Welding-Materials-Handbook-NAVFAC-P-433-US-Navy-1991-WW

0525-LF-458-9900JULYNAVAL CONSTRUCTIONP-4331991FORCEWELDING MATERIALSHANDBOOK

DISTRIBUTIONSNDL (One copy to each addressee unless otherwise indicated)27G COMNAVSUPPFORANTARCTICA FKN5 PWC NAVFACENGCOM39B COMCBLANT/COMCBPAC (2 ea) FKNl1 NAVCIVENGRLAB (Code L41 ) (2 ea)39C NCR 20TH, 31ST (4 ea) FTl CNET39D NMCB-1,3,4,5,7,40,74,133(4ea) FT18 CBU-401,402,404,407,408,419(2ea)39E PHIBCBONE/PHIBCBTTVO (4 ea) FT20 NAVCONSTRACEN Gulfport, PorHue (150 ea)39F COM20THNCR DEPLOYED SUPPORT DIV FT78 NAVEDTRAPRODEVCEN (Code 3 152)Gulfport (4 ea)COMCBPAC DET CAT GUAM (7 ea)39G UCT-1, UCT-2 (2 ea)COMRNCF/lST RNCB391 CBMU-302 (2 ea)RNMCB-2, 12, 13, 14, 15, 16, 17, 18,20,21,39R COMFIRSTNCB (30 ea)22,23,24,25,26,27,28A3 CNO (OP44)FA32 CBU41O, 411,412,414,415,420, 423 (2 ea)FB41 CBU-405, 406,409,413,416,417, 418,421 (2 ea)FF49 CBU-403, 422FKAIC NAVFACENGCOM (FAC 06)(4 ea) (09M13)FKM22 ASO NAVPUBFORM (100 ea)FKN2 CBC Davisville, Gulfport, PorHue (4 ea)CED Davisville, Gulfport, PorHue (2 ea)FKN3 OICCiiAdditional copies may be obtained from:Commanding Officer (Code 1571)NCBC, Port Hueneme, California 93043-5000Naval Publications and FormsNavy Aviation Supply Office5801 Tabor Ave., Phila. PA 19120-5099

ACKNOWLEDGEMENTSWhile the government neither recommends or endorses the products or manufacturing firmsmentioned below, acknowledgment is hereby extended to the following organizations forcontributing information necessary for the development of this handbook:MARCO COMPANY: For information incorporated in Section 1.THE STOODY COMPANY: For information incorporated in Section 2.THE LINCOLN ELECTRIC CO: For information incorporated in Section 2.MOLECULAR CONSERVATION, INCORPORATED: For information reprinted in Section 3.MAPP PRODUCTS: For information incorporated in Section 4.iii

FOREWORDThis handbook describes various welding materials and techniques available to the SEABEEwelder. The emphasis is placed upon interchangeability of materials ordinarily found in the NavalConstruction Forces Table of Allowance. Although complete coverage of all possible materialsand their various applications is not furnished, the data provided in this handbook will cover amajority of maintenance situations. The referenced welding materials can be requisitioned fromthe supporting Construction Battalion Centers. This handbook also describes several relatedmaintenance techniques. These include: Wearfacing, MAPP Gas Welding, and some coldprocesses that can be substituted for welding procedures in certain maintenance applications.This publication cancels and supersedes the NAVFAC P-433, January 1986 and has beenreviewed and approved in accordance with SECNAVINST 5600.16A.

CHANGE RECORDSignature ofChange No. Date Title and/or Brief Description Validating Officervii

CONTENTSSECTION 1 -WELDING MATERIALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mild Steel-Arc-AWS/ASTME-6011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mild Steel-Arc-AWS/ASTME-6012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Steel -Arc(low-alloy or mild) -AWS/ASTM E-7018 . . . . . . . . . . . . . . . . . . . . . . .Steel - Arc (low-alloy, high-strength steels) - AWS/ASTM E-11018 . . . . . . . . . . .Steel -GMA(low- to medium-carbon) -AWS/ASTME-70 S-3, orS-6 . . . . . . . . .Steel -Torch or GTA(low- and medium-carbon) . . . . . . . . . . . . . . . . . . . . . . . . . .Brazing -Torch (flux-coated rod for general brazing) . . . . . . . . . . . . . . . . . . . . . . .Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brazing -Torch (flux-coated rod for high-strength brazing) . . . . . . . . . . . . . . . . . .Silver Brazing Kits -Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cast Iron -Torch (flux-coated rod) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cast Iron -Arc (fully-machinable nickel base) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cast Iron -(fully-machinable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cast Iron -Arc (machinable nickel-iron base) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brazing -Arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Aluminum -Arc (extruded flux-coated rod) E-4043 . . . . . . . . . . . . . . . . . . . . . . . .Aluminum -GMA (base spooled wire) E-5356 . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brazing, Gas -Aluminum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Zinc -Die Cast and Aluminum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page1-11-11-21-31-41-51-71-81-91-101-111-111-121-131-141-151-161-171-181-19ix

CONTENTS (Continued)Stainless - Arc (all steels - medium - high carbon, alloy, and toolsteels) AWS/ASTM E 312-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Buildup -Arc (tungsten, high speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Overlay -Arc (manganese wearfacing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Buildup - Arc -tungsten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Buildup -Arc (FeMn A-Class 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Overlay -Arc (intermediate wearfacing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Overlay -Arc (wearfacing - high abrasion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Chamfering or Gouging -Arc... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Graphite (carbon electrodes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Solder (tin -lead 50/50) ASTM 50A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Solder (tin -lead 40/60 -acid core) ASTM 40A . . . . . . . . . . . . . . . . . . . . . . . . . . .Solder (tin-lead 60/40-rosincore) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Solder (tin-silver 96/4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Holding and Heat-Resisting Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Surface-Hardening (Case) Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Application Guides and Comparative Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Underwater Cutting (Electrode-Underwater Cutting) . . . . . . . . . . . . . . . . . . . . . . .SECTION 2- WEARFACING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Workpiece Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page1-201-211-221-231-241-251-261-271-281-291-291-301-301-321-331-341-442-12-12-1x

CONTENTS (Continued)Preheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Welding on Cast Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Buildup Materials and Base Metals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Workpiece Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Thickness of Hard-Facing Deposits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Types of Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Abrasion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Impact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Recommended Amperage and Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .The Difference Between Cross-Checking and Cracking . . . . . . . . . . . . . . . . . . . . .Oxy-MAPP Hard-facing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Flame Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .EARTH-MOVING AND HEAVY CONSTRUCTION EQUIPMENT . . . . . . . . . .Tractor Parts and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Track Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tractor Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tractor Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Top Carrier Rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page2-12-32-32-42-42-112-112-112-112-122-122-122-132-132-152-162-172-172-172-182-19xi

CONTENTS (Continued)Drive Sprockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tractor Gousers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ripper Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bulldozer End Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bulldozer Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ripper Shanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rock Rake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shovel Parts and Accessories.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shovel Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shovel Track Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shovel Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shovel Drive Tumblers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shovel House Rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shovel and Dragline Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shovel Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shovel Bucket Tooth Adapters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shovel Latch Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shovel Latch Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shovel Boom Heels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cable Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dragline Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dragline Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page2-202-212-212-222-232-242-252-272-282-282-292-302-302-312-342-352-372-382-392-402-412-41xii

CONTENTS (Continued)Dragline Clevis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Clamshell Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power Shovel Transmissions.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shovel Ring Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shovel Swing Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Horizontal Travel Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .House Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ditchers and Hole Augers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ditcher Drive Segments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ditcher Rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ditcher Drive Sprockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ditcher Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Post Hole Augers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Asphalt Mixers and Pavers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Asphalt Mixer Paddles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Asphalt Mixer Paddle Shanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Paving Machine Paddles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Paving Agitator Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Paving Screw Conveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Scraper Cutters and Sides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Scraper Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page2-422-432-462-462-472-472-482-482-492-492-502-502-512-522-532-532-542-542-552-552-562-57xiii

CONTENTS (Continued)Grader Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Grader End Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Scooplift Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Grapple Tines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Grid Compactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Sheepsfoot Tampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Curbing Machine Augers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Backhoe Sidecutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Trencher Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shredding Hammers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CRUSHING, GRINDING, AND SCREENING EQUIPMENT. . . . . . . . . . . . . . .Rebuilding and Hard-facing Crusher Roll Shells . . . . . . . . . . . . . . . . . . . . . . . . . .Initial Rebuild and Hard-face of Shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .When to Reapply Hard-facing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rebuilding Shells with the Manual Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rebuilding Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-facing Crusher Shells with the Manual Process . . . . . . . . . . . . . . . . . . . . .Welding Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .How to Repair Cracked Manganese Rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-facing Rotor Type Impactors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page2-582-582-592-602-602-612-632-642-652-662-672-672-672-672-672-712-722-722-732-762-79xiv

CONTENTS (Continued)Rotors and Bars .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . .Screen Grates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OTHER QUARRY AND MINING EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . .Crusher Jaws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wobbler Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Crusher Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...Scalping and Sizing Vibratory Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gravel Washer Auger Flights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Log Washer Paddles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...Elevator Bucket Lips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Quarry Drill Collars and Augers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 3 -MOLECULAR METAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Introduction . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . .Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ATOMIZED METAL REPAIR COMPOUD (M-41). . . . . . . . . . . . . . . . . . . . . .ALLOY GP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . .Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .Properties . . . . . . . . . . . . . . . . . . . . . . . . . .... . . .Directions For Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page2-792-792-802-802-802-822-822-832-842-842-853-13-13-13-23-23-23-23-33-3xv

CONTENTS (Continued)ATOMIZED METAL REPAIR COMPOUND (M-42) . . . . . . . . . . . . . . . . . . . . .SMOOTHCOAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Directions For Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ATOMIZED METAL REPAIR COMPOUND (M-43) . . . . . . . . . . . . . . . . . . . . . .SMOOTHCOAT LIQUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Directions For Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ATOMIZED METAL REPAIR COMPOUND (M-43) . . . . . . . . . . . . . . . . . . . . . .RAPIDSTEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Directions For Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 4- MAPP GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Introduction, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mapp Gas is Safe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page3-63-63-63-63-73-73-103-103-103-113-113-123-143-143-143-153-153-164-14-14-1xvi

CONTENTS (Continued)Disadvantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Breaktkough in Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .How to Set Up and Use a Welding or Cutting Unit . . . . . . . . . . . . . . . . . . . . . . . . .Setting Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lighting the Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Extinguishing the Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Welding and Brazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Use of Welding Tips with Mapp Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fusion Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Flame Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Carbon Steel Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Carbon Steel Pipe Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cast Iron Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Aluminum Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Copper Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Metallizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Flame Hardening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .How Flame Hardening Works.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Carbon Content and Hardness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Quenching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page4-14-14-24-24-34-34-44-44-54-54-74-94-94-94-94-94-94-104-104-104-10xvii

CONTENTS (Continued)Flame Hardenable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Flame Head Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .How to Flame Cut with Mapp Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preheat Flame Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oxygen Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Coupling Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Torch Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Nature of the Workpiece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tip Size and Style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oxygen Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Starting a Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Special Cutting Jobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gouging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Piercing and Washing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cutting Manganese Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operation Procedures -Bulk Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Start Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Temporary Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Extended Shutdown Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .The Use of Antifreeze in Flashback Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mapp Gas and Compressed Air Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page4-114-114-114-124-134-154-164-174-174-194-194-204-214-214-224-224-244-244-244-244-244-25xviii

FIGURESFigure No. Title Page2-12-22-32-42-52-62-72-82-92-102-112-122-132-142-152-162-172-182-192-20Hard-Facing Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cross-Checking and Cracking Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . .Flame Adjustments for Hard-Facing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tractor Parts and Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Track Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Tractor Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rebuilding Tractor Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Top Carrier Rolls.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Drive Sprockets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Tractor Grousers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Ripper Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Bulldozer End Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Bulldozer Blades. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Ripper Shanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Rock Rake Teeth.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shovel Parts and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Shovel Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Shovel Track Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Shovel Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Shovel Drive Tumblers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52-142-152-162-172-172-182-192-202-212-222-232-242-252-262-272-282-292-292-30xix

FIGURES (Continued)Figure No. Title Page2-212-222-232-242-252-262-272-282-292-302-312-322-332-342-352-362-372-382-392-40Hard-Facing Shovel House Rolls.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Shovel and Dragline Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Shovel Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Repointing Shovel Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Comparison of Hard-Facing Patterns for Shovel Teeth . . . . . . . . . . . . . . . . . .Hard-Facing Shovel Bucket Tooth Adapters . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Shovel Latch Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Shovel Latch Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Shovel Boom Heels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing and Rebuilding Worn Cable Sheaves . . . . . . . . . . . . . . . . . . . . .Hard-Facing and Rebuilding Dragline Pins . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing and Rebuilding Worn Dragline Chains . . . . . . . . . . . . . . . . . . . .Hard-Facing and Rebuilding Worn Dragline Clevises . . . . . . . . . . . . . . . . . .Hard-Facing Clam Shell Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power Shovel Transmission Components . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing and Restoring Worn Shovel Ring Gear Teeth . . . . . . . . . . . . . . .Hard-Facing and Restoring Worn Horizontal Travel Gear Teeth . . . . . . . . . .Hard-Facing and Restoring Worn House Ring Gear Teeth . . . . . . . . . . . . . . .Hard-Facing and Restoring Worn Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Ditcher Drive Segments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-312-332-342-352-362-372-382-392-392-402-412-422-432-442-452-462-472-482-492-49xx

FIGURES (Continued)Figure No. Title Page2-412-422-432-442-452-462-472-482-492-502-512-522-532-542-552-562-572-582-592-602-61Hard-Facing Ditcher Rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Ditcher Drive Sprockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Ditcher Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Post Hole Augers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Asphalt Mixer Paddles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Asphalt Mixer Paddle Shanks . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Paving Machine Paddles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Paving Machine Agitator Blades . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Paving Machine Screw Conveyors . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Scraper Cutters and Sides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Asphalt Mixer Scraper Blades . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Grader Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Grader End Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Scooplift Bucket Lips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Grapple Tines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Grid Compactor Grids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Sheepsfoot Tampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Curbing Machine Augers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Backhoe Sidecutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Trencher Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Shredding Hammers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xxi2-502-512-512-522-532-542-542-552-552-562-572-582-592-592-602-602-622-632-642-652-66

FIGURES (Continued)Figure No. Title Page2-622-632-642-652-662-672-682-692-702-712-722-732-742-752-762-774-14-24-34-44-5Wear Measurement of Crusher Roll Shells . . . . . . . . . . . . . . . . . . . . . . . . . . .Preventing Warpage of Crusher Roll Shells . . . . . . . . . . . . . . . . . . . . . . . . . . .Welding Limits on Crusher Roll Shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Insufficient and Proper Stepover Techniques Examples . . . . . . . . . . . . . . . . .Rebuilding Procedure for Crusher Roll Shells . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Crusher Roll Shells. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Crusher Roll Shell Rebuilding Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . .Repairing Cracked Manganese Crusher Rolls . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Rotor-Type Impactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rebuilding and Hard-Facing Crusher Jaws . . . . . . . . . . . . . . . . . . . . . . . . . . .Restoring Worn Areas on Wobbler Feeders . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Scalping and Sizing Vibratory Screens . . . . . . . . . . . . . . . . . . .Hard-Facing Gravel Washer Auger Flight . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Log Washer Paddles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Elevator Bucket Lips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing Quarry Drill Collars and Augers . . . . . . . . . . . . . . . . . . . . . . . . .MAPP Gas Torch Tip Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preheat Flame Characteristics.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Correct Measurement of Coupling Distance . . . . . . . . . . . . . . . . . . . . . . . . . . .Correct Torch Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MAPP Gas and Compressed Air Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xxii2-672-692-702-712-742-752-752-772-782-812-822-832-832-842-842-854-54-144-164-184-26

TABLESTable No. Title Page1-11-21-31-41-51-62 - 14 - 14-24-34-4Cast Iron Application Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Copper, Brass, and Bronze Application Guide . . . . . . . . . . . . . . . . . . . . . . . . .Aluminum Application Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Stainless Steel Application Guide... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Steel Application Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Welding Rod Comparison Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Metals Preheating Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Welding Tip Size and Application Using MAPP Gas . . . . . . . . . . . . . . . . . . .Welding Tip Counterbore Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oxy-Fuel Ratios/Flame Condition Comparisons . . . . . . . . . . . . . . . . . . . . . . .Hadfield’s Manganese Steel Cutting Conditions . . . . . . . . . . . . . . . . . . . . . . .1-351-371-391-401-421-452-64-64-84-124-23xxiii

Section 1. WELDING MATERIALSUSES, PROCEDURES, AND CHARACTERISTICSTYPE: MILD STEEL - ARC AWS/ASTM E-601 1NSN: 9GD 3439-00-165-4173 (1/8X 14)9GD 3439-00-165-4185 (5/32x 14)9GD 3439-00-262-2655 (3/16X 14)POSITION: AllPOLARITY: AC or DC Straight or ReverseRECOMMENDED AMPERAGES:1/8 - 80 to 1305/32 -130 to 160PROCEDURES:Flat: Very short arc. Stay ahead of puddle and usea slight w-hipping motion.Vertical: Start at the bottom and go to the top usinga slight whipping motion. When welding from top tobottom, don’t use any motion.Overhead: Use same technique as the verticalbottom to top. Multipass for buildup.CHARACTERISTICS :Deep penetration, light slag, fast freezing deposit.Tensile Strength: 62,000-72,000 psigUSES:Primary: Joining of mild steel.Secondary: Good for galvanized steel. Substitutefor cutting rod; soak coating and use on straightpolarity. On sheet metal, use straight polarity for aforceful spray arc.1-1

TYPE: MILD STEEL - ARC AWS/ASTM E-6012NSN: 9GD 3439-00-947-5383 (3/32X 14)9GD 3439-00-165-4176 (1/8X 14)9GD 3439-00-165-4175 (5/32x 14)POSITIONS: AllPOLARITY: AC or DC StraightRECOMMENDED AMPERAGES:3/32 - 40 to 901/8 - 80 to 1205/32 -120 to 190PROCEDURES:On flat butt joints, hold the rod at a right angle to theplate. On horizontal fillets, the rod is held 30 to 45degrees with horizontal and at a right angle to thelongitudinal axis. Weld vertical from top down. Use awhipping motion when welding from bottom to top.For overhead work, use a slight whipping motion.CHARACTERISTICS :Shallow to medium penetration, medium heavy slag,smooth bead, low spatter loss. Excellent for rustymetal.Tensile Strength: 67,000-80,000 psigUSES:Primary: Joining of mild steel. Small-diameter rodsfor sheet metal, large-diameter rods for fillets and poorfit-up.Secondary: A fast electrode for overlaying andcladding of worn and undercut surfaces prior towearfacing.1-2

TYPE: STEEL - ARC (low alloy or mild)AWS/ASTM E-7018NSN: 9GD 3439-00-165-4186 (1/8X 14)9GD 3439-00-479-1099 (5/32X 14)9GD 3439-00-853-2719 (3/16X 14)POSITION: AllPOLARITY: AC or DC ReverseRECOMMENDED AMPERAGES:1/8 -100 to 1505/32 -120 to 200USES:Primary: Excellent for joining low-alloy structuralsteels such as Cor-Ten, Mayari R, Lukens 45 and 50,or Yoloy. Use for welding well casings.Secondary: Joining all mild steels. Buildup prior towearfacing.PROCEDURES: Hold a short arc and use a slightweave.Flat: Use a high side of current range - weave up to2 1/2 times diameter of rod.Vertical: Make root pass with a straight upwardprogression and a short arc Some welders prefer aV shape motion for root passes. Hesitate at point ofthe “V” in the root to assure penetration. Each leg ofthe “V” should be about 1/8 in. No whipping shouldbe done. On subsequent passes, weave across the faceof the root, continuously building up a shelf. Theweave should pause at the sides of the first pass toclear out trapped slag.Overhead: Use only stringer beads. Fillets shouldbe made with electrode at a 30 degree angle off thevertical leg.Horizontal: Use stringer beads for fillets; direct rodinto joint at a 45 degree angle. On subsequent passes,use only stringer beads.CHARACTERISTICS:Soft arc, low spatter, good bead contour and wettingactions, produces highest quality X-ray deposits. Goodimpact resistance at normal and sub-zerotemperatures. Excellent for high-sulfur (freemachining) steels, and cold rolled steels.Tensile Strength: 70,000-78,000 psig1-3

TYPE: STEEL - ARC (low-alloy, high-strengthsteels) AWS/ASTM E-11018NSN: 9GD 3439-00-165-4167 (1/8X 14)9GD 3439-00-165-4165 (5/32X 14)POSITION: AllPOLARITY: AC or DC ReverseRECOMMENDED AMPERAGES:1/8 - ll0 to 1505/32 -120 to 200USES:Primary: Joining of low-allow, high-strength steelssuch as T-1, HY-80, HY-90, HY-100, SSS100 andJalloy 90 and 100.Secondary: Substitute for buildup for wearfacing.(NOTE: This rod is prefened over mild steelelectrodes for wearfacing buildup.)PROCEDURES:Hold a short arc and use a slight weave.Flat: Use high side of current range; weave up to 21/2 times diameter of rod.Vertical: Make root pass with a straight upwardprogression - short arc. Some welders prefer a “V”shape motion for root passes. Hesitate at “V” point inthe root to assure penetration. Each “V” leg should beabout 1/8 inch. Do not use whipping motion. Onsubsequent passes, weave across the face of the root tocontinuously build up a shelf. The weave should pauseat the sides of the first pass to clear out trapped slag.Overhead: Use only stringer beads. Fillets should bemade with electrode at a 30-degree angle off thevertical leg.Horizontal: Use stringer beads for fillets; direct rodinto joint at a 45-degree angle. On subsequent passes.use only stringer beads.CHARACTERISTICS:Fast, efficient metal transfer. Deposits have goodX-ray quality and excellent tensile and impactproperties.Tensile Strength: 110,000-114,000 psig1-4

