joints are not damage the metal that is of joining metals. Although of the solder. as strong aswelded joints (and, thus, cannotbe cause deterioration mechanical strength is A gas blowpipeof the type shown in figure used where any great 13-1 is often used to supplythe heat reqUired required),, soldering is aparticulatly useful end either to heat the electrical connec-for soldering. It may be used effective means o.: securing soldering coppers or to heatthe surfaces to be tions, joining sheet metal,and sealing seams can be used to join joined. against leakage. Soldering An alcohol torch isshown in figure 13-2. iron, nickel, lead, tin, copper,zinc, aluminum, This torch is aself-contained unit which re- and many alloys. quires no outside sourceof pressure. The al- This chapter describes theimplements and e o h ol tank is filledabout two-thirds full of alco- materials required for softsoldering, the three hol and then sealed.To operate the torch, basic methods employed tomake soldered joints remove the cap and lightthe wick. The flame from and, in addition, the specialtechniques required the wick heats the jettube, causing the liquid to solder aluminum alloyss alcohol in the container tovaporize and evand. The expansion of thealcohol forces the alcohol vapor from the jetopening, where it burns with SOLDERING EQUIPMENT a hot flame. If a gas oven or furnaceis available, you will Soldering requiresrelativelylittle equip-find that this is the bestdevice for heating sol- ment. For most solderingjobs, you will need dering coppers. One typeof gas oven that may only a source of heat,soldering coppers, solder, be used for heatingsoldering coppers is shown and a flux. in figure 13-3. SOLDERING COPPERS SOURC ES OF HEAT A soldering copper(sometimes called a sol- forged copper head, a for soldering vary dering iron) consists of a The sources of heat used handle, and an iron rod whichconnects the head according to the method usedand the equipment 13-4.) The handles may blowtorches, forges, and the handle. (See fig. available. Welding torches, be made of wood or of fiber.Handles are some- gas ovens or furnaces,and other heating devices ,times forced on the rodand sometimes screwed may beused. Most commonly,theheating devices are used to heatsoldering coppers which on. 284

1 Chapter 13SOLDERING 2 05-

VALVE TIP r OR HOSES POINT 1 TO - COSIPRESSID'A IR AND GAS SUPPLY

61 T OR HEAD 11.142 Figure 13-1.Gas blowpipe.

JET WICK

FILLER PLUGS ALCOHOL TANK

11.143 Figure 13-2. Alcohol torch. 11.145 Figure 13-4. Soldering copper.

INSULATED COVER HINGED AT BACK BOTTOM COPPER LIFITING HANDLE BIT OR HEAD

POINTED COPPER

STUB COPPER '

VALVE CONTROL TIP OR POINT

11.146 Figure 13-5.Soldering copper heads. 11.144 Figure 13-3.Gas oven. Electric soldering coppers (fig.13-6) are Heads are available in various shapes.Figure built with internal heating coils. The heads are 13-5 shows some of the most commonlyused removable and interchangeable. types of heads. The bottom copperis used for soldering seams in pails, pans, trays, andother Coppers that are not electrically heated are objects in which the seams are hard toreach. The supplied in pairs so that one copper may be used stub copper is used for solderingflat seamswhile the other is being heated. The size desig- where a considerable amount of heat isrequired. nation of coppers refers to the weight (in pounds) The pointed copper is used for generalsoldering of TWO copper heads. Thus a reference to a pair work. of 4-pound coppers indicates that each copper

1# 285

3 4. ) STEELWORKER 3 & 2

the file. Continue filing the tapered sides of the copper until they are bright and smooth. CAU TION: Remember that the copper is hoe Do not tauch it with your bare hands. 4. Smooth off the point of the copper and 1.26A smooth off any shell) edges. Figure 13-6. Electric soldering copper. 5. Reheat the copper so that it will be hot enough to melt th5 solder. hewi weighs 2 pounds. Pairs of coppers are commonly supplied in 1-pound, 1-1/2-pound, 3-pound, 6. Rub each filed side at the copper back and 4-pound, and 6-pound sizes. forth across a cake of sal ammoniac, as shown Heavy coppers should be used for soldering in figure 13-8. heavy gage metals, and light coppers slur:1d be used on thinner metals. A light copper will not 7. Apply solder to the copper until it is tin- hold enough heat to heat heavy metals properly, ned. The solder may be rubbed directly on the and a heavy copper is likely to overheat thincopper or it may be placed on the cake of sal metals. ammoniac. Do not push the iron into the cake of sal ammoniac. This can split the cake. Filing and Tinning Coppers If sal ammoniac is not available, powdered New soldering coppers must be tinned (coatedrosin may be used instead. In this instance, the with solder) before they are used. Also, copperspowdered rosin may be placed on top of a brick. must be filed and retinned whenever they have(See fig. 13-9.) The copper is rubbed back and been overheated or have for any reason lost theirforth to pick up the rosin. The solder can than coating of solder. The procedure for filing andbe placed directly on the copper. tinning a copper is as follows: Commercially prepared soldering salts may also be used in tinning soldering coppers. These 1. Heat the copper to a cherry red. salts are available in powder form; dissolve the powder in water to make a solution, following the 2. Clamp the copper in a vise, as shown in directions which accompany the material. Dip the figure 13-7, soldering copper into the solution, and then apply the solder. 3. File the coppor with a single-cut bastard file. Bear down on the forward stroke and release pressure on the return stroke. Do not rock Forging Soldering Coppers Soldering coppers may be reshaped by forging when they have become blunt or otherwise

U. "11 -".". ',.''''''''''''''',..,` ,s,"'', ..,,,,",,,,,,,,,z.,,,,,w,...... `. I .....--. '.....41

i%e'.74' /44,4'...

igt.?,',.:,.. , .:.A.'?.

11.148% 11.147% Figure 13-8. Tinning a copper (solder placed Figure 13-7.Filing a soldering copper. on cake of sal ammoniac).

