HEAVY WELD SHOP

This shop mainly deals with the fabrication of the engine block and base (B.G. & M.G.) Turbo
support. After cooler housing items. The engine block is the principal, structural member of the
diesel engine. It is composite weldment with heavy plates thickness varying from 16 mm to 75 mm
and steel forgives conforming to specification is 2062.

The spine being the most highly stressed item as we can say spine of the cylinder block is made out
of one piece bitted 5”x 7” thickness confirming to is 1895. The billet foundation plate and cylinder
walls are built around the steel forging saddles to form the air chambers which ensure the maximum
rigidity for successful fabrication of cylinder block special attention is paid to the following aspects
cylinder block special attention is paid to the following aspects.
1. Inspection standard
2. Proper materials
3. Proper electrodes and flux
4. proper welding technique
5. welfare of staff

SEQUENE OF FABRICATION OF ENGINE BLOCK

1. Set up of saddles foundation plates and spine on special fixture and weld saddles spine
founded on rails.
2. Set up welding of out side cylinder wall.
3. Set up of middle dock (Tack welded) with respect to target.
4. Remove can bearing shim from saddle face.
5. Intermediate machining operation remark in middle deck and chamber at top of spline.
6. Set up of inside wall and deck welded with spline.
7. Lay out of plane height.
8. Intermediate machining operation
Machine height of out side wall and inside wall with respect to marking and camber.
9. Set up of top deck (Both side) and lifter block (G.E. side only) for filament of eye bolt and
tack weld.
10.All in side (8x2 Beal welds) welding in done by sub are method.
11.Back gauging of saddle to foundation rail joint.
12.Lay out for bearing.
13.Set up for cam bearing with respect to pay out Si No.12.
14.Welding of the cam bearing and saddle with foundation rail bottom side (back gauge portion)
15.Set up of cam bearing rids and weld.
16.Say out for 8” machining.
17.Intermediate machining operation.
18.Flame cut counter of foundation plate to give relief clearance to free movement of counter
with respect to crank shaft.
19.Set up of the side sheets and sub arc weld of side sheets and top deck.
20.Set up of full control compartment sheet and weld.
21.Intermediate machining operation mills both and to lay out for end plates considering total
length and machining allowance.
22.Hydrostatic test of water compartment.
23.Set up of top end plates and weld.
24.Set up of top deck center and weld.
 25.Stress relieving weldment.
26.Kerosene oil test for control shaft compartment.
27.Shot plast.
28.Final debarring.
Note: Saddle out side and inside walls foundation rail are x ray joints.

ELECTRODE
Saddle, spline and foundation plates are sledded on a rotary fixture E 6020 electrodes 6.3 mm and 5
mm of M/s A Par Pvt. Ltd. Bombay and celorex of M/s Advani or Liken capable of giving X-Ray
quality joints are being used for the welding.
The coating is such that a stage containing iron oxide, manganese oxide and silicon is usually
produced other constituents containing the oxides of aluminum manganese of sodium are prevent
to modify the slag ferromanganese in the main de-oxygen and sodium silicate is used as the
binder. In most cases core wire is of remounted steel.

CARE OF ELECTRODE
Saddle spline rotary fixture E-6020 electrodes 6.3 mm and 5 mm.
Arc welding electrodes require special care in handling and storage to
That the flux coating may retain its original strength of bonding over
Long periods and give satisfactory welds on use so there electrodes are Kept in a store maintains its
room temperature at least 10 to 20 c
Higher then the out side temperature. When the storage atmosphere
In humid the moister gets deposited in the minute pores of the flux
Coating.
Stocking electrodes certain directly on the floor should be Avoided as also putting too many
of them once above the other because the electrodes at the bottom may get crushed. Due to the
weight above. It is good practice to stock. Electrodes shelves separately according to their sires types
and batches.

FLUX: - In D.L.W. auto melt gr I flux of advance linken (P) LTD. Bombay
In used. The flux in a mixture of power of deter mined practical size and each particle in
chemically basic in character these particles are not fused. the flux in heated period to use in
on over at 250 c for O2 hours as moisture flux generated the hydrogen in the arc and cause
cold cracks in the weld deposit and in the heat effected zero.