TYPE: STEEL - GMA (low-to-mediumcarbon)AWS/ASTM E-70, S-3, or S-6NSN: 9GD 3439-00-593-2241(.035 X 2 1/2 lb. spool)9GD 3439-00-903-7832(.045 x 25 lb. roll)POSITION: AllPOLARITY: DC ReverseWELDING DATA - ALL POSITIONSMaterialThickness(in.).037.050.062.125.187TravelAmps volts Speed(ipm)70 17 20-4085 18 20-50100 18 25-35150 20 15-25150 20 10-20(NOTE: The above are typical values. Specificwelding applications may require changes.)USES:Primary: Used for most mild steels.Secondary: Buildup for wearfacing.PROCEDURES:During welding, wire stickout (tip to work distance)should be approximately 5/16 in. Poor fit up willrequire lower amps and slower speed. At 17 volts orless, Argon-C0 2mixtures may offer better arccharacteristics than C0 2. Use only welding gradeC0 2gas at a flow of 15-20 cubic feet per hour.Mixed gas should be 75-percent argon to 25-percentC0 2. Use wind shield and increase flow rate inwindy conditions. This wire can be used with theGMA Spool-On Gun.CHARACTERISTICS:Remember! You do not have a flux to purge thedeposited molten metal; only a shielding gas preventsthe atmosphere from coming in contact with the arcstream. Any moisture, dirt, or oil on the base material,welding wire, or feed rolls will cause a defective weld.Tensile Strength: 78,000 psig1-5

TYPE: STEEL - TORCH or GTA(low- and medium-carbon)NSN: 9GD 3439-00-018-1625 (1/16X 36)9GD 3439-00-165-4198 (3/32X 36)(NOTE: This triple deoxidized rod should be used ifgas welding with MAPP Gas. It can also be used withacetylene gas.)MISCELLANEOUS USES:For faster buildup with arc, feed this rod into arcstream of the electrode. If you have a wearfacing rodthat is too hard for impact, feed this rod into arcstream. If you wish to cut stainless or cast iron withthe torch, feed this rod into the kerf.Tensile Strength: 62,000 psigUSES:Gas welding or GTA welding of low- andmedium-carbon steel where properties similar to thoseof the base metal are required or when the welded jointis subjected to heat. Small parts can be fabricatedfaster and with less distortion by using a brazing rod(NSN 9GD 3439-00- 165-4199). If joint strength isimportant, use NSN 9GD 3439-00-027-0953.1-6

TYPE: BRAZING - TORCH(flux-coated rod for general brazing)NSN: 9GD 3439-00-165-4199 (1/8X 18)9GD 3439-00-165-4197 (3/16X 18)9GD 3439-00-252-8357 (1/4X 18)USES:Joining of steel and cast iron and most copper-basedmetals, such as brass and bronze. Can be used onsome nickel alloys.(NOTE: Keep base metal of nickel alloys at lowestpossible temperature.)PROCEDURES:Clean joint and bevel heavy sections. On cast iron, usean excess oxygen flame to sear the weld area to a blueheat. Preheat heavy sections to 800°F. Apply fluxto weld area and continue heating until flux melts.Melt off a drop of the rod and flow it out - continue toadd more alloy drop by drop.CHARACTERISTICS :A low-fuming bronze rod that does not require fusionof the surface of the base metal. Flux for this rod isNSN 9GD 3439-00-255-4580.Tensile Strength: 60,000 psigIdeal for dissimilar metal combinations. Can be used tobuild up frictional wear-resistant surfaces that requirhardness of approximately 80 Brinell or 47 RockwellB.1-7

TYPE: STEELNSN: 9GD 3439-00-262-2649 (5/32)9GD 3439-01-155-2376 (1/8)9GD 3439-00-262-3876 (1/4)POSITION: AllPOLARITY: AC-DCCHARACTERISTICS:Excellent weld appearance. Free of spatter loss. Lightblue tip.Tensile Strength: 80,000 psigYield Strength: 68,000 psigElongation: 26-28 percentRECOMMENDED AMPERAGES:5/32 -80 to 175USES:Maintenance or production general weldingfabrication. Light and heavy gauge fabrication fortanks, machinery, frames, plates, angles, beams, sheetmetal.PROCEDURES:Clean weld area, bevel heavy sections. Set amperageand hold close arc. Electrode can be dragged for someapplications. Controllability of slag and non-bumthrough characteristics makes vertical down or up veryeasy.1-8

TYPE: BRAZING - TORCH (flux - coated rod forhigh-strength brazing)NSN: 9GD 3439-00-027-0953 (1/8X 18)USES:Primary: Torch joining of all carbon and alloysteels, including tool steel and carbides. Excellent forrepairing broken drills and joining extensions to drillsand reamers.Secondary: For joining and repairing nonferrousmetals, except aluminum, magnesium and die castzinc.on each side of joint until alloy penetrates the joint.When using as a bead-forming alloy, bevel heavypieces into a 60-900 vee and apply as a brazing rod.Do not melt base metal.CHARACTERISTICS :A flux-coated brazing alloy of high strength. Bondingtemperature -1400- 1600°F. Use NSN 9GD3439-00-165-4199 for brazing and for jobs notrequiring high strength.Tensile Strength: 100,000 psig.PROCEDURES:When using as a thin flowing alloy and extra flux isnot available, break off and pulverize some of the fluxcoating and mix it with a few drops of water to form apaste to paint the joint area.Clean joint thoroughly - close fit the joint with about0.003 in. clearance. Heat with neutral flame untilpreplaced flux liquefies - apply rod - continue heating1-9

TYPE: SILVER BRAZING KITS - TORCHNSN:9GD 3439-01-047-4141 (3/64x 34)(per Kit plus dry flux)9GD 3439-01-030-2412 (1/16)CHARACTERISTICS:Since this alloy does not contain cadmium, it is safeto use on any food or beverage equipment. Use thisrod only where the work is small, delicate, or requiresjoining by use of a torch at low temperatures. Thisalloy’s thin, flowing properties make it ideal for lap,square butt, and "T" joints because capillary actioncauses it to fill small-clearances and achieve higherstrength bonds.USES:For all silver brazing applications on ferrous andnon-ferrous metals (except the white metals). Usespecifically for instrumentation, tubing, controls,switches, and similar devices. Excellent for food Temperature: 1145- 1205°Fvessels, laboratory apparatus, and hospital equipment.Tensile Strength: 85,000 psigPROCEDURES:Clean thoroughly, heat broadly along the joint linewith a carburizing flame. Touch rod into jar of dryflux and flow into joint, then feed rod into joint. Keepflame at least 1 in. from joint. Continue feeding roduntil fillet is observed. When paste flux is needed, mixwith a few drops of water to form a paste and paint thearea where a preplaced flux is desired. Flux can beremoved by quenching in water. Joint clearanceshould be between 0.002 and 0.003 in. for maximumstrength. For color match on stainless, coat silversolder deposit with tin-silver solder 96/4 on page 1-40.1-10

TYPE: CAST IRON - TORCH (flux coated rod)NSN: 9GD 3439-00-027-0953 (1/8X 18)9GD 3439-00-254-5038 (1/4X 18)USES:Primary: A general-purpose, cast iron alloy fortorch joining of gray cast iron. Use this rod when welddeposit must have physical properties (resistance tobending, corrosion, heat resistance) similar to the basemetal. A cast iron manifold, built to withstand heat,should be welded with this rod because it deposits aweld that will withstand exhaust heat and expand andcontract at the same rate as the manifold.off a drop of the rod and flow it out. Continuedepositing alloy drop by drop, using a weaving motionof the torch. Slowly cool by covering with lime.CHARACTERISTICS:Deposits are color matching and dense with similarproperties of cast iron. The deposit will be machinableif cooled slowly.Bonding Temperature: 1400- 1600°FHardness: 200 Bhn (slow cooled)Tensile Strength: 40,000 psigSecondary: Use on cast iron parts too small and thinto arc weld. When no hard face rod is available, it willmake a hard deposit if applied as an arc rod.PROCEDURES:Bevel breaks and cracks to forma 75-90° vee. Useneutral flame and preheat uniformly. Keep torch inconstant motion. Melt a small amount of flux from therod and continue heating until the flux liquefies fromthe heat of the base metal. At this temperature, melt1-11

TYPE: CAST IRON - ARC(fully-machinable nickel base)NSN: 9GD 3439-00-262-2743 (l/8x14)POSITION: AllPOLARITY: AC or DC Straight or ReverseRECOMMENDED AMPERAGES: 1/8 -55 to 110USES:Primary: For welding cast iron in all positionswhere the weld must have high ductilitv andmachinability y in the bonded zone.Secondary: For joining cast iron to all other metalsexcept the white metals. It can be used for weldingnickel, monel, stainless and copper alloys when theproper rods for these metals are not available. Can beused as a cushion for wearfacing.400°F to reduce cooling rate. Use a short tomedium arc at the lowest amperage possible. Peenlightly to relieve stress. Skip weld to preventexcessive local heat. Cool casting slowly.CHARACTERISTICS:Excellent for out-of-position welding. Bare rod maybe used for GTA welding of the above metals. Thisrod is hot short; do not permit casting to overheat.Support properly during welding.Tensile Strength: 50,000 psigNOTE: If a nonconductive coating is required in tightfitting areas where arcing through the coating would beundesirable - use Marcoloy #302.PROCEDURES:Bevel breaks and cracks 75-900 vee. Use thegouging rod (NSN 9GD 3439-00-453-5950) to removeunwanted met al. For best machinability, preheat to1-12

TYPE: CAST IRON (fully-machinable)NSN: 3439-01-135-3913 (1/8)3439-01-135-3914 (5/32)POSITION: AllPOLARITY: AC-DC ReverseRECOMMENDED AMPERAGES:3/32 - 50-901/8 - 85-1205/32 -100-140CHARACTERISTICS :Green tip. Nonconductive coating. Excellent purgingcharacteristics.Tensile Strength: 56,000 psigNOTE: If a nonconductive coating is required intight fitting areas where arcing through the coating isundesirable - use Marcoloy #302.USES:Repair machining errors. Fill sand pockets, holes anddefects. Buildup and welding of gear teeth, cracks inhousings, blocks and cases.PROCEDURES:Clean weld area. Bevel crack. Use stringer beads(short deposits) to avoid overheating area.1-13

TYPE: CAST IRON - ARC(machinable nickel-iron base)NSN: 9GD 3439-00-165-4189 (1/8X 14)9GD 3439-00-165-4188 (5/32X 14)POSITION: AllPOLARITY: AC or DC ReverseRECOMMENDED AMPERAGES:1/8 - 80 to 1205/32 -90 to 140USES:Primary: For welding of gray and alloyed cast iron.The deposits give greatest crack resistance and shouldbe used where weld is subject to air, gas, or liquidpressure. Use to repair pump housings, valves,pressure chambers, cast, and malleable fittings.Excellent for crack-sensitive jobs such as joints underrestraint, dissimilar thicknesses, and the welding ofheavy sections. Can be used to join cast iron to steel.Secondary: Buildup for hardfacing on cast iron.PROCEDURES:Bevel cracks using gouging rod (NSN 9GD3439-00-453-5950), Keep uniform heat throughwelded section. On casting of dissimilar thickness,maintain interpass temperature of 5000 F. Peenlightly to relieve stress. Cool casting slowly.CHARACTERISTICS:If one section of the casting can move freely duringwelding, the welding can be continuous so thewelding job can be finished quickly. The welddeposit is not hot short like NSN 9GD3439-00-909-7951.Tensile Strength: 55,000-60,000 psig1-14

TYPENSN:BRAZING - ARC9GJ 3439-00-262-2739 (1/8x14)9GD 3439-01-131-4934 (5/32X 14)alloy sections 250- 400°F (except silicon, bronze).Use medium arc gap. (NOTE USE GOODVENTILATION. Hold electrode 10-15 degrees offperpendicular.)POSITION: FlatPOLARITY: DC ReverseCHARACTERISTICS:Has rapid deposition rate. Deposit is a copper-basealloy.RECOMMENDED AMPERAGES:Hardness: Deposited 130 BHN1/8 - 80 to 160 Work Hardens to 230 BHN3/16 -130 to 250Tensile Strength: 90,000 psigUSES:Primary: For high-strength joints on cast iron, steel,and copper alloys. For joints and dissimilarcombinations susceptible to cracking. Excellent foroverlaying surfaces subject to frictional wear andcorrosive attack by salt water.Secondary: Can be used for joining stainless,nickel, and nickel alloys.PROCEDURES:Bevel crack to 90° angle. Preheat heavy steel andcast iron sections to 200°F. Preheat heavy copper1-15

TYPE: ALUMINUM - ARC(extruded flux-coated rod) E-4043NSN: 9GD 3439-00-803-9496 (3/64x14)9GD 3439-00-165-4177 (1/8X 14)9GD 3439-01-139-3498 (5/32X 14)9GD 3439-00-246-0541 (3/16X 14)POSITION: Flat, horizontal, or verticalPOLARITY: DC ReverseRECOMMENDED AMPERAGES:1/8 - 90 to 1405/32 -125 to 175pulverize, mix with a few drops of water. Can be usedwith carbon arc, To use as a TGA rod, remove flux.PROCEDURES:Bevel 1/8 in. or heavier to 750 vee. On heavysections, preheat to 400°F. Maintain short arc.Hold electrode almost perpendicular to work orslightly in direction of travel. Back whip at crater.Chip slag before quenching. Use Marcoloy #500.CHARACTERISTICS:Keep rod dry; flux will absorb moisture from the aireasily.Tensile Strength: 25,500 psigUSES:Primary: Arc welding of all weldable grades ofaluminum in extruded, plate or sheet, and sand and diecastings. Use for welding aluminum landing matswhen GMA is not available or dirt, moisture, or windmake GMA impractical.Secondary: Use with torch for welding aluminum.To make an aluminum paste flux, break flux off rod,1-16

TYPE: ALUMINUM - GMA(Base Spooled Wire) E-5356NSN: 9GD 3439-00-803-9498(3/64 X 1 lb. spool)POSITION: AllPOLARITY: DC Reverse (Argon or helium gas)RECOMMENDED CURRENT SETTINGS:(3/16 plate-flat)volts Amen (cfh) Amps23-25 30-40 160-180Weld Speed in Min22-26(NOTE: There is a different setting for each plate,thickness, type of joint and position. Most of yourwelding will be in the above ranges.)USES:This wire is recommended for welding 5056,5083,5086,5154, and 5356 aluminum alloys. USE THISWIRE FOR WELDING ALUMINUM LANDINGMATS.PROCEDURES:Wire and joint to be welded must be clean. Set yourmachine and gas flow to the above settings and test ona piece of scrap of similar thickness and type of joint inthe position you will be welding. Dirt on your work,wire or feeding mechanism, or inadequate gascoverage of your molten weld puddle will result inporosity. Check for leaks into gas flow.CHARACTERISTICS:For general maintenance, use flux coated arcaluminum rod on page 1-23. Save this wire forwelding aluminum landing mats.Tensile Strength: 40,500 psigYield Strength: 21,000 psig1-17

TYPE: BRAZING, GAS —ALUMINUMNSN: 9GD 3439-01-030-2509 (3/32)9GD 3439-00-255-4576 (Flux)POSITION: FlatUSES:Joining of thin wall tubing, T-joints, lap and flanges,sheets, extrusions, repair of aluminum furniture,automotive trim, radiators, window frames, airconditioning parts, motorcycle parts.An extremely low melting aluminum alloy thatfeatures high strength welds on most aluminumswithout melting the base metal.Tensile Strength: 33,000 psiBonding Temp: 1070°FPROCEDURES:Remove all grease, dirt, oil and oxides. Dip rod intoMarcoloy #1500 Flux or mix flux with alcohol orwater and brush paste on weld area. Heat uniformlywith reducing flame until flux liquifies, add alloy untilit flows through joint. Cool slowly, wash fluxthoroughly with water.CHARACTERISTICS:Yellow tip.1-18

TYPE: ZINC DIE CAST and ALUMINUMNSN: 9GD 3439-01-132-0140Size: 1/8Tensile Strength: 25,000 psigUSES:Repair zinc die cast parts, automotive grills,carburetors, fuel pumps castings and kirksite dies.Aluminum castings and parts, such as sand holes, wornparts and machining errors, can be filled or overlayed, .PROCEDURES:Remove all grease, dirt, oil and oxides. Zinc die cast:Apply flux to surface, then heat with soft reducingflame until flux liquifies. Melt off rod and removeheat. Cool slowly. Wash flux off in water.Aluminum: File or grind surface, use no flux, heatindirectly and keep rubbing alloy on surface until itwets out. Remove heat and allow to cool slowly.TIG: No flux is required. Use high frequency AC andargon gas.CHARACTERISTICS:Brown Tip.Melting Point: 700°F1-19

TYPE: STAINLESS - ARC (all steels - medium,high carbon, alloy, and tool steels)AWS-ASTM E 312-16NSN: 9GD 3439-00-902-4209 (3/32X 14)9GD 3439-00-165-4169 (1/8X 14)9GD 3439-00-165-4166 (5/32X 14)9GD 3439-00-165-4168 (3/16X 14)POSITION: AllPOLARITY: AC or DC ReverseRECOMMENDED AMPERAGES:3/32 - 50 to 901/8 - 90 to 1205/32 -120 to 1603/16 - 150 to 190Secondary: Can be used for welding stainless (noacid) and salt-water pipe lines. Can be applied as abuildup on manganese steel or any wear probleminvolving frictional wear and impact.PROCEDURES:Bevel 90°. Preheat alloy steels to 400°F. Hold ashort arc. Use stringer beads. Run intermittent welds,especially on high alloy steel. Peen lightly to relievestresses.CHARACTERISTICS:Bare rod can be applied with gas or GTA torch. Sincemany other rods are capable of doing jobs that this rodcan do, conserve supplies and use it only for jobsrequiring its high tensile strength properties.Tensile Strength: 120,000 psigUSES:Primary: Use this rod when you need a highstrength weld deposit or when highly stressed joints,vibration or shock continually cause weld failure. Useon all steels and where destructive combinations ofwear, impact, corrosion, or heat are present.1-20

TYPE: BUILDUP - ARC (tungsten, high speed)NSN: 3439-00-105-9948 (1/4X 14)3439-01-032-5978 (1/16 X 14)3439-00-902-4210 (3/16 X 14)3439-00-105-9945 (3/32 X 14)3439-01-012-1002 (3/64 X 14)POSITION: AllPOLARITY: AC/DC, Straight/ReverseRECOMMENDED AMPERAGES:1/8 -100 to 1601/4 -200 to 2805/32 -140 to 1803/16 -180 to 240USES:Primary: To repair or rebuild high speed toolswithout having to reharden the tool.Secondary: Form tools, milling cutters, lathe bits,boring bars and other tools usually made entirely ofhigh speed steel can be made compositely with onlythe cutting surfaces made of high speed steel.PROCEDURES:For composite fabrication of cutting tools: machine orgrind surface, allow for approximately 3/16 in. offinished weld metal. Preheat to approximately400ºF. Apply one pass of Marcoloy #200 toeliminate pickup of impurities from base metal toensure sound, homogeneous deposit of high speed steelon the second pass.CHARACTERISTICS:This rod deposits a tungsten-moly high speed steel thatcan be used for compositely fabricating tools for awide range of cutting conditions. Its “as-welded”deposit is exceptionally tough and maybe used forrough, deep cuts. It has good impact-resistantcharacteristics. Tempered, this weld is ideal forfinishing cuts at higher speeds. Will hold its temperand cutting qualities up to 1050°F.1-21

TYPE: OVERLAY - ARC (manganese wearfacing)NSN: 9GJ 3439-00-165-4172 (5/32x 1/4)9GD 3439-00-165-4187 (3/16X 1/4)POSITION: AllPOLARITY: AC - DC ReverseRECOMMENDED AMPERAGES:5/32 -110 to 1403/16 -150 to 220USES:Primary: This electrode is used for buildup andoverlay where severe impact and compression will beencountered. This rod is excellent for building up andjoining manganese steel, for the restoration of buckets,bucket teeth and lips, and crushers. It can be used forjoining steel to manganese, and steel to steel.Secondary: Can be used for joining cast iron, if castrod is not available.PROCEDURES:Clean and remove remains of previous cracked orbrittle hard surfacing deposits. Keep the interpasstemperature on manganese steels low (less than500°F). This can be done by back stepping andskip-welding techniques that prevent localizedoverheating.CHARACTERISTICS :This is a manganese chrome nickel electrode. It can beused to build up worn steel parts, but should be heldfor manganese steel jobs if the supply is limited.(NOTE: DO NOT BUILDUP MANGANESECRUSHER ROLLS OR JAWS WITH A MILDSTEEL ROD OR A STEEL BUILDUP ROD UNLESSSTAINLESS ROD IS APPLIED FIRST.)Hardness: As deposited RB 80-90Work hardened RC 45-50Tensile Strength: 150,000 psig1-22

TYPE: BUILDUP - ARC - TungstenNSN: 3439-01-012-1002 (3/64)3439-00-105-9945 (3/32)3439-01-032-5978 (1/16)3439-00-105-9948 (1/4)3439-01-149-2831 (1/8)POSITION: AllPOLARITY: AC-DC Straight or ReverseRECOMMENDED AMPERAGES: 135 to 175USES:Primary: For repairing or rebuilding high speedtools (without the need to reharden the tools),sprockets, rollers, tractor parts, excavator equipment,etc. Excellent for heavy padding when toughness andresistance to deformation is needed.(NOTE: DO NOT USE AS A BUILDUP ONMANGANESE STEEL.)1-23

TYPE: BUILDUP - ARC (FeMn A-Class 3)NSN: 9GD 3439-00-752-7818 (3/16X 14)POSITION: AllPOLARITY: AC-DC Straight or ReverseRECOMMENDED AMPERAGES:3/16 -135 to 175PROCEDURES:On heavy sections, preheat 200- 300°F. Hold ashort to medium arc and use a stringer or weavingtechnique. Do not allow excessive heat buildup inbase metal. On large buildup, deposit succeedinglayers across previous layer to minimize peeling.CHARACTERISTICS: Deposits are machinable.Hardness: RC30USES:Primary: On ferrous (steel) parts subject to heavyshock loading and pounding. On hammers, sprockets,rollers, tractor parts, excavator equipment, etc.Excellent for heavy padding when high toughness andresistance to deformation is needed.(NOTE: DO NOT USE AS A BUILDUP ONMANGANESE STEEL.)Secondary: Can be used to join steel if steel rod isNOT available.1-24