286 Chapter 13SOLDERING 07

point on the copper by hammering the point back as the forging progresses; this is necessary because the copper would cool off too rapidly if the point is too sharp. Turn the copper often to produce the necessary squared-off sides. Reheat the copper as often as necessary during this part of the forging. 4. Reheat the copper to a bright red and use a flat-faced hammer to remove as many hollows as possible. 5. File and tin the copper by the procedure previously described. Dipping Solutions The soldering copper must be kept clean and bright while soldering. This can be done by dipping the hot soldering copper into a dipping solution just before soldering. The clipping solution removes the oxide from the- point, leaving 11.149X a clean and bright point. A dipping solution is Figure 13-9. Tinning a copper (solder placed made by dissolving about 1/8 ounce of powdered directly on copper). sal ammoniac in one pint of water. A solution made by dissolving soldering salts in water may also be used as a dipping solution. The acid or deformed. The procedure for forging a copper is flux should not be used as a dipping solution. as follows: The heat from the copper will change the color of the flux which will in turn stain the work. 1. File the copper to remove all old timing and to smooth the surfaces. SOLDERS 2. Heat the coper to a bright red. Most soft solders are alloys of tin and lead. Occasionally antimony, silver, arsenic, or bis- 3. Hold the copper on an anvil and forge it muth are added to give special properties to the to the required shape by striking it with a ham-solders. Solders used for joining aluminum are mer, as shown in figure 13-10. Keep a bluntusually alloys of tin and zinc or of tin and cadmium. As mentioned before, soft solders have melting points below 800° F and below the melting points of the metals being Joined. The melting points of most tin-lead solders range from about 360° F to about 465° F. Tin-leadsolders are usually identified by numbers which indicate the percentage of tin and the percentage of lead. The first number gives the percentage of tin, the second gives the percentage of lead. For example, a 30/70 solder is an alloy of 30 percent tin and 70 percent lead. A 50/60 solder (sometimes called half-and-half solder) is an alloy of 50 percent tin and 50 percent lead. A 15/85 solder is an alloy of 15 percent tin and 85 percent lead. Solders containing a high percentage of tin are more expensive than those containing a high percentage of lead. In general, the solders which contain a high per- 11.150X centage of tin have lower melting points than Figure 13-10. Forging a soldering copper. those which contain a high percentage of lead.

287

345 og STEELWORKER 3 ts 2

forms, in- chloride, pour a small amount of=agate acid Solders are available in various hydrochloric acid) into cluding bars, wires, ingots, andpowders. Wire (the commercial form of flux core. a container. Then addpieces of zinc to the solder is available with or without a muriatic acid until the liquid nolonger boils and bubbles when the zinc isadded. The zinc and FLUXES the acid enter into a chemicalreaction which hydrogen gas. When To make a satisfactory joint,both the metalproduces zinc chloride and be free of dirt, the liquid no longer boils andbubbles, the reac- to be joined and the solder must tion is complete and the liquid inthe container is grease, oxides, and etherforeign matter which instead, it is now a solu- would keep the solder from adhering tothe metal. no -longer muriatic acid; Fluxes are used to clean the joint area, to remove tion of zinc chloride in water. Strain the zinc chloride solutionbefore using the mdde film which is normally present on any which is not used im- metal, and to prevent further oxidation.Fluxes it as a flux. Any solution also decrease the surface tension of thesolder mediately should be stored in atightly sealed wetting agent. glass container. and thus make the solder a better Certain precautions must beobserved in pre- Table 13-1 shows the fluxes that aregenerally inhale the fumes used with some common metals. paring zinc chloride. Do not corrosive, given off by muriatic acid orby the mixture of Fluxes are generally classified as muriatic acid and zinc; thesefumes are injurious mildly corrosive, and noncorrosive. metals. Do not CORRCSIVE FLUXES have the mosteffective to personnel and corrosive to prepare zinc chloride in aclosed space. Hydro- cleaning action. However, anytrace of corrosive the zinc reacts chemi- flux that remains on the work will causesubse-gen gas is lib::rated as quent corrosion of the metal. Therefore,corro- cally with the muriaticacid. HYDROGEN IS soldering electrical VIOLENTLY EXPLOSIVE: Zincchloride should sive fluxes are not used for always be prepared out in the open or verynear connections and for other work in whichsubse- the danger quent corrosion would present a seriousprob- openings to the outside, to minimize of explosion. Also, precautionsshould be taken lem. from coming in con- The most commonly used corrosivefluxes to prevent flames or sparks tact with the liberated hydrogen. are sal ammoniac(ammonium chloride) and zinc that you may chloride. These fluxes ere frequentlyused in Another type of corrosive flux is evap- use is known as SOLDERINGSALTS. Commer- solution or in paste form. The solvent cially prepared soldering salts areusually fur- orated as the work is heated,leaving a layer powder is dissolved of solid flux on the work. At thesoldering tem- nished in powder form; the perature, this layer of flux meltsand partially in water to make a solution. The When a corrosive flux has beenused for sol- decomposes, liberating hydrochloric acid. removed from hydrochloric acid dissolves the oxidesfrom the dering, the flux residue should be the work as completely aspossible. Most cor- surface of the work and from the solder. water; washing the ACID rosive fluxes are soluble in Zinc chloride (sometimes called CUT work with soap and water andthen rinsing thor- or KILLED ACID)should be made up in small the amounts, as required for use. To preparezinc oughly with clear water usually removes residue of corrosive fluxes. Thiscleaning should be done immediately alter thesoldering has been 11.388 completed. Table 13-1. -- Fluxes used for soldering MILDLY CORROSIVE FLUXESsuch as citric Some Common Metals. acid in water are sometimes usedfor soldering. These fluxes have some advantagesof the more advantages Metals Fluxes strongly corrosive fluxes and some of the noncorrosive fluxes. Themildly corrosive Brass, copper, tin.. Rosin fluxes clean the surfaces of thework but do not Lead Tallow, rosin leave a strongly corrosiveresidue. Mildly cor- Iron, steel.. ... Borax sal ammoniac rosive fluxes are generally usedfor soldering Stainless steel and parts which can be rinsed withwater after they other nickel alloys..Phospheaic acid have been soldered, or for work inwhich a mildly Galvanized iron... Zinc chloride corrosive residue can be tolerated. Zinc Zinc chloride NONCORROSIVE FLUXES are usedfor sol- Aluminum Stearine, special flux dering electrical connections andfor other work

