MODEL N_ °

113.201372 _

Serial
Number

Model and serial

number may be found
at the rear
of the cabinet.

You should record both

model and serial number
in a safe place for
future use,

230 AMP
DUAL RANGE
CAUTION:
ARC WELDER
Read
SAFETY ® assembly
UNSTRUCTIONS
carefully
e operating
® repair parts

Sold by SEARS, ROEBUCK AND CO., Chicago, IL 60684 U.S.A.

Part No. 61337 Printed in U S A
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 SAFETY gNSTRUCTIONS TO OPERATOR

For your own protection, read and observe all instructions hydrocarbon vapors coming from degreasing,
included in this manual as well as the following specific cleaning, or spraying operations The heat of the rays
safety precautions: of the arc can react with solvent vapors to form
phosgene, a highly toxic gas, and other irritating
1, PROTECTION FROM ELECTRICAL SHOCK
products
a_ Do not let bare skin or wet clothing come between
h Unprotected spectators must be kept clear of the
the following combinations:
welding area due to the harmful nature of ultra÷violet
Electrode and infra-red arc rays, welding sparks, and welding
fumes and gases

3. FLAMMABLE AND EXPLOSIVE MATERIALS

Work Clamp Work Piece Metal Work 'Table a Remove flammable and explosive material at least 35
feet from the welding arc to prevent welding sparks
80 volts exist between these parts or molten metal from starting a fire Keep a type
when welder is onH!
ABC fire extinguisher within easy reach.
Wear dry hole-free, clothing,_ gloves and shoes to
protect and insulate the body. b, Welding on or near containers which hold combustibles
can cause ar_ explosion, even when they have been
b. Take special care to insulate" yourself from ground cleaned= For information purchase "Safe Practices for
using dry insulation (suchas dry wood) of-ad.equate Welding one Cutting Containers that Have Hel d
size when welding] in dam'p locations on metal floors Combustibles" (A6.0-65_ from the American Welding
or grat ngs, and m poslt_ons (such as s=ttmg or lying ! " :.Society 2501 Northwest Seventh St Miami, Florida
where parts-or"large"areas of your body can be ir
contact with phssible ground_. ; ".;_ r o "_
c. When not welding, place the electrode holder where it
C. Maintain the_.#l_ctr_de h_tder work clamp, w_ldin'g "" i_ ihs'61ated from the work clamp, work piece, or'
cable and welding_:rnach_ne'._n _Qd, safe operating._ wc_rk 'table_._ Ac_'idental grounding can cause
condition, : _ _; " " ,:' -' • " ,_ overheating of the_ables'and_welder, creating a fire
haz_rd_ _ ::_" _ "
Do not use weldm_ electrode as-a claarette hg_ter, . -
e. Connect the welder only to a source of electncal'.- iild Never-c_nnect the_work cablelor clamp to any obJect
power meeting the requirements, irrcluding b_ _'he 'worl<:p e_e o_ me.to _ork tab e Conr]ecting
grounding, of the National Electrical Code (ANSI Cl) to other objects such as bu_l_mg ground can create a
and local codes. fire hazard.

f. Electrode coating may be electrically conductive-

4. PREVENTATIVE MAINTENANCE
use welding gloves when changing electrodes.
a. Never apply power to the welder with any part of the
2. EYE AND BODY PROTECTION "cabinet" removed_ Position on-off switch in "Off"
a. Use helmet, filter, and cover plate complying with position and disconnect welder from the power
ANSI Z87 1 to protect your eyes and face from supply before doing maintenance work inside the
sparks and the rays of the arc when welding or machine. Removal of the welder cabinet should be
observing open arc welding, done only by a qualified service technician,
b Always wear safety goggles with side shields b. Before connecting the welder power cord to the
complying with ANSI Z871 when in a welding area,
receptacle, check the following:
or when near slag chipping operation
1 Inspect the power cord and welding cables for cuts
c. Wear oil free protective garments, such as leather or burns and make sure blades and ground pin on
gloves, heavy shirt, cuffless trousers and high shoes. the plug are straighL
d Protect other near-by personnel with suitable 2 Inspect "On-Off" switch lever for cracks or broken
non-flammable screening_ parts.
e Welding can produce fumes and gases which are 3 Inspect electrode holder jaw insulators for cracks
dangerous to health, Keep your head out of the or broken parts.
fumes, Use enough ventilation, exhaust at the arc, or
both, to keep fumes and gases from your breathing c. Never weld anything on or to the welder cabinet, as a
zone and the general area, Take even greater care burn through may cause transformer failure.
when welding on galvanized or cadmium plated steel
and other metals which produce toxic fumes d_ For additional safety information, purchase copies of
Ab-supplied helmets may be necessary "Practice for Occupational and Educational Eye and
Face Protection" (ANSI Z87.1), "Safety in Welding
f When working above floor level, protect yourself
and Cutting" (ANSI Z49.1), and "Fire Protection in
from a fall should you get a shock Never wrap the
Use of Welding and Cutting Processes" (ANSI/NFPA
electrode cable around arty part of your body
No. 518) from the American National Standards
g Do not weld in locations close to chlorinated institute, 1430 Sroadway, New York, N.Y 10018_

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 READANDOBSERVE
THEINSTRUCTIONS
APPEARING
ONTHEWARNINGLABELSFOUNDONTHEINSIDE
OF
THEWELDING
HELMET,
ANDONTHESELECTOR
PLATE,CABINET
ANDELECTRODE
HOLDER.
_MERIEAN N,_ 71ON,_L ST,INI,),_RDS hV_TITUTE
PttEC,_UTION_RY I Af]EL
WARNING - FOR YOUR SAFET'_
WARNII_G: prolel:I VotJt_ell _t_d {_thefs _e;l(I ;_f_{I
R_GAR_ING B0 VOLT POTENTIAL
unders14_mt lh_ I_bel CllRI0_ SHOC;{ AT ELECT}IOD_
F UJ%_ES AND GASES c;lll he (i,ln{J_ f al_s tn ymJl he_hh USe _lJ 101 IE,_ _n0 _y_ pi01egi0n
ARC RAYS call inlllle eyel and hum stroll ELECTRIC a_ins$ =nj_io_ rays Itom _c _ding
SHOCK cml kill _nd culling US_ propel shade li!I_
• Be,_d and understand _l_e incm_Hanh_fef _ =nslnJ_io_t_ plale _P¢_.I {ssi_IO _12 plo[_ction
and yo_Jt amployef's _alely pr acllce_ (Iil_ pble b_ck_up plale• s_p_lale
• Keep your head aut of _1_ h_nles salely spectacles) shou+d be worn
wheII U_l_ 0 this device It_cl fe- REGARDING POTENTIAL SHOCK ON CABINET
• U_a enmJ_h Vel_il_iOl_, _xha_Jst al Ihe ;_,c, ot boUI
sislanl plal_ ale DOT un_le.lkable
lo kee I) _ume_ and _ase_ from 7o_f I_re;_lhi_ I z_)m_ COW,FORMING TO 1H_ _ATIONAL _L_CTnlCAL COD_
and the {Jene[al area elted ¢_ s_la_h_d _Je_ t_u_ VISI_I
al_{_ 5_liO_$1 le_uc8 pI01eGIJ0r_--
• Wear cot _ecl eye, _ar _nd body ltlo_ectlon REGAROING £yE INJURY
{epia_eintricately
• Do I_O_ _ouch llve elec_ rical I)aFt_
Inspecl {(equ_Ily an_ immedi31_ly
• See American National Si,_nIt,_f(I Z49.1 S_lety in
I_p_u_ _om ot d_m_ged p_tls
Wl!h_hlg mid Cliilin=j ¸' i)_JIilillle(I I}7 lhe Ait/eficalt t,it4_ ir_ t¢=¢.¢_ =f JJ.I.L zr/1
Wohthlg Sociel¥ 2501 N W 71h SI,, _,tbm_ Florida DO NOT REMOVE "fills [/_3,E L REGARDING FIRE
33125; OSIIA Saf_W _1_{I He_hh SI,_ndatds 29 CFR
1910, availal)_J_ hont U S Dep_tmenl o_ Labor
Washinglon , DC 20210
DO NOT R E_,_OV E THIS LABEL LI_ O_AW _*nC eT_muY't

LENS
WARNING ELeCTR,C SHOCK CAN BE FATALt BEFORE
SHADENO
TURNING WELDER ON CHECK THE ELECTRODE HOLDER TO
BE SURE THAT THERE ARE NO PROTRUDING SCREW HEADS
AND THAT ALL INSULATION IS SECURE _ _ll!! 2

FULL ONE YEAR WARRANTY ON CRAFTSMAN ELECTRIC WELDER

If this Craftsman Electric Welder fails to perform properly, due to a defect in material or workmanship,
within one year from the date of purchase, Sears will repair it free of charge,
WARRANTY SERVICE IS AVAILABLE BY SIMPLY RETURNING THE WELDER TO THE NEAREST
SEARS STORE OR SERVICE CENTER THROUGHOUT THE UNITED STATES.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to
state,
SEARS, ROEBUCK AND CO. Sears Tower_ BSC 41-3, Chicago, IL 60684

LOCKING KNOB
MATERIAL THICKNESS GAUGE.

'IAMETER GAUGE

ON-OFF SWITCH.-.