TYPE: OVERLAY - ARC (intermediatewearfacing)NSN: 9GD 3439-00-165-4182 (5/32X 14)9GL 3439-00-165-4181 (3/16X 14)POSITION: Flat, vertical, and horizontalPOLARITY: DC ReverseCHARACTERISTICS:At least two passes must be used to reduce the effectsof dilution.Hardness: RC50NOTE: For an electrode with all positioncharacteristics, including overhead position, useMARCOLOY #702.RECOMMENDED AMPERAGES:3/16 -140 to 200USES:On hard overlays subject to abrasive wear and mediumimpact. When overlaying cast iron, first apply twopasses of cast iron rod, NSN 9GD 3439-00-165-4188.PROCEDURES:Preheat to about 200- 300°F on heavy sections.Use weaving or stringer technique while holding ashort to medium arc. Do not allow excessive heatbuildup in the base metal.1-25

TYPE: OVERLAY - ARC (wearfacing - highabrasion)NSN: 9GJ 3439-00-165-4178 (1/8X 14)9GD 3439-00-165-4179 (5/32X 14)9GD 3439-00-165-4180 (3/16X 14)POSITION: Flat - horizontalthan 6 inches, and stagger welds to reduce local heatbuild up. Use 1/8 in. diameter only on grader blades.CHARACTERISTICS:Any rate of cooling will give a high hardness.Hardness: RC60POLARITY: AC -DC StraightRECOMMENDED AMPERAGES:1/8 - 80 to 1305/32 -100 to 1603/16 -160 to 240USES:For applications that require resistance to high abrasionand erosion. (NOTE: use only where impact is low.)PROCEDURES:Use a medium arc with a slight weaving motion. Along arc is recommended when wide, thinner-flowingapplications are desired. Do not weld beads longer1-26

TYPE: CHAMFERING or GOUGING- ARCNSN: 9GD 3439-00-453-5950 (1/8X 14)POSITION: AllPOLARITY: AC -DC StraightRECOMMENDED AMPERAGES:1/8 -250 to 350USES:Primary: This electrode can be used for chamferingor gouging all metals. Used for preparing sectionsprior to welding, gouging out unwanted or defectiveweld metal.Secondary: Can be used for cutting or piercing allmetals. Use to sear oil-soaked cast iron prior towelding by holding a long arc and rapidly passing overoil-soaked area.plane of the work. Strike arc and push chamfering rodalong the line of cut, quickly for a shallow groove,more slowly or with a weaving motion, for a deepergroove. If a deeper groove is required, repeat theprocedure.CHARACTERISTICS:The coating on this rod is heat resistant and the arc’sforce is concentrated at the point of application.NOTE: For carbon arc gouging and cutting useMarcolite Aluminum Carbons, 1/4x 12 inches (NSN3439-01-138-3106, Electrode Carbon Arc Aluminum1/4 for arc air.PROCEDURES:Insert electrode into electrode holder and pointelectrode, like a lance, in the direction of travel. Holdelectrode at an angle not more than 300 with the1-27

TYPE: GRAPHITE (carbon electrodes)NSN: 9GD 3439-00-262-4228 (3/8X 12)POLARITY: DC StraightUSES:Brazing of sheet metal (galvanized). Preheating andpost-heating when a torch is not available. Cutting ofall metals (when a cutting rod or torch can’t be used).Soldering (small work) by shorting carbon electrodenext to joint and feeding solder into a prefluxed seam.Use to plug holes prior to welding or brazing or onreverse polarity to deposit carbon to harden base metal.CHARACTERISTICS:Slow oxidation of the carbon electrode generatescarbon monoxide and carbon dioxide; these gases offersome weld metal protection.TYPE: SOLDER (tin - antimony 95/5)NSN: 9GD 3439-00-088-8768 (1/8X 1 lb. spool)USES:Where moderately elevated temperature is a factor.This solder has a plastic range of 12 degrees; it melts at452°F and flows at 464°F. It has a higherelectrical conductivity than tin-lead solders and can beused where lead is objectionable. Do not use onaluminum, zinc, or zinc-coated metals such asgalvanized iron. When stocks are depleted, use thetin-silver solder 96/4 on page 1-40.PROCEDURES:Clean and roughen surface as this solder makes astronger joint on a rough surface than on a polishedone. Joint clearances can be from 0.003 in. to amaximum of 0.010 in. An improper fit requires moresolder and leaves the joint weaker. The flux to use isNSN 9GD 3439-00-255-4566. Remove flux residueafter soldering joint.1-28

TYPE: SOLDER (tin - lead 50/50) ASTM 50ANSN: 9GK 3439-00-163-4347 (BAR)9GD 3439-00-273-1637 (1/8X 5 lb. spool)USES:A general purpose solder recommended when acombination of a relatively narrow pasty range, goodwetting properties, strength, and economy are desired.Can be used as a wiping and sweating solder and onradiator cores, electrical connections, heating units androofing seams.PROCEDURES:Clean and roughen surface as this solder makes astronger joint on rough surfaces than on polished ones.Joint clearances can be from 0.003 in, to a maximumof 0.010 in. An improper fit requires more solder andleaves the joint weaker. The flux to use is NSN 9GD3439-00-255-4566. Remove flux residue aftersoldering joint.Melting Temperature: 361°FFlow Temperature: 421 ‘FTYPE: SOLDER (tin - lead 40/60) ASTM 40ANSN: 9GD 3439-00-188-6986 (3/8X 5 lb. spool)USES:This acid core, general purpose solder can be usedextensively on sheetmetal work. It is cheaper than50/50 solder and can be used in similar applications.No flux is needed on small work because of its acidcore. (NOTE: SEAL END OF WIRE AFTERUSING.)PROCEDURES:Clean and roughen surface as this solder makes astronger joint on a rough surface than on a polishedone. Joint clearances can be from 0.003 in. to amaximum of 0.010 in. An improper fit requires moresolder and leaves the joint weaker. If more flux isneeded, use NSN 9GD 3439-00-255-4566. Removeflux residue after soldering.Melting Temperature: 361°FFlow Temperature: 455°F1-29

TYPE: SOLDER (tin - lead 60/40 rosin core)NSN: 9GD 3439-00-184-8953 (3/32X 1 lb. spool)USES:For soldering instruments, where a “free” solder isneeded and temperature requirements are critical. Forsoldering wiring because it has a narrow pasty rangeand solidifies quickly. Use this solder on electricalwiring because its core of rosin flux has a relativelylow corrosive nature.PROCEDURES:Clean and roughen surface because solder makes astronger joint on a rough surface than on a polishedone. Joint clearances can be from 0.003 in. to amaximum of 0.010 in. An improper fit requires moresolder and leaves the joint weaker. In electrical work,a closer tolerance gives better conductivity.Melting Temperature: 361°FTYPE: SOLDER (tin - silver 96/4)NSN: 9GD 3439-00-968-3370 (1/8X 5 lb. spool)USES:For food and beverage containers requiring acadmium-free and lead-free solder. It retains a brightfinish, is a good color match for stainless steel, and isexcellent for joining dissimilar metals.. It is strongerand has better electrical conductivity than tin-leadsolders and may be used for refrigeration work iftin-antimony 95/5 solder is unavailable.PROCEDURES:Clean and roughen surface because solder makes astronger joint on a rough surface than on a polishedone. Joint clearances can be from 0.003 in. to amaximum of 0.010 in. An improper fit requires moresolder and leaves the joint weaker. Use flux NSN9GD 3439-00-018-1655. Remove flux residue aftersoldering joint.Flow Temperature: 374ºFUse flux for cleaning (NSN 3439-00-255-9935)1-30

TYPE: SOLDER (tin - lead 60/40 rosin core)NSN: 9GD 3439-00-184-8953 (3/32X 1 lb. spool)USES:For soldering instruments, where a “free” solder isneeded and temperature requirements are critical. Forsoldering wiring because it has a narrow pasty rangeand solidifies quickly. Use this solder on electricalwiring because its core of rosin flux has a relativelylow corrosive nature,PROCEDURES:Clean and roughen surface because solder makes astronger joint on a rough surface than on a polishedone. Joint clearances can be from 0.003 in. to amaximum of 0.010 in. An improper fit requires moresolder and leaves the joint weaker. In electrical work,a closer tolerance gives better conductivity.Melting Temperature: 361ºFTYPE: SOLDER (tin - silver 96/4)NSN: 9GD 3439-00-968-3370 (1/8X 5 lb. spool)USES:For food and beverage containers requiring acadmium-free and lead-free solder. It retains a brightfinish, is a good color match for stainless steel, and isexcellent for joining dissimilar metals.. It is strongerand has better electrical conductivity than tin-leadsolders and may be used for refrigeration work iftin-antimony 95/5 solder is unavailable.PROCEDURES:Clean and roughen surface because solder makes astronger joint on a rough surface than on a polishedone. Joint clearances can be from 0.003 in. to amaximum of 0.010 in. An improper fit requires moresolder and leaves the joint weaker. Use flux NSN9GD 3439-00-018-1655. Remove flux residue tiersoldering joint.Flow Temperature: 374°FUse flux for cleaning (NSN 3439-00-255-9935)1-30

CHARACTERISTICS:This solder is lead-, antimony-, and cadmium-free andhas good corrosion resistance.Flow Temperature: 430°FTensile Strength: 15,000 psigShear Strength: 11,200 psigElectrical Conductivity: 11.05 x 10-6 ohms/cmNOTE: Soldering Kit, Lead-Free (NSN 9GD3439-01 -297-3284) consists of 1 pound of corrosionresistant solder, 1/16 in.; a 2 oz. plastic bottle of whitepaste flux, melting point of 390°F; soft solder forstainless, copper, brass, nickel and bronze alloys; to beused with torch, solder iron or furnace applications.1-31

TYPE: HOLDING AND HEAT-RESISTINGCOMPOUNDNSN: 9GS 3439-01 -2664557(5 lb. can)USES:Excellent for holding irregular shapes or parts duringwelding, brazing, or soldering. Protects threads andflammable materials from flame, arc heat and spatter.For easy removal after soldering wire, first cover thewiring with a sheet of asbestos or aluminum foil. Ifthis compound is unavailable, use a high temperatureinsulation, fire clay, or carbon paste instead.PROCEDURES:Place a small amount under each section and pressparts into the holding compound until properly aligned.CHARACTERISTICS:Can be used many times over by mixing with a smallamount of water. It is easily removed from holes orthreads and will not melt, bum, crack, expand, orcontract to disturb alignment.l-32

TYPE: SURFACE-HARDENING (CASE)COMPOUNDNSN: 9GD 6850-00-139-5936 (10 lb. can)USES:For rapid surface-hardening of all types of mild- andlow-alloy steel. Will not increase the dimensions ofthe part. It can surface-harden cams, small tools,shafts, gears and collars, as well as bolt and nut threadsto help prevent stripping.PROCEDURES:Method No.1: After removing all scale, etc., heatthe part to a uniform bright red (1650 -1700°F).Roll, dip, or sprinkle the compound powder onto thepart or section to be surface-hardened. The powderwill melt and adhere to the surface. Reheat again to1650- 1700°F and hold at this temperature for a fewminutes before quenching in cold, clean water. Thepart will now have a case hardness of uniform depth.Method No. 2: When a deeper case hardness for apart is required, place it on a can lid, or a similar tray(bum off tin before using), and cover it completelywith surface-hardening compound. Heat it to a brightred color (1650°F) for 5 to 30 minutes, ridingon the depth of hardness required. Remove the partwith dry tongs and quench it in clean, cold water.PENETRATION RATES:After heating apart to 16500F using Method No. 2:Case Time in Case Time inDepth Minutes Depth Minutes.005 15 .015 40.010 30 .020 50-55Method No. 3: Heat the part to be hardened to a dullred color (1400 - 1600ºF) before covering it withsurface-hardening compound. Cover flat sections byapplying compound with a knife or spatula. Roundsections can be dipped or rolled in compound. Allowthe part to seal, let it air for 30 seconds and then reheatit to a dull red color. Keep it at heat for one minute,then immediately quench it in water.For deeper penetration, apply fresh compound at oneminute intervals for several minutes while the part is atred heat, then immediately quench it after the last1-33

TYPE: SURFACE-HARDENING (CASE)COMPOUND (Continued)heating cycle. Hot water will easily remove anyresidue.CHARACTERISTICS:This material is free of poisonous compounds, such ascyanide, but take precautions to avoid breathing itsfumes. Do not add fresh powder when it weakens;instead, simply discard and use a new can.APPLICATION GUIDES AND COMPARATIVEINDEXThis section includes Quick Reference Guides forWelders (Tables 1-1 through 1-5). These applicationguides reference pages in this manual and coverprimary and alternate electrodes to be used whenwelding the different metals listed. This section alsoincludes a comparative index (Table 1-6) to further aidthe welder in identifying comparable weldingproducts. Two or more products in this index maybelisted as being comparable under a National StockNumber (NSN) whereas, in reality, they differ.Remember, specifications merely state minimumrequirements. Although two products meet the samespecifications, they may have different performancecharacteristics. Table 1-6 is provided to help thedeployed welder identify the right electrode, or thenext best one from available welding products, andshould not necessarily be construed to mean theproducts are the same or that they all meet therequirements for a particular National Stock Number(NSN). Space limitations required abbreviation ofsome product designations - For example: nickelmanganese has been listed as Ni Mang.1-34

TABLE 1-1. Cast Iron Application GuideApplicationGeneral UseHeavy CastingsThin CastingsAlloy Cast IronCracksGearsCutting, GroovingGTAJoining to Other MetalsMotor BlocksArc1-201-201-171-201-171-171-321-171-221-17PrimaryElectrodesTorch1-151-151-151-1oArc1-171-171-201-171-201-201-201-171-20AlternateElectrodesTorch1-1o1-1o1-1o1-1o1-1o1-121-151-35

TABLE 1-1. Cast Iron Application Guide (Continued)ApplicationOverlay-MachinablePipesPulleysValve SeatsMalleable IronDuctile IronArcI-221-201-171-201-201-20PrimaryElectrodesTorch1-1o1-151-151-151-1o1-1oArcAlternateElectrodesTorch1-20 1-121-17 1-1o1-20 1-1o1-171-171-17 1-121-36

TABLE 1-2. Copper, Brass, and Bronze Application GuideApplicationPrimaryElectrodesAlternateElectrodesArcTorchArcTorchGeneral Use1-221-161-171-12Light Gauge1-13Very Thin Gauge1-391-37Aluminum Bronze1-231-25Bus Bar1-13Beryllium Copper1-221-13Casting (Heavy)1-221-1o1-12Castings (Light)1-13Cutting, Grooving1-341-35Gears1-221-101-171-121-37

TABLE 1-2. Copper, Brass, and Bronze Application Guide (Continued)ApplicationPrimaryElectrodesAlternateElectrodesArcTorchArcTorchManganese Bronze1-221-101-171-12Naval Bronze1-221-101-171-12Overlay-Machinable1-221-101-12Phosphor Bronze1-221-101-171-12Piping, Flanging1-221-131-17Plumbing, Heating1-13Sealing1-391-37Sheet, Brass, Bronze1-131-37Tubing1-131-371-38

TABLE 1-3. Aluminum Application GuideApplicationPrimaryElectrodesAlternateElectrodesGeneral UseBrazingCastingsArc1-231-23GMATorch1-231-23ArcGMA1-241-24TorchCastings to Sheetor plateCrankcaseCutting, GroovingThin PartsTubingLanding Mats1-231-231-341-241-231-231-231-231-241-39

TABLE 1-4. Stainless Steel Application GuidePrimaryAlternateApplication Electrodes ElectrodesGeneral UseBrazing, Silver AlloysPiping, FlangingSolderingStainless to MonelArc1-281-271-17Torch Arc1-12 1-171-131-13 1-171-401-13 1-22Torch1-391-121-40

TABLE 1-5. Steel Application GuideApplicationPrimaryElectrodesAlternateElectrodesArcGMATorchArcGMATorchGeneral Use1-11-71-91-21-12Alloy Steels, low1-31-71-121-271-10T-1 Steels1-51-121-27Well Casings1-31-121-51-10Pipe1-11-71-91-21-12Shafts1-31-121-11-10Brazing Applications1-221-121-10Spring Steel1-271-121-13Carbon Steel, (High)1-271-12Tool Steel1-271-121-131-41

TABLE 1-5. Steel Application Guide (Continued)ApplicationPrimaryElectrodesAlternateElectrodesArcGMATorchArcGMATorchCarbon Steel (Low)Chrome, MolyCutting, GroovingGears1-1 1-71-30-C1-341-271-91-121-121-21-31-101-101-10Stainless Cladding1-27Tool Tipping1-13Tungsten1-30 (a)(b)Instrumentation1-13Manganese Steel1-291-271-42

TABLE 1-5. Steel Application Guide (Concluded)ApplicationArcPrimaryElectrodesGMATorch Arc GMA TorchOverlays:AbrasionBronzeCorrosion ResistanceMachinableHeat ResistanceImpact Resistance1-331-221-271-311-271-291-101-121-321-17 1-121-22 1-101-31-201-271-43

TYPE: UNDERWATER CUTTING (Electrode -Underwater cutting)NSN: 9GD 3439-01-256-3361 (1/8X 14)PROCEDURE:Rod can be bent 900 for hard-to-reach cuts or forcutting around blind corners without restricting theoxygen flow or decreasing its cutting efficiency.MIL SPEC: MILE- 17764POSITION: AllPOLARITY: AC/DCRECOMMENDED AMPERAGE: 450USES:To cut ferrous or non-ferrous metals, concrete, rock,even the space shuttle’s heat shield!CHARACTERISTICS:Readily ignited when submerged, this rod will continueto burn - even without power - until its oxygensupply is cut off. This advanced cutting rod works inconjunction with any cutting torch or weldingmachine, but reaches maximum efficiency when usedwith an oxy-arc cutting torch.1-44

Table 1-6. Welding Rod Comparison ChartType of AWS/ASTM WeldingWeld/Cut C l a s s P r o c e s s A l l o y R o d s Marco Hobart L i n c o l n McKayPageT e c h A l l o y U n i b r a z e E u t e c t i c NO.Aluminum ER 5356 GMA N/A 501.M 5356 N/A N/A N/A N/A N/A1-17ER 4043 SMAW1 N/A 500 4043Alumin/weld N/A N/A N/A N/A 1-16OAW/GTA N/A 1570 N/A N/A N/A N/A N/A N/A1 - 1 9ERCuAL-A2 SMAW N/A 400 N/AN/A N/A N/A N/AN/A1 - 1 5OAW 4lFC1300FC N/A N/A N/A N/A 410FC N/A1 - 7RBCuZn-D OAW l l F C 1200 N/A N/A N/A N/A110FCN/A1 - 9OAW N/A 1900 N/A N/A N/A N/A N/A Silver Weld Kit 1-10Cast Iron ENi CL-A SMAW N i c k e l A r c 9 9 301 N/A Softweld 99 Ni N/A N/A N/A N/A1 - 1 2SMAW N/A 302 N/A N/A N/A N/A N/A N/A1 - 1 3EFiFE-Cl SMAW N/A 3 0 0 / 3 0 3 C a s t - T e x 5 5 S o f t w e l d 5 5 N/ATech-Rod 55 H a r r i s 5 5 Xyron-23 1 - 1 4RCIOAW N/A 1301/327 N/AN/A N/A N/A N/A 1 - 1 1S t e e l OAW N/A 1300FC N/A N/A N/A MMSO.062 N/A N/A 1 - 7E–6012 SMAW SW612 202 12 FW-7 N/A RACO6012 N/A N/A1 - 2E-6011 SMAW SW142 0 3 / 2 1 1 3 3 5 A / 3 3 5 C FW-35 6011 RACO6011 N/A N/A 1 - 1E-701B SMAW Atom Arc 7018 201 718/718MC Jet Weld LH-70 7018-M RACO7018 N/ACEC9708 1 - 3E11018 SMAW Atom Arc 210 Haballoy 11018-M Jetweld LH110MR 11018-M RACO 11018-M N/A N/A1 - 4E70, S-3, S-6 SMAW Spool-Arc 85 201M HB-25, HB-33 L - 5 0 S - 3 RACO-121 N/A1 - 5E312-16 SMAW ARCALDY 312ACDC 200 SOUDOCR-OM312-16 N/A 312AC-DC RACO 312-16 Harris 312-16 EUTEC 3026 1-20Cutting,Chamfer/ SMAW DH-4 800 W/A N/A N/A N/A G r o v r o d Chamfer Trade 1 - 2 7GougingArcBuild-up l - A - 2 b SMAW 31P W/A Tufanhard 250 BU-90 H a r d a l l o y 3 2 N / A M a t r i x Ferro-Rod 2B 1 - 2 4Wearfacing EFeMn-B SNAW Super–WH 701 160 N/A Chrome Mang N/A HS-44 3205 1 - 2 2Buildup SMAW 51P 702 375/400 600 Abrasoweld H a r d a l l o y 5 8 N / A N/AS t e e l t e c t i c 2 1 - 2 5SMAW 4 0 700 580F a c e w e l d H a r d a l l o y 5 5 W / A U/A 5505 6606 1 - 2 61-45