288 3 It; Chapter 13SOLDERING

protect the surfacefrom oxida- from any in this manner, mixture of . which must becompletely protected tion by coveringit with a protective residue. Rosin isthe most charcoal, and soda. trace of corrosivenoncorrosive flux. Inthe solid powdered borax, commonly used When as state, rosin isinactive and noncorrosive. 4. After making asoldered joint, remove it becomessufficiently active to flux as posC,ble.Ideally, it is heated, thus per- much of the corrosive removed. In reduce the oxides onthe hot metal and all of the corrosiveflux should be form the fluxingaction. Rosin maybe obtained practice, however, it maynot be possible to re--, in the form ofpowder, paste, or liquid. move all tracesof the flux. Rosin fluxes frequentlyleave a brown stainon This stain isdifficult to re- SOLDERING WITHCOPPERS the soldered metal. by move, but it can beprevented to some extent not elec- , of turpentine tothe rosin. For solderingwith coppers that are adding a t. mall amount this procedure: Glycerine is sometimesadded to the rosinto trically heated, follow make the flux moreeffective. soldering coppersof the proper 1. Select done. File and size and shapefor the work to be METHODS OFSOLDERING tin the coppers ifnecessary. should 2. Heat one copper.(The other copper The three solderingmethods that you are are using thefirst one for (1) soldering withcop- be heated while you most likely to use are soldering by soldering.) pers, (2) torchsoldering, and (3) support. 3. Position thework on a suitable sweating. strokes of general considerationsapply 4. Apply the fluxwith one or two The following swab. to most methodsof soldering: a brush or a soldering copperwith sal.: be soldered 5. Clean the hot this chapter. 1. Be sure thatall surfaces to ammoniac, asdescribed earlier in and free of oxide,dirt, grease, or are clean so other foreign matter. 6. Touch the solderwith the hot copper of solder flows overthe tip for thethat a small amount 2. Use a fluxwhich is appropriate of the copper, asshown in figure13-11. particular job. Somework requires the useof while other workrequires the to be solderedis not already corrosive fluxes, that the 7. If the seam held to- use of noncorrosivefluxes. Remember tacked, grooved,riveted, or otherwise the flux must beBELOW the pieces together sothat the work. melting point of solder you gether, tack the melting point of theparticular type of are going to use. to melt the 3. Heat thesurfaces just enough solder. Solder willnot stick tounheated sur- should be verycareful not faces. However, you or sur- to overheatsolder, soldering coppers, In general, soldershould not faces to be joined. temperature. be heated muchabove the working of molten solder isincreased, As the temperatureis increased.When molten the rate of oxidationin air, more tinthan lead solder is overheated by oxida- is lost by oxidation.Any scum formed skimmed off anddiscarded. This tion must be changes the proportionsof skimming process of the sol- tin and leadremaining in the rest lead oxidize atdifferent rates. der, since tin and carried When solder mustbe melted and then some distanceto the work, itis necessary to 11.151X temperature slightlyhigher Picking up solder. heat the solder to a is heated Figure 13-11. than the workingtemperature. If solder 289

:31 2. t 0 STEELWORKER 3 & 2 often soldered tomake soldering Riveted seams are shows the pro- will stay inposition while you are them watertight.Figure 13-13 should be positionedso that the a riveted seam. it. The piece directly on the support. cedure for soldering seam itselfdoes not rest prevent loss of This is necessaryin order to Solder beads orsolder shots aresometimes (see fig. 13-12). square,rectangular, or cylin- heat to the support used for soldering solder beads, hold _ drical bottoms.To make the pieces have beenfirmly fastened hot copper andallow the beads 8. After the hold- solder against a shown in figure. together, solder the seam.Heat the spot by to drop onto aclean surface, as against the work.The metal to ing the copper from the 13-14. be soldered mustabsorb enough heat the solder, orthe solder will copper to melt tapered not adhere. Holdthe copper so that one side of the headis flat againstthe seam, as 13-12. When thesolder begins shown in figure the copper- to flow freelyinto the seam, draw with a slow,steady motion. along the seam without rais- Add as muchsolder as necessary, ing the copperfrom the work. becomes too cool, use 9. When the copper first one. Change the other copperand reheat the necessary. Remember,how- coppers as often as seams aremade by ever, thatthe best soldered from the work soldering withoutlifting the copper and without retracingcompleted work. the solder to 10. Allow thejoint to cool and set before movingthe joint. 11. If you used acorrosive flux,clean the joint by rinsingit with waterand then brushing or wiping itwith a clean, dampcloth.

11.153X Figure 13-13.Soldering a riveted seam.

FLAT ON SEAM

11.154X 11.152 Figure 13-14.Making suiderbeads. Figure 13-12.--Soldering a seam, 290 Chapter 13SOLDERING

To solder the bottom seam with solder beads, The general procedure for torch soldering is first flux the seam. Then drop one of the coldto play the flames from the torch ontothe sur- beads of solder in the bottom of the container.faces to be joined and then apply cold solder Heat, clean, and dip the soldering copper andin bar or wire form. The heated surfacesmelt place it against the seam, as shown in figure the solder. As the solder melts, any excess sol- 13-15. Hold the soldering copper in one position der should be wiped off with a damp clothbefore until the solder starts to flow freely into the it has time to become completely hard. seam. Draw the copper slowly along the seam, Soldered joints in low pressure, low temper- turning the work as you go. Add more beads asature piping systems are sometimes made upby you need them. Reheat the copper as necessary. the torch soldering method. Figure 13-16 shows a pipe joint being torchsoldered. If you must To heat an electric soldering copper, you solder a joint near a previously solderedjoint, merely plug it in. Otherwise, the procedure for wrap the previously solderedjoint with a cool using electric soldering coppers is much the wet rag to keep the solder from melting. same as that just described. Be verycareiul not to overheat an electric soldering copper. SOLDERING BY SWEATING Never go off leaving an electric solderingcolS- The sweating method of soldering is com- per plugged in. Overheating is likelyto burn out monly used for maldng electrical connections. the electricat-element as well as damage the To make a sweated joint, clean and fluxeach sur- tinning. face to be joined; then tin each surface. Hold the pieces firmly together and heat the joint with a soldering copper or with a torch-until the solder TORCH SOLDERING melts and begins to run out. Remove the source Torch soldering is often used for small jobs of heat and hold the parts firmly in positionuntil or for work whichif;relatively hard to reach. the solder has completely hardened. A gasoline blowtorch, a gas blowpipe, an alcohol torch, or some other type of torch may be used for torch soldering. . SOLDERING ALUMINUM ALLOYS Soldering aluminum alloys is moredifficult than soldering many other metals. Thedifficulty

mm 111111111111111111111111111111111111111101111

11.155X 11.156.0 Figure 13-15. Soldering a bottom seam. Figure 13-16. Torch soldering a pipejoint.

