Lincoln_Electric_Welding_System

Customer Assistance Policy

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, pur- chasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, includ- ing any warranty of fitness for any customer???s particular purpose, with respect to such information or advice. As a matter of practi- cal consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice cre- ate, expand or alter any warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely with- in the control of, and remains the sole responsibility of the cus- tomer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying this type of fabrication methods and service requirements.

Subject to Change ??? This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.

-2-

Table of Contents

Welding Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34

Out-of-Position Welding

(Vertical and Overhead) . . . . . . . . . . . . . . . . . . . . . .4-7

High Deposition Welding . . . . . . . . . . . . . . . . . . . .8-15

Welding Inclined Plates . . . . . . . . . . . . . . . . . . . .16-17

High Speed Welding (Sheet Metal) . . . . . . . . . . .18-23

Low Hydrogen Welding . . . . . . . . . . . . . . . . . . . .24-34

Minimum Preheat and Interpass Temperatures . . . .35

Stick Electrode Selection Guide . . . . . . . . . . . . . . . . .36-38

Welding Safety Precautions . . . . . . . . . . . . . . . . . . . .39-48

-3-

WELDING PROCEDURES

Out-Of-Position Welding (Vertical and Overhead)

When welding out-of-position, the molten metal tends to spill out of the joint. To offset this tendency, an electrode with a fast freezing deposit is needed.

Welding made with out-of-position electrodes is slow, relatively expensive and require a high degree of operator skill. Therefore, whenever possible, work should be positioned for downhand welding using High-Deposition electrodes ??? see pages 8-15.

Procedures

Vertical Up Groove Welds . . . . . . . . . . . . . . . page 6 Vertical Down Welds . . . . . . . . . . . . . . . . . . . page 6 Vertical Up Fillet Welds . . . . . . . . . . . . . . . . . . page 7 Overhead Fillet Welds . . . . . . . . . . . . . . . . . . page 7

For vertical up and vertical down pipe welding technique, request Lincoln bulletin C2.420, Welding Pressure Pipelines.

Alternate Electrodes

Vertical, overhead, and horizontal groove welds on plate thicker than 1/2??? are most economically done with low hydrogen electrodes ??? see pages 24-34.

Vertical Up vs. Vertical Down

Vertical down is recommended for fastest welding of 18 gauge to 3/16??? thick steel. A description of the recommended drag technique along with sheet metal procedures are given in the section High-Speed Welding on pages 18-23.

Vertical up techniques provide deeper penetration and lower overall welding costs on plate over 3/16??? thick.

Electrode, Current and Polarity

The vertical up and overhead procedures in this section recommend 3/16??? and smaller Fleetweld 5P or 5P+ (E6010) electrode using electrode positive and currents in the lower portion of the electrode???s range. When only AC otuput is available, use Fleetweld 35 or Fleetweld 180 (E6011) electrode at about 10% higher current.

-4-

Vertical Up Techniques for Fillet and Groove Welds

Whip??? first pass

Box weave??? second pass

Straight weave

1.Make first pass root beads with a whipping technique. Whip the electrode tip out of the molten crater and up for a short time to let the crater cool before returning the electrode tip to the crater area to add more weld metal.

2.Root pass beads, particularly when made with a whipping technique, tend to be humped in the middle.

Therefore, a box weave is often needed for the second pass to assure good fusion along the edge of the first bead. The box weave is similar to the straight weave except a slight upward motion is made at both sides of the weld. Maintain a short arc with no whipping.

3.Employ a straight weave for the final passes. Simply move the electrode tip back and forth across the surface of the weld pausing slightly at both edges to insure penetration and wash-in without undercut.

Overhead Techniques

Weld overhead as a series of root beads using a slight circulation motion in the crater sometimes accompanied by a whip. Weave beads are too fluid and will spill.

-5-

High-Deposition Welding

High deposition applications includes groove, fillet, lap and corner welds in 3/16??? and thicker plate welded with the work level or slightly downhill. These joints are capable of holding a large molten pool of weld metal as it freezes.

These welds are made with Jetweld electrodes because the high iron powder content in the coating produces high deposit rates to fill joints in the shortest time for economical welding.