INTRODUCTIONSection 2. WEARFACINGAbrasion-resistant alloys have poor impact properties.Conversely, impact-resistant alloys have poor abrasionresist ante. The higher an alloy’s abrasion resistance,the lower its ability to withstand impact, andvice-versa. Between these two extremes are numerouswearfacing alloys that combine varying degrees ofresistance to abrasion with the ability to absorb a fairamount of impact. The selection of a wearfacing alloyfor a certain application is determined by therequirements of its anticipated service.The Seabee Welder can greatly extend the usable lifeof construction equipment by selecting the appropriatealloy and applying it with the correct procedure. Aregular wearfacing program extends equipment life,allows it to operate more efficiently, with less downtime, and greatly reduces the need for spare parts.The following section illustrates various parts ofconstruction equipment and describes the correct repairwelding procedures to use on them. Each diagramprovides one or more electrodes that maybe used asalternates whenever the most desirable rod is notavailable. The numeral given is the page numberwhere information on the recommended rod can befound.WORKPIECE PREPARATIONRemove dirt, oil, rust, grease and other contaminantsbefore welding. If you do not, you are invitingporosity and possible spalling. Prepare a soundfoundation by removing fatigued, rolled-over metal.Repair cracks with compatible electrodes.PREHEATPreheating of base metal is sometimes necessary tominimize distortion, to prevent spalling or cracking orto avoid thermal shock. Preheat temperature isinfluenced by two important factors; the carboncontent and alloy content of the base metal. Thehigher the carbon content, the higher the requiredpreheat temperature. The same is true, to a slightlylesser degree, for the total content of other alloys.After the surface has been brought to the required2-1

PREHEAT (Continued)preheat temperature, the part must be held at thistemperature until heat has reached the core; this iscommonly referred to as soaking time. All preheated 8.parts should be slow-cooled.to Hadfield’s manganese steel.The greater the alloy content insteels.air-hardeningThe need for preheating increases as the following 9.factors are changed:The more the air-hardening capacity of thesteel.1.2.3. .4.5-.6.7.The larger the mass being welded. 10.The lower the temperature of the pieces beingwelded.The lower the atmospheric temperature.The smaller the weld rod diameter.The greater the speed of welding.The higher the carbon content of the steel.The higher the manganese content in plaincarbon or low alloy steels. This does not applyThe more complicated the shape or sectionthe parts.Base metal composition must be determined foraccurate Preheat requirements. Carbon steels andaustenitic manganese steels can be differentiated withthe use of a magnet. Carbon steels are magnetic;austenitic manganese steels are not. (Austeniticmanganese steel will become magnetic after beingworkhardened so a magnetic check should be made ina non-worked area. ) Cast iron can be determined by aspark when a metal-working chisel is applied to thebase metal; cast iron will chip or crack off; cast steelwill shave.of2-2

PREHEAT (Continued)Table 2-1 shows recommended preheat temperatures forwelding. Temperatures higher than those indicated onthis chart are sometimes required when hard-facing,depending on the size and shape of the part and the typeof hard-facing alloy to be applied.WELDING ON CAST IRONRebuilding and hard-facing of cast iron is not generallyrecommended since it is extremely crack sensitive.However, some cast iron parts, primarily those subject tostraight abrasion, are being successfully hard-faced.Under any circumstances, cast iron parts require highpreheat temperatures, from 1000- 1200°F (dull red),and must be slow cooled after welding. Weld deposits oncast iron should be peened to help relieve stresses.BUILDUP MATERIALS AND BASE METALSConsiderable differences exist between welding materialsused to buildup worn equipment and those used forhard-facing overlays.Prior to hard-facing, badly worn parts must be restoredwith an appropriate buildup material to within 2/16 -3/8 in. of their finished size. The buildup materialmust have sufficient mechanical strength to sustainstructural requirements. It must resist cold flowing,mushing under high compressive loads and plasticdeformation under heavy impact. If the buildupmaterial doesn’t possess these properties, a hard-facingoverlay, which has comparatively little ductility, willspan for lack of support. In addition to thesemechanical requirements, a buildup material must becompatible with the base metal and the hard-facingoverlay.Use electrode on page 1-24 as the primary source andelectrodes on pages 1-5 and 1-3, in that order, asalternate sources to rebuild carbon steel parts prior tooverlaying with hard-facing electrodes. Whenhard-facing with the high alloy group, apply therecommended hard-facing material before placing it inservice and do not allow it to wear more than 1/4 in.(two layers) before hard-facing. If carbon steel parts2-3

BUILDUP MATERIALS AND BASE METALS(Continued)that are to be hard-faced with the high alloy grouprequire buildup, it is vital that high interpasstemperatures are maintained while observing thefollowing procedures as illustrated in Figure 2-1. Useweaving bead instead of stringer bead when applyinghard-facing. Limit single pass bead thickness to 3/16inch. Use same technique for second layer. Avoidsevere quench.THICKNESS OF HARD-FACING DEPOSITSA deposit of a hard-facing alloy that is too thick cangive you more problems than no deposit at all. In mostcases, hard-facing materials should be limited to twolayers; the first layer will produce an admixture withthe base metal and the second layer will produce thedesired wear-resistant surface.To rebuild austenitic manganese steel parts, use theelectrode on page 1-29 as the primary source and theelectrode on page 1-27 as the secondary source.WORKPIECE POSITIONINGYou will get the job done quicker and moreeconomically if the part being hard-faced is positionedfor downhand welding. When down-hand welding isnot practical, select an electrode recommended forall-position welding.2-4

OSCILLATE ROD-HARD-FACING WEAVE, FIGURE 8OVERLAYOR HORSESHOEFIGURE 2-1. Hard-Facing Techniques2-5

TABLE 2-1. Metals Preheating ChartMetal Metal RecommendedGroup Designation PreheatPLAIN Plain Carbon Steel - Below .20%C Up to 200°FCARBON Plain Carbon Steel - .20-.30%C 200°F-300°FSTEELS Plain Carbon Steel - .30-.45%C 300°F-500°FPlain Carbon Steel - .45-.80%C500°F-800°FCARBON Carbon Moly Steel -.10-.20%C 300°F-500°FMOLY Carbon Moly Steel -.20-.30%C 400°F-600°FSTEELS Carbon Moly Steel -.30 -.35%C 500°F-800°FMANGANESESTEELSSilicon Structural Steel300°F-500°FMedium Manganese Steel300°F-500°FSAE T 1330 SteelSAE T 1340 Steel500°F-800°FSAE T 1350 Steel600°F-900°F12% Manganese Steel Usually not required2-6

TABLE 2-1. Metals Preheating Chart (Continued)MetalGroupHIGHTENSILESTEELSMetalDesignationManganese Moly SteelJalten SteelManten SteelArmco High Tensile SteelDouble Strength #1 SteelDouble Strength #1 SteelMayari R SteelOtiscoloy SteelNax High Tensile SteelCromansil SteelA. W. Dyn-El SteelCorten SteelChrome Copper Nickel SteelChrome Manganese SteelYoloy SteelHi-SteelRecommendedPreheat300°F-500°F400°F-600°F400°F-600°FUp to 200°F300°F-600°F400°F-700°FUp to 300°F200°F-400°FUp to 300°F300°F-400°FUp to 300°F200°F-400°F200°F-400°F400°F-600°F200°F-600°F200°F-500°F2-7

TABLE 2-1. Metals Preheating Chart (Continued)MetalGroupNICKEL STEELSMEDIUM NICKELCHROMIUM STEELSMetalDesignationSAE 2015 SteelSAE2115 Steel2-1/2% Nickel SteelSAE2315 SteelSAE 2320 SteelSAE 2330 SteelSAE 2340 SteelSAE3115 SteelSAE 3125 SteelSAE 3130 SteelSAE 3140 SteelSAE 3150 SteelSAE 3215 SteelSAE 3230 SteelSAE 3240 SteelSAE 3250 SteelSAE 3315 Steel2-8RecommendedPreheatUp to 300°F200°F-300°F200°F-400°F200°F-500°F200°F-500°F300°F-600°F400°F-700°F200°F-400°F300°F-500°F400°F-700°F500°F-800°F600°F-900°F300°F-500°F500°F-700°F700°F-l00°F900°F-1100°F500°F-700°F

TABLE 2-1. Metals Preheating Chart (Continued)MetalGroupMEDIUM NICKELCHROMIUM STEELSMOLY BEARINGCHROMIUMandCHROMIUM NICKELSTEELSLOW CHROME (Cr)MOLY (Me) STEELSMetalDesignationSAE 3325 SteelSAE 3435 SteelSAE 3450 SteelSAE 4140 SteelSAE 4340 SteelSAE 4615 SteelSAE 4630 SteelSAE 4640 SteelSAE 4820 Steel2% Cr. - 1/2% Mo. Steel2% Cr. - l/29% Mo. Steel2% Cr. - 1% Mo. Steel2% Cr. -1% Mo. SteelRecommendedPreheat900°F-1100°F900°F-1100°F900°F-1100°F600°F-800°F700°F-900°F400°F-600°F500°F-700°F600°F-800°F600°F-800°F400°F-600°F500°F-800°F500°F-700°F600°F-800°F2-9

TABLE 2-1. Metals Preheating Chart (Continued)Metal Metal RecommendedGroup Designation PreheatMEDIUM CHROME (Cr) 5% Cr. - 1/2% Mo. Steel 500°F-800°FMOLY (Me) STEELS 5% Cr. - 1/2% Mo. Steel 600°F-900°F8% Cr. - 1% Mo. Steel 600°F-900°FPLAIN HIGH 12-14% Cr. Type 410 300°F-500°FCHROMIUM (Cr) 16-18% Cr. Type 430 300°F-500°FSTEELS 23-30% Cr. Type 446 300°F-500°FHIGH CHROME (Cr) 18% Cr. - 8% Ni. Type 304 Usually does not requireNICKEL (Ni) 25-12 Type 309 preheating but it maybeCOLUMBIUM (Cb) 25-20 Type 310 desirable to removeSTAINLESS STEEL 18-8 Cb. Type 347 chill.18-8 Mo. Type 31618-8 Mo. Type 3172-10

TYPES OF WEARAbrasionA grinding action caused by abrasive solids sliding,rolling or rubbing against a surface. Referred to asgouging when combined with high compressive loads,HeatSoftens metallic structures and may acceleratechemical attacks like oxidation and scaling; however,it may cause phase changes that increase hardness andbrittleness.ImpactA blow or series of blows to a surface, resulting infracture or gradual deterioration,2-11

CorrosionDeterioration of metal by chemical or electrochemicalreaction with its environment.RECOMMENDED AMPERAGE AND POLARITYTHE DIFFERENCE BETWEEN CROSS-CHECKING AND CRACKINGDeposits made with high allov electrodes should checkon the surface. The check pattern is highly desirableas it reduces residual stresses. Without checking, theresidual (or locked-in) stresses when combined withservice stresses can reach a magnitude greater than thetensile strength and result in deep cracks or spalling(Figure 2-2). If checking does not occur naturally, itmust be induced to avoid future failure. For example,as heat builds up in large parts, less cross checking willtake place. To rectify this, forced checking can beaccomplished by sponging the deposit with a wet clothor by spraying the surface with a fine water mist.Checking may also be accelerated during the coolingperiod by occasionally striking the deposit with ahammer. If a check-free deposit is necessary, use asofter alloy and observe preheat and postheatrequirements. .Weld data showing recommended amperage andpolarities is listed in Section 1 on each page for everyelectrode.2-12

OXY-MAPP HARD-FACJNGGeneral Rules1.2.3.4.Use the oxy-MAPP method for hard-facing thincutting edges; electric arc welding is more apt tobum through. oxy-MAPP is also preferred whereminimum dilution is required.Most small parts made of low-, medium-orrelatively high-carbon steel can be hard-faced bythe oxy-MAPP process. The hard-facing of castiron is not recommended.Use a tip approximately four sizes larger than thatordinarily used to deposit a mild steel rod of thesame diameter.Where possible, use a jig to quickly position thepart for downhand welding, especially when thepart must be turned two or more times. This willsave time and gas.5. Lineup smaller parts like ditcher teeth or coalcutter bits in a row for easy pm-heating duringwelding.6. Clean all areas to be hard-faced with a grindingwheel regardless of whether the part is new orused. Grinding helps eliminate pin holes andmakes it easier to apply the hard metal. Theground surface should always extend beyond thehard metal deposit. In other words, if the hardmetal deposit is to be 1 in. wide, the ground areashould be 1-1/2 in. wide.7. When you hard-face any type of an edged tool youincrease its thickness. It is therefore desirable todraw out or sharpen all types of edged implements,new or used, before the hard metal is deposited.2-13

FIGURE 2-2. Cross-Checking and Cracking Comparison2-14

FLAME ADJUSTMENTSThree basic flame adjustments are used to deposithard-facing rods.The excess MAPP flames (3X and 4X as shown inFigure 2-3) are used to:(1) Spread the heat to minimize possibleburn-through on thin edges;(2) add excess carbon to the skin of the part beinghard-faced.The additional carbon lowers the melting point andsweating temperature of the part, facilitating thedeposit of the hard-facing alloy.FIGURE 2-3. Flame Adjustments forHard-Facing.2-15

Earthmoving and Heavy Construction EquipmentFIGURE 24. Tractor Parts and Accessories2-16

TRACTOR PARTS AND ACCESSORIES (SeeFigure 2-4)(NOTE: TO PREVENT DAMAGE FROMELECTRICAL ARC. REMOVE BEARINGSBEFORE WELDING)Track RollersPrimary Electrode: Page 1-24Alternate Electrodes: Pages 1-5, 1-3Tractor IdlersPrimary Electrode: Page 1-31Alternate Electrodes: Pages 1-5, 1-3Welding Procedures: Mount idler in jig for downhandwelding. Beads are often applied transversely (Figure2-6).Welding Procedures: Mount roller on jig fordownhand welding. Apply transverse beads onrunning face and flange (Figure 2-5).FIGURE 2-5. Hard-Facing Track Rollers2-17FIGURE 2-6. Hard Facing Tractor Idlers

TRACTOR PARTS AND ACCESSORIES(Continued)Tractor RailsCarbon SteelPrimary Electrode: Page 1-24Alternate Electrodes: Pages 1-5, 1-3Welding Procedures: Do not rebuild rails until theyhave worn to recommended service limits. Buildupoutside edges to same level as center. Apply washpasses 1/2 in. wide until entire surface is covered.Work alternately on four links to avoid overheating.Use only buildup materials; do not hardface (Figure2-7).FIGURE 2-7. Rebuilding Tractor Rails2-18

TRACTOR PARTS AND ACCESSORIES(Continued)Top Carrier RollsCast IronPrimary Electrode: Page 1-14Carbon Steel:(NOTE: DO NOT USE BUILDUP ELECTRODE ONCAST IRON)Carbon Steel - Follow same procedure withrecommended alloys, but preheat is not necessary(Figure 2-8).Primary Electrode: Page 1-24Alternate Electrodes: Pages 1-5, 1-3Welding Procedures: Cast Iron - Mount roller on jigfor downhand welding after bushings have beenpressed out and surfaces cleaned. Preheat part to 1000- 1200°F. Play burner flame on roll during entirewelding operation. Apply two layers of electrode onpage 1-14 in wide transverse beads; weld alternatelyon opposite ends of roll. Slow cool in asbestos or limebox.FIGURE 2-8. Hard-Facing Top Carrier Rolls2-19

TRACTOR PARTS AND ACCESSORIES(Continued)Drive SprocketsCarbon SteelPrimary Electrode: Page 1-24Alternate Electrodes: Pages 1-5, 1-3Welding Procedures: Position sprocket for downhandwelding. Use buildup material on badly worn areas(Figure 2-9). Use template to obtain proper shape.Grind high spots.FIGURE 2-9. Hard-Facing Drive Sprockets2-20

TRACTOR PARTS AND ACCESSORIES(Continued)Tractor GrousersCarbon SteelPrimary Electrode: Page l-25Alternate Electrodes: Pages l-22,1-20Welding Procedures: Anneal induction-hardenedgrousers before welding bar stock on grousers (Do nothardface new grousers). Rebuild cleat to originalheight by welding steel reinforcing bar stock to padwith appropriate electrode on page 1-3. Mark grouserlengths for three equal parts (Figure 2-10). Face outerthirds by beginning passes from center and workingout. Entire length of grouser can be faced if desired,but method shown avoids stress buildup.FIGURE 2-10. Hard-Facing Tractor GrousersRipper TeethCarbon SteelPrimary Electrode: Page 1-26Alternate Electrodes: Pages 1-25, 1-222-21

TRACTOR PARTS AND ACCESSORIES(Continued)Ripper Teeth (Continued)Welding Procedures: Apply to top and sides of toothcovering area about 2 in. back from point. Hard-faceremainder of tooth as shown in Figure 2-11.Bulldozer End BitsCarbon SteelPrimary Electrode: Page 1-25Alternate Electrodes: Pages 1-22, 1-20Welding Procedures: Place end bit in flat position andapply beads across outer comer and along edges. Onworn end bits, weld new corner and hard-face (Figure2-12). If work involves impact, use above mentionedelectrodes; in case of severe abrasion and moderateimpact, use electrode on page 1-26.FIGURE 2-11. Hard-Facing Ripper Teeth2-22

TRACTOR PARTS AND ACCESSORIES(Continued)Bulldozer BladesCarbon SteelPrimary Electrode: Page 1-25Alternate Electrodes: Pages 1-22, 1-20Welding Procedures: Position blade in suitableprehending jig or where necessary, bolt blade tomoldboard. Use skip weld technique. Apply stringerbeads to make deposit 1-1/2 in. wide (Figure 2-13). Ifwork involves impact, use electrode on page 1-25; incase of severe abrasion and moderate impact, useelectrode on page 1-26 which provides maximumservice life. NOTE: HIGH CARBON BLADESMUST BE PREHEATED BEFORE HARD FACING.FIGURE 2-12. Hard-Facing Bulldozer End Bits2-23

TRACTOR PARTS AND ACCESSORIES(Continued)Welding Procedures: Some ripper shanks are made ofdifficult-to-weld steels but can be protected withoutever striking an arc on the base metal by fabricating asleeve that fits tightly around the shank. Cut side andback panels from 1/2 in. mild steel plate; use 1 in. plowsteel for front panel. Join front and side panels withmild steel electrodes and slip unit around shank(Figure 2-14). Weld back panel in place. For manualwelding, apply above-mentioned electrodes in wafflepattern on front panel and on side panels. Shanksmade of weldable steels can be protected by applyingsame patterns directly on base metal.FIGURE 2-13. Hard-Facing Bulldozer BladesRiper ShanksCarbon SteelPrimary Electrode: Page 1-26Alternate Electrodes: Pages 1-25, 1-222-24

TRACTOR PARTS AND ACCESSORIES(Continued)Rock RakeCarbon SteelPrimary Electrode: Page 1-26Alternate Electrodes: Pages 1-22, 1-20Welding Procedures: Hard-face rock rake teeth whennew for best service life. Deposit electrode in slightweave beads running parallel to flow of rock; overlaytop and sides of each tooth with heavy wash pass about2 in. from tip. Do not allow teeth to wear more than1/4 in. before rehard-facing (Figure 2-15).FIGURE 2-14. Hard-Facing Ripper Shanks2-25

FIGURE 2-15. Hard-Facing Rock Rake Teeth2-26

FIGURE 2-16. Shovel Parts and Accessories2-27

SHOVEL PARTS AND ACCESSORIES(Continued)Shovel RollersCarbon SteelPrimary Electrode: Page l-24Alternate Electrodes: Pages l-5,1-3Welding Procedures: Construct jig so roller can beturned for downhand welding. Rebuild with buildupmaterial to original size (Figure 2-17).Shovel Track PadsCarbon SteelPrimary Electrode: Page 1-24Alternate Electrodes: Pages 1-5, 1-3Manganese SteelPrimary Electrode: Page 1-22Alternate Electrodes: Page 1-25Welding Procedures: Start application on lugs. Withmanual process, rebuild worn areas to original sizewith recommended buildup material (Figure 2-18).FIGURE 2-17. Hard-Facing Shovel Rollers2-28

SHOVEL PARTS AND ACCESSORIES(Continued)Welding Procedures: Construct jig so idler can beturned for downhand welding.Rebuild with buildup material to original size (Figure2-19).FIGURE 2-18. Hard-Facing Shovel Track PadsShovel IdlersCarbon SteelPrimary Electrode: Page l-24Alternate Electrodes: Pages l-5,1-3FIGURE 2-19. Hard-Facing Shovel Idlers2-29

SHOVEL PARTS AND ACCESSORIES(Continued)Shovel Drive TumblersCarbon SteelPrimary Electrode: Page l-24Alternate Electrodes: Pages l-5,1-3Manganese SteelPrimary Electrode: Page l-22Alternate Electrodes: Page l-20Welding Procedures: Construct jig so tumbler can beturned for downhand welding. Rebuild with buildupmaterial to original size. Use template to obtain propersize (Figure 2-20).FIGURE 2-20. Hard-Facing Shovel Drive TumblersShovel House RollsCarbon SteelPrimary Electrode: Page 1-24Alternate Electrodes: Pages 1-5, 1-32-30

SHOVEL PARTS AND ACCESSORIES(Continued)Welding Procedures: House rolls are generally madeof high carbon steel and should be preheated to at least500°F. Mount roll on jig for downhand welding.Rebuild worn rolls with recommended buildupmaterial in transverse beads across face. Machine orgrind to proper size (Figure 2-21).Shovel and Dragline BucketsSelection of one weld pattern over another whenhard-facing shovel and dragline buckets is important.One hard-facing alloy will not work satisfactorilyunder all wear conditions. Likewise, one hard-facingpattern will not perform the same under all wear -conditions.A bucket working in sand with hard-facing beadsapplied at right angles to the flow of material will havea longer service life than one with beads appliedparallel to the flow.A waffle pattern of beads gives even better protectionto a bucket because the pattern forms small pocketswhere damp dirt becomes packed. This results inabrasive soil working against more soil. Both thehard-facing and the base metal are thus protected.FIGURE 2-21. Hard-Facing Shovel House RollsA bucket working in dry, large-sized slag with hardfacingbeads applied at right angles to the flow ofmaterial will be subjected to high abrasive wear.Beads applied in the same direction of flow will, in thiscase, allow slag to ride on top of the hard metal beads2-31