291 Al2- STEELWORKER 3 & 2 arises largely from the fact that aluminum al-pool is scratched so that the oxide coatingis loys are always covered with a layer of oxide,abraded and broken up. The oxide floats to the the thickness of the layerdepen8ing on the type -surface of the solder puddle. The solder then tins the bare aluminum surface froin which theoxide of alloy and the conditions to which it has been alumi- exposed. has been removed. After such tinning, two Many aluminum alloys can besuccessfully num surfaces can easily bejoined by applying soldered, however, if the proper techniques are heat to melt additional solder on the tinned area used. Wrought aluminum alloys are usually to form a fillet or to fill the joint. although not alwayseasier to solder than cast aluminum alloys. Heat treated aluminum alloys Although mill files, soldering rods, soldering are extremely difficult to solder,á are alumi- copper points, and other tools ordevices may be used to abrade the oxide film and remove itfrom num alloys containing more than1 percent for magnesium. the surface of the aluminum, the best device The solders used for soldering aluminum al-this purpose is* a glass fiberbrush.The brush is loys are generally tin-zinc or tin-cadmium al-very easy to use and is moreeffective than other loys; they are usually referred to as ALUMINUM tools in breaking up the mdde film. When aglass SOLDERS. Most of these solders have higherfiber brush is used, the friction soldering proc- melting points than the tin-lead solders usedfor ess produces better solderedjoints than are pro- ordinary soldering. Both corrosive and noncor- duced by any other aluminum soldering process. rosive fluxes are used for soldering aluminum. A stainless steel wire brush can alsobe used The first step in soldering aluminumis to to clean the oxides from aluminum. clean the surfaces completely and removethe layer of oxide. If a thick layer of oxide is present, remove the main part of it mechanically by SOLDERING SAFETY filing,scraping,sanding, or wirebrushing. A thin layer of oxide can often cos removed by using Soldering operations should not be under- a corrosive flux; the flux, of course,must betaken by the Steelworker unless he has aknowl- completely removed from the joint after theedge of the nature of the fluxes andsolders he soldering is finished. will be using. If questions ariseregarding the use After cleaning and fluxing the surfaces, tinof a flux or solder, the recommendationsof the the surfaces with aluminum solder.Apply flux manufacturer often can be used as a guide. to the work surfaces and to the solder. You can with Fluxes, in particular, must be handled care- tin the surfaces with a soldering copper or from a torch. If you use a torch, donot apply heat di- fully.It is also important that the fumes rectly to the work surfaces, to the solder, orto fluxes be carried away from operatingpersonnel' part by suitable ventilation equipment. Somefluxes the flux. Instead, play the torch on a nearby And some of the work and let the heat be conductedthrough give off poisonous fumes when heated. the metal to the work area. Do not use any more fluxessuch. as hydrazine-based fluxescan tin cause serious skinirritation. Bear in mind heat than is necessary to melt the solder and organic the surfaces. Work the aluminum solderwell into that many fluxes are either toxic (such as chlorides) or flammable (such as alcohol).Com- the surfaces. After the surfaces have beentinned, the skin as well the parts may be sweated together. mon acid fluxes will corrode A procedure that is sometimesused for sol- as equipment. If any skin isexposed to flux dering aluminum alloys is to tin thesurfaces contact, make sure you wash theaffected area with an aluminum solder and then to use a reg-thoroughly and immediately. You will find that ular tin-lead solder to actually jointhe tinned gloves often are helpful during soldering oper- surfaces. This procedure may be used when the ations. shape of the parts prevents the use of the sweating method or when a large amountof'soIder is Each of the soldering processes involves the required to joint, the parts. When using tin-lead use of different equipment. Be surethis equipment is kept in proper operatingcondition. In solder with aluminum solder, it is not necessary this equip- to use a flux. view of the safety of the operators of Another method of soldering aluminumis byment, the handles of soldering irons should provide adequate insulation from theheat. Also, "friction soldering." In this method, a molten irons pool of solder is deposited on the aluminum. The the electrical connections to the soldering surface of the aluminum underneath the molten should be grounded.

292 is P4-3.6),/ .43

CHAPTER 18

REINFORCING STEEL

As a Steelworker, you must be able to bend, Steel also works well as a reinforcement place,and tie the reinforcing steel which isfor concrete because it makes a good bond with utilized by Builders to strengthen the concrete the concrete. This bond strength is proportional structures they erect. This chapter, then, willto the contact area surface of the steel to the describethe types and shapes of reinforcingconcrete. In other words, the greater the sur- steel commonly used by Steelworkers, the pur-face of steel exposed to the adherence of the pose of reinforcing steel in construction work, concrete,the stronger the bond. A deformed and the techniques and tools usedby Steelworkers reinforcing bar is better than a plain round or to bend, place, and tie reinforcing steel. Thesquare one. In fact, when plain bars of a given chapter also provides information on some ofdiameter, approximately 40% more plain bars the duties which the Steelworker may perform must be used. asa crew leader of Steelworker team/work Also,the rougher thesteelsurface, the crews. bettertheadherence of the co.Lerete. Thus, steel with a light, firm layer of rust is superior to clean steel, but steel with loose or scaly PURPOSE AND TYPES OF rust is inferior. Loose or scaly rust may be REINFORCING STEEL removed from the steel by rubbing the steel The term "reinforced concrete" refers to with burlap. concrete containing steel as reinforcement, and The requirements for reinforcing steel are designed on the assumption that both materials that it be strong in tension and, at the same time, act together in resisting force. Reinforcing steel ductile enough to be shaped or bent cold. is used in various types of concrete construction, Steel for reinforcing rods -comes in three such as retaining walls, foundation walls, beams, classesmild, medium, and high carbon steel. floor slabs, and footings. However, in certainThe most common type in use is the medium types of construction, such as some pavements grade because it is ductile enough to be bent and floors, reinforcing steel may not be re-cold and also is fairly hard, with moie tensile quired. strength than mild carbon steel. Steal that is Concrete is strong in compression but weak very high in carbon is so hard that; is almost intension. The tensile strength is generally impossible to bend it cold without breaking it. rated about 10 percentofthe compression. In some cases the greater ductility of the mild Thus, concrete works well for columns andcarbon steelis an asset, and in others the posts which are the oompression members in a greater strength of high carbon steel is desirable. structure.But, whenitis used for 'tension membersfor beams, girders, foundation walls, Reinforcing steel may be used in the form of or floorsconcrete must be reinforced to attainbars, or rods, which are either plain or de- the necessary strength in tension. formed, or in the form of expanded metal, wire, Steel is the best material for reinforcingwire fabric, or sheet metal. Each type is useful concrete because the coefficients of expansionfor a different purpose, and engineers design ofboth the steel and the concrete are con- struchues with these purposes in mind. sidered almost the same. That is, at a normal Plain bars are usually round in cross-secton. temperature, they will expand and contract at an They are used as main tension reinforcement almost equal rate. (At very high temperatures, for concrete structures. They are the least used steel will expand more rapidly than the concreteof the rod-type reinforcement because they offer and the two materials will separate.) only smooth even surfaces for the adherence