GETTING TO DUTLETJACKS

KNOW YOUR
ARC WELDER
HELMET

AND
ELECTRODE HOLDER

WORK CABLE AND WORK CLAMP

TABLE OF CONTENTS
OPERATING INSTRUCTIONS Operating Controls ................................ 6
Safety I nstructions to Operator .............................. 2 Operating Instructions ........................... 7
Warranty ............................................ 3 Trouble Shooting ............................... 8
Getting to Know Your Welder ............................. 3 ARC WELD IT YOURSELF MANUAL .............. 1-1
Unpacking and Checking Contents .......................... 3 WELDING ROD SPECIFICATIONS ............... 2-1
Assembly ................................... 4 REPAIR PARTS ..................................... 2-6

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 SPECIFICATIONS
Input Volts (AC): ........... 230 Fuse or Circuit Max Open Circuit
Hertz (Cycles): ................ 60 Breaker Required: ......... 50 Amps Output Volts .......... 80
Output Amperage: ........ 30 to 140 Arc Voltage: ............... 25 Power Factor ........... 66%
40 to 230 KVA: .................... 108 Duty Cycle: ........ 20 to 100%
Rated Input Amps: ............... 50 KW: ........................... 7 1 Electrode Capacity: 1/16" to 3/16"
Short Circuit Input Amps: ......... 66

UNPACKING AND CHECKUNG CONTENTS

SET-UP INSTRUCTIONS
received by the purchaser Remove all items from the
This Craftsman welder is shipped complete in one carton carton and identify item as shown in the exploded view
In order to facilitate packaging, certain items have been illustration These "Loose Parts" should be accounted for
removed at the factory and must be assembled when before discarding any packaging material.
LOOSE PARTS LIST

Key
No. Part Name O.ty.
i
1 WeldingHelmet (Partially assembled) .......... t
2 Helmet band assembly (Not Assembled) ........ 1
3 Electrodecable assembly ......................... 1
4 LooseParts Bag- Containing the following items: I
Electrode Holder ..................................... 1
Work Clamp ........................................... 1
Screw, Hex.-Hd., 1/4-20 x 3/4 in............... 1
Nut, Hex., 1/4-20 ........................... 1
Washer,Flat 17/64 in............................... 1
Loci{washer,1/4 in 1
3 4

ASSEMBLY
TOOLS NEEDED

,,lOinch
wrenchScrewdriver
(medium)
ATTACHING ELECTRODE HOLDER ............. ....
TO ELECTRODE CABLE
I. Grasp the electrode holder and locate the slotted head,
handle locking screw near the mid-point of the insulating
handle Loosen this screw approximately two turns, or
until the handle can be slipped off the electrode bolder..
2 Do not remove this screw completely. Slide tile handle
off electrode holder and insert end of electrode cable
assembly through the handle.
The electrode cable is the one with insulation stripped
from one end

3 Using a screwdriver, back out the slotted-head set screw,

located near the end of electrode holder until the end of
screw does not protrude into the wire socket in the end
of holder
4. Make sure the wire strands on stripped end of electrode
cable have not been "frayed" Twist together with
fingers if necessary.
5 Insert stripped end of electrode cable into electrode
holder and tighten the slotted-head set screw very
firmly

4
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 _i_i ii _' _ i

6 Slide the handle back into place on electrode holder and

position it until the hole in handle is directly over the
head of handle locking screw Tighten the screw
clockwise @ just enough to secure the Inandle on
electrode holder

ATTACHING THE WORK CLAMP

TO THE WORK CABLE SCREW

1. Attach the terminal on end of work cable to the work

clamp, at the hole near the nose of the clamp with the
1/4-20 x 3/4-inch screw, 1/4-20 nut, 17/64-inch flat
washer and I/4-inch Iockwasher furnished in the loose LOCKWASHNUTE_ HWORKCABLE
parts bag
2_ Do not use either of the holes in handle ends of work
clamp

3_ Tighten the screw firmly enough to insure good contact

and prevent the cable terminal from slipping on the
clamp

CONNECTING WELDER TO POWER SOURCE

CAUTION: Do not attempt to connect this welder to a RECEPTACLE
regular household outlet. Make sure the power-line voltage k GREENWIRE_. Connect to ground bussin
and frequency agree with the ratings shown on the selector
plate attached to front of eabinet.
Electrical connections between the welder and grounded
230-volt, single-phase, 60-cycle a-c power source should be Connect to hot wires o[ Q
powerponet
made by a qualified electrician. All wiring must comply single phase system only
with the National Electrical Code (ANSI C1) and local
codes FUSES OR CIRCUIT BREAKERS
1. Install an individual (separate) line for the welder with
delayed action type circuit breaker or fuses in the line Electrical Code (ANSI C1) and may not be adequate for
For best results, this circuit should be as short as other loads Consult a qualified electrician before using for
possible The size of the supply conductors will depend other loads
upon their length as shown in the table below
2 Install 50 ampere circuit breakers or fuses
Supply Conductor (Incl. Extension Cords)
3 Connect 230wolt power lines and ground as shown in
Up to 30 feet ............................ No_ 10 AWG Copper
30 to 50 feet ............................. No 8 AWG Copper figure
Over 50 feet ................................... No 6 AWG Copper 4 Use Sears Cat #20691 Power Receptacle available
NOTE - These conductor sizes are for use with a welder through most Sears Retail or Catalog outlets or any
having a rated input not more than 60 amps at 20% duty certified 50 amp, 250 volt, 2 pole, 3 wire, grounding
cycle in accordance with Article 630 of the National type receptacle.

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 OPERATnNG CONTROLS
_TAL TABLE AT THE SAME TIM

REGARDING POTENTIAL SHOCK ON CABINET

The name "dual range" arc welder is derived from the fact
1 CONNECT ONLY TO A GROUNDING POWER SOURCE
that your new arc welder is equipped with two separate CONFORMING TO THE NATIONAL ELECTRICAL CODE
welding ranges, (A N S I C1) AND LOCAL CODES
The beginner or less-experienced welder will find the REGARDING EYE INJURY
30-140 amp range easier to use because it provides extra arc 1 WEAR WELDING HELMET WITH NO 12 OR DARKER FIL-
TER LENS MEETING REQUIREMENTS OF A NSI. Z87,1.
stability when welding with some of the "more difficult to 2 WEAR GOGGLES OR FACE SHIELD WHILE CHIPPING OR
weld with specialty rods" which are prone to pop-outs BRUSHING SLAG.
3 KEEP OTHER PERSONS AND PETS OUT OF WORK AREA
The 40-230 amp range requires less line (input current)
draw for any given amp setting and permits the use of the REGARDING FIRE
maximum amp settings with minimum effect on other' KEEP COMBUSTIBLES OUT OF RANGE OF WELDING SPARKS
electrical appliances, motors, and lights, on your electrical
uSE FOR MINIMUM UsE FOR MAXIMUM
system, LINE DRAW ARC STABILITY
Either range may be used, depending on operator
preferences when the electrode diameter permits

AMP AMP Z
RANGE/

CONNECTING ELECTRODE
AND WORK CABLES
insert the tapered plug on the end of the electrode cable
into the proper outlet jack depending on amperage required
or operator preference.
To insure a good electrical connection always twist the
electrode plug slightly while inserting_ To remove the plug
twist in the opposite direction while removing
NOTE: If you extend the welding cables beyond those
already supplied, they must be No= 4 AWG or larger to
avoid an undue drop in welding current Do not extend
cables over 50 feet,

Connect the work clamp to the piece to be welded, (to

complete the electrical circuit) or to the welding table itself
provided it is metallic or will conduct electricity!

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 OPERATING RNSTRUCTIONS

We feel that welding with your new Craftsman dual range

arc welder is as simple as A B C
A Determine what diameter electrode should be used by
gauging the piece to be welded on the material thickness
gauge The fractional number directly beneath the bar
chart dictates what the proper electrode diameter is for
given thicknesses of metals You will note that a specific
diameter of electrodes can be used on varying
thicknesses of material. This is accomplished by
adjusting the heat selector for more or less amperage•

B Next verify the electrode diameter, by placing the bare

portion of the electrode into the electrode diameter
gauge on the right side of the cabinet
Because electrodes are mass produced, there may be
small burrs on the bare ends of the electrode Make sure
the bare end of the rod is as clean as possible for
accurate sizing,

C, Finally, determine the type of electrode by the

identification on the package or by the American
Welding Society number stencilled on the coated portion
of the electrode, bearing in mind the type of electrode
you have chosen - E6013 or E7014, and also its'
diameter (as previously determined)_
Locate that band on the amp scale There are two E6013
bands and two E7014 bands, use the band which
coordinates with the amp range you have selected•

Now loosen the heat selector knob and move the pointer
until the fractional number matching your electrode
diameter appears in the pointer window
Tighten the heat selector knob
Insert the electrode cable into the proper jack
(depending on the range selected), Connect the work
clamp to the work.
Wear Welding Helmet,
Turn the On-Off switch to the "ON" position and you
are ready to weld
Because metals vary in their make up and the technique
of each operator is different, you may find it necessary
to increase or decrease the amperage output accordingly,
CAUTION: Do not loosen and move heat selector while
welding
The duty cycle ratings bracketing the amperage scales are minutes out of 10 minutes is a 60% duty cycle To avoid
provided for your convenience and protection of your new possible overheating of the welding transformer, which
welder_ Duty cycle is the performance level of the welder could shorten the life of your welder, Do Not exceed the
based on a 10 minute time span. For example welding for 6 duty cycles listed on the nameplate

7
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 TROUBLE SHOOTING

WARNING: Removal of the welder cabinet top for any reason must be done by
a qualified service technician.

TROUBLE SHOOTING CHART

TROUBLE PROBABLE CAUSE SUGGESTED REMEDY

Fan and welder do not 1. Improperly fused or 1. Use 50 ampere fuses of the delayed
operate, or continually protected_ action type such as "'Fusetron" or
blow fuses. "Fustat" or 50 ampere 240 volt
circuit breaker.

2 Blown fuse, or open 2 Replace fuse, or reset the circuit

circuit breaker_ breaker.

3_ "On-Off" switch not "On". 3 Turn switch "On".

Welding current low 1. Low line voltage, 1_ Have a voltage check performed by
or weak, the local power company_
2_ Welding current 2. Check current recommended for
setting too Iow_ the electrode being used.
3, Poor connections. 3, Check electrode holder, work and
electrode cable connections

Can't hold an arc. 1 Using a D.C. welding 1_ Use AC or AC-DC rods

rod.

2. Low hydrogen rod 2, Use rod of 1/8-inch maximum

dian'leter, or' smaller on 30-140
amp range.

SERVICE TIPS

FAN MOTOR
No provision has been made for lubricating the fan motor,
as extra large oil reservoirs provide lubrication for the life
of the motor.

SELECTOR PLUGS OR CONTACTS

WARNING: Be positive you have disconnected the power

supply to the welder_
If for any reason the selector plugs or mating contacts
become burned or pitted, tiley should be cleaned-up with a
fine grade of emery cloth or dressed very lightly with a fine
file,

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 f

A COMPREHENSIVE
GUIDE FOR YOUR
NEW CRAFTSMAN
ARC WELDER AND
WHAT iT W_LL DO
CONTAINS:
INFORMATION ABOUT
o VARIOUS TYPES OF RODS
o USEFUL ACCESSORIES
TIPS ON CUTTING, WELDING
AND BRAZING
,,,J

Form No SP574-4 1-]

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 IJELD gT Y©U SELF

TABLE OF CONTENTS

Page

Your WelderandWhat It Will Oo ............. 1-3

How the CraftsmanContactRodSimplifiesWelding 1-3
What HappensWhenYou Weld? .............. 1-3
ReadBeforaWelding ....................... 14
LearnBy Doing .......................... 1-5
PositionWelding ......................... 1-11
Cast-IronWelding ........................ 1-14
HardSurfacingWornCutting Edges .......... 1-15
TheTwin CarbonArc Torch ............... 1-16
CuttingandOther Miscellaneous Operations ..o 1-17
Inert-GasMetal-ArcWelding ................ 1-19

Read this Manual carefully for additional welding information.