WIRE:-Wire used in the sub are welding is the auto melt gr. A cold copper
Coated size 5m.m. with low carbon content confirming to IS 2879
Manufactured by M/S Advani lincon P. ltd. Bombay. The chemical composition of the wire in
carbon 0.08% m.m. 0.46% P.0.018% S0.022%.

STRESS RELIVE OF CYLINDER BLOCK.

After completion of welding the cylinder block in then stress relieved at the temp. Ranging
from 115 F obtating total timing 28 Hrs ie.
(1) Pre heat time 14 Hours.
(2) Soaking time 04 Hrs and
 (3) Cooling time 10 Hrs in stress relative’s furnace capable to accommodate to B.G. block
at a time. As the engine block in machined to very close tolerances. It is necessary that
all stresses developed during the fabrication stages are completely relieved before
machining. This would ensure a longer life in service without any distortion which
would normally result on account of very alternating stresses that the engine block is
subjected to during its service.

KEROSINE OIL TEST-

Check that there should not be any leakage at the bottom side of the fuel control compartment
welding joint after powering kerosene oil. The engine block is then shat blasted at pneumatic
compressed air a pressure of 75ibs/sgu.inch.

DEBURING-
It is to be ensured that the completes (welding) weldment is free of any spatter welding
defects and sharp corrosion of important welded joint have been ground then the cylinder block is
marked and handed over for machining operation to H.M.S.

DESINING RECOMBINATION FOR CAMBEARING SUPPORT

Earlier design of cam bearing support welded with cylinder side waits then welded with the
ribs (3/4”Th welded grc) due to heavy vibration and less welding area development of cracks wire
observed in the com bearing supports. (Mainly upper portion)
To over come the problem of cracks and strengthen new design of cam bearing are welded all
round with the ribs and then ribs are wide with the side cylinder wall.
Hydrostatic test
Water compartment are fully filled with water and after air light covering are pressure of 75
lbs/squ inch minimum is maintained for about half on hours. It there is any leakage in welds
arranged welded and water listed.
Heavy weld shop
1. Heavy weld shop ha three important sections.
2. Flame cutting, grinding and straightening section.
3. Cylinder blocks fabrication section.
4. Main base, turbo support and miscellaneous section.
Flame cutting, grinding and straightening section
All the flame cutting items required for the B.G. & M.G. engine for block, base & turbo
support are cut in the section by flame cutting machine. For all cutting of different types of items.
The different types of plates are use as per their specification and thickness. Following important
items are cut here.
Spline, top deck, middle deck side sheet, main base and plates top rail cross web, back, plate,
centers block flanges levers etc.
In grinding section above items are deslaged and ground by pneumatic. Grinder.
In straighten section important items of cyl-block main base and turbo support are
straightened.
Cylinder block fabrication section
The following components for B.G. Cylinder block assly are required.
1. End seal
2. Side plate L.S & R.S.
 3. Angle L.S. & R.S.
4. Foundation plate L.S. & R.S.
5. Saddle machined inters main bearing I no.
6. Saddle machined gen end I no.
7. Saddle machined centre main bearing I no
8. Spline I no
9. Cyl side wall out side L.S. & R.S.
10.Cyl side wall in side G.S. & R.S.
11.Middle deck L.S. & R.S.
12.Cam bearing (inter, gen and & frill end ) 18 nos
13.Cam ribs 18 nos
14.Top deck L.S. & R.S. and top deck centre
15.Weld strip (gen-end) R.S. & L.S.
16.Plate ( water compt drive)
17.Frill end plate.
18.Self cont. compt L.S. & R.S.
19.End plate ( gen end)
20.Cover (cont compartment )
21.Diaphragm
22.Lifter block ( gen end)

Sequence of Fabrication Assembly:

Setting of saddles on the fixtures as per drawing with the foundation plat L.S. & R.S. and one
spine on the top of the saddle. Tacked and welded all these with each other burn run of the saddle
with spline, clean and grind the opening of the spline, then set and face the out side and inside walls
L.S. & R.S. both sides of the saddle burn run off and clean grind of the wall opening
After that setting up the middle deck weld from bed bottom side of deck and lifter block weld
16 beets all welding as quality. Saddle to foundation plate, saddle to spline and saddle to out side
wall welding is check as joints.

