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The Welding Handbook – Wilhelmsen Ship Service

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The Welding Handbook – Wilhelmsen Ship Service The Welding Handbook 1.00 Maritime Welding Handbook Welding and Related Processes for Repair and Maintenance Onboard 14th edition 2nd revision Notice: All welding is carried out on the welder’s own risk and account. Welding should be executed by a qualified and experienced welder and adequate safety measures should always be adhered to. The information and guidelines in this Welding Handbook are based on general information and knowledge at hand and are believed to be accurate and reliable, but the information and guidelines are not to be taken as a guarantee or warranty for a special purpose. The information and guidelines are provided to the welder solely for his own consideration, and Wilhelmsen Ships Service AS assumes no legal responsibility or liability for eventual damages and/or losses should the information and/or guidelines turn out to be incorrect or un-suitable. Wilhelmsen Ships Service AS is not liable for any loss or damages whatsoever and howsoever arising which is due to force majeure, other events beyond the reasonable control of Wilhelmsen Ships Service AS or events that could not reasonably be foreseen by Wilhelmsen Ships Service AS when this Welding Handbook was made. Wilhelmsen Ships Service AS is in no event liable for indirect, incidental or consequential damages or losses, including dam- ages for loss of profits, resulting from lack of conformity, including but not limited to loss resulting from goods or software not working when connected to other goods/software or for any related cause thereto. Wilhelmsen Ships Service AS’s liability shall in any event not exceed the total purchase price of theWilhelmsen Ships Service AS goods used during the welding operations. These conditions are automatically accepted by anybody using the information and guidelines in this Welding Handbook. INTRODUCTION A ship at sea depends upon the knowledge, skills and self-reliance of the crew to carry 1.00 out necessary maintenance and repair work. One of the important skills required is a good command of modern welding techniques. The purpose of the Welding Handbook for maritime welders is to provide guidance in modern welding and related processes and to provide the welder with a source of practical information on the right solution to specific onboard welding problems. Experience gained from user contact and welding training of crewmembers showed that documentation aimed specifically at on board welding solutions was needed. This led to the development of the first welding handbook for on-board repair and maintenance welding already the 1950es. This edition of the UNITOR Welding Handbook builds upon all the earlier editions and on Wilhelmsen Ships Service’s business activity. Wilhelmsen Ships Service AS enjoys close co-operation with its customers and would like to thank the many who have taken the effort to contribute with examples of successful solutions to real life maintenance situations. Unitor’s business activity traces back to 1905 and the company NAG with Acetylene production as a basic activity. The first maritime deliveries from this period were supply of Acetylene as fuel gas for the guiding light beams from numerous lighthouses along the long and weather- beaten coast of Norway. The focus changed towards gas and arc welding techniques when these were developed to useful production and repair methods through the 1930es. A main objective became to develop and maintain a range of welding equipment that is suitable for onboard welding, backed by a worldwide service network, training and documentation. In 1943 the company name was changed to UNITOR. Mergers and increasing activity in the department for sales to ships led to the establishment of this department as a separate company; Unitor Ships Service AS in 1968. In 2005 the company was bought by Wilh.Wilhelmsen ASA and the brand Unitor is now incorporated in Wilhelmsen Ships Service AS, a part of Wilhelmsen Maritime Services AS, a company in the Wilh. Wilhelmsen Group 2 UNITOR WELDING HANDBOOK 1 SAFETY IN WELDING 9 1.00 2 SOLUTIONS 2.01 Introduction & quick guides to processes 35 2.01 2.02 Filler material consumption 47 2.02 2.03 Metal identification 50 2.03 2.04 Unalloyed / low alloyed steel 55 2.04 2.05 Problem steels 62 2.05 2.06 Stainless steels 65 2.06 2.07 Cast iron 78 2.07 2.08 Copper and copper alloys 104 2.08 2.09 Aluminium 112 2.09 2.10 Evaluation of welds 114 2.10 3 CONSUMABLES 3.01 Coated Electrodes 125 3.01 3.02 TIG Welding Rods & Fluxes 197 3.02 3.03 Wires for Wire Welding 217 3.03 3.04 Gas Welding Rods & Fluxes 241 3.04 3.05 Brazing Rods & Fluces 249 3.05 3.06 Cold Repair Compounds 275 3.06 4 ARC WELDING AND 4.01 Electrode welding & gouging 331 4.01 CUTTING PROCESS 4.02 TIG Welding 381 4.02 & EQUIPMENT 4.03 Wire Welding 403 4.03 4.04 Plasma Cutting 441 4.04 5 GAS WELDING AND 4.05 Current Distribution System 459 4.05 CUTTING PROCESS & EQUIPMENT 5.01 AC/OX cutting, welding, brazing 465 5.01 5.02 Gas Supplies and gas distribution system 517 5.02 6 MISCELLANEOUS INFORMATION 535 6.00 3 UNITOR WELDING HANDBOOK 1.00 1 SAFETY IN WELDING .................... 