SHOVEL PARTS AND ACCESSORIES(Continued)without imposing wear on the base metal between thebeads.Another effective hard-facing pattern is the use ofsmall dots of hard metal alloy spaced close together.This method produces an effective hard-facing pattern,while reducing the heat input from the weldingoperation. Chance of overheating high grade steelused in some buckets is practically eliminated.The dots arc first applied on wide centers, the weldergradually fills in the spaces until the area to behard-faced is covered with closely spaced dots of hardmetal (Figure 2-22).Successful hard-facing patterns are found by trial anderror. What works in one instance may not in another.Knowing the type of wear encountered, how it isimposed, and the proper alloy to use, will help to applythe most effective bead pattern. Check the service lifereceived and the wear pattern developed. Next timehard-facing is applied, alter the pattern as required andcheck results against previous application.Recommended Alloys:For relatively moderate wear, use electrodes on page1-25 as a primary choice, and electrodes on page 1-22,or 1-27 as alternate choices. For extreme abrasion, useelectrodes on page 1-26 as a primary choice andelectrodes on pages 1-27 or 1-22 as alternate choices.Skip weld on manganese buckets to avoidoverheating. Where possible, position for downhandwelding.Wear Plates:Use stainless steel electrodes on page 1-20 to weldwear plates to worn buckets. For best service life,hard-face wear plates as described above.2-32

SHOVEL PARTS AND ACCESSORIES (Continued)FIGURE 2-22. Hard-Facing Shovel and Dragline Buckets2-33

SHOVEL PARTS AND ACCESSORIES(Continued)Shovel TeethHard-face shovel teeth when they are new, beforeputting them in service. The weld bead pattern used onshovel teeth can have a marked effect on service life.Teeth working primarily in rock should be hard-facedwith beads running the length of the tooth to allow therock to ride on the hard metal beads. When working indirt, clay or sand, run the beads across the flow ofmaterial (Figure 2-23) so it will fill cavities betweenthe weld beads and give the base metal addedprotection. Another effective pattern is the waffle orcross hatch (Figure 2-24). Apply hard-facing to thetop and sides of the tooth 2 in. up from point. Stringerbeads behind a solid deposit reduces wash (Figure2-25). Where abrasion and impact are extreme, useelectrodes on pages 1-25, 1-22, or 1-20. In caseswhere impact is moderate and abrasion severe, useelectrodes on pages 1-26, 1-25, or 1-22.FIGURE 2-23. Hard-Facing Shovel Teeth2-34

SHOVEL PARTS AND ACCESSORIES(Continued)Repainting Shovel Teeth:Weld manganese repointer bars to manganese teethwith electrodes on page 1-22 or page 1-20. Weldcarbon steel bars to carbon steel teeth using electrodeson page 1-3, 1-1, or 1-2. Weld dissimilar metals (forexample, manganese bars to carbon steel teeth) withstainless electrodes on page 1-20. Hard-face repointedteeth.Shovel Bucket Tooth AdaptersCarbon SteelPrimary Buildup Electrode: Page 1-24Primary Hard-Face Electrode: Page 1-25Alternate Buildup Electrodes: Page 1-5, 1-3, 1-22, or1-20FIGURE 2-24. Repainting Shovel Teeth2-35

FIGURE 2-25. Comparison of Hard-Facing Patterns for Shovel Teeth2-36

SHOVEL PARTS AND ACCESSORIES(Continued)Alternate Hard-face Electrodes: Pages 1-22, or 1-20Manganese SteelPrimary Buildup Electrode: Page 1-22Primary Hard-face Electrode: Page 1-26Alternate Buildup Electrode: Page 1-20Alternate Hard-face Electrodes: Pages 1-25, or 1-22FIGURE 2-26. Hard-Facing ShovelWelding Procedures: Buildup badly worn areas withBucket Tooth Adaptersrecommended material. Apply stringer beads ofhard-facing alloy in waffle pattern over entire wearing Shovel Latch Platessurface (Figure 2-26). Use electrodes on page 1-25,1-22, or 1-20 for areas of relatively moderate wear. Carbon SteelFor extreme abrasion and impact, use electrodes onpages 1-26, 1-25, or 1-22. Primary Electrode: Page 1-24Alternate Electrodes: Pages 1-5 or 1-32-37

SHOVEL PARTS AND ACCESSORIES(Continued)Manganese SteelPrimary Electrode: Page 1-22Alternate Electrode: Page 1-20Welding Procedures: Rebuild to size as shown (Figure2-27).Shovel Latch BarsCarbon SteelPrimary Electrode: Page 1-24Alternate Electrodes: Pages 1-5, or 1-3Manganese SteelPrimary Electrode: Page 1-22Alternate Electrode: Page 1-20Welding Procedures: Rebuild as shown (Figure 2-28);grind to size.FIGURE 2-27. Hard-Facing Shovel Latch Plates2-38

SHOVEL PARTS AND ACCESSORIES(Continued)Manganese SteelPrimary Electrode: Page 1-22Alternate Electrode: Page 1-20Welding Procedures: Apply hard-facing to worn areas(Figure 2-29). Use template to insure fit.IFIGURE 2-28. Hard-Facing Shovel Latch BarsShovel Boom HeelsCarbon SteelPrimary Electrode: Page 1-24Alternate Electrodes: Page 1-5 or 1-3FIGURE 2-29. Hard-Facing ShoveI Boom Heels2-39

SHOVEL PARTS AND ACCESSORIES(Continued)Cable SheavesCarbon SteelPrimary Electrode: Page l-24Alternate Electrodes: Pages l-22 or l-20Welding Procedures: Position on jig so sheave can beturned for downhand welding. Build up badly wornareas and apply alloy in circumferential beads. Useslight weave (Figure 2-30). Be sure to use properpreheat and postheat where necessary.FIGURE 2-30. Hard-Facing andRebuilding Worn Cable Sheaves2-40

SHOVEL PARTS AND ACCESSORIES(Continued)Dragline PinsCarbon SteelPrimary Electrode: Page 1-26Alternate Electrodes: Pages 1-25 or 1-22Welding Procedures: Hard-face ends of pin usingabove-mentioned electrodes (Figure 2-3 1).Rebuild bearing surface of pin using electrodes onpages 1-24, 1-5, or 1-3. Grind to proper size.Dragline ChainsCarbon SteelPrimary Electrode: Page 1-24Alternate Electrodes: Pages 1-5 or 1-3Manganese SteelPrimary Electrode: Page 1-22Alternate Electrode: Page 1-20FIGURE 2-31. Hard-Facing andRebuilding Dragline PinsWelding Procedures: Rebuild link-to-link wear areason carbon steel and manganese steel chains usingabove-mentioned electrodes (Figure 2-32). Hard-faceoutside wear areas of chains using electrodes on pages1-27, 1-26, or 1-24.2-41

SHOVEL PARTS AND ACCESSORIES(Continued)Dragline ClevisCarbon SteelPrimary Electrode: Page 1-20BUILDUP MATERIALAlternate Electrodes: Pages 1-5, 1-3Manganese SteelPrimary Electrode: Page 1-22Alternate Electrode: Page 1-20Welding Procedures: Rebuild metal-to-metal wearareas on steel and manganese clevises using abovementioned electrodes (Figure 2-33). Hard-face outsidewear areas using electrodes on pages 1-26, 1-24, or1-22.FIGURE 2-32. Hard-Facing andRebuilding Worn Dragline Chains2-42

SHOVEL PARTS AND ACCESSORIES(Continued)Manganese SteelPrimary Electrode: Page 1-22Alternate Electrode: Page 1-20Welding Procedures: Skip weld manganese lips. Steellips need no special care other than usual procedure toprevent warpage (Figure 2-34).FIGURE 2-33. Hard-Facing andRebuilding Worn Dragline ClevisHard-face top, bottom and sides of lip using electrodeson pages 1-26, 1-25, or 1-23. Wear strips on bucketshould also be hard-faced.Clam Shell BucketsCarbon SteelPrimary Electrode: Page 1-24Alternate Electrodes: Pages 1-5 or 1-32-43

SHOVEL PARTS AND ACCESSORIES(Continued)FIGURE 2-34. Hard-Facing Clam Shell Bucket2-44

FIGURE 2-35. Power Shovel Transmission Components2-45

POWER SHOVEL TRANSMISSIONSShovel Ring GearsCarbon SteelPrimary Electrode: Page 1-24Alternate Electrodes: Pages 1-5 or 1-3Welding Procedures: Restore worn teeth with buildupand hand-grind to finished dimensions (Figure 2-36).Be sure to use proper preheat and postheat whererequired.FIGURE 2-36. Hard-Facing and RestoringWorn Shovel Ring Gear Teeth2-46

POWER SHOVEL TRANSMISSIONS (Continued)Shovel Swing GearsCarbon SteelWelding Procedures: Restore worn teeth with buildupmaterial and hand-grind to finished size. Be sure touse proper preheat and postheat where required.Primary Electrode: Page 1-24Alternate Electrodes: Pages 1-5 or 1-3Welding Procedures: Restore worn teeth with buildupand hand-grind to finished dimension (Figure 2-37).Be sure to use proper preheat and postheat whererequired.Horizontal Travel GearsCarbon SteelPrimary Electrode: Page 1-24Alternate Electrodes: Pages 1-5 or 1-3FIGURE 2-37. Hard-Facing and Restoring WornHorizontal Travel Gear Teeth2-47

POWER SHOVEL TRANSMISSIONS (Continued)House RingsCarbon SteelPrimary Electrode: Page 1-24Alternate Electrodes: Pages 1-5 or 1-3Welding Procedures: Shovel house rings should bepreheated to 500°F. Use recommended material tobring ring to size and finish-machine (Figure 2-38).FIGURE 2-38. Hard-Facing and Restoring WornHouse Ring Gear TeethShaftsCarbon SteelPrimary Electrode: Page 1-24Alternate Electrodes: Pages 1-5 or 1-3Welding Procedures: Most shafts are made ofweldable medium- or low-alloy steel and can bereconditioned using the above-mentioned electrodes toproduce a check-free surface with outstanding physicalproperties. Large shafts should be thoroughlypreheated to, and kept at, 600- 700°F duringwelding. Small shafts should be thoroughly soakedwith a preheat of 400- 500°F. Slow cooling ismandatory.After observing preparatory procedures, deposit 1 in.wide weave beads of the above-mentioned electrodeslongitudinaly across the shaft. Overbuild about 1/8 in.to allow for finish-machining (Figure 2-39).2-48

POWER SHOVEL TRANSMISSIONS (Continued)Welding Procedures: Position for downhand welding(Figure 2-40). Apply hard-facing using a template toobtain proper shape. Apply beads transversely. Grindhigh spots.FIGURE 2-39. Hard-Facing and RestoringWorn ShaftsDITCHERS AND HOLE AUGERSDitcher Drive SegmentsCarbon SteelPrimary Electrode: Page 1-24Alternate Electrodes: Pages 1-5 or 1-3FIGURE 2-40. Hard-Facing Ditcher Drive Segments2-49

DITCHERS AND HOLE AUGERS (Continued)Ditcher RollsCarbon SteelPrimary Electrode: Page 1-24Alternate Electrodes: Pages 1-5 or 1-3Welding Procedures: Construct jig so roller can beturned (Figure 2-4 1). Apply weld metal to face and toflange where necessary. Grind high spots.Cast Iron Rollers - Preheat to 1000- 1200°F andmaintain. Use electrode on page 1-14 in widetransverse beads. Slow cool.FIGURE 2-41. Hard-Facing Ditcher RollsDitcher Drive SprocketsCarbon SteelPrimary Electrode: Page 1-24Alternate Electrodes: Pages 1-5 or 1-32-50

DITCHERS AND HOLE AUGERS (Continued)Welding Procedures: Position for welding (Figure Welding Procedures: Apply above-mentioned2-42). Apply buildup using a template. Apply beads electrodes starting at the point and extend deposits 1transversely. Grind high spots. in. upward (Figure 2-43).FIGURE 2-42. Hard-Facing Ditcher Drive SprocketsDitcher TeethCarbon SteelPrimary Electrode: Page 1-26Alternate Electrodes: Pages 1-25 or 1-22FIGURE 2-43. Hard-Facing Ditcher Teeth2-51

DITCHERS AND HOLE AUGERS (Continued)Post Hole AugersCarbon SteelPrimary Electrode: Page 1-26Alternate Electrodes: Pages 1-25 or 1-22Welding Procedures: Apply above-mentionedelectrodes to upper face of flight and flight periphery;hard-face top side of cutter teeth for self-sharpeningaction and apply hard-facing to reaming edge andcutting wings of pilot bit (Figure 2-44).FIGURE 244. Had-Facing Post Hole Augers2-52

ASPHALT MIXERS AND PADDLESAsphalt Mixer PaddlesCarbon SteelPrimary Electrode: Page 1-26Alternate Electrodes: Pages 1-25 or 1-22Welding Procedures: On weldable steel paddleshard-face outer edge and leading edge solid usingabove-mentioned electrodes. Apply stringers on leadingface of paddle in line with material flow (Figure 2-45).Apply stringer beads around bolt hold.FIGURE 2-45. Hard-Facing Asphalt Mixer Paddles2-53

ASPHALT MIXERS AND PAVERS (Continued)Asphalt Mixer Paddle ShanksCarbon SteelPrimary Electrode: Page 1-26Alternate Electrodes: Pages 1-25 or 1-22Welding Procedures: Build up leading shoulder toprotect bolt; weld on suitable patch as filler. Applyhard-facing to areas shown in Figure 2-46.Paving Machine PaddlesCarbon SteelPrimary Electrode: Page 1-26Alternate Electrodes: Pages 1-25 or 1-22Welding Procedures: Face edge and top usingabove-mentioned electrodes (Figure 2-47). -FIGURE 2-46. Hard-FacingAsphalt Mixer Paddle ShanksFIGURE 2-47. Hard-Facing Paving Machine Paddles2.-54

ASPHALT MIXERS AND PAVERS (Continued)Paving Agitator BladesPaving Screw ConveyorsCarbon SteelCarbon SteelPrimary Electrode: Page 1-26 Primary Electrode: Page 1-26Alternate Electrodes: Pages 1-25 or 1-22 Alternate Electrodes: Pages 1-25 or 1-22Welding Procedures. Apply hard-facing to top and Welding Procedures: Apply above-mentionedboth faces of blade (Figure 2-48).electrodes where wear occurs on flight face and edges(Figure 2-49).FIGURE 2-48. Hard-Facing PavingMachine Agitator BladesFIGURE 249. Hard-Facing PavingMachine Screw Conveyors2-55

ASPHALT MIXERS AND PAVERS (Continued)Scraper Cutters and SidesCarbon SteelPrimary Electrode: Page 1-26Alternate Electrodes: Pages 1-25 or 1-22Welding Procedures: Remove bolt-on cutter bladesfrom scraper before hard-facing. Overlay leading andbottom edge using above-mentioned electrodes asindicated by wear pattern (Figure 2-50). Hard-facesides with waffle pattern using electrodes on pages1-25, 1-22, or 1-20.FIGURE 2-50. Hard-Facing Scraper Cutters and Sides2-56

ASPHALT MIXERS AND PAVERS (Continued)Scraper BladesCarbon SteelPrimary Electrode: Page 1-26Alternate Electrodes: Pages 1-25 or 1-22Welding Procedures: Position blades of weldable steelin suitable prehending jig or bolt blade to scrapermoldboard. Preheat to at least 400°F. Applyabove-mentioned electrodes with slight weavingmotion. Deposit need not exceed 1-1/2 in. width.Another method is to bolt pair of blades back-to-backand use skip-weld technique, starting at center andworking toward each end, welding on the four cuttingedges alternately (Figure 2-5 1).FIGURE 2-51. Hard-Facing AsphaltMixer Scraper Blades2-57

ASPHALT MIXERS AND PAVERS (Continued)Grader BladesCarbon SteelPrimary Electrode: Page 1-26Alternate Electrodes: Pages 1-25 or 1-22Welding Procedures: Position blade of weldable steelin suitable prehending jig or bolt two bladesback-to-back and preheat to 500- 600°F. Applyabove-mentioned electrodes in stringer beads. Useskip weld method (Figure 2-52). Start at center andwork toward each end. Deposit should extend 1-2 in.up edge. (NOTE: USE ONLY 1/8 IN. DIAMETERELECTRODE.)FIGURE 2-52. Hard-Facing Grader BladesGrader End BitsCarbon SteelPrimary Electrode: Page 1-26Alternate Electrodes: Pages 1-25 or 1-22Welding Procedures: Place grader end bit in flatposition and apply beads diagonally across outercomer and along edges (Figure 2-53).2-58

ASPHALT MIXERS AND PAVERS (Continued)Welding Procedures: Hard-face underside of lip(Figure 2-54). If bucket is badly worn, fabricate newlip and attach, using suitable electrodes.FIGURE 2-53. Hard-Facing Grader End BitsScooplift BucketsCarbon SteelPrimary Electrode: Page l-26Alternate Electrodes: Pages l-22 or l-20FIGURE 2-54. Hard-Facing Scooplift Bucket Lips2-59

ASPHALT MIXERS AND PAVERS (Continued)Grapple TinesCarbon SteelPrimary Electrode: Page 1-26Alternate Electrodes: Pages 1-25 or 1-22Welding Procedures: Hard-face tine up about 10 in.from point with above-mentioned electrodes anddeposit electrode from the point to about 4 in. up thetine (Figure 2-55).Grid CompactorsCarbon SteelPrimary Electrode: Page 1-26Alternate Electrodes: Pages 1-25 or 1-22Welding Procedures: Raise compactor for downhandpositioning. Hard-face grids (Figure 2-56).FIGURE 2-55. Hard-Facing Grapple Tines2-60FIGURE 2-56. Hard-Facing Grid Compactor Grids

ASPHALT MIXERS AND PAVERS (Continued)Sheepsfoot TampersCarbon SteelPrimary Electrode: Page l-26Alternate Electrodes: Pages l-22 or l-20Welding Procedures: Drive short lengths of old pipe toworn tamp. This can be done on round, square, orrectangular tamps. To prevent hard metal spill duringhard-facing, seal the cup where it is joined to thetamp. Fill hole in ring with above-mentionedelectrodes (Figure 2-57). Once welding begins, theoperation should be continued until entire tamp isrebuilt.For best service life, hard-face tamps when they arenew, before putting them to work. Hard-face comersand edges with a single wash pass of electrodes onpage 1-33, 1-32 or 1-29. Do not allow wear toprogress more than 3/16 in. before rehard-facing.2-61

FIGURE 2-57. Hard-Facing Sheepsfoot Tampers2-62

ASPHALT MIXERS AND PAVERS (Continued)Curbing Machine AugersCarbon SteelPrimary Electrode: Page 1-26Alternate Electrodes: Pages 1-25 or 1-22Welding Procedures: Hard-face flight faces,peripheries, and shaft with above-mentioned electrodes(Figure 2-58). Reapply hard-facing as necessary.FIGURE 2-58. Hard-Facing Curbing Machine Augers2-63

ASPHALT MIXERS AND PAVERS (Continued)Backhoe SidecuttersCarbon SteelPrimary Electrode: Page 1-26Alternate Electrodes: Pages 1-25 or 1-22Welding Procedures: Hard-face edge about 2 in. offront side of each sidecutter along edge, usingabove-mentioned electrodes (Figure 2-59). Aperpetual self-sharpening action occurs as theunprotected bottom wears.FIGURE 2-59. Hard-Facing Backhoe Sidecutters2-64

ASPHALT MIXERS AND PAVERS (Continued)Trencher TeethCarbon SteelPrimary Electrode: Page l-26Alternate Electrodes: Pages l-25 or l-22Welding Procedures: Hard-face edge and face ofteeth, using above-mentioned electrodes (Figure 2-60).Reapply hard-facing as necessary.FIGURE 2-60. Hard-Facing Trencher Teeth2-65

ASPHALT MIXERS AND PAVERS (Continued)Shredding HammersCarbon SteelPrimary Electrode: Page 1-26Alternate Electrodes: Pages 1-25 or 1-22Welding Procedures: Hammers used to shred andblend top soil, clay, peat, humus compost and otherabrasive materials should be hard-faced when they arenew, using the above-mentioned electrodes. Applyhard metal to striking edge of hammer and lead edge ofrotor plates (Figure 2-61).FIGURE 2-61. Hard-Facing Shedding Hammers2-66

REBUILDING AND HARD-FACING CRUSHERROLL SHELLSInitial Rebuild and Hard-face of ShellsCrushing, Grinding and Screening EquipmentTo relieve stress before hard-facing, new Manganeseshells should be operated for a short period of time.After this brief initial period, during which wearshould be limited to approximately 3/16 in., a regularschedule of roll upkeep should be established. If rollsare worn less than 3/1 6 in.. they can be hard-faced withrecommended alloys. If excessive wear has occurred,the worn rolls must be rebuilt to size and contourbefore hard-facing. The amount of wear can bemeasured (Figure 2-62).FIGURE 2-62. Wear Measurementof Crusher Roll ShellsGeneral RecommendationsThere are certain procedures that are common to rollrebuilding whether welding is done manually,semi-automatically or automatically; the success of therebuilding and hard-facing operation is as dependentupon them as upon subsequent welding techniques.2-67

REBUILDING AND HARD-FACING CRUSHERROLL SHELLS (Continued)1.2.3.4.Worn crusher shells should be cleaned to preventarc interference, weld metal contamination, andpossible porosity.The ground should be made directly to the rollshell being welded to avoid arcing through thebearings. A rotating ground attached to the rollshaft end will provide a positive contact.Cracks in the roll shell should be repaired beforerebuilding. A chamfering rod can be used to gougeout any cracks down to sound metal. The crackshould be filled with recommended alloys prior torebuilding.Where extensive welding is planned on one-pieceshells, wedge bolts should be loosened beforewelding begins and retightened after the roll shellhas cooled. This allows for expansion andcontraction of the shell and reduces the possibilityof cracking, breaking, or warping (Figure 2-63).5.6.7.Roll shells must be kept round and both shellsrebuilt to the same diameter. Out-of-round shellsproduce a variation in the crushing zone, resultingin unsatisfactory control of material size. Inaddition, unnecessary wear and strain are imposedon the bearings and shafts.Weld beads are subjected to tension as they cool; tominimize surface checking or cracking, depositsare sometimes peened while hot to produce plasticflow and to change tension to compression.Weld beads must not be deposited over the rolledge. Base metal cracking generally begins here.The beads should be started and stopped about 1 in.short of the roll edge (Figure 2-64), or at least farenough from the edge to allow sufficient clearancefor cheek plates.2-68