Procedures

Lap welds . . . . . . . . . . . . . . . . . . . . . . . . . . . page 11 Corner Welds . . . . . . . . . . . . . . . . . . . . . . . . . page 11 Groove Welds . . . . . . . . . . . . . . . . . . . . . . . . page 12 Flat Fillet Welds . . . . . . . . . . . . . . . . . . . . . . . page 14 Horizontal Fillet Welds . . . . . . . . . . . . . . . . . . page 15

Alternate Electrodes

When desired, the following alternate electrodes can be used with similar procedures:

Jetweld Operating Techniques

Polarity and Current ??? Use AC for fast welding speeds, high deposit rates, and good arc characteristics. DC can be used but the resulting arc blow may complicate control of the molten puddle.

Optimum current for most jobs is 5-10 amps above the center of the electrodes range. Do not exceed the center of the range for x-ray quality deposits.

Use a Drag Technique ??? Tip the electrode 10 to 30?? in the direc- tion of travel and make stringer beads. Weld with the electrode end lightly dragging on the work to force the molten metal out from under the electrode tip allowing adequate penetration. The smooth welds look almost like automatic welds.

-8-

Slow travel

WRONG

Fast Travel

RIGHT

Electrode coating touches plate lightly

Travel fast, but not too fast for good slag coverage. Stay about 1/4??? to 3/8??? ahead of the molten slag. If travel speed is too slow, a small ball of molten slag may form and roll ahead of the arc causing erratic bead shape, spatter, and poor penetration.

Deep Groove Groove Welds ??? To hold the large pool of molten weld metal from Jetweld electrodes, either a weld backing plate or a root pass made with deep penetrating electrode (usually E6010 or E6011) is required. Deposit Jetweld beads with a stringer technique or a slight weave to obtain fusion to both plates. Split weave welds are better than a wide weave near the top of deep grooves. Size the second to last layer so the last layer will not exceed a 1/16??? buildup.

-9-

Fillet and Lap Welds ??? The ideal fillet or lap weld has equal legs and a flat or slightly convex bead. Excess convexity wastes weld metal. A concave bead is susceptible to shrinkage cracks.

Flat fillet and lap welds are made with the same general techniques as groove welds.

Weld single pass fillets using a drag technique with the tip of the electrode touching both plates. Usually weld with the electrode at a 45?? angle (end view) from the horizontal plate. However, adjust this angle from as little as 30?? to as much as 60?? when required to maintain equal leg sizes on both plates.

When two passes are needed, deposit the first bead mostly on the bottom plate. To weld the second pass hold the electrode at about 45?? angle fusing into the vertical plate and the first bead.

1 2

Make multiple pass horizontal fillets as shown in the sketch. Put the first bead in the corner with fairly high current even though there may be slight undercut, succeeding passes will burn it out. Deposit the second bead on the horizontal plate fusing into the first bead. Hold the electrode angle needed to deposit the filter beads as shown, putting the final bead against the vertical plate.

-10-

Groove Welds

T 1/16"?? 1/32"

Do not use for code quality work

This square edge groove joint requires the deep penetration of Fleetweld 5P or 5P+.

(1)Both passes.

(2)Total for all passes. 100% operating factor.

Groove Welds

First Pass

30??

3/16??? Jetweld 2 E6027

300 amps. AC at 14???/Min.

(1)First pass only. On later passes adjust arc speed to obtain proper bead size.

(2)Total for all passes. 100% operating factor.

(3)Plus .228 lbs. of 3/16??? E6027/ft. of weld for first pass.

-12-

Flat Fillet Welds

Also see Low Hydrogen Procedures.

(1)First pass only. On later passes adjust arc speed to obtain proper bead size.

(2)Total for all passes. 100% operating factor.

For X-ray quality:

1.Use low hydrogen procedures, pages 24-34.

(or)

2.Weld 3/16??? to 5/16??? fillets with E6027 electrodes at the E7024 procedures. Weld 3/8??? and larger fillets with 1/4??? E6027 at about 400 amps. Travel speed will be slower.

-14-

-15-

(1)First pass only. On later passes adjust arc speed to obtain proper bead size.

(2)Total for all passes. 100% operating factor.

For x-ray quality:

1.Use low hydrogen procedures, pages 24-34.

(or)

2.Weld 3/16??? to 1/2??? plate, use E6027 at slightly lower currents and arc speeds.

Welding Inclined Plate

These procedures are used when:

1.The work cannot be positioned in the level position for high speed welding with High Deposition Jetweld electrodes.