372 Cilapter 18 REINFORCINGSTEEL of concrete.By the rods are way, reinforcingbars or commonly referredtoas rebars. Deformed barsare like the plain Table 18-1. 127.167 that they haN bars except Standard ReinforcingBars a eitherindentations in ridges on them,or both, in them or The twistedbar, for a regular pattern. ing a plain example, is madeby twist- square bar cold.The spiral Weight Nominal Dia. along thesurface of the ridges Bar Numbers its bond strength deformed barincrease with concrete, (Pounds Diameter are the roundand square Other formsused Per Foot) bars are corrugated bars.These (Inches) formed withprojections around surface whichextend into the the crete and surroundingcon- #2 prevent slippage. .167 .250 formed withlongitudinal fins Another type is surface to projecting fromthe #3 prevent twisting.Figure 18-1 .376 .375 a few of thevaricus types of shows available. Inthe United deformed bars #4 .668 are used almost States, deformedbars .500 both deformed exclusively, whilein Europe, #5 and plain barsare used. 1.043 .625 There are 10standard sizes #8 bars. Table 18-1lists the bar of reinforcing 1.502 .750 and nominaldiameter of the number, weight, Bar #3 through 10 standardsizes, #7 2.044 411, inclusive,are deformed .875 bars. Rememberthat bar numbers #8 the nearestnumber of 1/8 are based on 2.670 1.000 nominal diameter inches includedin the of the bar.To measure you mustmeasure across the rebar, 3.400 1.128 tion where round/squarepor- there is nodeformation. The #10 portion of thedeformation is not raised 4.303 1.270 measuring therebar diameter.considered when #11 5.313 Expanded metal 1.410 for reinforcing or wire meshis also used by partly concrete. Expandedmetalis made shearing a sheetof steel view A, figure18-2. The sheet as shown in sheared in parallel steel has been expanded to formlines and thenpulled out or parallel cut, a diamond shapebetween each Another typeis squarerather

igure 18-1.Types of deformed (a) reinforcing Figure 18-2.-- bars. 29.182 Expanded ordiamond mesh steel reinforcement. 127.74 373

3 =4; 5 STEELWORKER 3 & 2 than diamond shaped, as shown in vie!,B, figure beam to bend or sag. Now, from thecenter of 18-2. Expanded metal is frequently usedduring the beam tothebottom, the forces tend to plastering operations. Wire mesh of thewelded stretch or lengthen the bottom portionof the concretebeam. This part is said to be intension, and wire fabric type is more often used for need- footings and slabs. that is where the steel reinforcing bars are Four figures are used to designatethe styleed. As a result of the combinationof the con- of wire mesh; for example, 6 x6 - 8/8 (sometimescrete and steel, the tensile strength inthe beam thisresiststhe forceof the load and keeps the written 6x6 x8 x8). The first figure (in center of case, 6) indicates the lengthwisespicing of thebeam from breaking apart. At the exact wire in inches; the second figure (6 inthis case)1the beam, between the compressive stressand the indicates the crosswise spacing of the wireifftensile stress, there is no stress atall-Lit:s inches; and the last two figures (8/8)indicate neutr al. the size of the wire on the, Washburn and Moen In the case of a continuous beam,it's a little different. The top of the beam may be in com- gage. Sheet metal reinforcement is used mainly inpression along part of its length and intension along another part. This is because acontinuous floor slabs and in stair and roof construction. the It consistsof annealed. sheet steel bent intobeam rests on more than two supports. Thus grooves, or corrugations,about 1/16 inch in bending of the beam is not all in onedirection, depth, with holes punched at regular intervals. but is reversed as it goes overintermediate Wire is often used for joiningreinforcement supports. rods together. A few wraps around therods To help the concrete resist thesestresses, with 16-gage soft-annealed iron wirewill hold engineers design the bends of reinforcingsteel the rods in place. Thick wires are used ascir- so that the steel will set intothe concrete just cular reinforcement in columns, tanks, and pipes. where the tensile stresses take place.That's Woven wire' is used mostly in light slabsand why you may have to bend somereinforcing rods walls. in an almost zigzag pattern. Thejoining of each Wire fabric is made by weaving or welding bar with thenext, the anchoring of the bar wire or rods together to form rectangular or ends within concrete, and the anchoringby over- triangular shapes. These shapes are usuallylapping two bar ends together are someof the designed with main or load carrying wiresand importantwaystoincrease and keep . bond transverse or spacing wires. Thecarrying or strength. Some of the bends which youwill be load wiresact asthe reinforcment and the required to make in reinforcing bars areshown spacing wires complete the patternand hold the in figure 18-3. main wires in place. This type ofreinforcement floors. The drawings for a job will provideall the is used largely for light walls, roofs, and information necessary for cutting andbending reinforcing bars. Reinforcing steel may be cut tosize with shears or with anoxyacetylene BENDING REINFORCING BARS cutting torch. The cutting torch isnormally The job of bending reinforcing ba.rswill be used in the field. quite interesting if you have some basicknowledge Before you start bending the reinforcing as to why bending is necessary.There are several bars, you should check them and sortthem at reasons. First, let us go back tothe reason the job site. Only after you check the bars will for using reinforcing steel in concretethetensile you be sure that you haveall you need for the strength and compressive strength of concrete.job. Follow the construction drawingswhen you You might compare the hidden actionwithin asort the bars, so that they willbe in proper beam from live and dead loads to thebreaking orderto be bent and placed in theconcrete of a scantling with your knee. You've seenhow forms. After you have divided the different sizes the splinters next to your knee pushtoward the into piles, label each pile ao that youand your middle of the scantling when you applyforce, crew can find them easily. Thesymbols for re- while the splinters from the middle to the op- inforcedconcrete constructionare given in posite side pull away from the middle.Well, Structural Symbols, MIL-STD-18A. this is simikr to what happens insidethe beam. For instance, take a simplebeam (a beam For the job of bending, a numberof types resting freely on two supports near itsends). of benders may be used. Stirrups andcolumn The dead load (weight of the beam) causesthe ties are normally less than 014 bar and you can

374 STEEL Chapter 18REINFORCING

-7;