SEARS, ROEBUCK AND COMPANY

AND SIMPSONS-SEARS LIMITED

1o2

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 YOUR WELDER and what it will do = °.
Your CRAFTSMAN Arc Welderis a sturdilyconstructedend thoroughlytestedmachineengineeredto
give many years of efficient trouble-free service. It is listed by Underwriters' Laboratories,
incorporated,which meansthat it passesall requirementsof safety,fire hazardand temperaturerise
limits asspecifiedin theirStandard for Transfer-TypeArc-WeldingEquipment,

HOW THE CRAFTSMAN ELECTRODE

SIMPLIFIES WELDING

Craftsman Contact Electrode is self-starting-plus automatic

restarting , The electrode startson contacL
Craftsman Contact Electrode is serf-cleaning..... Under normal
conditionsthe slagremovesitselfasthe weld cools, Spatter is almost
nen-existenL Craftsman Contact Electrode has an exceptionally
good appearance _ With fine ripple, unusually clean, smooth
appearance,andreduced slaginclusions
Craftsman Contact Electrode depositsmore metal faster . Because
the powdered iron in the flux goesinto tile weld_

Arc Welding is the process of fusing two or more pieces of

metal together to form one piece. It is accomplished by
heating adjacent metal surfaces to the melting point with an
electric arc, then adding a sufficient amount of molten
metal to provide reinforcement and fill any vacant space
between the parts being joined, as shown in the accompany-
ing illustrations

The arc is created when an electric current, regulated by

a welding transformer, flows across an air gap between an
electrode and the work being welded, The intense heat
generated by the arc is ideally suited for welding, as it
can be directed to affect only the part of the metal to be
welded, Uniform heat from the arc, is acquired by keeping
its length the same for a given rod size and current setting,

At the instant an arc is "struck", a portion of the base

metal directly beneath it, is melted, resulting in a small
pool of molten metal, some of which is forced out by the
blast of the arc and deposited along the weld path, The
depth of the crater thus formed, is the distance the weld
will extend into the base metal and is referred to as the
penetration of the weld

Some of the electrode (which consists of o metal rod sur-

1 Beth edges of the metal 2 they melt and flow to rounded by a flux coating) is melted simultaneously with
are heated by the arc, gether forming one piece,
until -- instantly -- the base metal and is carried by the arc to the liquid pool
This added metal combines with the base metal to form
the deposited weld,

During th_s operation a part of the flux coating burns off

and forms a gaseous smoke screen that completely en-
velops the arc, protecting the molten metal from harmful
effects of oxygen and nitrogen in the surrounding atmos-
phere, The remainder of the flux coating that melts is
carried to the molten pool where it mixes with the metal
3 mere molten metal and 4 fills the crater andcovers to combine with various impurities It then floats to the
flux is added from the the top of the weld with
rod, which- slag, surfaces to form a coating of slag which covers the de-
posited weld metal, protecting it from the atmosphere and
5 This process continues the entire length of the weld
retarding its cooilng

I-3

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 READ 5EFORE WELDI NG

When operating a welder, certain precautions must

be taken to prevent minor injuries to yourself and
others, Although injuries may not be serious or per-
manent, knowing how to use the protective equip-
ment to safeguard against them is the first step in
learning to weld_

The effects of heat and light given off by the arc, while sparks than ordinary clothing. High top shoes (not oxfords)
electric welding, may be compared to that of the sun's rays_ should be worn. If a great deal of welding is to be done,
Even greater precautions are necessary for electric arc foundrymen's shoes are best.
welding. Before starting a weld, caution anyone in the
Precautions must also be taken to protect property and
immediate vicinity against looking at the arc_ in case of
equipment against flre_ A large fire extinguisher should be
occidental eye injury, contact a physician immediately.
within easy reach. The welding area should have a concrete
or cinder floor, kept dry and clear of inflammable rubbish.
To protect the face and eyes a heat-resisting, fibreglass Sometimes, it is necessary to weld close to a fuel tank. If
helmet is used. The special tens, which allows the user practical, remove the part to be welded. If not, drain the
to view the arc safely, is inserted into the framed opening
tank and completely fill it with water.
of the helmet The clear glass, which should be replaced
from time to time, protects the expensive special lens Few tools, in addition to those supplied with the welding
from breakage and weld spatter. The helmet is held firmly machine, are needed and most of them can be found in
in place on the head with an adjustable head band, thereby the average shop Two sawhorses supporting a 1/4-inch
leaving both hands free° A close-flttlng skull cap should steel plate makes an excellent welding table A permanent
be worn with the helmet° As the helmet is used only when bench, using the same steel plate, can be made of angle
actually welding, a tilting arrangement permits it to be iron or pipe. A chipping hammer is used to clean slag off
swung up clear of the face. When the welding is resumed a weld and pliers will be useful for handling hot metak A
a slight nod of the head tips the helmet down over the face. wire brush is used to clean the work before welding and
To protect the eyes further while cleaning the weld, goggles remove small pieces of slag after chipping_
should be worn by the welder and others working around Small pieces of mild-steel scrap iron, reasonably free of
him_ Animals are also affected by the rays and should be
rust and paint, should be used for practice welding_ Angle
kept at a safe distance_ iron, bar stock or plate steel are good examples. Do not
use scrap cast iron, high carbon or hardened steel as these
To safeguard the hands against heat and weld spatter, metals require special electrodes and welding techniques.
gauntlet-type leather gloves should be worn. A leather These should be set aside for future practice after com-
jacket will give better protection against the shower of pleting elementary practice lessons°

1-4

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 LEARN BY DOBNG

I
90
OFWELG
OIRECTiON

Experience has proven that short periods of practice at first attempting to weld. insert a small, mild-steel welding
regular intervals are the best way to teach yourself how electrode in the electrode holder and connect the welding
to weld. As learning to weld is simply a process of trial cables to produce the heat specified by the CONTROL
and error, all practice work should be done on scrap metal panel Connect the ground cable to the work and set the
that can be discarded. Do not attempt to make repairs on indicator in the current range recommended for the
valuable equipment until you have satisfied yourself that diameter of rod used.
your practice welds are of good appearance and free of
slag or gas inclusions. Remember, what you fail to learn Any method of bringing the tip of the rod in contact with
while practicing, must be learned through a series of the work, then quickly raising it until there is approximately
mistakes and rewelds later am
a 1/8-inch gap between the rod and the work, will start an
arc_ The easiest way for a beginner to strike an arc is to
A comfortable body position is important when learning, scratch the tip of the rod a short distance on the surface of
as tensed muscles will result in fatigue and lack of control.
the work, as you would a match, then lift it (quickly) the re-
Sit on a low stool and grasp the electrode holder in one quired 1/8-1nch (fig. 1). Another method is to strike the work
hand with the cable drawn across the lap. Allow enough
a hard blow with the tip of the rod and allow it to bounce
slack to move the holder freely and yet keep the weight
and drag of a long length of cable from becoming tiring, up to form the arc gap. The important thing is to strike
the arc qelckly and not allow the rod to remain in contact
with the work
The ground connection is as much a part of the welding
circuit as the cable and electrode holder_ A poor ground
connection can render the best welding equipment ineffi- A common mistake often made by a beginner is to point
cient. When using a table with a steel top, fasten the lug of the rod toward the work and, after lowering the helmet,
the ground cable to it securely with a bolt or C<lamp, so that feel slowly about until the tip of the rod touches the work.
any piece of iron placed on the table top will be propedy This always results in sticking or "freezing" of the rod
grounded. If a steel table is not used, connect the ground which produces a direct short circuiL When this occurs the
cable d_recfly to the work with a ground clamp or bolt rod can be loosened by bending it from side to side while
pulling on the holder (fig 2). If this fails, turn the welder
off_ The electrode must be released in a matter of seconds
Select a fairly large piece of steel plate approximately
to avoid unnecessary heating of the welder or damage to
1/4-inch thick and clamp it to the table top to prevent it the flux coating on the rod
from lifting, should the electrode stick or "freeze" when

,'/,'II'U]I
Figure 1 Figure 2
\\
,,',/ To strike an arc, scratch the
end nf the red ne the plate
Should the rod stick or
"freeze" bend it from side
\
\ /
and then quickly raise ap- to side while palling upward \ /
I
proximately 1/8-inch, on the rod ho_er.

1-5
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 Figure 3 Figure 4 Figure 5 Figure 6

To lay a weld bead only two Watch the weld puddle to Fill the crater, when starting To widen the head, work the
movements are used, dowfi- keep the slag from flowing a new rod, by striking the red from side to side slight
ward and in the direction the in front of it, causing inclu- arc at A then moving to 8 ty, with a slow, zigzaggmg
weld is to he laid. sions and gas pockets and back to C position crescent-shaped motion

If difficulty is experienced after repeated attempts to After laying a number of beads, try "working" the rod
maintain an arc, check the ground connection for proper from side to side slightly (fig. 6) This movement should
contact with the work If this does not help, increase the be slow and not wider than the diameter of the rod being
welding current Also check the rod size, as larger rods used. Experiment with different current settings, rod sizes
require higher current settings. and rates of travel.. Compare results with welds shown in
Practice striking and maintaining an arc for a few seconds, the diagrams (fig, 9).
then snap it out by rapidly pulling the rod away from the
work_ Repeat this operation until the arc can be started Too low a current setting tends to deposit the bead on top
and the gap maintained as uniformly as possible. In a of the plate with very little penetration. The arc sound will
short time you will find the arc length can be controlled by be an intermittent crackle with irregular sputtering Too
the crackling or "frying" sound which may be recognized high a current setting (for the size of the rod being used)
by gradually shortening the arc until it sputters irregularly wiII provide sufficient penetration but the bead will be thin
as though it were going to "choke out'* and stick--then and undercut in places. The arc makes a hissing sound and
slowly lengthening the arc by pulling the rod away from the rod becomes red hot before it is half used.
the work until it snaps out_ Somewhere between these two
extremes the steady crackllng sound of a proper arc length If travel is too slow it will pile up a wide, heavy bead with
will be heard_ good penetration but with overlap of the weld metal on
sides without fusion_ A large area surrounding the weld is
To lay a weld bead, only two movements are used, a
heated to a high temperature which produces distortion,
steady downward feeding of the rod to maintain the correct
arc length and a slow travel in the direction in which the even on a simple weld If the rod is moved too fast the
small bead will result w_th little more than melted base
weld is to be lald (fig. 3)_ Watch the weld puddle and
arc length, and move the rod steadily in a straight llne as metal. An extremely long arc causes the rod to melt off in
the back end of the crater fills up (fig 4). The slight angle globules, with little or no penetration, and a very irregular
weld surface The arc produces a hissing sound.
of the rod will keep the flux or slag flowing over the
deposited weld metal to form a protective coating. If the A good weld laid with correct current setting, speed and arc
rod is moved too slowly the slag will flow in front of the length will produce a surface that is rippled uniformly, with
puddle and be trapped in the weld, producing inclusions the same width throughout its length, and well formed
and gas pockets. crater. The cross-sectional view shows it to have good pene-
Lay a bead approximately four inches long. After allowing tration and no undercut or overlap.
it to cool slightly, remove the slag coating, which covers the
top of the weld, by scraping along each edge of the weld
with a cold-chlsel foJowed by wire brushing until it is bright
and clean_ Inspect the surface of the weld carefully before
starting another_ The surface of a good weld is rippled I I
unlformly, which results from a steady rate of travel and
uniform arc length_