2.The weld is made partly in the level position and partly downhill.

Fleetweld 47 electrodes have a fairly high iron powder content in the coating, which provides a good deposition rate consistent with downhill welding ability.

Using a drag technique, maintain about a 5/32??? distance between the end of the electrode and the molten slag. If the distance is too great, skips occur in the weld. If the distance is too short, the slag will flow under the arc causing slag holes.

-16-

High Speed Welding (Sheet Metal)

Welding sheet steel (18 through12 gauge) requires electrodes that weld at high travel speeds with minimum skips, misses, slag entrapment, and undercut.

Procedures

Groove welds . . . . . . . . . . . . . . . . . . . . . . . . . page 20 Edge Welds . . . . . . . . . . . . . . . . . . . . . . . . . . page 20 Fillet Welds . . . . . . . . . . . . . . . . . . . . . . . . . . page 21 Lap Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . page 21 Corner Welds . . . . . . . . . . . . . . . . . . . . . . . . . page 22 Burnthrough Spot Welds . . . . . . . . . . . . . . . . page 23

Alternate Electrodes

When the recommended electrodes are not available, or if preferred, the following electrodes can be substituted using approximately the same procedures:

Welding Techniques

Generally, use the highest current possible that will not burn- through, undercut, or melt the edges of lap, corner, or edge welds. Fast welding depends upon the operators skill at staying on the joint and traveling at a uniform speed. A few days practice may be needed by good welders when first starting sheet metal welding.

For maximum welding speed, minimum distortion and flat welds generally position joints for welding 45?? to 75?? downhill.

The procedure tables assume tight fit-up and adequate clamping or tacking for fast travel speeds and minimum distortion. Use copper backing whenever possible to decrease burnthrough tendencies. When poor fit-up is encountered:

1.Reduce the current.

2.Increase the drag angle.

3.With E6010 or E6011 electrodes use a quick whip technique with a slight circular motion in the crater to bridge the gap.

4.With E6012 or E6013 electrodes, use a small quick weave technique to bridge the gap.

-18-

When welding with High Speed electrodes (E6012 and E6013) deposit the entire weld in one pass using non-weave beads or a slight weave. Drag the electrode on the joint and stay ahead of the molten pool. Use enough drag angle so the arc force pushes the weld metal back. Use currents in the high portion of the elec- trode???s range.

When welding with Out-Of-Position electrodes (E6010 and E6011), deposit the entire weld in one pass using non-weave beads or a slight weave. Hold a 1/8??? or shorter arc. Move as fast as possible while maintaining good fusion. Use currents in the middle of the electrode???s range.

Weld overhead joints using E6010 or E6011 electrodes with a whip technique and a slight circular motion in the crater. Do not weave. Point the electrode directly into the joint and slightly for- ward into the direction of travel. Use a fairly short arc and travel fast enough to avoid spilling. Use currents in the lower portion of the electrode???s range. Overhead welding of 18 gauge and thinner is not recommended.

-19-

Corner Welds

(1)45 to 75?? downhill position is recommended for easy welding and fast speeds. Corner welds on 10 gauge steel can be welded 5-7 in./min. faster when positioned 75 to 90?? downhill rather than 45 to 75?? downhill.

(2)For AC welding use:

a.E6011 in place of E6010 or E6013 in place of E6012

b.The same electrode diameters.

c.About 10% higher current.

d.The following arc speeds:

Arc Speed (inch/min)

(3) For ft. of weld/hr. multiply in./min. by 5. 100% operating factor.

-22-

Low Hydrogen Welding

Low hydrogen electrodes are recommended for three broad areas of application:

1.On low alloy, high carbon, high sulfur, or other steels where cracking is a problem.

2.When specified by governing codes.

3.For lowest costs on vertical, overhead and horizontal groove welds on heavy (over 1/2???) plate.

Procedures

Vertical Up Groove Welds . . . . . . . . . . . . . . . page 27 Overhead Groove Welds . . . . . . . . . . . . . . . . page 27 Vertical Up Fillet Welds . . . . . . . . . . . . . . . . . . page 28 Overhead Fillet Welds . . . . . . . . . . . . . . . . . . page 28 Horizontal Groove Welds . . . . . . . . . . . . . . . . pages 29-30 Flat Fillet Welds . . . . . . . . . . . . . . . . . . . . . . . pages 31-32 Horizontal Fillet Welds . . . . . . . . . . . . . . . . . . pages 33-34

Jetweld LH-3800 (E7028) Techniques

Employ the same techniques for this High-Deposition electrode as recommended for E7024 electrodes. Clean the slag from every bead on multiple pass welds to prevent slag inclusions which would appear on X-ray inspection.