9 2.06.02 Austenitic Stainless Steel ..... 66 1.01 Introduction....................... 10 2.06.03 Ferritic Stainless Steel ........ 68 1.02 How to use the handbook ............ 11 2.06.04 Martensitic Stainless Steel .... 69 1.03 Welding instructions and training .... 12 2.06.05 Duplex Stainless Steel ........ 70 1.04 Personal protection ................. 13 2.06.06 Clad Steel ................... 71 1.04.01 Arc welding face shields ..... 14 2.06.07 Stainless Steel corrosion types 72 1.04.02 Protective goggles ........... 18 2.06.08 Storing and handling of Stainless Steel onboard ...... 74 1.04.03 Welder's protective clothing . 20 2.06.09 Grinding/cutting consumables 1.05 Work site protection ................ 22 for Stainless Steel ........... 75 1.05.01 Welding curtain .............. 22 2.06.10 Unitor Safety Grinder ......... 77 1.05.02 Welding blanket ............. 22 2.07 Cast iron ........................... 78 1.05.03 Fire extinguisher ............. 23 2.07.01 Introduction ................. 78 1.06 Welding fumes ..................... 24 2.07.02 Grey cast iron ............... 79 1.06.01 Welding fumes .............. 26 2.07.03 White cast iron .............. 80 1.06.02 Fume extraction ............. 27 2.07.04 Malleable cast iron .......... 80 1.07 Safety check list ................... 30 2.07.05 Ductile cast iron ............. 81 1.07.01 Equipment . 30 2.07.06 High alloy cast iron .......... 82 1.07.02 Work place .................. 31 2.07.07 Identification of cast iron ..... 83 1.07.03 Hot work procedure .......... 32 2.07.08 Preparation of the 1.07.04 Operator protection .......... 32 work piece .................. 84 2.07.09 Arc welding of cast iron . 87 2 SOLUTIONS ............................ 35 2.07.10 Braze welding of cast iron .... 95 2.01 Introduction....................... 36 2.07.11 Cold repair on cast iron ....... 97 2.01.01 Quick reference for cutting . 37 2.08 Copper and copper alloys ........... 104 2.01.02 Quick reference for joining .... 38 2.08.01 Introduction ................. 104 2.01.03 Quick reference for rebuilding, 2.08.02 Brass ....................... 104 hardfacing and coating ....... 41 2.08.03 Aluminium brass (Yorcalbro) . 105 2.01.04 Quick reference to 2.08.04 Bronze ...................... 106 cold repairs ................. 43 2.08.05 Nickel bronses (Cunifer) ...... 107 2.02 Filler material consumption .......... 45 2.09 Aluminium ........................ 112 2.03 Metal identification ................. 48 2.10 Evaluation of welds ................. 114 2.04 Unalloyed / low alloyed steel . 53 2.10.01 Typical welding faults ........ 114 2.04.01 Introduction ................. 53 2.10.02 Inspection of welded joints ... 118 2.04.02 Unalloyed steel .............. 53 2.10.03 Crack detection .............. 123 2.04.03 Low alloyed steel ............ 53 2.04.04 Heat resistant steel .......... 53 3 CONSUMABLES ......................... 125 2.04.05 Low temperature steel ........ 54 3.01 Coated Electrodes .................. 126 2.04.06 Weathering steel ............ 54 3.01.01 Introduction ................. 127 2.05 Problem steels ..................... 62 3.01.02 Types of electrodes .......... 128 2.06 Stainless steels .................... 65 3.01.03 Storing and re-drying ......... 134 2.06.01 Introduction ................. 65 3.01.04 Classification and approvals .. 140 3.01.05 Welding positions ............ 148 4 UNITOR WELDING HANDBOOK 3.01.06 GPO-302 N 3.01.24 NICKEL-333 N 1.00 General Purpose Electrode Nickel Electrode for Cast Iron 184 For Mild Steel ............... 150 3.01.25 TINBRO-341 3.01.07 GPR-300H Electrode for Copper Alloys ... 186 High Recovery Electrode 3.01.26 ALBRONZE-344 for Mild Steel ................ 152 Electrode for Copper Alloys ... 188 3.01.08 SPECIAL-303 N 3.01.27 ALUMIN-351 N Double Coated Electrode for Electrode for Aluminum ....... 190 Mild and Ship Quality Steel .... 154 3.01.28 CH-2-382 3.01.09 LH-314 N Electrode for Chamfering ..... 192 Low Hydrogen Electrode for 3.01.29 ACA-384 Ship Quality Steel ............ 156 Electrode for Air Carbon Arc 3.01.10 LHH-314 H Gouging . 194 High Recovery Low Hydrogen Electrode for Ship Quality Steel 158 3.02 TIG welding rods and fluxes . 197 3.02.01 Introduction ................. 198 3.01.11 LHV-316 N Vertical Down Welding Low 3.02.02 Classification ................ 199 Hydrogen Electrode for 3.02.03 IMS-210 .................... 200 Ship Quality Steel ............ 160 3.02.04 ICROMO-216 . 202 3.01.12 LHT-318 N 3.02.05 18/8 Mo-221 ................. 204 Electrode for High Temperature 3.02.06 ALUMAG-235 ................ 206 Steel ....................... 162 3.02.07 IDUPLEX-222 . 208 3.01.13 LHL-319 N 3.02.08 ICUNI-30-239 .
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