If the scrap plate used is small, it will become very hot after
laying a few beads. This will alter welding conditions
which could be very confusing to a beginner Have several
scrap pieces handy so each may be allowed to cool before
laying a second bead,

When starting with a new rod, chip slag from the crater Figure 7 Figure 8
and strike the arc at the forward end as shown at "A" in
figure 5, Then move the rod to "B" and back to "Ci" at Lay the weld beads about A pad of weld metal is built
one inch apart, ffemove the up by running a series of
about twice the normal rate of travel to give the rod and slag and examine each weld beads in layers at right
base metal time to heat up for proper fusion before starting the next angles to each other,

1.6

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 CURRENTTOO LOW TRAVELTOO FAST
Arc is difficult to maintain. Small bead undercut in
Vurylittle peflctrationHigh some places. Rough top
bead, and little penetration

CURRENTTOO HIGH ARC TOO LONG

Wide thin bead, undercut, Surface of weld rough
Crater pointed and long, Rod melts off in globules
Rod hurns off very fast, Arc makes hissing sound.

TRAVELTOO SLOW NORMAL CONDITIONS

Metal piles up. making a Uniform ripples on surface
wide heavy bead, over° of weld, Arc makes steady
lapped at sides in places crackling sound,

Figure 9

Practice laying beads approximately one inch apart until

a good weld can be produced with all the different rod
sizes the welder will handle (fig, 7). After becoming pro-
ficient in running a bead, build up a pad of weld metal,
Clean each bead before laying the next and make sure
they are fused together (fig. 8) Run the second layer at
right angles to the first and the third at right angles to the
second, etc_, _sntil a pad approximately 1/2-inch thick has
been built up This type of welding is used to build up F_gure 10
round or flat surfaces or reinforce parts that are rusted thin_

To avoid distortion when building up the end of a shaft,

run the beads parallel to the axis and lay each successive
bead on the opposite side as shown by the numbered steps
in figure 10. Cover the entire shaft with weld metal for
the desired length. If the place to be welded is not at the
end of the shaft, weld around it and turn the shaft slowly
to keep the weld puddle in the flat position (fig_ 11). Clean
off the slag after each bead, then machine the shaft to
proper size.

1-7
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 FLAT WELDING

SLIGHT / / St;EEl"
GAP / ,
METAL

k___J\
BACK-UP
STKIP
Figure 4

TACK Figure 3

• WELOS

REINFORCEMEHT
Flat welding includes all types of joints in which the weld Figure 5

is horizontal, and the electrode is fed down as in the practice Figure 6

welds of previous pages The five types of joints in figure 1

can be welded in the flat position
Butt welds on llght material should be practiced first on
scrap stock_ Use 16-gauge mild steel sheet metal (approxi=
mately 1/16-inch thick) and 5/64-1ech rods with the welder
set at approximately 30 to 50 amperes, Butt edges of metal Figure 7
together and tack-weld approximately every three inches
(fig. 2)_ (Tack welds are small beads 1/4 to 3/8-1nches in
length_) Place bars of scrap iron under ends of the work to
provide an air space above the table. Simply move the rod
in a straight llne directly above the edges to be joined.

If the weld burns thro.ugh in places, reduce the welding cur-

rent or increase the rate of travel. Some difficulty may be
experienced in starting the arc at these low current settings

However, once the arc is started, there wlll be sufficient

heat to make a sound weld. After laying a bead, turn the
work over and inspect the underside which should also have
a small uniform bead. To prevent burning through where
the edges are not butted tightly together, move the rod back
and forth with short quick strokes in the direction of the
weld to bridge the gap and give the metal in the crater a
chance to solidify (fig 3).

Butt welds on sheet metal lighter than 18 gauge should

not be attempted by the beginner without the use of a
back-up strip (fig 4). This consists of a bar of copper over and weld a similar bead on the other side (fig. 7) A
clamped tightly against the underside of the seam to absorb higher weidlng current can be used on this side as there is
the heat of the arc and prevent the weld from burning no danger of burning through and fusion with the first
through To assure complete penetration with butt welds bead will be assured
on 8-gauge metal or heavier, a 1/16 to 3/32-1nch gap
should be allowed between them (fig .5) insert a wedge or Although butt welds can be made on steel plates up to
screwdriver between the plates when tack-welding to main* 3/8-inch thick, with a 295-ampere machine using 1/4-1nch
tain the gap, then turn the piece over, so the tack welds are rod, the same results can be obtained with the 180 and
on the underside_ 230-ampere machines if edges of plates are beveled (fig. 8)
Metal of almost any thickness can be welded in this manner
Use enough current to melt edges of plates to a depth of by depositing a number of beads, one on top of the other
at least one-half their thickness Clean off the slag and until the groove is completely filled= If the plate can be
inspect it for smoothness, penetration and height of rein- welded from both sides, always use a double bevel (fig_ 9)_
forcement Agood weld should havea relnforcement slightly If only one plate is beveled, the angle should be at 45 de-
more than flush with the surface (fig 6) Turn the plate grees (fig 10)

1-8
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 Run the first pass on beveled plates with a 5/32-1rich rod
and use as high a current as you can handle to obtain a
UNDERCUT GASPOCKET small bead on the underslde_ If this is not done, insufficient
penetration will result, as shown in figure 11. Be sure to
clean each pass before laying on the next All beads are
la_d by moving the rod in a straight llne with no weaving
EHT or slde-to-side movement_ On the last or reinforcing pass,
PENETRATION a weaving motion must be used to obtain a wide weld that
Figure II will completely cover preceding beads. For the beginner,
the slde-to-side movement (with a slight hesitation at each
end) will produce a smooth top without undercut or overlap
Select several practice welds of different thicknesses and
Figure 12
cut them into 1-1/2-inch strips. Clamp each strip in a vise
and bend it at the weld (fig. 12)_ If it breaks through the
weld, study it to find the cause of failure

Corner welds are made on light sheet metal by running

a single bead along the top, after tack-weldlng at three-
inch intervals to prevent warping (fig 13)_ if numerous gaps
are present, a back-up strip may be used, On heavier
Figure 13
metal two passes may be necessary and, if the design
permits, a smaller pass can be lald on the underside.
Beveling may be used to advantage on the thicker metals

FgLLET WELDS

I
I WELD

BREAKING
THEWELD
Figure 4

Fi9ure 6

WELD

Fillet welds are used to join two pieces of metal with sides or this type should always be at least four times their size in
edges at right angles to each other The size of such a length; that is, a 1/4-inch fillet weld should never be less
weld is based on the leg length of the largest isoscelesright than one inch long, The direction in which the load is applied
triangle that can be inscribed within the cross sectional to a weld greatly affects its strength, which can be clearly
area, as shown by the dotted-line triangle (fig 1). The demonstrated by breaking the weld (fig 4) A joint so
size of a fillet weld may also be measured with a square roaded should always be welded on both sides with fillets
and ruler, subtracting 1/32-inch from all dimensions under equal to the plate thickness (fig 5) If this cannot be done,
3/16-inch and 1/16-inch from all over 1/4-inch (fig. 2) bevel the plate to assure complete penetration and position
For example, a 1/4-inch fillet weld should measure 5/16- the work at a 45-degree angle if possible.
inch This will offset any inaccuracy due to the slight radius
at the toe of the weld and allow for concavity of the bead. For practice, tack-weld three pieces of scrap iron together
to form a cross (flg_ 6) Use a 5/32-inch rod with high current
When a fillet weld is stressed to its maximum capacity, and hold it as indicated in the front and side views. Move
failure will usually occur through the throat section (fig. 3) the rod at a steady even pace along the seam without any
Therefore, the strength is determined by the throat dimen- side-to-side movement and deposit one inch of weld for
sion multiplied by the Fength of the weld Finished welds of each inch of rod melted. The surface contour of a good weld

1-9
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 ROD
SIZE

UNBERCUT
f _P

_,,-CENTER
_OF SEAM

Figure 8

Figure 9

Figure 11

Figure 10

INTEBMII_ENT
WELOS

I'_ !EXCESS

BLA
Figure 13 STAGGERED
INTER-
MITTENT
WELOS
Figure 16

Figure 17

LAPWELDS WELDON BOTHSIDES

LAPWELDS
AT ENDOF JOINT
Figure 14 Figure 15

should be nearly flat with a slight radius at the sides or will come with experience. If the arc is advanced too fast,
toes_ Avoid excessive concave or convex surfaces of the or held too close to the vertical plate, undercutting may
fillet (fig_ 7) Undercuts and colddaps are caused by not result (fig. 12). Too slow travel will cause overlapping and
holding the rod in the center of the seam (flg_ 8)_ if the an extremely dose arc or low current will produce a bead
desired fillet weld cannot be made with a single pass, with a convex surface (fig. 13). To check the penetration and
soundness of the bead, break some of the welds for inspec-
several passes are used to build it up to required size (fig_ 9).
Slag must be cleaned from each pass before depositing tion, as shown in figure 4_
the next. Fillet welds over 1/2-inch in size are rarely used When making a lap weld, care should be taken not to melt
because joints requiring more strength can be made more too much of the upper corner on the top plate (fig. 14)
economically by beveling and groove-welding, followed Some melting will take place, but proper advance of the
by a small concave fillet weld to provide a radius in the rod will cause the weld metal to build up and blend into the
corner_
top surface. On sheet metal, hold the 3/32-inch rod almost
perpendicular and move the arc rapidly. Welds of this
Horizontal fillet welding is used when the side or edge of type should be wider than they are high, somewhat like a
one member of the joint is in the vertical position particularly flat bead (fig_ 15) A slight discoloration on the underside
for small single-pass welds where the work cannot be tilted. of the lower sheet indicates good penetration, On heavy
For practice, tack-weld two pieces of scrap together to metal, a 3/8-inch fillet weld can be lald in one pass with a
form a tee-joint (fig. 10)_ Use a 5/32-inch rod held at 1/4-1nch rod using a 295-ampere machine However, with
angles indicated, and direct the arc into the corner of the smaller machines, the same weld or larger can be made by
joint. The arc length should be somewhat shorter than for building up with a number of passes (flg_ 16)_ When
flat fillet welding_ To assure penetration at the root, use the welding long narrow pieces, stagger the welds in short
highest welding current that can be handled (fig 11)_ intermittent beads, first on one side then on the other side,
Good penetration is of prime importance and appearance to minimize distortion (fig_ 17).