EXX18 Welding Techniques

Procedures and techniques for E7018 electrodes can be used for E8018, E9018, or E11018 Lincoln electrodes.

Polarity - Whenever possible use electrode positive for 5/32??? and smaller electrodes. AC can be used at about 10% higher currents.

Use AC on 3/16??? and larger diameter electrodes to minimize arc blow for best operating characteristics. DC+ can also be used at about 10% lower currents.

-24-

Drag the electrode lightly. Since low hydrogen electrodes rely on the molten slag for shielding, never hold a long arc, whip, leave the crater, or move rapidly in any direction. Failure to follow these techniques may result in porosity and/or reduce mechani- cal properties.

For Clean Tie-Ins ??? Strike the arc ahead of the crater, move quickly back into the crater, then proceed in the direction of welding. This technique welds over the striking area, eliminating porosity or tendency for poor starting bead shape.

Multiple Pass Welds ??? Clean the slag after each bead. When welding in the downhand position, use stringer beads or small weaves rather than wide weaves to avoid slag inclusions.

Vertical Techniques

Use 5/32??? or smaller electrodes and currents in the lower portion of the electrode???s range. Techniques are as follows:

1. Use a triangular weave for heavy single pass welds.

Heavy Single Pass

Triangular weave

Multipass

Stringer bead

Straight weave

-25-

2.For multipass welds, deposit a first pass bead using a slight weave. We emphasize the importance of moving into the corner to assure penetration into the corner. Weld additional layers with a side-to-side weave hesitating at the sides long enough to melt out any small slag pockets and minimize undercut. Travel slow enough to maintain the shelf without spilling weld metal.

3.With this technique, slag spills down the weld. As long as no metal spills, operation is normal. Once welders are familiar with the EXX18 techniques, they will quickly learn to make sound welds of excellent appearance.

Horizontal Groove and Overhead Weld Techniques

Weld with a series of first pass beads using a slight circular motion in the crater. Do not whip. Use 5/32??? or smaller electrodes and currents in the lower portion of the electrode???s range.

-26-

Vertical Up Groove Welds

Also see Out-of-Position Procedures, page 4.

First Pass

3/16" Fleetweld 5P (E6010), 150 amps DC+, 4-1/2 in./min.

Last Pass - back gouge before welding.

60??

1/8"

Overhead Groove Welds

(1)First low hydrogen pass only. On later passes adjust Arc Speed to obtain proper bead size.

(2)Total for all passes. 100% operating factor.

(3)Plus .280 lbs. of 3/16??? E6010/ft. of weld for first pass.

(4)Plus .160 lbs. of 1/8??? E6010/ft. of weld for first pass.

-27-

Minimum Preheat and Interpass Temperature(1)

For stick electrode welding only

Based on AWS Specification D1.1

Definitions

T ??? Thickness of the thickest part at point of welding.

Col. 1 ??? For the following steels when welded with other than low hydrogen electrodes ASTM A36; A53 Grade B; A106 Grade B; A131 Grades A, B, CS, D, DS, E; A139 Grade B; A381 Grade Y35; A500 Grades A, B; A501; A516; A524 Grades I & II; A570 All grades; A573 Grade 65; A709 Grade 36 (??? 3/4 in. [20mm]); AP15L Grades B, X42; ABS Grades A, B, C, D, CS, DS, E.

Col. 2 ??? For the following steels: All steels listed in Column 1, and additionally: ASTM A36 (>3/4 in. [20mm]); A53 Grade B; A106 Grade B; A131 Grades A, B, CS, D, DS, E, AH32 & 36, DH 32 & 36, EH 32 & 36; A139 Grade B; A381 Grade Y35; A441; A500 Grade A, Grade B; A501; A516 Grades 55 & 60, Grades 65 & 70, A524 Grades 1 & 2; A529 Grades 50 & 55; A537 Classes I & II; A570 All Grades; A572 Grades 42, 50, 55; A573 Grade 60; A588, A595 Grades A, B, C; A606; A607 Grades 45, 50, 55; A618 Grades Ib, II, III; A633 Grades A, B, Grades C, D; A709 Grades 36 (??? 3/4 in. [20mm]), 50, 50W; A710 Grade A, Class 2 (??? 2 in. [50mm]); A808; A913 Grade 50; A992; API 5L Grade B, Grade X42; API Spec. 2H Grades 42, 50; API 2W Grades 42, 50, 50T; API 2Y Grades 42, 50, 50T; ABS Grades AH 32 & 36, DH 32 & 36, EH 32 & 36; ABS Grades A, B, D, CS, DS, Grade E