REBUILDING AND HARD-FACING CRUSHER ROLL SHELLS (Continued)Normally tension on wedge bolts During welding, manganese shell As roll contracts after welding.end tapered edges is exactly the same all expands, causing wedges to pull in. wedges-unless Ioosened prior to weldingaroundshell to assure positive seating.do not back out and shell may dish orcrack.FIGURE 2-63. Preventing Warpage of Crusher Roll Shells2-69

REBUILDING AND HARD-FACING CRUSHERROLL SHELLS (Continued)8. Correct amperage and stepover will insure properbonding of weld bead to base metal. This isparticularly true of high-alloy materials which, bynature, are very fluid.The proper combination of welding variablesproduces sound weld beads and provides maximumdeposition rate (Figure 2-65).9. The submerged arc process should not be used forrebuilding rolls; heat input can cause seriouscracking and roll failure.FIGURE 2-64. Welding Limits on Crusher Roll Shells2-70

REBUILDING AND HARD-FACING CRUSHERROLL SHELLS (Continued)When to Reapply Hard-facingAdditional hard-facing should be applied after 70-80percent of the previous overlay has worn away, butbefore the base metal is exposed. Hard-facing can berepeated several times, depending on how much of theprevious overlay is allowed to wear away. Generally,wear is uneven and eventually excessively thick hardmetal deposits on some areas of the roll may span.When this occurs the roll should be allowed to wearuntil all the hard metal is gone and the shell casting hasbeen worn 1/8 - 3/16 in. The roll can then be restoredto size with recommended buildup alloys. Afterrebuilding the shell should be overlaid with awear-resistant alloy. If sufficient welding time isavailable, all striping should be reapplied.If time is limited, apply only every second or thirdgripper bead. Do not apply more welding beads to oneside or section of the roll than another. This will putthe roll out of round, reduce sizing efficiency, andaccelerate wear on other crusher components.FIGURE 2-65. Insufficient and Proper StepoverTechniques Examples2-71

REBUILDING AND HARD-FACING CRUSHERROLL SHELLS (Continued)Rebuilding Shells with the Manual ProcessAlways rebuild badly worn, dished rolls beforehard-facing. On manganese castings, use electrodes onpages 1-22 or 1-20 with the manual process. (NOTE:NEVER USE MILD STEEL FOR REBUILDINGROLLS.)Rebuilding ProcedureUsing the skip weld process, apply transverse beads inthe center section of the roll in the area of deepest wear.Deposit three or four beads about 6 in. apart and turnthe roll to a new position. Follow this pattern untilweld beads are applied to the entire circumference ofthe roll. Continue the skip weld process untilsuccessive spaces between the original beads aregradually closed in and the entire center area of the rollis overlaid. See steps number 1 through 3 in Figure2-66.After the center section of this roll has been built up bythis first layer, repeat the same procedure usingtransverse beads of longer length. See steps numbers 4through 6 in Figure 2-66. Generally two layers aresufficient to restore roll size. If the shell is badly worn,apply additional layers. The rolls must be brought tosize and correct contour before hard-facing.A crescent weave bead of 1/2 - 3/4 in. maximum widthwill produce a sound deposit.Hard-facing Crusher Shells with the Manual ProcessUse electrode on page 1-25 to hard-face crushershells. If a more abrasive resistance on the shell isdesired, use electrode on page 1-26.2-72

REBUILDING AND HARD-FACING CRUSHERROLL SHELLS (Continued)Welding TechniquesTo assure efficient crushing, the hard metal overlaymust not only be wear-resistant, it must also supply thenecessary gripping action to sustain an adequate flowof material through the rolls. Maximum wearprotection from any high-alloy, hard-facing overlay isprovided by a two-layer deposit. DO NOT USEMORE THAN TWO LAYERS. Stacking layer uponlayer will result in cracking and eventual spalling.The best gripping and crushing action is determined bythe arrangement of striping ribs on the roll face. Thepattern used is determined by the type of materialbeing crushed, the desired aggregate size, and theseverity of abrasion.One of the more popular methods of hard-facing is tocover the entire surface of the rebuilt roll shell with asingle layer of hard metal, using the skip-weldprocedure. After applying the first layer of hard metal,weld transverse beads of the same material acrossthe crusher face 1-2 in. apart to provide grippingaction (Figure 2-67).Another hard-facing procedure particularly effective incrushing 3/4 in. or larger material incorporates the useof weave beads spaced 1/2 in. apart. Steps 1 through 4(Figure 2-68) show method of application. Use theskip-weld process to stripe the center two-thirds of theroll face, first on wide spacing of about 6 in. apart,then gradually filling in areas between until the beadsare no more than 1/2 in. apart.Repeat the same procedure and skip-weld weave beadsacross the face of the shell directly over the firstbeads. Remember to start and stop welding short ofthe roll ends. This method of application deposits adouble layer of hard metal on the center two-thirds ofthe roll shell, the area subjected to the most severewear. It also results in a more uniform wear patternacross the entire roll shell surface.2-73

FIGURE 2-64. Rebuilding Procedure for Crusher Roll Shells2-74

REBUILDING AND HARD-FACING CRUSHERROLL SHELLS (Continued)FIGURE 2-67. Hard-Facing Crusher Roll ShellsFIGURE 2-68. Crusher Roll Shell RebuildingTechnique2-75

REBUILDING AND HARD-FACING CRUSHERROLL SHELLS (Continued)It is often desirable to stripe only one roll whenextremely fine aggregate is being produced. Atransverse deposit of hard metal is applied to theentire surface of the smooth roll, using weldingprocedure outlined in the section on roll rebuilding.The hard metal overlay should not be reapplied untilmost of the previous metal has worn off. Otherwise,severe cracking or spalling may occur.How to Repair Cracked Manganese RollsThe following procedures describe how to repaircracked manganese rolls (Figure 2-69).1. Loosen all wedge bolts and wedges.2. Vee out the crack to provide a 600 angle forwelding. Remove all hard-facing adjacent toand back about 6 in. from the edges of thecrack.3. Weld heavy 4 in. angle iron 1 in. from, and parallelto, each side of the crack. Use electrode on page1-27 to join angle iron to shell.4. Drill or bum 1-1/8 in. holes in each angle iron on 6in. centers to accommodate 1 in. bolts, Run boltsthrough angle irons and tighten nuts progressivelyto bring shell together.5. Use electrodes on pages 1-22 or 1-20 to weldshell. Use weave or oscillating beads to work outall gas from molten puddle.6. Scarf off angle iron and rehard-face wherenecessary.7. Secure wedge bolts and wedges.2-76

REBUILDING AND HARD-FACING CRUSHER ROLL SHELLS (Continued)FIGURE 2-69. Repairing Cracked Manganese Crusher Rolls2-77

FIGURE 2-70. Hard-Facing Rotor-Type Impactors2-78

HARD-FACING ROTOR TYPE IMPACTORS(Continued)Rotors and BarsManganese SteelPrimary Buildup Electrode: Page 1-22Alternate Buildup Electrode: Page 1-20Primary Hard-face Electrode: Page 1-26Alternate Hard-face Electrodes: Pages 1-25 or 1-22Welding Procedures: Rebuild dished rotors and barswith recommended buildup material; apply two layersof hard-facing alloy in stringer beads. When crushingmaterials that are extremely abrasive yet relativelyeasy to crumble, use electrodes on pages 1-26 or 1-25.When crushing tougher materials, and higher impact isinvolved, use electrodes on pages 1-25, 1-22, or 1-20.Screen GratesManganese SteelPrimary Buildup Electrode: Page 1-22Alternate Buildup Electrode: Page 1-20Primary Hard-face Electrode: Page 1-26Alternate Hard-face Electrodes: Pages 1-25 or 1-22Welding Procedures: Rebuild badly worn grates withrecommended buildup material and apply two layers ofhard-facing alloy in transverse weld beads.2-79

OTHER QUARRY AND MINING EQUIPMENTCrusher JawsCrusher jaws are being rebuilt and hard-facedsuccessfully, but they represent one of the most criticalapplications in the crushing industry and closeadherence to welding procedures is a must.CAUTION: Do not overheat jaws made of manganese(and almost all of them are). Prevent, or at least,minimize warpage.Welding Procedures: Pre-bend the jaw in a heavy,tilting fixture fabricated of railroad rails or equivalent(Figure 2-7 1). Skip weld to avoid overheating; do notheat jaws above 5000 for prolonged periods. Tackshort manganese bars to jaws using electrodes onpages 1-22 or 1-20, as shown in Step A of Figure2-71. Complete fillet as shown in Step B. Buildupsides of corrugations using the above-mentionedelectrodes and apply two layers of electrodes onpages 1-26, 1-25, or 1-22 to top of corrugations (StepC). Complete sides with hard-facing alloy (Step D).Welding on the reverse side of jaw will normallycorrect minor distortion caused by shrinkage.If you overheat the jaw or allow it to warp too much, itmust be heated, straightened, reheated, and quenched -uneconomical at best.Wobbler FeederThis rock feeding and scalping mechanism is subject tovery high impact and severe abrasion. Use electrodeson pages 1-22, or 1-20 to restore worn areas (Figure2-72).2-80

FIGURE 2-71. Rebuilding and Hard-Facing Crusher Jaws2-81

OTHER QUARRY AND MINING EQUIPMENT(Continued)Crusher PointsRebuild points with electrodes on pages 1-22 or 1-20and overlay using electrodes on pages 1-26, 1-25, or1-22.Scalping and Sizing Vibratorv ScreensBolt or clamp light screens to heavy plate to minimizedistortion. Insert copper or carbon blocks of desiredsize into openings. Deposit electrodes on pages 1-22,or 1-20 around blocks. Overlay with electrodes onpages 1-26, 1-25, or 1-22 (Figure 2-73). Use samealloys on rails and screen surfaces on scalpers.FIGURE 2-72. Restoring Worn Areason Wobbler Feeders2-82

OTHER QUARRY AND MINING EQUIPMENT(Continued)Gravel Washer Auger FlightsHard-face periphery and leading flight faces usingelectrodes on pages 1-26, 1-25, or 1-22 (Figure 2-74).FIGURE 2-73. Hard-Facing, Scalping,and Sizing Vibratory Screens2-83FIGURE 2-74. Hard-Facing GravelWasher Auger Flight

OTHER QUARRY AND MINING EQUIPMENT(Continued)Log Washer PaddlesClamp copper plates to worn paddle to form propersize (Figure 2-75). Weld-cast electrodes on pages 1-22or 1-20 to within 1/4 in. of finished size. Overlay withelectrodes on pages 1-26, 1-25, or 1-22.Elevator Bucket LipsHard-face lips using electrodes on pages 1-26, 1-25, or1-22 (Figure 2-76). If bucket is badly worn, fabricatenew lips and attach with electrode on page 1-20 andhard-face. Hard-facing of cast iron bucket lips is notrecommended.FIGURE 2-75. Hard-Facing Log Washer PaddlesFIGURE 2-76. Hard-Facing Elevator Bucket Lips2-84

OTHER QUARRY AND MINING EQUIPMENT(Continued)Quarrv Drill Collars and AugersUse electrodes on page 1-25 to hard-face flutes on drillcollars. Use electrode on page 1-26 to hard-faceperiphery and leading flight face of drill augers (FigureFIGURE 2-77. Hard-Facing QuarryDrill Collars and Augers2-85

NOTES2-86

NOTES2-87

NOTES2-88

Section 3. MOLECULAR METALINTRODUCTIONCOMPONENTS:The first part of this section contains generalinformation about the uses, procedures, andcharacteristics of the Atomized Metal RepairCompound (M-41 ) used by the Department of Navy.The remainder of this section covers a more specificdescription of molecular metal, its uses, and usefulness.ATOMIZED METALLIC MATERIALS KITNSN: 8030-01-232-1246CODEM-41M-42M-43M-44M-50M-5 1M-52* 2 Units* 1 Unit* 1 Unit* 1 Unit18 OZ.1 Pint** 1 each2 each2 eachAlloy GP MetalSmoothcoat MetalSmoothcoat Liquid MetalRapid MetalNobond Release AgentCleaner/DegreaserReinforcing BandageInstruction SheetsSpatulas* Unit = approximately 2 lbs.** 216 square inchesThis kit consists of atomized metallic materials,chemical aids and accessories for the repairs andoverlays of most metals with a minimum of effort andtechnique. This kit costs $389.00.3-1

ATOMIZED METAL REPAIR COMPOUND(M-4l)ALLOY GP:A general purpose compound for patching, falling and bonding, and ideal for in-place repairs. Itsdimensional stability allows casting to exact tolerances without machining. For example, restoringoversized bearing housings without reboring. Simply clean I.D. of housing, apply ALLOY GPclose to size and insert into housing after coating proper size bearing with Nobond. Removeexcess compound and allow deposit to harden.APPLICATIONS:Keyways Shafts Damaged Castings Hydraulic Rams Engine Blocks Gear HousingsPROPERTIES:Coverage per one (1) unit container --------15 cubic inchesStrength begins to diminish after prolongedexposure to temperatures over ----------225°FColor of hardened deposits -------------- Dark GrayConsistency of mixed compound ---------- Putty3-2

DIRECTIONS FOR USE1) See general information.2) Mix reactor (R) into Base Alloy (A) in ratios:By Volume -1 part A to 1 part RBy Weight -2 1/2 parts A to 1 part R3) Working time is approximately 25 minutes at room temperature.4) Deposits reach handling strength in 4 to 8 hours.5) 100% strength is attained in 16 to 24 hours.NOTE: SURFACES TO BE BONDED MUST BE ABSOLUTELY CLEAN AND FREEOF OIL FILM OR MIST. USE CAUTION IN SELECTING CLEANINGSOLVENTS. COMPRESSED AIR USED FOR DRYING MAY CONTAIN OILOR MOISTURE.GENERAL INFORMATIONFor maximum bonding, prepare areas to be repaired by grit blasting, machining or abrading.Clean with M-5 1 Cleaner Conditioner. Be sure areas being bonded are dry and free frommoisture. Bonding and hardening are enhanced when metal surfaces are above 75 oF. In coldenvironments, heat parts with a flame, heat lamp or forced hot air. Be sure flame sources do notleave carbon or other deposits.3-3

Mix Base Alloys and matching reactors to specified ratios. Variances may cause failures. Mixthoroughly until smooth lump-free consistency is achieved. Completed mix should be an evencolor, without streaks.Small quantities (1 unit or less) are easily mixed by hand for 2 to 5 minutes. Large quantitiesshould be mixed with a power paddle. A large mass will cure faster and working time is reduced.When ambient temperature or temperature of surface is below 60°F, compounds will notachieve full strength. Low temperatures may inhibit hardening. Heat deposit and part beingrepaired with indirect heat (lamp or warm air) to room temperature. In general, deposits hardenfaster when parts and deposit are heated. CAUTION: DO NOT EXPOSE DEPOSITSDIRECTLY TO FLAME.Smooth finishes can be obtained by placing a sheet of polyethylene or waxed paper over softdeposits. Remove when hardened. Trowels or spreading tools can be moistened with waterbetween strokes for smoother deposits when applying.Use M-50 Nobond Wax on surfaces not to be bonded. For detailed reproductions from molds andpatterns apply Nobond in several coats. Allow each coat to dry then buff before applyingadditional coats. Brush a thin coat of compound on mold surfaces before casting the remainder ofthe mix.3-4

Use reinforcing screens and tapes to minimize warpage and to increase overall strength. Whencasting large, deep shapes, pour compounds in several steps, allowing prior deposits tosemi-harden and cool before adding additional compound.3-5

ATOMIZED METAL REPAIR COMPOUND(M-42)SMOOTHCOATThis unique alloy provides self-lubricating properties and is used to repair and protect componentsthat have lost dimension from rubbing, sliding, galling or other frictional wear problems. Coatedareas are dry, yet permanently lubricated throughout the deposit thickness. Use SMOOTHCOATto restore and create new bearing surfaces.APPLICATIONS:Shafts Bearing Housings Bushings Wear Pads Slides Guides Machine Ways Pipesupports Axles Pistons Cam Followers Cams.PROPERTIES:Coverage per one (1) unit container --------21 cubic inchesStrength begins to diminish when exposed toservice temperature exceeding ----------250°FColor of hardened deposits --------------Dark GrayConsistency of mixed compound ----------Putty3-6

DIRECTIONS FOR USE:1) See general information.2) Mix reactor (R) into Base Alloy (A) in ratios:By Volume -1 part A to 1 part RBy Weight -4 parts A to 3 parts R3) Working time is approximately 30 minutes at room temperature.4) Deposits reach handling strength in 4 to 8 hours.5) 100% strength is attained in 16 to 24 hours.NOTE: SURFACES TO BE BONDED MUST BE ABSOLUTELY CLEAN AND FREEOF OIL FILM OR MIST. USE CAUTION IN SELECTING CLEANINGSOLVENTS. COMPRESSED AIR USED FOR DRYING MAY CONTAIN OILOR MOISTURE.GENERAL INFORMATIONFor maximum bonding, prepare areas to be repaired by grit blasting, machining or abrading.Clean with M-5 1 Cleaner Conditioner. Be sure areas being bonded are dry and free frommoisture. Bonding and hardening are enhanced when metal surfaces are above 75°F. In coldenvironments, heat parts with a flame, heat lamp or forced hot air. Be sure flame sources do notleave carbon or other deposits.3-7

Mix Base Alloys and matching reactors to specified ratios. Variances may cause failures. Mixthoroughly until a smooth, lump-free consistency is achieved. Completed mix should be an evencolor, without streaks.Small quantities (1 unit or less) are easily mixed by hand for 2 to 5 minutes. Large quantitiesshould be mixed with a power paddle. A large mass will cure faster and working time is reduced.When ambient temperature or temperature of surface is below 60°F, compounds will notachieve full strength. Low temperatures may inhibit hardening. Heat deposit and part beingrepaired with indirect heat (lamp or warm air) to room temperature. In general, deposits hardenfaster when parts and deposit are heated. CAUTION: DO NOT EXPOSE DEPOSITSDIRECTLY TO FLAME.Smooth finishes can be obtained by placing a sheet of polyethylene or waxed paper over softdeposits. Remove when hardened. Trowels or spreading tools can be moistened with waterbetween strokes for smoother deposits when applying.Use M-50 Nobond Wax on surfaces not to be bonded. For detailed reproductions from molds andpatterns apply Nobond in several coats. Allow each coat to dry then buff before applyingadditional coats. Brush a thin coat of compound on mold surfaces before casting the remainder ofthe mix.3-8

Use reinforcing screens and tapes to minimize warpage and to increase overall strength. Whencasting large, deep shapes, pour compounds in several steps, allowing prior deposits tosemi-harden and cool before adding additional compound.3-9

SMOOTHCOAT LIQUID:ATOMIZED METAL REPAIR COMPOUND(M-43)This is a lower viscosity compound that can either be brushed on or poured on. Deposits exhibitexceptional anti-friction properties. Deposits are self-leveling and smooth as applied. Thisformulation makes it ideal for fabricating holding fixtures and machining jigs as parts being heldwill not mar or scratch. When SMOOTHCOAT LIQUID is used to cast fixtures or patterns, detailis held to exacting tolerances. SMOOTHCOAT LIQUID is ideal for forming irregular bearingsurfaces.APPLICATIONS:Anti-Friction Surfacing of all Metal Components.Creates Bushing and Bearings without dismantling machinery.Fabricate easy to strip Molds and Patterns.3-10

PROPERTIESCoverage per one (1) unit container --------19 cubic inchesStrength begins to diminish when exposed toservice temperature exceeding ----------250°FColor of hardened deposits --------------Dark GrayConsistency of mixed compound ----------PuttyDIRECTIONS FOR USE:1) See general information.2) Mix reactor (R) into Base Alloy (A) in ratios:By Volume -2 parts A to 1 part RBy Weight -4 parts A to 1 part R3) Working time is approximately 30 minutes at room temperature.4) Deposits reach handling strength in 4 to 8 hours.5) 100% strength is attained in 16 to 24 hours.NOTE: SURFACES TO BE BONDED MUST BE ABSOLUTELY CLEAN AND FREEOF OIL FILM OR MIST. USE CAUTION IN SELECTING CLEANINGSOLVENTS. COMPRESSED AIR USED FOR DRYING MAY CONTAIN OILOR MOISTURE.3-11

GENERAL INFORMATION:For maximum bonding, prepare areas to be repaired by grit blasting, machining or abrading.Clean with M-5 1 Cleaner Conditioner. Be sure areas being bonded are dry and free frommoisture. Bonding and hardening are enhanced when metal surfaces are above 75°F. In coldenvironments, heat parts with a flame, heat lamp or forced hot air. Be sure flame sources do notleave carbon or other deposits.Mix Base Alloys and matching reactors to specified ratios. Variances may cause failures. Mixthoroughly until a smooth, lump-free consistency is achieved. Completed mix should be an evencolor, without streaks.Small quantities (1 unit or less) are easily mixed by hand for 2 to 5 minutes. Large quantitiesshould be mixed with a power paddle. A large mass will cure faster and working time is reduced.When ambient temperature or temperature of surface is below (60°F, compounds will notachieve full strength. Low temperatures may inhibit hardening. Heat deposit and part beingrepaired with indirect heat (lamp or warm air) to room temperature. In general, deposits hardenfaster when parts and deposit are heated. CAUTION: DO NOT EXPOSE DEPOSITSDIRECTLY TO FLAME.3-12

Smooth finishes can be obtained by placing a sheet of polyethylene or waxed paper over softdeposits. Remove when hardened. Trowels or spreading tools can be moistened with waterbetween strokes for smoother deposits when applying.Use M-50 Nobond Wax on surfaces not to be bonded. For detailed reproductions from molds andpatterns apply Nobond in several coats. Allow each coat to dry then buff before applyingadditional coats. Brush a thin coat of compound on mold surfaces before casting the remainder ofthe mix.3-13