Arc wilding done machine on the cylinder block where the welding by machine is called
submerged are welding. Copper coated mild steel class II were with flux is used.
After x-ray welding test, the assembly is sent for lay our of cam bearings in marking section. The
cambering are set up tack and weld with the cam ribs and water compartment plates. After that again
x-ray text of bottom plates is done. Then burn opening and Skelton grinding operation is done. Then
send this block assembly in the machine section for 8 machining of side sheet. Set and weld the side
sheets on the 8 machining. Weld fuel self compartment on the positioned welding machine. Weld
side sheet foundation rails. Side sheet to cam ribs. Out side wall of full self compartment. After that
the block assembly is again sent to M/C section. For end milling to maintain the length of the block
as per marking and size. Then hydraulic water test is done at 75 P.S.I.

At last set up the end plates (gen and free end) both side of the block assembly, tack and then
setup the top deck centre in the centre of the block and weld it by sub are welding M/C
After complete fabrication the block is sent to H.T.S. sec. for stress reliving to 700 c then shot
blasting the block and sent the machine section for final machining.
Main base fabrication
The following components are required for the assly of main base.
1. Side sheet L.S. and R.H.
2. Pipe assembly with plates
3. Engine mount free end and gen end CH/RH
4. Rib (engine mount free end & gen.end)
5. Top rail
6. Bottom. Plate (Gen end, free end & centre)
7. Plug L.O. drain.
8. Cross web G.A. 1,2,3,4,5,6,7,8, & 9
9. Cross web auxiliary assembly
10.End plate free end & gen end.
11.Oil drain compartment.
12.Pad
13.Brass engine mount free end.
14.Brass engine mount gen end.
15.L.O. suction pipe (sub. Assembly)

Sequence of Fabrication:-
Setting top rails on the fixture and mach the centre of the fixture. Set the side sheet R.S. &
L.S. with the cross webs to maintaining the width of 31 ¾ of main base, tack and weld with cross
webs. After that bottom plates gen end and free end are set up. Tacked and weld on its proper place.
Then set and tack and weld the end plates gen end & free end with lo suction pipe. at post L.O. drain
plug is set up and dip strike on it proper place. Engine mount free end and generator end CH/RH, T,
welding is to be completed.
After fabrication, the main base is sent to H.T.S. for stress reliving at 700 c temperature and cooled
in furnace. Then shot and de burn. Then sent to machine section for complete machining.

TURBO SUPPORT FABRICATION:-

It is the support for turbo which is mounted on cylinder block on free end side. Following
components are required for it.
1- Flange bottom 2
2- Back plate 1
3- Side plate l.s 1
4- Side plate R.H 1
5- Flange oil catcher 1
6- Top plate air chamber 1
7- Front wall air chamber 1
8- Bottom Plate 1
9- Centre Plate 1
10- Back wall pt. 1
11- Side plate R.S 1
12- Partition plate 1
13- Patch plate 2
14- Gasket 4
 15- Pipe segment 1
16-Cover 1
17-Ribs 1
18-Flange 1
19-Side pipes 2
20-Side plate air chamber 1

PROCEDURE OF FABRECATION
1. Dressing and setting of flange bottom and back plate on support. Welding of the flange from
the centre of fixture.
2. Setting and tacking of back plate, buck wall and portion plate.
3. Tacking of right side plate on back plate.
4. Welding of 2” I.P.S extra heavy coupling on left side and its setting and tacking on back plate.
5. Grinding ,dressing , setting & tacking of centre on side plate R.S.&L.S
6. Setting & tacking of flange oil catcher.
7. Marking and gas cutting of 4 ¼ “dia hole in bottom plate and welding of ring on the hole of
the plate.
8. Setting and tacking of above bottom P.t. on top plate on fixture.
9. Setting and tacking of side R.S
10.Dressing of back wall and its setting and tacking.
11.Setting and tacking of front and bottom plate & front wall.
12.Setting and tacking of pipe segment cover.
13.Inspection hole cutting in front wall.
14.Setting and welding of flange and side piece.
WELDING PROCESS
(1) Out side bottom plate, top plate, centre plate to side plate both sides an rest welding is
down from bottom is top in sequence numbest for inside welding bottom pt, top plate
and rest, from bantam is tip is done.
(2) In this operation the support is clamped on positioned with top plate and all the rest
wadding is completed. After these gauging
Is done on flange oil catcher. Then later welding is done and base is welding.