Col. 3 ??? For steels ASTM A572 Grades 60 and 65, A633 Grade E; API 5L Grade X52; ASTM A913 Grades 60, 65; A710 Grade A, Class 2 (??? 2 in. [50mm]); A710 Class 3 (??? 2 in. [50mm]); A709 Grade 70W; A852, API 2W Grade 60; API 2Y Grade 60

Col. 4 ??? All thicknesses ??? 1/8 in. [3mm]. ASTM A710 Grade A (all classes); ASTM A913 Grades 50, 60, 65. SMAW electrodes capable of depositing weld metal with a maximum diffusible hydrogen content of 8 ml/100g (H8), when tested according to AWS A4.3.

-35-

Minimum Preheat and Interpass Temperature(1) Continued

For stick electrode welding only

Based on AWS Specification D1.1

Notes

(1)Welding shall not be done when ambient temp. is lower than 0??F. Parts on which metal is being deposited shall be at or above the specified temperature for a distance equal to the thickness of the part being welded, but not less than 3???, in all directions from the point of welding. Preheat and interpass temperature must be sufficient to prevent cracking. Temperature above the minimum may be required for highly restrained welds. For ASTM A709 Grade 70W and ASTM A852 Grade 70, the maximum preheat and interpass tem- perature shall not exceed 400??F for thicknesses thru 1-1/2???, and 450??F for greater thicknesses.

(2)When the base metal temperature is below 32??F, preheat to at least 70??F and maintain this minimum temperature during welding.

Stick Electrode Typical Operating Procedures

???Out-of-Position??? Group

All-purpose stick electrodes for general purpose fabrication and maintenance weld- ing. Capable of x-ray quality welds out-of-position. Particularly good for vertical and overhead. Deep penetration with maximum admixture. Light slag and flat beads with distinctive ripples.

-36-

???High Deposition??? Group

Highest deposition rates of all electrodes. Flat, horizontal and slightly downhill (15?? maximum) position only. Easy slag removal and smooth, ripple-free beads are flat or slightly convex with minimal spatter.

(1) Range for 3/32??? is 65-120 amps AC or 60-110 amps DC??.

???High Speed??? Group

Operates in all positions, but most widely use downhill, horizontal or in the flat posi- tion. Ideal for irregular or short welds that change direction or position. Medium deposit rates and medium penetration. Appearance ranges from smooth and ripple- free to even with distinct ripples.

(1)Range for 5/64??? Fleetweld 37 is 50 - 80 amps AC or 45-75 amps DC. 1/16??? Fleetweld 37 is 20-45 amps AC or DC.

-37-

Low Hydrogen Group

For welding carbon and low alloy steels that require 70,000 psi tensile strength deposits. These low hydrogen electrodes can produce dense, x-ray quality welds with notch toughness properties. The E7018 electrodes have ???Fill-Freeze??? characteristics and the E7028 electrode has ???Fast-Fill??? characteristics.

Low Hydrogen, Low Alloy Steel Group

Made for welding low alloy steels that require specific mechanical or chemical properties of one of these electrodes. Specifically for use in cryogenics, high temperature applications, and for x-ray quality requirements. These electrodes have Low Hydrogen ???Fill-Freeze??? operating characteristics similar to Jetweld LH-70.

-38-

NOTE1: Joining Electrodes, Non-Charpy V-Notch Rated

These electrodes (see below) and others of the same AWS classification, are not required to deposit weld metal capable of delivering any minimum specified Charpy V-Notch (CVN) properties. It should not be used in applications where mini- mum specified CVN properties are required. Typical applica- tions where minimum specified CVN properties are required include, but are not restricted to, bridges, pressure vessels, and buildings in seismic zones. The user of this product is responsible for determining whether minimum CVN proper- ties are required for the specific application.