1-10

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 _i_ _¸ _ __

POSMTION WELDING

weld, run a few practice beads to get the feel of the

arc_ Tack-weld a piece of scrap iron to an old practice plate
so it is positioned vertlcal]y (fig 3). Use l/B-inch rods for
the first welds and a current of about 75 to 115 amperes
BUTT WELD Experiment with various amperage settings until you are
using the highest current you can handle Hold the rod at
right angles to the plate laterally, with the tip pointed up
at the angle shown in figure 3 Start the weld at the top
of the plate and move the rod in a straight line downward
The correct rate of travel can be determined by gradually
reducing the speed unti! molten metal in the puddle can no
longer be kept in place Then, increase the speed slightly
while watching the puddie, arc length and angle of the rod
A short arc provides better control of the molten meta!
Follow the same procedure with 3/32 and 5/32-inch rods
It will be noted that the larger the rod the more difficult it
is to control the puddle For this reason smatler diameter
in order to derive the greatest benefits from your welder, rods are always used for position welding
you should practice until you can make a welded iolnt
in almost any conceivable position. The ability to do this Lap or tee-joints are made by simply directing the arc into
is especially useful when making repairs on machinery as the cornel of the joint as in fiat welding and moving the
the amount of welding in most cases is small and does not rod down the seam at a steady pace Butt welds may require
warrant disassembling the parts to weld them in the flat more practice, as there is a tendency to burn through on
position Welds of this type have been classified into three light gauge material if this occurs, continue until the seam
is completed and patch the hole by chipping the slag and
groups according to their location and are referred to as
vertical, horizontal and overhead welds (fig 1) Of the wire brushing until clean Then, with slightly lower current,
three positions, vertlca[ welding will be used the most and strike an arc on the weld directly above the hole and quickly
should be practiced first. Skill gained in this type of weld bring the rod down to the lower rim of the hole to deposit
will make horizontal and overhead welding easier a small amount of metal Raise the rod far an instant to
let the metal solidify and repeat until the hole is welded
VERTICAL WELDING Hold a long arc when raising, so there will be no metal
deposited except when the rod is lowered Any hesitation
The two methods of welding in the vertical position are in the rate of travel will cause a "burn through/' if this
commonly known as "vertlcal-down" and "vertlcal-up" happens repeatedly, lower the welding current
welding (fig_ 2)_ In the former the bead is started at the
top and welded in a straight llne downward In the latter Leave a slight gap between pieces for butt welds on material
the bead is started at the bottom and welded up, usually over 3/32-1nch thick_ Inspect the back side after welding
with a weaving motion for small bead along the seam, indicating complete pene-
The chief difficulty encountered with any position weld is tration (fig 4) Butt joints on material around 3/16-1nch
thick should be welded on both sides.
keeping the molten metal in the puddle from falling out.
To prevent this the arc must be held as short as possible and
Vertical-down welds may be made on heavier material by
the weld puddle kept fairly small so it will solidify rapidly
laying in a number of passes (fig 5), however, this practice
Verficabdown welding is the easiest to perform and is used is not recammended as it takes longer than a heavier single*
on material up to 1/8-inch thick Before attempting a vertical pass weld made by the vertical-up method

VEBTtCAL-
OOWNWELO
VEffTICAL.DOWN
WELDING /3EB PASS

DlflECTIOH -2HO PASS

BKVEL

A SMALL BEAD OH -IST FkSS

BACK SiDE [HBICATES
COMPLETEPEHETRATIOH

Figure 4
Figure 3
Figure $

I-I1

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 VERTICAL*UP 90°
WELOIHG

Figure 9

Figure 6

4",
J

Figure TO

Use 1/8 and 5/32-1nch rods for all vertical-up welds and weave (fig 9). This will produce a "shelf" upon which
start by running practice beads from bottom to top of a additional metal is deposited _ntermlttenfly as the welding
3/16 or 1/4-inch plate, tack-welded in a vertlca_ position progresses. There should be a slight pause in the weaving
Hold the rod as shown in figure 6, noting that the angle motion at the toes of the weld to avoid making a bead that
of the rod is not as steep as for vertical-down welding, but is too convex. Materials 1/4-inch and thicker must be bev-
tilted just slightly (approximately five degrees) so the tip eled on one or both sides, depending upon the joint
of the electrode points upward. Strike and hold o short arc
Practice making a wide bead using a side-to-side weaving
until a small amount of metal is deposited, then quickly
motion with a very slight whipping action at each end to
raise the rod upward with a wrist movement to increase the
give the metal at each end a chance to solidify and avoid
length of the arc at the top of the stroke (fig. 7). As soon
undercutting along the sides of the weld (fig 10). This type
as the metal deposited in the crater has solidified, bring the
of bead is used on welds that require more than one pass
rod down and deposit more metah Keep repeating this
and is called the finish bead or "wash" pass. Hold a short
whipping motion, while gradually moving the rod upward
arc, making the bead approximately 3/4-inch wide and
and toward the plate as the electrode burns off. The length
fairly light, Multiple vertical welds may be made as shown
of the stroke will depend upon the amount of metal de_
in the series of diagrams, figure 11_
posited and the welding current esed_ Keep the rod in
constant motion once it has left the crater. The purpose
of a long arc is to prevent any metal from being deposited
except when the rod is held at the crater. If globules of
molten metal drop from the tip of the rod when the arc is
lengthened, either the current is too high or the rod has
remained away from the crater too long. Care should be
token not to break the arc at the top of the stroke. Do not
deposit too much metal at one time as this will cause the
weld to sag and result in a high narrow bead undercut
along the sides. Better penetration can be had by the
vertical-up method_ This can be demonstrated by ioinlng
two pieces of 3/16-inch metal with a butt weld, using the
whipping motion.. Leave a gap between the plates and use
a 5/32-inch rod with a fairly high current, determined by
experimenting. The whipping motion will melt the corners of
the plate and form a pocket in which to deposit the weld
metal (fig_ 8)°
Burn the rod in deep so the crater extends through to the
back side. After completing the weld, inspect the back
side for the small bead, which indicates 100-percent pene-
tration. Butt welds on heavier materials should be welded
on both sides.

On materials up to 1/4-inch thick, use the whipping motion

on small single-pass fillet welds for lap and tee-joints Larger
single-pass fillet welds can be made by the whipping motion
with a slight side-to-slde weave added and combined with Figure 11

the up and down movement to make a triangular shaped

1-12

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 _/_ UHRERCUT
Figure 14

Figure 12 DEPOSITMETAL
OH GOWHSTROKE

OVER-LAPPED I]ACI(-Up STRIP

Figure 13 Figure 15

HORIZONTAL WELDING

Horlzontal welding refers to one type of butt weld between one side_ if the seam has numerous gaps, use a back-up
two plates in a vertlcal plane. For practice, set up a plate strip, albwlng a slight gap between edges of 1/8-inch
as for vertical welding and run straight beads across from thick metal and weld from both sides (fig 15), All metal
left to right (fig 12)_ Use the same current settings as for 3/16-1nch thick and over should be beveled and welded
vertlcal-down welding and hold the rod as indicated with with a number of passes (fig_ 16) Thoroughly clean each
a short arc. Move the rod in a straight line and deposit bead before laying the next and use higher current than
a light bead. The rate of travel will depend upon the current for single-pass welding
used Too slow a travel will cause the bead to sag (fig 13).
Practice with 3/32, 1/8 and 5/32-inch rods untll a wel! The appearance of a multlple-pass horizontal weld can be
formed bead can be made with each size rod (fig 14). improved by vertical down beads laid closely together.
Use a swift circular motion to the right; slowly downward
Sheet metal up to 1/16-inch thick can be butt welded from while welding (fig 17)

OVERHEAD WELDING
Although overhead welding is generally considered diffl-
celt, do not become discouraged, as it is being done every
day by people who have taught themselves_ Once theeart
of maintaining a short arc has been mastered, the rest
will be easy