127.75 bar bends. reinforcement Figure18-3. Typical hard to bebent inplace. By when thebars on oneside of bending table jaws ofthe hiekey cold by meansof the placing the and pulling onthe handle, bend them Typical stirrupand column the centerof the bend, smooth,circular shown infigure 18-4. figure 18-5.Stirrups possible toproduce a is desired. aredown in figure 18-6. it is almost anyangle that tie shapes asillustrated ,in bend through for hooks,around are usedin beams in positionin figure Make bends,except those than sixtimes are shown diameter ofnot less Column ties pins with a the bar is1 inch orlarger, 18-7. bend steelbars larger the bardiameter. If should beeight times Wheneverpossible, machine. The pin diameter on abar-bending Heating the minimum than#3cti:liar when youbend it. the barsize. bends whenbending d be cold except for#9 bars smooth sharp rod. steel sh not necessary To get pipe cheaterover the is normally have ahydraulicreinforce- large rods,slip agives you abetter hold on and larger.If yqii in figure18-8, of pipe operation bender likethat shown ,This piece makes thewhole ment bar cold up to a2-inch the roditself, and bars andlarger be used tobend bars You canheat 49 make it can smoother. before bendingthem, but diameter. illustrated infigure to acherry red A hickey,like the onefor bendingbars, 18-9, isanaffective tool 375 STEELWORKER 3 & 2 2, 17

TABLE 3'.2" X 10'4" X314" HIGH STEEL PLATE

BENDING PIPE

2" PIPE 6'4" LONG THREADED AT ENDS SO THAT 03UPLING IS TURNED FOR LS\3" PIPE FULL LENGTH

127.76 Figure 18-4. Bar-bending table.

r r

127.77 Figure 18-6. Stirrup and columnties. p sure you don't get them anyhotter. If the steel becomes too bot, it will losestrength, become brittle, and may even Irack. If you don't want your rodto crack while itis being bent, bend it gradually,not with a jerk. Don't make your bends toosharp. Bends msde on a bar-bending table orblock are usually too sharp and the bar issomewhat weakened. Certain minimum innd diametershave, therefore, been established for the differentbar sizes and for the various types of hooks.These bending LONGITUDINAL details are shown in figure18-10. You'll find REINFORCEMENT there are many different typesof lends to make, be placed. dapending on where the rods are to 46.481 For example, there arebends on heavy beam and girder bars, bends forreinf rcement of Figure 18-6.Steel in place in a beam.

376

- :3 ) Chapter 18 REINFORCING,STEEL

4s.

29.183 Figure 18-8. A2-inch capacity automatic reinforcement bar bender.

127.78 Figure 18-9.Hickey. 46,482A Figure 18-7. Columnsteel in place. inforcing bars isobjectionable because itreduces bond between thebars and the concrete. \ the bars of rust, Use a piece ofburlap to clean the at or near floor\levels, stir- or otherforeign matter. vertical columns reinfo r cement, and scale, grease, mud, rups andcolumn ties, slab A tight film ofrust or mill scaleis ilot objec- bars or wire forcolumn spiral renforcement. some time and a work, try tionable. To save yourself time, in- to make all bendsof one kind at otie Bars are markedto show wherethey will stead of remeasuringand resettingtemplates on according to either oneof the bends.\ fit. You may work bars. Which- your bendingblock for different two most-usedsystems for marklng ever systemis used, it oughtto agree with system which appearson the en- PLACING AND TYING the marking drawings. In one systert, REINFORCING STEEL gineering or assembly all of the bars in onetype of memter aregiven reinforcing steel informs, member. With thissystem, Before placing Oil on re- the mark of that all form oilingshould be completed. 377

t 0 STEELWORKER 3 dz 2

Recommended sizes-180' hook Bar size Bar 3 Approx. d exten. H Bar extension 4 2 3% required for hook 012 4 04 3 6 3 4 6 4 4% 6 7 5 5 6 8 6 6 10 7 7 D= 6d for 7 L- 8 13 10 9 4d Mi n. bars *2 to 47 9 15 113 10% H D=8d for 10 17 12.i 11% 4 bars *8 to #11 11 19 14 123%

Approx. Minimum sizes-180* hook Bar size Bar J d exten. H Ext. ld si mon _ _ __1 / D= 5 d Min. D= 5d Max. H Note: Minimum size hooksto be used only for special conditions.Do not use

Recommended minimum sizes-90' hook Bar size Bar Approx. d exten. J Ext. se 3A 4 d 5?4, 6 ----3 3 . 4 71i 81i -TN I9 1014 12c1 D= 6d for *2 toSt7 56 10Y21-014 Min. D=8d for *8 to09 7 1-0141 - 214 --/-D=10 d for *10 to411 8 1-2%1-6 T 9 1-4141-7 * 10 1-6 1-11 11 1-8142- 1% Bar 6.9.8 Bar H Recommended sizes-135 stirrup hook d exten. Ext H 02 3 2% MO 4111 MOO MO 3 4 2i D= 6d 4 444 3 5 614 33%

Note: Stirrup hooks may be bent tothe diameter of the supporting bars.

127.79 Figure 18-10. Standard hookdetails.

378 357 Chapter ISREINFORCING STEEL

thereare columnbars, beam bars,footing bars, and SO OIL\ In the other system the barsaxe marked in greater detail. These marks show exactly where the bar is to be placed. In addition tothe type member (e.g. beam (B), wall (W), column(C), and so on), the marks show which floorthe bars are to be placed on, and the size and individual number of each particular bar. Instead ofshow- ing the bar size by its diametermeasurement, the mark shows the bar size in code, byeighths. The examples shown below illustrate thesecond type of marking system. 2 = second floor B = beam member 2B805 8 = 8/8 or 1 inch, square bar 5 = part of the second floor plan desigzated by the number 5 2 = second floor B = beam member 2B0605 06 = 6/8 or 3/4 inches, round bar 5 = part of second floor plan designated by the number 5