ATOMIZED METAL REPAIR COMPOUND(M-43)RAPIDSTEELThis Rapid Hardening Compound is ideal for emergency repairs. It will form water-tight seals oncopper, aluminum, steel or any material used for fluid piping and storage. Even the most severelycorroded pipes can be restored to better than new condition. To repair large areas or badlydamaged sections , apply a thing coating of RAPIDSTEEL directly to surfaces, then wrap tightlywith reinforcing bandage (available in various sizes). Apply a cover coat of compound and spreadto desired shape.APPLICATIONS:Tanks Vessels Radiators Condensor Coils Fuel Tanks Plumbing Pipes and FixturesFoundations and Retaining Walls.For leveling pads under machine bases.3-14

PROPERTIESCoverage per one (1) unit container --------14 cubic inchesStrength begins to diminish when exposed totemperatures over ------------------225°FColor of hardened deposits --------------Dark GrayConsistency of mixed compound ----------PuttyDIRECTIONS FOR USE.1) See general information.2) Mix reactor (R) into Base Alloy (A) in ratios:By Volume -1 part A to 1 part RBy Weight -2 parts A to 1 part R3) Working time after mixing is approximately 2 to 5 minutes at 70°0F.4) Deposits reach handling strength in 10 to 20 minutes.5) 100% strength is attained in 8 to 12 hours.NOTE: SURFACES TO BE BONDED MUST BE ABSOLUTELY CLEAN AND FREEOF OIL FILM OR MIST. USE CAUTION IN SELECTING CLEANINGSOLVENTS. COMPRESSED AIR USED FOR DRYING MAY CONTAIN OILOR MOISTURE.3-15

GENERAL INFORMATION.For maximum bonding, prepare areas to be repaired by grit blasting, machining or abrading.Clean with M-51 Cleaner Conditioner. Be sure areas being bonded are dry and free frommoisture. Bonding and hardening are enhanced when metal surfaces are above 75°F, In coldenvironments, heat parts with a flame, heat lamp or forced hot air. Be sure flame sources do notleave carbon or other deposits.Mix Base Alloys and matching reactors to specified ratios. Variances may cause failures. Mixthoroughly until a smooth, lump-free consistency is achieved. Completed mix should be an evencolor, without streaks.Small quantities (1 unit or less) are easily mixed by hand for 2 to 5 minutes. Large quantitiesshould be mixed with a power paddle. A large mass will cure faster and working time is reduced.When ambient temperature or temperature of surface is below 60°F, compounds will notachieve full strength. Low temperatures may inhibit hardening. Heat deposit and part beingrepaired with indirect heat (lamp or warm air) to room temperature. In general, deposits hardenfaster when parts and deposit are heated. CAUTION: DO NOT EXPOSE DEPOSITSDIRECTLY TO FLAME.3-16

Smooth finishes can be obtained by placing a sheet of polyethylene or waxed paper over softdeposits. Remove when hardened. Trowels or spreading tools can be moistened with waterbetween strokes for smoother deposits when applying.Use M-50 Nobond Wax on surfaces not to be bonded. For detailed reproductions from molds andpatterns apply Nobond in several coats. Allow each coat to dry then buff before applyingadditional coats. Brush a thin coat of compound on mold surfaces before casting the remainder ofthe mix.Use reinforcing screens and tapes to minimize warpage and to increase overall strength. Whencasting large, deep shapes, pour compounds in several steps, allowing prior deposits to semihardenand cool before adding additional compound.3-17

Section 4. MAPP GasINTRODUCTIONMethylacetylene propadiene (MAPP) gas is a versatile,multi-purpose industrial fuel gas that offers excellentperformance, safety, and economy. It is used to flamecut, flame weld, braze, solder, pre-heat, and for stressrelief. The only equipment usually required to convertfrom acetylene to MAPP gas are new torch tips. Onecylinder of MAPP gas will do the work of fiveacetylene cylinders.MAPP GAS IS SAFEAt 70°F MAPP gas can be used safely at fullcylinder pressures of 94 psig (pounds-per square inchgauge). Acetylene is limited to 15 psig.MAPP gas toxicity is rated “very slight”, but highconcentrations (500 ppm) can have an anestheticeffect. Local eye or skin contact with MAPP gasvapor has caused no adverse response, but the liquifiedfuel may cause frost-like burns. MAPP gas ischemically inert to most common materials includingsteel, brass, most plastic and rubber. There is a slightpossibility MAPP gas may react with copper, or alloysof more than 67 percent copper, to produce explosiveacetylides when the gas is under high pressure. To beon the safe side, use steel or aluminum fixtures.DISADVANTAGESStabilized MAPP gas requires special tips for oxygencutting. Sometimes high capacity mixers are requiredto convert equipment from acetylene to stabilizedMAPP gas.BREAKTHROUGH IN PERFORMANCEThe performance of acetylene had never been equaleduntil the advent of MAPP gas. It has little or nobackfire or flashback, even when the torch tip is placedright up against the work. On aluminum braze welds,MAPP gas will leave no spatter, carbon smutting orlarge areas of metal flux on the surrounding metal.4-1

MAPP gas is excellent for selective flame-hardening.It bums efficiently at various oxygen-to-fuel ratios andport velocities, and permits a wide range of hardnessdepths. The stable, clean burning MAPP gas flamevirtually eliminates dangerous flashback.It is ideal for cambering large beams and other heatingapplications because it heats wider areas to a highertemperature faster than other fuels.HOW TO SET UP AND USE A WELDING ORCUTTING UNITThe importance of setting up and using welding andcutting equipment CORRECTLY for all fuel gasescannot be understated since its improper use can bevery dangerous. The following steps should be usedfor a safe operating procedure.Setting Up:(1) Be sure cylinders are securely fastened so theywill not fall over.(2) Before attaching oxygen and fuel regulators tocylinders, crack the valve slightly to blow outdirt or dust. Stand away from valve openings.(3) Be sure regulator inlet connections are clean.Attach regulators to cylinders and tightenconnection nuts firmly. Never use oil on oxygenregulators or fittings or wear oily gloves whenhandling oxygen equipment.(4) Be sure the regulator adjusting screw is backedall the way out. Crack the oxygen cylinder valveuntil pressure has built up, then open it all theway. Do not stand in front of or behind aregulator when the oxygen valve is open. Standto one side.(5) Be sure the fuel regulator adjusting screw isbacked out. If it is, then open the fuel cylindervalve one turn.4-2

SETTTNG UP (Continued)(6)(7)(8)Connect the correct hoses to the oxygen andMAPP gas regulators. The oxygen hose is greenand its fittings have right hand threads. TheMAPP gas hose is red and its fittings, notched onthe outside, have left hand threads.Open the torch’s oxygen valve and adjust itsregulator to the desired pressure. Purge theoxygen for approximately ten seconds for eachhundred feet of hose, then turn its torch valve off.Open the torch’s fuel valve and adjust to desiredpressure; purge for ten seconds for each hundredfeet of hose, then turn it off.(NOTE: Purging procedures remove any mixture ofgases from hoses that could cause a possible backlash.)Lighting the Torch:(2) Adjust the oxygen and fuel gas in successivesteps to the desired flame.Extinguishing the Torch:(1) Close the torch fuel valve, then close the torchoxygen valve,(2) Close both cylinder valves.(3) Open the torch fuel valve, bleed off the fuel gas,then close it.(4) Open the torch oxygen valve, bleed off theoxygen, then close it. Release the oxygen last toprevent trapping fuel in the torch.(5) Back out both regulator adjusting screws.(1) Crack the fuel gas valve about 1/4 turn and crackthe oxygen valve slightly. Light the torch with astriker.4-3

WELDING AND BRAZINGUse of Welding Tips with MAPP GASIf you use a standard acetylene tip with MAPP gas andintroduce enough oxygen to create what appears to be aneutral flame, it is actually an oxidizing flame. Althoughunsuitable for welding, this type of flame isrecommended for most brazing operations. For brazing,the performance and consumption of MAPP gas has beendetermined to be generally equivalent to that ofacetylene. MAPP gas has a slower flame propagationrate, so, to accommodate the same amount of fuel it isnecessary to increase tip size by about one number.Counterboring is required for jobs that need a harsh yetstable flame. Table 4-2 lists the counterbore drillnumber for each tip drill size. In every case the depthof counterbore is 1/16 in.The counterboring schedule (Table 4-2) is for use withwelding tips only. Because of different flamerequirements, different counterboring schedules areused for flame hardening heads and other equipment.A tip that overcomes the oxidizing effects of flamesadjusted to the neutral position has been perfected. Itconsists of a flame curtain around the primary flame coneto protect it from atmospheric gases. This tip design isshown in Figure 4-1.A tip that works well with MAPP gas is one or two sizeslarger than a tip designed for acetylene (Table 4-1).4-4

FUSION WELDINGFlame AdjustmentA MAPP gas flame, with its characteristically longerinner cone, differs in appearance from an oxygenflame, so welders must accustom themselves to adjustthe MAPP gas flame correctly. Although standardacetylene welding equipment is used to make a MAPPgas flame, a slightly larger tip is still required becauseof a greater gas density and a slower flame propagationrate. For welding steel, a triple deoxidized rodanalyzed at 0.06-0.12 C, 1.75-2.10 Mn, 0.50-0.80 Si,0.025 max P, and 0.4-0.6 Mo is best.FIGURE 4-1. MAPP Gas Torch Tip DesignMost MAPP gas welding requires a neutral flame.Laboratory studies have shown neutral flames have afuel-to-oxygen ratio of 1:2.3. Investigations of 1/4in.-thick mild steel plate butt welds have shown thatflame adjustment has a great effect on weld strength.Neutral flame welds had an average tensile strength of66,000 psig, while oxidizing flame welds were as lowas 35,000 psig. Welds made with a reducing flameaveraged 52,000 psig.4-5

TABLE 4-1. Welding Tip Size and Application Using MAPP GasInner Flame Regulator Pressure Range* MAPP Gas MetalDrill Size Length Consumption Thicknessof Tip (Inches) MAPP Gas Oxygen (cfh) (Inches)72-70 1/4 1-2 5-6 1-3 UP TO 1/3265-60 7/16 1-3 5-6 2-4 1/32-1/1656-54 5/8 1-5 6-8 3-8 1/16-1/849-48 1 2-8 8-10 5-18 1/8-3/1643-40 1 1/8 3-9 10-12 6-30 3/16-1/436 1 1/4 5-1o 12-15 6-35 1/4-3/8* For injector type equipment use 1-2 psig (pounds per square inch gauge) MAPP Gas and 25-30psig oxygen for all size tips.4-6

Carbon Steel WeldingCarbon steel welding is done in a fixed horizontalposition. Edges are prepared by machining, grinding,or flame cutting. Remove all oxidized metal with agrinder before any flame cutting welding is done. Allslag, scale, rust, paint and other foreign material 1 in.from both edges, top and bottom, must be removedbefore welding.The bevel must be 40 degrees on each part or 80degrees included angle minimum. It should have asharp edge; no land is allowed. Tack the joint at fourequally spaced points with a minimum of 1/8 in.spacing. The tacks must be filed or ground to removeall oxides and tapered out to each edge of the tack.Use calibrated flow meters to keep the ratio of MAPPgas to oxygen at 1:2.7. This gas flow ratio is verycritical and must be maintained. The flame will appearoxidizing.THE PROPER WELDING TIP IS ONE SIZELARGER THAN THAT NORMALLY USED FOROXY-ACETYLENE WELDING.Use the forehand method, which requires the weldingto be done uphill. Hold the end of the inner cone about1/4 - 1/8 in. from the molten puddle at an angle of20-250 from a perpendicular line to the weldingsurface. Protect the molten puddle from any drafts.Apply filler metal by melting the end of the rod intothe molten puddle (dip method). If a weld requiresmore than one pass, file or grind the preceding pass toremove all oxides. It is important that 100 percentpenetration be achieved. No under cuts are permittedin the base metal at the edge of the weld. Deposit theweld metal so that it has a 1/16 - 1/8 in. reinforcementand gradually increases from the center to the edge ofthe weld.Remove all oxides, scale, paint, grease, and otherforeign materials before welding starts and betweenpasses. Remove all cracks, pinholes, cold laps, andoxidized areas with a grinder before making the nextpass. Preheat and/or stress relieving procedures areunnecessary except when the National Welding Coderequires them.4-7

TABLE 4-2. Welding Tip Counterbore ScheduleTip Drill SizeCounterbore DrillTip Drill SizeCounterbore Drill7674727068666462605856545251504948474645444342395250484644424038363432303634333231302928272625244-8

Carbon Steel Pipe WeldingPipe welding studies comparing MAPP gas andacetylene show that they allow comparable weldingspeeds on pipe 2 in. or less in diameter. Oxy-acetylenewelding is somewhat faster on larger pipe.Cast Iron WeldingMAPP gas readily welds cast iron. Use a neutral flamewith a welding tip that produces a bulbous pattern.Aluminum WeldingWelding aluminum with MAPP gas requires a flameadjusted to slightly reducing. A welding tip thatproduces a long pointed flame is best. Use thestandard procedures of precleaning, fluxing andpreheating.Copper WeldingBRAZINGA MAPP gas flame, with its deep-soaking heatcharacteristic, is ideal for many brazing operations.When brazing with MAPP gas, use a tip approximatelyone size larger than that required for acetylene toproduce an oxidizing flame. Heavy braze sectionsusually require a tip that produces a bulbous flame.Fluxing procedures and filler rod composition arestandard.METALLIZINGMAPP gas can be used in most common metallizingequipment to spray any material that can be sprayedusing any other fuel gas. The conversion to MAPP gascan be accomplished with only minor equipmentmodification. It is also very suitable for applicationssuch as preheating work pieces and fusion of powderdeposits.Weld copper with an oxidizing flame. A rod meetingAWS Specification P Cu (phosphorous deoxidizedcopper) offers best results.4-9

FLAME HARDENINGFlame hardening is a rapid, economical method forselectively hardening specific areas on the surface of apart. The process is applied only to flame-hardenablematerials, principally carbon and alloy steels, certainstainless steels, and cast irons. Flame hardening isused to harden parts to depths of 1/64 -1/4 in.How Flame Hardening WorksFlame hardening is any process that uses an oxy-fuelgas flame to heat carbon or alloy steel, tool steel, castiron, or hardenable stainless steels above a certain“critical” temperature, followed by a rapid quenching.This causes the heated material to harden to somedepth below its surface.Carbon Content and HardnessFlame hardening seldom requires tempering becausethe hardening effect is shallow. Tempering also tendsto reduce maximum hardness to some degree.However, insufficient heating (not up to the criticaltemperature, or not long enough above it), will producea very low hardness on the workpiece surface. Mostparts can be reheated after cooling to correct thisproblem.Too much heat can cause low surface hardness byburning carbon out of the surface (decarburization).The workpiece will have a high carbon steel core and asoft, low-carbon iron skin. Decarburized workplacesusually cannot be reheated without cracking.QuenchingCooling speed during quenching depends on the typeand temperature of quenching medium used, and howfast it is agitated. Self-quenching, when a part has asufficiently large, cool mass to draw heat away fromthe surface causing it to quench itself, is the slowestmethod and produces the lowest surface hardness.Forced air is a mild quenchant that rapidly cools aworkpiece with minimal risk of surface cracking,especially in higher-carbon steels. Oil and soluble-oilmixtures give relatively high hardness without too4-10

Quenching (Continued)severe a cooling rate. Water is a severe quenchant,and brine is even more so. They produce highhardness but must be used carefully to prevent surfacecracking. Water gives a higher hardness than oil andcan be used where surface cracking is not likely to be aproblem (as it is in very high-carbon steels). Mostflame hardening is done with water-cooled orwater-quenching flame heads because of the extremeheat reflected from the workpiece.Flame Hardenable MaterialsPlain carbon steels for flame hardening should have atleast 0.30 percent carbon. Lower carbon-steel gradescan be hardened if they have first been carburized.Cast iron can be flame hardened if it has acombined-carbon content of 0.35 percent -0.80percent. It responds much the same way as steel ofequivalent total carbon content. However, cast ironalso has a lower melting point than most steels, so caremust be exercised to prevent surface melting duringflame hardening.Flame Head DesignFlame head design is another important considerationin successful flame hardening. MAPP gas flame headsdiffer from flame heads used for other fuel gases.MAPP gas flame heads usually have No. 69 drill-sizeflame ports counterbored 1/16 in. deep with No. 56drills. The rows and ports are on 1/8 in. centers andthe rows are offset 1/1 6 in. Acetylene flame headsusually have No. 56 drill-size flame ports with theports and rows on 1/4 in. centers; the ports are offset1/8 inch, row to row.HOW TO FLAME CUT WITH MAPP GASQuality cuts are readily obtained with MAPP gas. Butquality cuts require a proper balance between preheatflame adjustment, oxygen pressure, coupling distance,torch angle, travel speed, plate quality, and tip size.Fortunately, this balance is easy to achieve with thefollowing simple operating procedures:4-11

Preheat Flame AdjustmentMAPP gas is similar to acetylene and other fuel gasesbecause it can be made to produce a carburizing,neutral, or oxidizing flame (Table 4-3). Flame cuttingwill most likely require adjustment to a neutral flame.To adjust to a slightly carburizing flame, light thetorch, then slowly increase preheat oxygen until theyellow flame turns blue with some yellow feathersremaining on the end of the pre-heat cones. To adjustto a neutral flame, twist the oxygen valve slightly untilthe feathers disappear and the preheat cones becomesharply defined and turn a dark blue color. This flamewill remain neutral, even with the addition of a smallamount of preheat oxygen. To adjust to an oxidizingflame simply give the oxygen valve a further slighttwist. The neutral flame will suddenly change color,from dark blue to a lighter blue, and the preheat coneswill shorten. An increase in sound will also be noted(Figure 4-2).TABLE 4-3. Oxy-Fuel Ratios/Flame Condition ComparisonsFlameVERYCARBURIZINGSLIGHTLYCARBURIZINGNEUTRALOXIDIZINGVERYOXIDIZINGOxy-MAPPGas Ratio2.0 TO 12.3 TO 12.5 TO 13.0 TO 13.5 TO 1Different fuel gases will produce different flames fromthe same tip. MAPP gas preheat flame cones will be atleast one and one-half times longer than acetylene4-12

Preheat Flame Adjustment (Continued)preheat cones. Operators accustomed to acetylene andgiven a one-piece MAPP gas tip tend to adjust theflame as if they were using acetylene and may thinkthe gas is too cold. In fact, such a setting with MAPPgas will not have sufficient fuel volume to produceenough heat for the job at hand.Neutral flame adjustments are used for most cutting.Carburizing and oxidizing flames are used in specialapplications.Use a “slightly carburizing” flame to stack cut lightmaterial because slag formation is minimal. If astrongly oxidizing flame is used, slag produced in thekerf may be enough to weld the plates together andslag-welded plates often cannot be separated after thecut is completed.For cutting or piercing, use a “moderately oxidizing”flame for fast starts because it produces a slightlyhotter flame temperature, and higher burning velocitythan a neutral flame. An oxidizing flame is commonlyused with a “high-low” device. Use a large “high”oxidizing flame to obtain a fast start. As soon as thecut is started, drop to the “low” position and continuethe cut with the neutral flame.An “oxidizing flame” may be used for beveling. Whenthe tip is at an angle to the surface it is not using all ofits preheat flames to make the bevel cut, therefore, anoxidizing flame is used to get maximum heat from thesmall portion of the preheat flame actually heating thecritical area.Do not use “very oxidizing” flames for fast starts. Anoverly oxidizing flame actually increases startingtime. The extra oxygen flow does not contribute tocombustion, but instead cools the flame and oxidizesthe steel surface.Oxygen PressureThe term flame-cutting oxygen pressure always refersto the pressure at the torch, not at some remotelylocated regulator. Reasons for this are discussed indetail in the Oxygen Supply paragraph on page 4-23.4-13

CARBURIZING FLAMENEUTRAL FLAMEOXIDIZING FLAMEFIGURE 4-2. Preheat Flame Characteristics4-14

Preheat Flame Adjustment (Continued)A simple test will quickly show the best oxygenpressure to use for any given tip.Put a low volume, soft flame on the tip, then turn thecutting oxygen on and vary the pressure to find thebest looking stinger (visible oxygen cutting strewn).Low pressure gives a very short stinger, maybe two tothree inches long, that breaks up at the end. Increasepressure to define and lengthen the stinger. This is thecorrect cutting oxygen pressure for a given tip. Thelong stinger will remain over a fairly wide pressurerange, but as oxygen pressure is increased, the stingerreturns to the short, broken form it had under lowpressure. If too much oxygen pressure is used,concavity may show on the cut surface.Too much oxygen pressure notches the cut surfacebecause the high velocity oxygen is blowing the metaland slag out of the kerf so fast that the cut iscontinuously being started. If the pressure is too low,the operation will slow down too much. Excessivedrag and slag dormation result, and a wide kerf maybefound at the bottom of the cut.Cutting-oxygen pressure and travel speed affect thetendency of slag to stick to the bottom of a cut. Thistendency increases as the amount of metallic iron inthe slag increases.Two things can cause high iron content in slag. Toomuch cutting-oxygen pressure - Oxygen forcedthrough the kerf so fast that it blows out molten ironbefore it can be oxidized. Cutting speed too fast - Notenough time to thoroughly oxidize the molten iron,with the same result as high oxygen pressure.Coupling DistanceThe distance between the end of the flame cones andthe workpiece is the coupling distance. Some considerthe distance between tip and workpiece to be thecoupling distance, however, since flame lengths varywith different fuels and flame adjustments, the distancebetween the end of the preheat cones and theworkpiece is the preferred measure (Figure 4-3).4-15