Since there will be a shower of sparks, wear a leather

jacket and keep the practice plate slightly higher than the
top of your head when standing To keep sparks out of your
glove, grasp the electrode holder as indicated in figure 18
and hold the rod in a nearly vertlcal position with a slight
tilt to the right_ Drape the cable over your shoulder so its
weight will not interfere with the use of the electrode_ Use
1/8-1nch rods and a current setting the same as for vertical
welding, and move the rod in a straight llne without any
weaving or whipping motions A reasonably fast rate of
travel must be used to prevent the bead from sagging and
undercutting along the edges. Vary the rate of travel and
notice its effect on the size and appearance of the weld.
When you feel you can run a satisfactory bead, try the
slde_to-side weaving motion and deposit a thin weld ap- Figure 19
proximately 3/4-inch wlde_ The movement must be somewhat
faster than for other positions to keep the bead from
sagging (This method of weaving is used only for the
last pass on heavy welds where improved appearance is
Fillet welds for lap or tee-joints are most common in the
necessary)
overhead position. Tacbweld two pieces of scrap iron
The whipping motion is used where a gap exists between together to form a tee-jolnt, and clamp in the overhead
the plates as it provides better penetration with higher position so one plate is held vertically (fig. 19)_ Hold the
we]dlng current, For practice work, set up two plates ap- rod at angles indicated and deposit a light bead from left
proximately 1/8-inch thick, allowing a gap between them to right without weaving or whipping movements. A slightly
Burn in deep for good penetration with 1/8 and 5/32-inch higher current than used for overhead butt welds will be
rods, varying the plate size and gap distances. necessary to get good penetration at the root of the weld

t-13

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 METAL BENDS
WHEN COOLED

DISTORTION TRENOS
Figure 22 WHEN COOLING

Egff W[LO

[RtH Y_LO

F Figure 23

Figure 20

Figure 24
Figure 21

To simulate actua! conditions tack-weld a piece with an surrounding metal is free to move (not clamped or tacked)
irregular edge to another piece leaving numerous gaps it cannot resist these forces and bends (flg_ 22)
along the joint_ Use the whipping motion and deposit a
The weld also contracts in width, as well as in length,
fairly heavy bead, slowing down the rate of travel where tending to pull the plates together, resulting in locked-up
the gaps are widest to build up a weld of uniform size stresses (fig_ 23) This is not too serious when welding mild
throughout its length. If the gaps are rather wide, fill them
steel up to 1/2-inch thick, as the ductility and elongation of
first, clean off the slag and lay in a fillet weld the entire
the metal will pelmit it to deform slightly to compensate
length of the joint (fig. 20)
for these forces, and prevent cracking. On sheet metal and
When you can lay single-pass butts and fillet welds you will light structural members, long continuous welds may cause
be able to make an overhead weld of any size, as it is considerable bending and resuJt in a badly distorted weld-
simply a matter of fusing a number of straight beads to- ment Fortunately most of this can be avoided by studying
gether, one on top the other (fig 21) the effects of expansion and contraction, as related to the
job before welding and working out a procedure to follow.
Weld appearance can be improved by grinding with a For example: first assemble the job with tack welds, and
properly guarded abrasive wheel mounted on the end of install temporary braces tack-welded to support parts that
a flexible shaft might bend. The braces can be removed after the job is
cornpleted_ Lay the beads so the stresses will counteract
EXPANSION AND CONTRACTION or nbutralize one another, by running a short pass first on
one side then on the other, etc. Often the neutralizing weld
Metals expand when heated; contract when cooled. In arc is at the other end of the job Do not concentrate too many
welding, the deposited metal and edges being joined are welds in one place but space them to distribute the heat
molten and the metal surrounding the weld is heated suf- and stresses throughout the entire structure Use intermittent
ficiently to cause expansion_ When the deposited metal welds whenever possible_ If continuous welds are necessary
solidifies, it becomes a part of the plates; but, being unre- to make a water-tight compartment, use the back-step
stricte_ in its expansion in the molten state, it tends to method as shown in figure 24, fusing each bead together
contract more than the heated surrounding metal If the at the end

CAST IRON WR=LD|NG

Previous experience in handling the arc, plus good judg- weld or the casting_ Because of low tensile strength and
ment regarding expansion and contraction, will enable lock of ductility it cannot bend, stretch or distort itseff to
you to weld gray cast iron successfully in a short time. conform to the contraction of the weld metal In some cases
Two types of electrodes are used, namely: non-machinable it may be necessary to pre-heat the entire casting before
for use in cases where the weld does not have to be welding_ However, as most cast iron welding jobs can be
machined, and machinable which deposits a file-soft weld done without pre-heatlng, this method will be considered
that can be drilled or machined to close tolerances Non- first.
machinable rods are used for most repair jobs such as
cracked motor blocks, water jackets, pump and gear hous- The part must be free of rust, grease, paint or dirt; cleaned
ings, etc. If the weld must be made across a machined by wire brushing, grinding or washing with solvent. The
surface that need not be refinished to a close tolerance, crack should be beveled for penetration. If the parts are
the face of the weld may be ground flush with an abrasive broken apart completely,they may be ground on an abrasive
wheel. wheel to a single or double bevel, depending upon the
thickness of parts and whether or not the ioint can be
As cast iron is very brittle, care must be taken to control welded from both sides. Do not bevel to a sharp edge along
expansion and contraction, and thus avoid cracking of the the entire crack Instead, allow approximately 1/16-inch

1-14

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 of the fractured surface to line up the two pieces Tack-weld brush each bead before depositing the next Then continue
or clamp parts in position If the crack has not separated to fill the groove with short weld beads as before, working
the casting, a vee-groove can be chipped out with a dla-
rapidly when depositing and peening the bead Allow plenty
mond-polnt chisel Chip an inch or so beyond the visible of time for cooling. Examine the casting for cracks that may
ends of the crack as it may extend under the surface. On develop during cooling periods if any of the beads crack,
cracked water jackets, where only a sea! is required, the chip them out and re-weld If cracking persists, preheat
depth of the groove need only be one-half the thickness the entire casting slowly to a dull red heat with an oxyacety-
of the casting. lene torch or blow-torch When the preheated method is
Keep the casting as cool as possible and do not expect to used, the welding can be continuous After completing the
complete a weld in cast iron as rapidly as in the same length weld, cover the casting with warm dry sand or slaked lime
so it will cool slowly
in mild steel Use a smaller rod and a slightly higher current
than for the same thickness of steel. Lay a short bead, about Malleable iron is ordinary gray cast iron that has been heat
an inch long, at one end of the crack and peen it immediately treated to give it a tough ductile outer skin The method of
with a cross-peen hammer or blunt chisel to spread the welding is the same as for cast iron
weld metal and relieve locked-up stresses, Do not strike the
edges of the casting. Place the second bead at the opposite
end of the crack and the next in the center, etc (fig 1)r
AllOW enough time between welding to permit your bare
hand to be held on it Never use water or a blast of air
to cool the casting Although cracks may not show up
immediately, the locked-up stresses due to uneven cooling
will cause the casting to fail after it is back in service_ Wire

HARD FACING WORN CUTTltNG EDGES

DRtHO OFF WEAVE DEARS

PLOW

SMALLBEAR-
Figure 2
RARD EACIRR Figure 3
HA_DEACIHR

CULTIVATOR
SHOVEL

SOFTBASEMETAL
SPIKE / WEARSAWAYEASTER MILD,STEEL PATCD
HARROW TRAHRAflDFACIDG WELDS
Fieure 5
TOOTH .'ULTIVATOR
SWEEP
Figure I

must be deposited along the edge to build it up (fig. 3)

Excavating equipment, earth_cutting farm machinery or Make beads heaviest where the wear will be greatest, but
others such as plow shares, lister shares, cultivator shovels, avoid excessive build-up as the metal cannot be filed or
sweeps, subsoilers, spike harrow teeth, tractor treads, ex- machined If shaping is required, heat the weld metal and
cavating buckets, or any surface subject to abrasive action forge it. Smoothing and sharpening can be accomplished
wil! last much longer and require less sharpening when by grinding.
their cutting edges are hard faced with hard surfacing
electrodes The arc welding process consists of depositing For plow and lister shares, cultivator shovels and similar
a layer of abrasion resisting weld metal on the worn cutting cutting points, deposit the weld metal on one side only
edges as indicated in red on the parts shown in figure 1 which will result in a self-sharpenlng edge (fig 4) The
softer base metal on the other side will wear away first and
Prepare the part for welding by cleaning the surface to be leave a knlfe-like edge of hard facing material Parts that
welded by grinding it approximately 1-1/2 inches back must wear uniformly on both sides should be hard faced
from the edge (fig. 2) Position the part so weld metal can on both sides The condition of the worn part must also be
be deposited in the flat position If the material is 1/4_inch taken into consideration If the part requires a number of
thick or less, use a I/8-inch rod and as low a current as passes to bring it up to the desired thickness, use mild-steel
possible that will still permit the metal to flow out smooth welding rods first; then cover with deposited metal from
and fairly thin (1/16 to 1/8-1nch thick) Weave the rod hard surfacing rods If the edge is entirely worn away, a
from side-to-side in a crescent-shaped movement and de- steel patch (cut to fit) may be welded in place with mild-steel
posit a bead about 3/4 to 1-1nch wide Several passes electrodes, then hard faced (fig 5) To prevent distortion
(lald side-by-slde) may be necessary where the worn sur- when hard facing small parts, peen the deposited weld
faces are quite wide In some cases a small straight bead metal before it cools

1-15

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 To prepare the torch for use, connect its two cables to the
TRUMB KHOB ground and electrode cables of the welding machine.
Grounding of the work is not necessary as the operation of
CARBORELECTRODES the arc flame is entirely independenL With the thumb knob
on the handle in the "off" position, insert two 3/8-inch car-
bon electrodes in the holders and clamp in place at approxi-
mately one-half their length (fig, 2) Do not clamp them
on or near the ends opposite from the arc as this will cause
overheating of the carbons When tightening the clamping
CORRECTTO
GROUNDAND:
screws, be careful not to apply too much pressure on the
SCREWS ELECTRODE
CABLESOF
carbons, as they are very brittle and break easily Use only
ELECTRODETiPS A C WELDER enough pressure to hold them firmly in place. If the tips
of the carbons do not llne up with each other, an adjustment
Figure 1 may be made by turning the longest of the electrode holders
slightly; too much turning will loosen it, and make it neces-
sary to disassemble the torch to again tighten it properly,

Do not make any turning adlustments wl h the s,id ng holder

Work ordinarily done with a gas weldlng torch is possible as this would spoil the contact tension in the switch.
with the twln-carbon arc torch connected to an A.C welder,
The carbon-arc flame is similar to the flame of a gas weld- To strike the arc, turn on the welding machine and set it for
ing torch in that it provides heat by radiation, rather than approximately 70 amperes Lower the welding helmet and
by direct arc between work and electrode, This flame heat hold the torch up to silhouette it against the light of a win-
greatly widens the scope of work possible with the arc dow Slowly move the thumb knob forward until contact
welder for brazing, soldering, welding of non.ferrous metals is made between the tips of the carbons. This will start the
and localized heaffng for bending, forging and hardening, arc Then immediately move the knob back to increase the
gap between the carbons The actual distance can be deter-
The arc torch (fig. 1) consists of an insulated handle wlth minecl with a little practice When the carbons are too close
two projecting carbon electrode holders, one of which is ad- the arc flame will have a sharp crackling noise As the
justable to permit striking and breaking an arc at the carbon distance between the carbons is increased, the crackling
tips. A thumb knob on the handle performs the adjustment will change to o soft purring sound which indicates the best
and operates a shut-off switch built into the handle There arc flame There are two heat zones and the small inner
are no valves or gouges that require fine adjustment as
zone is by far the hottest, having an estimated temperature
with an oxyacetylene torch. The same protective equipment
of 9000 degrees Fahrenheit (fig, 3)
used for ordinary arc welding is used when operating the
carbon-arc torch.
The shape of the flame gleatly influences the way in which
it must be used For example: on beveled work the torch
A wide selection of flame heats may be had by varying
should be held parallel to the groove so the flame will reach
the current and size of the carbon electrodes, Although the
the bottom (fig 4), If held at right angles to the groove, the
actual temperature of the arc remains the same for any
flame straddles the groove and the heat will not reach the
current setting, the volume of transferable heat increases
bottom (fig 5). Filler rods, as for gas welding, must be used
with an increase in amperage° However, amperages in
excess of those given below will only cause short carbon life. on joints of this type.