Tie wire is used to hold rebar in placeso that when concrete is placed the bars willnot shift out of position. As ,mentionedearlier, 16- gage wire is used to tie reinforcing bars. About 12 pounds of wire 113 required to tiean average 127.80 ton of bars. Incidentally, tie wire adds nothing Figure 18-11.-- Types of ties. to the strength of the steel. A number of different 1:ypes of tiescan be C. SADDLE TIE. The wires pass halfway used with reinforcing bars; someare more effec- around one of the bars on either side ofthe tive than others. Figure 18-11 illustrates sixcrossing bar and are brought squarelyor di- types of ties, which are identified below accord- agonally around the crossing bar, with the ends ing to letters of the alphabet used to showin-twisted together and cut off. This tie is used dividual ties. on special location (walls). A. SNAP TIE or SIMPLE TIE. The wire is simply wrapped once around the twocrossing D. SADDLE TIE WITH TWIST. This tieis a bars in "a diagonal rummer with the two endson variation ofthe-addle tie. The tie wire is top, and these are twisted together witha pair carriedcompletel,iround one of the bars, of sidecutters until they arevery tight against thensquarely across and halfway around the the bars. Then the loose ends of thewire are other, either side of the crossing bars,and cut off. This tie is used mostly on floor slabs. finallybroughttogetherandtwisted either squarely or diagonally across. The sadeletie B. WALL TIE. This tie is made by goingwith twist is used for heavy mats thatare to about one and a half times around the vertical be lifted by crane. bar, then diagonally around the intersection, twisting the two ends together until the connection E. DOUBLE STRAND SINGLE TIE. This tie is right, but without breaking the de wire,then is a variation of the simple tie. It isused in cutting off the excess. The wall tie is usedon some localities, and is especially favored for light vertical mats of steel. heavy work.

379 3 50 STEELWORKER 3 & 2

reinforcing bars F. CROSS TIE or FIGURE-EIGHTTIE. This Other tools used in typing of causing littleinclude sidecutters; leath3r gloves;50-foot tape type of tie has the advantage measure; and keel crayon,either yellow, red, or no twist in thebars...; When you are tying reinforcingbars you must or blue. available. There are The proper location for thereinforcing bars have a supply of tie wire is usually given on drawings.In order for the several ways you can carry yourtie wire. One it must carry, way is to coil it to adiameter of 18 inches, structure to withstand the loads and under oneplace the steel in the positionshown. Secure then slip it around your neck the bars in position in such a waythat concrete arm as shown infigure 18-12, view A. This Coil enough wireplacing operations will not movethem. This leaves a free end for tying. can be accomplishedby the use of the reinforc- so it weight about 9pounds. figures 18-14, 18-15i Another way to carry tiewire is in aning bar supports shown in and 18-16. automatic coiler. You cansuspend the coiler structural mem- from your belt as shown in figure18-12, view Footings and other principal about a pound of tiebers which are against the groundshould have B; the coiler shown holds at least 3 inches of concretebetween steel and wire. ground. If the concrete surface isto be in con- Stillanother way to carry tie wir: to to the weather take pieces of wire about9 inches long, fold tact with the ground or exposed belt; then you after removal of the forms, theprotective cov- them and hook one end in your ering of concrete over the steelshould be 2 can pull the wires out asneeded. 1/2 inches for You may at times receivetie wires of ap-inches. It may be reduced to 1 each end. Abeams and columns, and 3/4 inchforslabs and in- propriate length with a loop in terior wall surfaces, but it shouldbe 2 inches versatiletool used to pull the looptight is This measure- the automatic twister shown inview A, figure for all exterior wall surfaces. basically on thement, incidentally, is takenfrom the main re- 18-13. The twister functions bar, not the stirrups or ties. same principle as theyankee screwdriver, except not shown in view B, Where splices in reinforcing steel are that the twister is pulled as dimensioned on the drawings,the bars should figure 18-13.

8 A

.127.81 Figure 18-12. Carrying tiewire.

380 3 Chapter 18REINFORCING STEEL g 2

127.82 Figure18-I3.Twister.

1 P TIE WIRE .4 i i'' p! MIME PRighaf=4

METHOD OF USING CONCRITI CONTINUOUS NIGHCHAIS-CHC /RECAST CONCRETE ILOCK MON CHAIR-NC EL= 127.83 block used Figure 18-15.--Precast concrete for reinforcingsteel support.

the bar diameter, zW4 be lapped notless than 30 times nor less than12 Inches. BUM $OISTO-St SUS SOLSTIR -SS mesh, a numberof methods a.re To lap wire side used, two ofwhich are: theend lap and the 45.480 lap. Figure 18-14.Steel -accessories. 381 3 S_TEELWORKER 3 & 2

12 inches. Tie thebars together with a snap WOOD STRIP tie as shown in figure18-17. TIE WIRE The bars ctih also bespliced by metal arc welding. For bars which areplaced in a vertical position, a butt weld ispreferred. The end of the bottom bar is cut square,and the end of the top bar resting on it isout in a bevel fashion, thus permitting a buttweld. For bars which will bear a load in ahorizontal position, afillet weld is preferred. Usuallythe two bars are placed endtoend (rather thanoverlapping) I and pieces of flat bar (orangle iron) are placed 1 on either side. Filletwelds are then made where the metals join. Thewelds are made to a depth 1 of one-half the bardiameter and for a length R " eight times the bar diameter. The minimum clear distancebetween parallel eic (me bars in beams, footings, walls,and floor slabs should either be 1 inch, or 11/3 times the largest size aggregateparticlein the concrete, UMW MA whichever distance is greater.In columns, the clear distance betweenparallel bars, should always be not less than1 1/2 times the bar diameter, or 1 1/2 timesthe maximum size of REMOVE THESE WIRES always uaing the larger BEFORE CONCRETE SETS the coarse aggregate, of the two. The support forreinforcing steel in floor slabs is shown in figure18-18. The height of the 127.84 by the concrete pro- steel hung in place. slab bolster is determined Figure 18-16. Reinforcing tective cover required.Concrete blocks made of 'sand-cement mortar canbe used in place of the .slab bolster. Woodblocks should never be In the end lapmethod, the wire mesh is if there is any possibility full mesh measuredused for this purpose lapped by overlapping one that the concrete canbecome wet and if the from the end of longitudinalwires in one piece type. Bar chairs wires in the adjacentconstruction is of a permanent to the end of longitudinal 6" of a type shown in figure18-1ft can be obtained piece, and then tying thetwo pieces at 1, in heights up to 6inches. If a height greater centers with a snap tie. than this is required,make the chair of No. 0, In the side lapmethod, the two longitudinal Tie the bars together side wires are placed onealongside and over-soft, annealed iron wire. then are tied with aat frequent intervalswith a snap tie where lapping the other, and they cross to hold thebars firmly in position. snap tie every 3feet. tension bar oan be trans- Steel for column ties maybe assembled with The stress in a the verticals into cages,by laying the veritoal mitted through the concreteand into another column horizontally splice of proper length.bars for one side of the adjoining bar by a lap across a couple ofsawhorses. Theproper number The lap is expressed asthe number of bar di- make the lap at leastof ties are slipped overthe bars, the reinaining ameters. If the bar is #2 vertical bars are added,and then the ties are spaced out as required bythe placing plans. All intersectiono are wiredtogether to make the LAP AT LOW 30 x SAX NAPALM assembly rigid, so that it maybe hoisted and set as a unit. Figure18-19 shows a typical column tie assembly. After the column israised it is tied to the carried up fr om below. dowels or reinforcing steelposition at the base. 127.85 This holds it firmly in The column form iserected and the reinforcing Figure 18-17.Barsspliced by lapping.