Fleetweld 7

Fleetweld 22

Fleetweld 37

Fleetweld 47

Jetweld 3

NOTE 2: Joining Electrodes, Non-Low Hydrogen

These electrodes (see below) and others of the same AWS classification, are not required to deposit weld metal that is low in diffusible hydrogen. Therefore, these electrodes should not be used in applications where the hydrogen content of the weld metal is required to be controlled, such as applications that involve steels with higher carbon and alloy content, and higher strength.

WARNING

ARC WELDING can be hazardous.

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS

INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER

WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE

OPERATING.

Read and understand the following safety highlights. For additional safety infor- mation it is strongly recommended that you purchase a copy of ???Safety in Welding & Cutting - ANSI Standard Z49.1??? from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. AFree copy of ???Arc Welding Safety??? booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE,

AND REPAIR PROCEDURES ARE PERFORMED ONLY BY

QUALIFIED INDIVIDUALS.

-39-

ELECTRIC SHOCK can kill.

1.a. The electrode and work (or ground) circuits are electrically ???hot??? when the welder is on. Do not touch these ???hot??? parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.

1.b. Insulate yourself from work and ground using dry insula- tion. Make certain the insulation is large enough to cover your

full area of physical contact with work and ground.

In addition to the normal safety precautions, if welding must be per- formed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:

???Semiautomatic DC Constant Voltage (Wire) Welder.

???DC Manual (Stick) Welder.

???AC Welder with Reduced Voltage Control.

1.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically ???hot???.

1.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.

1.e. Ground the work or metal to be welded to a good electrical (earth) ground.

1.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.

1.g. Never dip the electrode in water for cooling.

1.h. Never simultaneously touch electrically ???hot??? parts of electrode holders con- nected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.

1.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

1.j. Also see Items 4.c. and 6.

ARC RAYS can burn.

2.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.

2.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.

2.c. Protect other nearby personnel with suitable non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

-40-

FUMES AND GASES can be

dangerous.

3.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and

gases away from the breathing zone.When welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or

on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possi- ble and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circum- stances, outdoors, a respirator may be required. Additional precau- tions are also required when welding on galvanized steel.

3.b. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products.

3.c. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.

3.d. Read and understand the manufacturer???s instructions for this equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer???s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.

3.e. Also see item 7b.

WELDING SPARKS can cause

fire or explosion.

4.a..Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.

4.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to ???Safety in Welding and Cutting??? (ANSI Standard Z49.1) and the operating information for the equipment being used.

4.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.

4.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been ???cleaned.??? For information purchase ???Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances???, AWS F4.1 from the American Welding Society (see address above).

4.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

4.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.

4.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can cre- ate fire hazards or overheat lifting chains or cables until they fail.

4.h. Also see item 7c.

-41-

CYLINDER may explode if damaged.

5.a. Use only compressed gas cylinders containing the correct

shielding gas for the process used and properly operating reg-

ulators designed for the gas and pressure used. All hoses, fit-

tings, etc. should be suitable for the application and main- tained in good condition.

5.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

5.c. Cylinders should be located:

???Away from areas where they may be struck or subjected to physical damage.

???A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

5.d. Never allow the electrode, electrode holder or any other electrically ???hot??? parts to touch a cylinder.

5.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

5.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

5.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, ???Precautions for Safe Handling of Compressed Gases in Cylinders,???available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY powered

equipment.

6.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.

6.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the

manufacturer???s recommendations.

6.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer???s recommendations.

-42-

FOR ENGINE powered equipment.

7.a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

7.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

7.c.Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.

7.d. Keep all equipment safety guards, covers and devices in position and in good repair. Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other mov- ing parts when starting, operating or repairing equipment.

7.e. In some cases it may be necessary to remove safety guards to per- form required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

7.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

7.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

7.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

ELECTRIC AND MAGNETIC FIELDS

may be dangerous

8.a. Electric current flowing through any conductor caus- es localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines.

8.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

8.c. Exposure to EMF fields in welding may have other health effects which are now not known.

8d. All welders should use the following procedures in order to minimize expo- sure to EMF fields from the welding circuit:

8.d.1. Route the electrode and work cables together - Secure them with tape when possible.

8.d.2. Never coil the electrode lead around your body.

8.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.

8.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.

8.d.5. Do not work next to welding power source.

-43-