1/4-ira carbons ............ 30 to 40 amperes The soft, bushy flame is pressureless and has no tendency
5/16-im carbons .............. 40 to 65 amperes to blow the mohen metal This is a distinct advantage when
3/8-im carbons ............... 65 to 90 amperes welding thin sheet metal Joints on light material should be

CORRECT FLAME POSITION INCORRECT FLAME POSITION

Figure 2 Figure 3 Figure 4 Figure 5

,r.,,,,,

1-16
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 bent and edges fused together by melting down the excess
metal to form a bead (fig 6) No filler rods are required Figure 6
The carbon-arc torch is ideally suited for brazing and
soldering small tubing+
Cast and malleable iron can be brazed with excellent
results A bronze filler red and common brazing flux are
used Rust, paint or grease must be cleaned from the area
to be brazed If it is a butt joint, such as a crack in a casting, B
grind or chip out a beveled groove as for arc welding
Apply the heat from the arc flame gradually by passing
it over the metal surrounding the joint+ When the casting
has become warm, concentrate the arc flame at the joint
The important thing to remember when brazing cost iron
is never to heat the edges of the joint to the melting point
The temperature of the work should not exceed the melting
paint of the filler rod The carbons are held as close to the
work as possible without causlr_g the metal to bubble Hold
the filler rod in the left hand and heat the end of it slightly
aluminum alloy, use aJumlnum flux The filler rod should
by passing it through the arc flame Then dip the heated
be of the same analysis as the work if regular welding
end in brazing flux Raise the torch slightly and deposit
rod is not available, strips of the parent metal may be used
some of the flux at the part of the joint being heated. When
the surface of the heated metal takes on a shiny or wet A back-up strip should be used when welding thin material
appearance, the filler rod can be applied Small diameter carbons and low amperage setting are
Do not put the rod directly in the flame, but hold it on the used for soldering. The torch is held so the work is just within
work and let the heat of the edge of the flame and the work the visible edge of the flame. Apply the soldering flux and
play the flame over the work until it is just hot enough to
melt the rod Deposit only enough metal to fill the part of +
melt the solder. If the joint is to be sweat-soldered, tin the
the joint that has been coated with flux As the metal is
being deposited, move the !orch along the joint slowly, surfaces to be iolned, then press them together and reheat,
adding mare solder at the edges of the joint
applying flux to the rod and joint as required
One of the most practical uses of the arc torch is heating
Copper and copper-base alloys such as bronze and brass
metal for bending, forging, etc, Set the torch for a wide,
may also be brazed, but as their melting temperatures are
so close to the melting point of the filler rod, the process enveloping-type flame and apply the heat to the bottom of
the work (fig 7) Since a red heat is not visible through the
in many cases becomes one of welding rather than brazing
A bronze filler rod and common brazing flux are used. dark weldlng glass, the helmet must be raised periodically
so the work can be inspected to avoid overheating To pro-
Most non-ferrous metals can be welded by manipulating tect the eyes from the rays of the arc, hold the torch to
the torch and filler rod in the same manner as for brazing, one side and above your head The carbon-arc torch is
with the exception that the edges of the joint are heated to not recommended for welding mild-steeL However, it may
the melting point before depositing the filler metar. If the be used for brazing mild-steel if the metal is too thin for
work is a copper alloy, use common brazing flux If it is an regular metallic-arc welding

CUTTgNG
and other miscellaneous operations

CUTTING WITH THE ELECTRIC ARC

\\ \\

Arc cutting is simply the continuation of a "burn through"

such as you probably experienced when practicing with
light sheet-metal welding When this action is accelerated
by using extremely high currents, it becomes an efficient
method of cutting metals Although the edges of the cut
ST_T
surfaces are not as smooth as when cut with a saw or CUT d,..-MOLT]_H METAL
ffEI1E STEEL
oxyacetylene torch, there are many cases where such pre-
COHTA_HER
cision is not required. Ordinary mild-steel welding rods
may be used The current will vary with the type and thick-
ness of the material. In general, high currents increase the F_gure 1
speed of cutting but also increase the rod burn-off rate and
width of the cut

117

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 BOLT AND RIVET CUTTING
MOVERODUPANO--_.
DOWN
VERTICALLY
_:..., _ _'_ Removing rusty bolts or rivets is an easy job with an electric
arc welder The arc is struck on the head or nut of the bolt
and worked around in a slight circular movement until the
head is completely melted off (fig. 4). A punch is then
used to drive out the remaining part. The bolt or rivet con
be removed by heating the head almost to the melting point,
then quickly shearing it off with a cold chisel Care must be
taken not to cause the bolt to become welded to the metal
,_ --' _" START
CUT
HERE
HOLE PIERCING

Another usefu] application of the welding arc is piercing

Figure 2 holes in metal Coated metallic electrodes ore best far
this purpose because of their small size and insulation
afforded by the coatlng_ The process is extremely fast and
To make a trlal cut, place a bar of steel approximately
a surprisingly clean circular hole can be made For practice,
1/4-inch thick on the table so that one end projects over
place a piece of scrap iron 1/4-inch thick (or less) on the
the edge. Use a 3/32-1nch rod and a current setting of
table and allow it to project over the edge as for arc
around 140 amperes HoJd the rod as shown in figure 1 and
cutting Use a 3/32-1nch rod and the same current as for
strike an arc on the tap corner at the edge of the bar where
cutting_ At the place where the hole is to be pierced, strike
the cut is to be made, Feed the rod into the molten puddle
an arc and hold it until a molten puddle is formed_ Then
and keep the crater burning through as the rod is moved
push the electrode down against the molten puddle and
across the bar. To catch the molten metal, place a metal
force it through the plate_ It is possible to hold the electrode
container on the floor directly under the cut
against the melted plate because the metal core meffs off
When cutting metal heavler than 1/4-1nch, the arc is started faster than the coating_ The coating (not the rod) touches
at the bottom corner and worked up and down vertically the molten metal (fig 5) 1"he gap maintained by the pro-
as shown in figure 2, advancing the bottom of the cut truding coating prevents the metal core of the electrode
slightly ahead of the top of the cut to permit molten metal from sticking or freezing to the plate
to run out more easily_ if a smooth edge is desired, the
if a larger diameter hole is desired, first pierce a hole as
pieces can be ground on an abrasive wheel. Electrodes
described. Then, holding o fairly long arc, melt the edges
designed especially for cutting may also be used_
of the hole away by moving the rod around it (flg_ 6). Holes
of almost any diameter can be mode_ To pierce a hole
REMOVING SEAMS through material thicker than 1/4_inch, work from the
underside
In addition to cutting, the electric welding arc can be used
for beveling the edges of material to be welded, gouging
out cracked welds for rewelding or removing tack-welds. HEATING
The surface of the metal being worked upon should be ap-
proximately in the vertical position, or tipped slightly toward The carbon arc provides a convenient method for localized
the arc (flg_ 3)_Start at the bottom of the seam to be gouged heating of aJI metals. S_mply strike an arc on the part to be
out and work upward. The rate of speed will depend upon heated and "play" it across the surface until the required
the depth of the groove and the amount of metal removed. temperat_ure is reached

GQUGIRG

Figure 3 Figure 4 Figure 6

!-18

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 mNERT-GAS METAL-ARC WELDING (Nonconsumabne)

GROUNDED WORK
PIECE ANYCRAFTSMAH
WELDER
ALLCABLES
SHOULD BE ORWORK TABLE MAYBEUSEDWiTHHF,
KEPTSHORT TOELECTRODE / ATTACHMENT
ASPOSSIBLE HOLDER /
/ GROURB
CLAMP
(Donotex-
ceed12-f/2
feet[nlength)
[] D
O_

K.F.ATT WELDER
_/\ GROUND CABLE I GROUND
o o WELDER
CABINET
CABLE MUSTBE
_,,o g 230VOLT GROUNDER
_=========E_6O
CYCLE
SINGLE
PHASE
WELDING
CABLE
TO WELDER
HiGHFREQUENCY ACORDOWELDER
ATTACHMENT

Figure I Figure 2

HIGH FREQUENCY ATTACHMENT Alloil, grease, paint, rust, dirt or other contaminants must
be removed either by mechanical means or by the use of
The Craftsman, High-Frequency Attachment may be used vapor or liquid cleaners, Files, chisels and stainless wire
with any Craftsman welder or other single-phase, trans- brushes may be used Grinding is not recommended, Liquid
former_type welder of high quality construction having an cleaners such as naphtha, mineral spirits, alcohol, acetone
AC, or AC/DC power output Tungsten inert gas (T.LG.) and methyl-ethyl-ketone can be used All surfaces must be
welding has many useful and advantageous applications wiped dry with a clean cloth, Cleaners should not be used
as described in the following paragraphs_ In order to use after a joint is assembled prior to welding,
the T.LG. process with an AC welder, a high-frequency
attachment must be provided_ Figure 1 shows a typical Striking the arc may be accomplished as follows:
hookup using this high-frequency attachment with a Crafts- 1_ Touching the electrode to the work momentarily and
man welder_ When not using the TJ.G, welding process, the
quickly withdrawing it a short dlstance_ (DC power source)
high-frequency attachment also permits easy "arc" start.
ing and greatly improved results with many hard-to-weld 2 Use of an apparatus which will cause a spark to jump
rods (low hydrogen rods) as well as making the welding without touching the electrode to the work. (AC power
operation much easier to perform. source with high-frequency unit attachment)
The use of a hlgh-frequency attachment makes possible the The high-frequency arc stabilizer provides for this latter
establishment of an arc without touching the electrode to method of starting the arc. Such devices are not required
the work., Once the arc has been established, it isstabilized with DC, consequently it is usually necessary to touch the
by the hlgh-frequency output_ This is essential in the T.I.G. electrode to the work to start the arc.
process in order to avoid contaminating the tungsten elec-
trode or the work.. For manual welding, once the arc is started, the electrode
holder is held with the electrode positioned at an angle of
PRINCIPLES OF OPERATION about 75 degrees to the surface of the weld puddle as
shown in figure 2 To start the welding, the holder is usually
The necessary heat for inert-gas welding (nonconsumable) moved in a small circle until a pool of molten metal of suit-
is produced by an electric arc maintained between the non- able size is obtained. Once adequate fusion is achieved at
consumable electrode and the work-piece. The electrode any one point, a weld is made by gradually moving the
used for carrying the current is usually a tungsten or tungsten electrode along the parts to be welded to melt the adjoin-
alloy rod_ The heated weld zone, the molten metal and the ing edges progressively, adding filler rod as required.
nonconsumable electrode are shielded from the oxidizing Solidification of the melted metal follows progression of
effects of the atmosphere by a blanket of inert gas fed the arc along the joint and completes the welding cycle_
through the TJ_G. torch and the weld is made by applying
the arc heat until the abutting edges of the work-places are Material thickness, joint design and weld characteristics
desired will determine whether or not filler metal should
melted, adding filler rod if necessary_ The resultant pool
of molten metal, upon solidifying, joins the edges of the be added to the joints_ When filler metal is added during
members togethen The process may also be used for adding manual welding, it is applied by hand feeding the filler rod
metal to surfaces, Iocally-meltlng and spot-joinlng parts. (from the side) into the pool of molten metal in the region
of the arc. Filler rod is added in essentially the same manner
A thorough cleaning of the surface to be welded isrequired_ when welding by the oxyacetylene method.