382 , 1 L \ j ic'e , ,/, ',_-.4 t tt [,tI II. '1 L I it -11 1 ': t\ L [ ',11 I. '.,i' "c't - :,,..--'t;"4 ----' zee. - I( c, , v , I t i iT .,, it 1 15., ,tet -,- t -11 1 . 1 :h t 1 - n.,, t t . A .11, . 4 . k I % L i f 4,, 4_ 4_ i ' I t _r --0-Ai 1 i V k , j,.. t.,, frt. :t.._,1,01 ' t ..tok' ee,.,/ l. 1 1 1 t 1 '4.1!t t e4.1ty , , i c, , A STEELWORKER 3 & 2

us was steelistied tq the column form at 5-foot intervals, as shown in figure 18-20. The use of metal supports to holdbeam reinforcing steel in position is shown infigure 18-6. Note the position of the beambolster. The stirrups are tied to the mainreinforcing steel with a snap tie. Whereverpossible you should assemble the stirrups and mainreinforcing steel outside the form and then placethe assembled unit in position. Wood blocksshould be substituted for the metal supportsonly if there is no possibility of the concretebecoming wet or if the construction is known tobe tem- porary. Precast concrete blocks, asshown in figure 18-15, may be substituted formetal supports or, if none of the types of barsupports described above seems suitable,the method shown in figure 18-16 may be used. Placement of steel in walls is the same as CONCRITIpootuo for columns except that the steel iserected in place and not preassembled. Horizontalsteel is times in 127.88 tied to verticvl steel at least three Figure 18-21.Steel in place in awall. any bar length. Steel inplace in a wall is shown in figure 18-21. The wood block isremoved when the form has been filled up tothe level of and placed after the forms havebeen set. A the block. For high walls, ties inbetween the typical arrangement is shown infigure 18-22. top and bottom should be used. Steel mats in large footings areconstructed in Steel is placed l. footings verymuch as it place. is placed in floor slabs, Stones,rather than steel supports, may be used to.support the steel HANDLING AND STORING at the proper distance above thesubgrade. Steel OF REINFORCING BARS mats in small footings are generallypreassembled Special careshc-Ildbe exercisedinthe pwcarantgar eicp handling and storing of reinforcingsteel. Some

PIKAST CONCUTI CLOCK 01 STONE OP PlOPfl SIZE

A 1TailWalran::::-1?.N Si tiartai 411111111111114 pi al 'AA-0 .SMILMINIIKWaRINIZEI .i ,4; !77.77. 1:rgrzmor.,171111..,24*:Limmica711:1117:1".

TIE WIRE -44,74' su-r45414 127.87 holding column 127.89 Figure 18-20. Method for footing. steel in place. Figure 18-22.Steel in place in a

384 Chapter 18REINFORCING STEEL of the safety precautions to be observed areor SW work/crews consistingof 3 to 5 men. types of listed below. A team/work crew may perform various When unloading incoming bundles of reinforc- worksuch as place and tie reinforcing steel, ing bars from a truck, see that both ends leaveerect prefabricated buildings, or assemble pon- the truck at the same time. If pushed off thetoon structures. Your duties as a crew leader At most truck,theend of the bundle that leaves the may vary from one activity to another. truck last has a tendency to WHIP UP, andactivities, however, a crew leader's duties may this can cause serious injury to the man oninvolve planning work assignments, preparing the truck. requisitions, and keeping time cards.Information Stand clear several feet from any bundle of that will aid you in carrying out these duties reinforcing bars leaving.a truck. is given below. When two men carry lengths of reinforcing steel, both should release the load at exactly the same time to avoid a serious fracture or PLANNING WORK ASSIGNMENTS injury. When lifting heavy loads, remember to flex The planning of day-to-day work assignments the knees in a stooping position to avoid strain- for team/work crews can be a difficult jobuniess ing. the crew leader is familiar with the capabil- Wear leather gloves and other suitable cloth- ities of his men and equipment needed to coming when handling reinforcing steel. Avoid un-plete the work projects assigned. This is partic- necessary belts or pockets whichcould become ularly true in a combat zone where the priorities caught on projecting objects. of construction may be subject to changedaily. Never raise bundles of reinforcing steel byYou may have your best team/work crew on a the bundle wire. Use a wire rope sling. Wrapprefabricated steel erection project, when sud- the sling completely around the bundle of bars,denly an emergency job comes up that requires on the center of the buadle, andmake sure you soma of your team/work crewmembers plus a attach the sling so that it will tighten itself. Bynumber of pieces of your equipment to bedis- attachingthesling in this manner, the rodspatched to another jobsite. Since the original cannot slip out of the bundle nor twist withinerection project must continue, you must be able the bundle. to re-organize and assign team/work crew mem- Reinforcing bars should be stored so that bers so that work on the erection project can excessiverustingorcoating by grease,oil, continue. By knowing your crews and their cap- dirt, and other objectionable materials will be abilities you should be able to control the project avoided. All rebar stored on the ground must and: be on dunnage to keep it out of the mud. Stor- age should be in separate piles orracks so as 1. Plan work to avoid wasted or poorlyutilized to avoid confusion or loss of identificationafter manpower. bundles are broken. Incoming stocks of reinforcing bars are stored 2. Be sure that each element in aproject according to size or bar number; for instance,is really needed. Eliminate or combine oper- all #2 bars in one pile, 43 bars in a separateations. pile, and so on. Ina reinforcing steel bendingshop, racks 3. Arrange priorities of projects and have often may be used for storing rods that have second or third priorities ready so that crews been bent. When this is done, it isimportant to can shift work if delayed on aprimary project. designate and label each rack according to the size of rod to be stored in it. 4. Make sure tools, supplies, andmaterials are on hand.

ASSIGNMENT AS CREW LEADER 5. When necessary, determine typesof manpower required for different elementswithin a The SW who wants to get ahead canexpect project. to be called upon to assume moreresponsible duties as he gains experience insteelworking 6. Establish rates of work. How manyhours operations. These heavier responsibilities will should a particular job take under normal con- probably include the assignment as crew leader diti,ons ? and under adverse conditions?

385 t.