Coupling Distance (Continued)Keep preheat cones about 1/16 - 1/8 in. off the surfaceof the work when using MAPP gas to cut ordinaryplate thicknesses of 2-3 inches. Let the preheat conesimpinge on the surface for faster preheating forpiercing, or very fast starts. Above 6 in. platethickness, increase the coupling distance to get moreheat from the secondary flame cone as the secondaryMAPP gas flame preheats thick plates far ahead of acut. For material 12 in. thick or more, use a couplingdistance of 3/4 to 1-1/4 in. long.in. thick, acute lead angles offer no advantage andshould be cut with the torch perpendicular to theworkpiece surface.Torch AngleThe torch angle, or lead angle is the acute anglebetween the axis of the torch and the workpiecesurface when the torch is pointed in the direction of thecut (Figure 4-4). When cutting light-gauge steel (up to1/4 in. thick) a 40-50 degree torch angle allows muchfaster cutting speeds than a torch mountedperpendicular to the plate. Speed can be increased onplate up to 1/2 in. thick by increasing the torch leadangle to 60-70 degrees. When cutting plate over 1/2FIGURE 4-3. Correct Measurementof Coupling Distance4-16

Torch Angle (Continued)An angled torch cuts faster on thinner-gauge material.The intersection of the kerf and the surface presents aknife edge which is easily ignited. Once the plate isburning, the cut is readily carried through to the otherside of the work. This avoids problems of non-dropcuts, incomplete cutting on the opposite side of thethicker plate, gouging cuts in the center of the kerf andsimilar problems.Travel SpeedEach job has a best cutting speed. A high quality cutwill be obtained on plate up to about 2 in. thick whenthere is a steady “purring” sound from the torch andthe spark stream under the plate has a 15 degree leadangle; the angle made by the sparks coming from thebottom of the cut in the same direction the torch istraveling. If the sparks go straight down, or evenbackwards, travel speed is too high.Nature of the WorkpieceVariations in cut quality are the result of differentworkpiece surface conditions or plate compositions.For example, rusty or oily plates require more preheat,or slower travel speeds than clean plates. Mostvariations from the ideal condition of a clean, flat,low-carbon steel plate tend to slow down cutting action.For a very rusty plate, set as big a preheat flame aspossible on the torch and run it back and forth over theline to be cut. Extra preheat passes do two things.First, they span off much of the scale that interfereswith the cutting action, and they put extra preheat intothe plate to allow improved cut quality and speed.Cut a little bit slower when working with high-strengthlow-alloy plates (ASTM A-242 steel), or full alloyplates (ASTM A-5 14). Also, because these steels aremore sensitive to notching than ordinary carbon steels,use low oxygen pressure.Clad carbon alloy, carbon stainless, or low-carbon--high-carbon plates require a lower oxygen pressure,and perhaps a lower travel speed than straightlow-carbon steel. Be sure the low-carbon steel side is4-17

FIGURE 4-4. Corrrect Torch Angles4-18

Nature of the Workpiece (Continued,on the same side as the torch. The alloyed or highercarbon cladding does not bum as readily as the carbonsteel.By putting the cladding on the bottom, and the carbonsteel on the top, a cutting action similar to powdercutting results. The low-carbon steel on top bumsreadily and forms slag. As the iron-bearing slag passesthrough the high-carbon or high-alloy cladding, itdilutes the cladding material. The torch, in essence,still bums a lower carbon steel. If the clad orhigh-carbon steel is on the top surface, the torch isrequired to cut material that is not readily oxidizable,and forms refractory slags that can stop the cuttingaction.Tip Size and StyleAll steel sections have corresponding tip sizes to allowthe most economical operation for a particular fuel.Any fuel will burn in any tip, of course, but not asefficiently and may even overheat enough to melt thetip or cause problems in the cut.For example, MAPP gas does not operate at peakefficiency in most acetylene tips because the preheatorifices are too small. If MAPP gas is used with anatural-gas tip, the tip will overheat and becomesusceptible to flashback. In an emergency, anatural-gas tip can be used with MAPP gas byremoving its skirt. Similarly, an acetylene tip can beused if inefficient burning can be tolerated for a shortrun.Oxygen SupplyOxygen supply means two things - volume andpressure. Both are needed to obtain a decent stinger toprovide a good quality cut. If all the oxygen volume inthe world is available, and the pressure is low, theoxygen system will be deficient. Also, very highoxygen pressures will not help when only a smallvolume of oxygen is available over a given time.It is as important to have a generous supply of oxygenas it is to have well-trained burners, good equipment,and a quality fuel gas. Insufficient oxygen usually4-19

Oxygen Supply (Continued)results from undersized piping coming into a plant, orregulators that do not have sufficient capacity formaking heavy cuts. Deficient cutting oxygen suppliesoften result from very long hoses, hoses too narrow indiameter, or hoses that have been chopped up andpatched together with couplings.When depressing the oxygen lever results in a largepressure drop, something is wrong. This pressure dropis most readily seen in two-hose torches becauseinsufficient oxygen causes the preheat flame tobecome very carburizing when the cutting oxygenvalve is opened. Check the regulator and the oxygenpiping system immediately.Cutting oxygen is usually at least 99.7 percent pure.When lower purity oxygen gets into the lines, it is justabout impossible to make a decent cut at respectablespeeds. Impure oxygen is often the last thing onesuspects, and is often not discovered until a cylinderchange - and suddenly everything starts working theway it should.Starting a CutCuts can be started at an edge or any other point on thesurface of a plate.There are several ways to start an edge cut, but themost common procedure is to position the tip (eitherby hand or by machine) so that the preheat flames heatthe top comer of the plate while the cutting oxygenhole is centered over the comer. When the platebecomes bright cherry-red, turn on the cutting oxygenand start torch travel.Another edge-starting technique is preheating theplate. Move the torch slowly back and forth along theline of cut several times for a distance equal to theplate thickness. Pull the torch slightly away from theedge, turn on the cutting oxygen and begin torchtravel. A cut started with this technique allows normalcutting speeds the moment the torch reaches the plateedge.Piercing is used to start cuts at some point away froman edge when the shape or location precludes an edgestart.4-20

Starting a Cut (Continued)When hand piercing for a start, the flames shouldimpinge on the plate surface while the torch is movedwith small circular motions over the area to bepierced. When a hot spot is formed, the cuttingoxygen is turned on slowly while the torch is raisedsimultaneously, and travel is started along the line ofcut .A hole can be pierced in very thin plate withoutmoving the torch, however, it is very important to raisethe torch on thicker plate as travel begins. If this is notdone, slag will blow out and hit the torch tip, eithergetting it dirty or burning it. Travel should never bedirectly away from the operator because slag andsparks will emerge in a direction opposite the line ofcut and may cause bums.Another hand piercing method is to make a hot spot,then rotate the torch so the tip is angled away from thedirection of travel. Start the cutting oxygen, rotate thetorch until the tip is perpendicular to the plate, then liftthe torch and keep it moving along the line of cut.Machine piercing starts are essentially the same ashand piercing starts. Some machines are equippedwith torch lifters so that torches can be moved up asthe pierce is started. Other machines have “Hi-Lo”devices with a heavy preheat flame for making a hotspot without getting the tip too close to the platesurface. Some machines also have an oxygen ease-onvalve so that cutting oxygen will build up to fullvolume slowly. Cutting oxygen and travel shouldalways be started simultaneously. Always protect thecutting tip from blown slag.SPECIAL CUTTING JOBSGougingGouging applications include removing tack welds,defective welds, blowholes or sand inclusions incastings, welds in temporary brackets or supports,flanges from piping and heads, and old tubes fromboilers. Gouging is also used in demolition work andto prepare plate edges for welding.4-21

Gouging (Continued)Manual gouging is a rapid metal removal method.Speeds from 12-84 ipm (inches per minute) arepossible; 24 ipm across 1/4 in. plate will make a gouge3/8 in. wide. Gouging accuracy can be controlled towidth and depth tolerances of about 1/16 in.,depending on the skill of the operator.Piercing and WashingPiercing is used to cut holes in a workpiece. Animportant example is rivet piercing. Rivets and similarfasteners can be removed entirely from a workpiece byburning them out. It is possible to do this withoutdamaging the holes in the plates through which therivets pass.Flame piercing is used when the rivet shank cannot beremoved because of poor alignment of the originalholes in the mating plates. After piercing, use theoxygen stream to wash away the remaining rivetmaterial. This method requires a high degree of skilland great care must be exercised.Alternatively, use the cutting flame to wash a rivethead away. This leaves the rivet shank accessible to apunch and washed plates undamaged and unmarked.Merely punch the shank of the rivet out and thediameter of the hole in the plate remains unchanged.The rivet washing process has wide application whenplates and rivet holes are to be reused.Cutting Manganese SteelVery high quality cut surfaces can be produced whenMAPP gas is used to cut Hadfield’s manganese (Mn)steel (approximately 13 percent manganese). With twoimportant exceptions, cutting manganese steel issimilar to cutting mild carbon steels. One, a preheat isrequired, and two, cutting oxygen pressure should bekept as& as possible. Without a preheat, and withtoo much oxygen pressure, a very rough, notchedsurface will result.CAUTION: The preheat should be applied only alongthe line of cut since heating can destroy desirable4-22

Cutting Manganese Steelproperties of this material. Do not preheat the entirepiece since Hadfield’s manganese steel becomesembrittled if heated above 500°F.Preheating for hand cutting can be accomplished byusing the torch to heat several inches ahead of the cutand then dropping back to make the cut. Preheatingcan also be performed with another torch.For machine cutting, pre-heating is best accomplishedby positioning the preheat torch about 3 in. ahead ofthe cutting tip. Use a cutting tip about the same size asthe heating tip or use the MAPP H-O heating tip.Select cutting tip size the same as when selecting tipsfor mild carbon steel. MAPP FS tips provide the bestpreheat pattern. Use only standard pressure tips sincecutting oxygen pressure should be from 30-40 psig(pounds per square inch gauge).Table 4-4 gives a few examples of the conditions usedto obtain very high quality, slag free cuts withHadfield’s manganese steel.TABLE 4-4. Hadfield’s ManganeseSteel Cutting ConditionsMetal Preheat cutting cuttingThickness Tip Tip Speed(inches)(ipm)7/16 FS-56 FS-61 30-323/4 FS-56 FS-54 233/4 H-O FS-54 25Pressure (PSIG)MAPP OxygenGas7/16 7 30-403/4 7 30-403/4 7 30-404-23

OPERATION PROCEDURES - BULK-SYSTEMSStart Up ProcedureSlowly open the globe valve located downstream fromthe regulator. This valve is opened slowly to preventclosing the excess flow valve in the tank. Turn on,electric power to the vaporizer.Temporary Shutdown ProcedureClose the globe valve located downstream from theregulator.Extended Shutdown ProcedureClose the globe valve located downstream from theregulator. Turn off electric power to vaporizer.CAUTION: Only authorized trained personnel are toadjust the line pressure regulator and thepressure-temperature controls within the vaporizer.THE USE OF ANTIFREEZE IN FLASH-BACKARRESTORSThere are some important points which should beemphasized with regard to the use of antifreeze inflashback arrestors. Use antifreeze with no waterfor all interior flashback arrestors. For flashbackarrestors installed outdoors, use a solution of 90percent single phase glycol-based antifreeze and 10percent water. This will prevent freezing down toa temperature of -27°F.The percentage of water in antifreeze should bekept to a minimum because water vapor is harmfulto MAPP gas pipe lines (rust) and to MAPP gasflames (lower flame temperature).A good grade, one phase glycol-based antifreezeshould be used. The two phase (oil added)anti-freeze, such as Prestone, should not be used.Some single phase antifreezes are listed below:(1) Weatherset Antifreeze& Summer Coolant4-24

THE USE OF ANTIFREEZE (Continued)(2) Sentinel Antifreeze Coolant(3) Factory replacement materialFord-Fomoco or RodundaChrysler-MoparAmerican-RamblerGeneral Motors-G.M. -1899M(4) Major Oil Company ProductsStandardShellPureMobileOther products not containing oil inhibitorsAntifreeze levels should be checked periodically,(three to six months) and changed as needed.Inspectors should check flash-back arrestors to lookfor signs of glycol foaming or frothing, the frostindication that antifreeze should be changed. Drainand refill antifreeze at regular intervals (two or threemonths) in large usage areas to prevent foam fromgetting into the pipeline or equipment.MAPP GAS AND COMPRESSED AIR BURNERThis burner, simple in design, is effective for bendingrails, beams, and other steel.Take a 4 in. pipe cap, thread a 1/2 in. pipe to its center,then (for aspirated air), drill 10 equally spaced 1/4 in.holes on a 2-7/8 in. diameter circle and 10 equallyspaced 1/4 in. holes on a 3-3/4 in. diameter circle(Figure 4-5). Attach it to a burning skirt of 9 in. long,4 in. diameter, Sch. 80 pipe. Make a No. 28 drill holein the 1/2 in. pipe’s cap for MAPP gas and compressedair. This set up should have a Y-connection withneedle valves and reverse-flow checks for MAPP gasand oxygen.Operating pressures: approximately 20 psig MAPPgas and 20 psig compressed air, Consumption:approximately 100 cfh MAPP gas with the burneradjusted to a high velocity roaring sound. Anoxidizing flame should extend a short distance beyondthe end of the burner.By modifying this basic design, different size burnerscan be made for use with MAPP gas.4-25

FIGURE 4-5. MAPP Gas and Compressed Air Burner4-26

NOTES4-27

NOTES4-28

NOTES4-29

INDEXASPHALT MIXERS AND PAVERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Backhoe Sidecutters . . . . . . . . . . . . . . . . . . . . . . . . . . . .Curbing Machine Augers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Grader Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Grader End Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Grapple Tines . . . . . . . . . . . . . . . . . . . . . . . . . .Grid Compactors . . . . . . . . . . . . . . . . . . . . . . . . . . .Mixer Paddles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mixer Paddle Shanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .Paving Agitator Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Paving Machine Paddles . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .Scooplift Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Scraper Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Scraper Cutters and Sides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Sheepsfoot Tampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shredding Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Trencher Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page2-532-642-632-582-582-602-602-532-542-552-542-592-572-562-612-662-65AUGERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52, 2-63, 2-83, 2-85BUSHINGS, BONDING TO SHEET METAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6Index-1

INDEX (Continued)COMPRESSED AIR BURNER, AND MAPP GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .COUPLING DISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CRACKSRepairing Manganese Crusher Rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CRUSHER ROLL SHELLSPreventive Warpage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rebuilding Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rebuilding Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wear Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Welding Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CRUSHING EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page4-254-152-762-682-722-732-672-682-67CRUSHING, GRINDING, AND SCREENING EQUIPMENT . . . . . . . . . . . . . . . . . . . .Cracked Maganese Rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Crusher Roll Shells2-672-76Hardface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67,2-71,2-72Rebuild . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-67. 2-72Hard Facing (See HARD FACING)Index-2

INDEX (Continued)PageRebuilding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67.2-72Rotor Type Impactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78Rotors and Bars, Hardface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79Screen Grates, Hardface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79Welding Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73DITCHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Drive Segments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Drive Sprockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .EARTH-MOVING EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FLAME, PREHEAT CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .GRINDING EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .HARDFACINGAsphalt Mixer Paddle Shanks... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Asphalt Mixer Paddles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Asphalt Mixer Scraper Blades. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-492-492-502-502-512-164-142-672-542-532-57Index-3

INDEX (Continued)HARD FACING (Continued)Backhoe Sidecutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bulldozer Blades . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . .Bulldozer End Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cable Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .Clamshell Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cross-Checking and Cracking Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Crusher Jaws . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Crusher Roller She's . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Curbing Machine Augers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ditcher Drive Segments . . . . . . . . . . . . . . . . ... .... . . . . . . . . . . . . . . . .Ditcher Drive Sprockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ditcher Rolls . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .Ditcher Teeth . . . . . . . . . . . . . . . . . . . . . . . . ....Dragline Chains . . . . . . . . . . . . . ......... . . . . . . . . . . . . . . . . . . . . . . .Dragline Clevises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dragline Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Drive Sprockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Elevator Bucket Lips . . . . . . . . . . . . . . . . . . .Flame Adjustments . . . . . . . . . . . . . . . . . . ...Grader Blades . . . . . . . . . . . . . . . . . . . . . .Grader End Bits . . . . . . . . . . . . . . . . . . . . .Index-4Page2-642-232-222-402-432-122-802-672-632-492-502-502-512-412-422-412-202-842-152-582-58

INDEX (Continued)HARD FACING (Continued)Grapple Tines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gravel Washer Auger Flights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Grid Compactor Grids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Horizontal Travel Gear Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .House Ring Gear Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Log Washer Paddles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Paving Machine Agitator Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Paving Machine Paddles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Paving Machine Screw Conveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Post Hole Augers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Quarry Drill Collars and Augers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ripper Shanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ripper Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rock Rake Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rotor-Type Impactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Scalping and Sizing Vibratory Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Scooplift Bucket Lips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Scraper Cutters and Sides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Sheepsfoot Tampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shovel and Dragline Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page2-602-832-602-472-482-842-552-542-552-522-852-242-212-252-782-822-592-562-482-612-33Index-5

INDEX (Continued)HARD FACING (Continued)Shovel Boom Heels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shovel Bucket Tooth Adapters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shovel Drive Tumblers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shovel House Rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shovel Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shovel Latch Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shovel Latch Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shovel Ring Gear Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shovel Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shovel Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shovel Teeth, Comparison of Hard-Facing Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . .Shovel Teeth, Waffle or Cross-Hatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shovel Track Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shredding Hammers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Top Carrier Rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Track Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tractor Grousers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tractor Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tractor Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Trencher Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page2-392-352-302-302-292-382-372-462-282-342-362-342-282-662-52-192-172-212-172-182-65Index-6

INDEX (Continued)PageHEAVY CONSTRUCTION EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16MAPP GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Antifreeze in Flashback Arrestors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24Brazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4,4-9Compressed Air Burner and MAPP Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2, 4-11,4-20,4-21,4-22Disadvantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Flame Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Coupling Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Nature of the Workpiece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oxygen Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oxygen Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preheat Flame Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Starting a Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tip Size and Style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Torch Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Flame Hardening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Carbon Content and Hardness.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Flame Hardenable Materials.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Flame Head Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Index-74-14-114-154-174-134-194-124-204-194-164-174-1o4-1o4-114-11

INDEX (Continued)MAPP GAS (Continued)Metallizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating Procedures -Bulk Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Extended Shutdown Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Start Up Procedures . . . . . . . . . . . . . . . . . . . . . . . .Temporary Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...WeldingFusion Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .Aluminum Welding . . . . . . . . . . . . . . . . . . . . . . . ..... ...Cast Iron Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...Carbon Steel Pipe Welding . . . . . . . . . . . . . . . . . . ......Carbon Steel Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Copper Welding. . . . . . . . . . . . . . . . . . . . . . . . . . .....Flame Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . .Welding and Brazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Welding Tips with MAPP Gas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Welding or Cutting Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Extinguishing the Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lighting the Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Setting Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page4-94-244-244-244-244-14-14-84-94-94-94-74-94-54-44-44-24-34-34-2Index-8

INDEX (Continued)PageMINING EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-67, 2-80MOLECULAR METAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1ALLOY GP (M-41) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Atomized Metallic Materials Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2, 3-7, 3-12,3-16Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3.3-7. 3-11, 3-15RAPIDSTEEL (M-43 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .RepairingAxles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bearing Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cams and Cam Followers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Condenser Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Damaged Castings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Foundations and Retaining Walls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gear Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Rams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Keyways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Index-93-143-63-63-63-63-143-23-23-143-143-23-63-23-2

INDEX (Continued)PageMOLECULAR METAL (Continued)Machine Ways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pipe Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Plumbing Pipes and Fixtures.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Radiators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2.3-63-143-63-63-143-143-6Slides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6Surface Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3,3-7,3-11,3-15Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14Vessels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6Wetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4,3-8,3-13,3-17SMOOTCOAT (M42) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SMOOTHCOAT LIQUID (M-43 )....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-63-10PIPES, JOINING DISSIMILAR DIAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .POST HOLE AUGERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .POWER SHOVEL TRANSMISSION COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . .3-532-522-45Index-10

INDEX (Continued)QUARRY AND MINING EQUIPMENT, OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Crusher Jaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Crusher Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Elevator Bucket Lips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gravel Washer Auger Flights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Log Washer Paddles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Quarry Drill Collars and Augers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vibratory Screen, Scalping and Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wobbler Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page2-802-802-822-842-832-842-852-832-82QUARRY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67,2-80SCREENING EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SHOVEL PARTS AND ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Boom Heels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Buckets, Clam Shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cable Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Clams Shell Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bucket Tooth Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dragline Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dragline Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-672-272-392-432-402-392-352-332-42Index-11

INDEX (Continued)SHOVEL PARTS AND ACCESSORIES (Continued)Dragline Clevis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dragline Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Drive Tumblers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .House Rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Latch Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Latch Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Track Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Horizontal Travel Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .House Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ring Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Swing Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page2-432-412-302-302-292-382-372-282-342-282-452-472-482-462-482-47STEPOVER TECHNIQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71TORCH ANGLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16Index-12

INDEX (Continued)TORCH TIP DESIGN, MAPP GAS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TRACTOR PARTS AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bulldozer Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bulldozer End Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Drive Sprockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ripper Shanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ripper Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rock Rake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Top Carrier Rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tractor Grousers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tractor Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tractor Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tractor Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WEARFACING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Abrasion Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Base Metals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Buildup Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cast Iron Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Corrosion Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page4-52-162-232-222-202-242-212-252-192-212-172-182-172-12-112-122-32-32-32-12Index-13

INDEX (Continued)WEARFACING (Continued)Cracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cross-Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Flame Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing/Deposits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hard-Facing/Oxy-MAPP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heat Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Impact Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Types of Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Abrasion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Impact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Welding on Cast Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Workpiece Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WorkPiece Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page2-122-122-152-42-132-112-112-122-112-112-122-112-112-32-42-1WELDING MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Aluminum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16, 1-17Application Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34Brazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7,1-9,1-10Index-14

INDEX (Continued)PageWELDING MATERIALS (Continued)Buildup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21Cast Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1, 1-12, 1-13, 1-14Chamfering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-27Gouging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .1-27Graphite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28Holding and Heat Resisting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32Mild Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 1-1, 1-2Overlay . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22, 1-25, 1-26Silver Brazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10Solder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29, l-25,1-26Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-3, 1-4, 1-5, 1-6,1-8Surface Hardening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33zinc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19WOBBLER FEEDERS, RESTORING WORN AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82Index-15