1-19

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 (2) MOVE (3) ADD '_
THE PUDDLE TILLERMETAL
TORCH
DIRECTION
(1) DEV_.LOP _,/,//////////,',/,/,,'/,,////,,/
_/27_
OF WELD"._
_///I/I///f////////////J
f
WOREPIECE (5) MOVETORCH ADDITIONOF
TO LEADINGEDGE_ FILLERMETAL
(VERTCAL -_s°'_ I
(4) REMOVE
ROD
/7 OT
POD L POSITIO_

_////////////_;///////////_/_
Figure 3

The filler rod is usually held at an angle of approximately electrodes are alloyed with small percentages of thorium
15 degrees to the work and slowly fed into the weld puddle. or zirconium. Such electrodes have the advantage of greater
One of the most commonly used techniques for feeding filler current-carrying capacity for a given diameter, a more
rod is shown in figure 3. Another method, used most often stable arc at low current values, and longer life with less
in multlple-pass welding of vee joints, is to press the filler deposit of tungsten in the welds.
rod into the vee groove in line with the weld and melt it
along with joint edges_ Still another method, used fre- TYPES OF GAS TO USE
quently in making large welds, is to feed filler metal con- Either argon, helium, or a mixture of the two can be used with
tinuously into the weld puddle by oscillating the filler rod
and arc from one side of the weld to the other° The filler the T.I.G process. Argon is used most frequently because:
rod moves in one direction while the arc moves in the 1. It provides general suitability with a wide variety of
opposite direction, but the filler rod is at all times in close metals
proximity to the arc and feeding into the weld puddle.
2. It maintains a stabilizing influence on the welding arc.
Joints may be welded by the T.I.G process include all 3_ It costs less (due to the lower flow rates required).
standard types, such as square abutting edge, vee butt, tee
and lap connections, It is seldom necessary to bevel edges Helium is generally used when welding heavy metal sections
of material 1/8-1nch or less, although heavier materials are because it provides greater weld penetration. Mixtures of
usually beveled. Whenever joints are beveled, filler ma- argon and helium are useful when a balance of these char-
terial must always be added_ acteristics is desired_

The accompanying tame provides a guide to the type of Argon is generally supplied in K-cyllnders, having a capacity
current recommended for welding some typical materlals. of approximately 238 cubic feet at a pressure of 2200 psi,
Electrodes used for the T.I.G. (nonconsumable) process may or in T-cylinders, having a capacity of approximately 330
be pure tungsten or tungsten aBoy. Pure tungsten electrodes cubic feet at a pressure of 2640 psi. Purity of commercial
were formerly used exdusively_ At this time, however, many argon ranges between 99,95% and 99_99%

Matetla]

CurrentSelectionfor Inert-gas Magnesium up to _i_-imthick

Magnesium above_'iG.in thick
(nonconsumable)
welding Magnesium castings
AIuminumup to _32.in thick
Aluminumover_-in thick
Aluminumcastings
Stainlesssteel
Brass alloys
iliconcopper
;liver
Higb-chlomium, nickelbase,high.
temperaturealloys
Silver cladding
Hard facing
Cast iron
Lowcarbonsteel, O015 to 0 030 int
Lowcarbonsteel, 0.030 to 0.125 in.
High.carbonsteel, 0015 to O,O30in
High.carbonsteel, 0030 in andup
DeoxidizedcopperP
*Where aIternating current _s recommended as a second choice, use about 25% higher current than that
recommended fat DCSP,
t Co no use _lte nang cu rent on tigEhlly jigged p_rts.
Use brazing flux or sl con-bronze _x o_ /4, nch and h ck_

1-20

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 WELDgNG RGD $PEC FmCATmONS

AWS E-6Gll MILD STEEL AC-DC

GENERAL APPLICATIONS: Farm Equipment o Sheet Metal o Car and Truck •

Body and Fender = Pipe o Tanks o Maintenance o Jigs and Fixtures o Cabinets
o General Repairs oStructuralSteel

SIZES AND HEATS (AMPS)

Diameter .... 1/16" 3/32" 1/8" 5132" 3/16" 7132"" t/4'*

Flat 20"55 20-80 75"130 100-175 t50-225 175-250 200-375

Vertical 20"55 20"65 75"115 100-t50 150-200
Overhead 20-55 20"B5 75"115 100-150

SPECl FICATIONS

MEETS AmericanWelding Society ..................... Class:E-6011

THESE Military ....................................... MIL-E-15599C
REQUIREMENTS _' American Bureauof Shipping .............. Class:E-5011

Physical Properties of Deposited Metal: As Welded Stress Relieved

Tensile Strength .......................................... 70,000 to 75,000 psi 65,000 to 70,000 psi
Yield Point .......................................... 60,000 to 65,000 psi 55,000 to 60,000 psi
% Elongation in 2-inches 23% to 25%
.................................... 30% to 35%
Reduction in Area ..................................... 50% to 55% 65% to 75%

DESCRIPTION

The AWS E-6011 is an AC-DC (reverse polarity) electrode with a special coating that provides strong
fluxing action for high quality welds, even in dirty, rust covered, galvanized or plated steels, An extremely
stable, spray type penetrating arc, is produced that is easy to start and restart after interruption. It is a
versatile electrode, producing welds far beyond the requirements of its A.WS. classification It adapts to a
wide variety of jobs due to the wide range of amperage settings at which top quality results are obtained
Features: Deeper Penetration - Fast-Freeze Puddle - Greater Arc Stability.

WELDING PROCEDURE: Weld with AC or DC (reverse polarity) Strike the arc by brushing rod tip lightly
at the point where weld is to be made. After the arc is established and weld material is deposited,
concentrate on holding a short arc that is just long enough to keep the electrode from touching the molten
metal, In the flat position, use a slight oscillating motion as you advance, In vertical position, on sheet steel
start at the top of the seam and weld down, This provides a more rapid speed of travel, lower penetration,
and minimum warpage When welding overhead use a straight stringer bead or a circular motion Keep the
molten pool as small as possible_ Use small electrodes overhead, none larger than 5/32 diameter_

2_1
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 AWS E-6013 MBLD STEEL AC-DC
multi-purpose all position

GENERAL APPLICATIONS: Farm Equipment o Car and Truck o Sheet Metal o

Pipe o Tanks e Boilers = Structural Steel o Maintenance Repairs o General Repair
Work

SIZES AND HEATS (AMPS)

Diameter ...... 5/64'" 3/32" 118" 5/32" 3/16" 1/4"

Fiat 20-55 20-75 75-130 100-175 150-225 200"375
Vertical 20-55 20-65 75-115 100.150 150-200
Overhead 20-55 20_65 75-115 100-150

SPECl FICATIONS
MEETS
THESE Military ................................................
MIL-E-15509C
REQUIREMENTS _) mericanWelding Society .................... Class:E-6013
& MI L-E-S043A
American Bureauof Shipping ................... Class:E-0013

Physical Properties of Deposited Metal: As Welded Stress Relieved

TensileStrength ...................................................... 75,000 to 00,000 psi 05,000 to 70,000 psi

Yield Point ................................................ 62,000 to 07,000 psi 50,000 to 00,00g psi
% Elongation in 2-inches ...................................... 20% to 29% 27% to 35%
Redaction in Area ................................................. 40% to 55% 00% to 70%

DESCRIPTION

The AWS, E-6013 is a general purpose mild steel electrode for use with AC or DC It produces a very stable,
easily handled arc throughout a wide amperage range_ The moderately penetrating and easily directed arc
provides excellent results in all positions (fiat, vertical or overhead) and is ideal for single pass horizontal
fillet welds_ Spatter loss is low, as the weld metal solidifies quickly producing a closely rippled deposit with
good appearance.
Even though it is designed for production welding in mild steel fabrication, this rod is excellent for
multi-purpose use where sound durable welds are required,
The arc is easily started, even at low amperage settings for light gauge steel, yet is stable at the high
amperages needed for higher welding speeds, and for heavier sections.
Use with AC or DC (see recommended amperages) Hold a short arc, just long enough to keep the electrode
from touching the molten metal. In flat position single pass fillets or butt welds may be made with or
without weaving. Weld from bottom up on vertical welding of heavy sections Welding down on light
material or fillets produces excellent results Use 5/32-inch or smaller electrodes for overhead work, making
either stringer or weaving beads.

2-2
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 WELDWNG ROD SPECIJFICATiONS

HARD SURFACING AC-DC

medium chrome-carbon electrode

GENERAL APPLICATIONS: Tractor Grousers and Rollers o Scraper Blades o Agri-

cultural Implements o Plow Shares o Hitches • Power Shovel o Dipper Teeth and
Drive Sprockets = Coal Cutters e Conveyor Rolls • Mining Buckets • Rock Crushers
o etc,

SIZES AND HEATS (AMPS)

Diameter .... 3/32" 1/8" _ 5/32" 3/10" 7/32" 1/4"

Amperes 55-85 100-130 1 130-150 175-200 175-250 225-275

SPECl FICATIONS

THESE
MEETS Military ................................. MIL-E-19141C
REQUIREMENTS

Physical Properties of De_positedMetal

As Welded Condition (Rockwell "C" 46-50) .................................................... 450-500 Brinell Hardness
After Cold Working (Rockwell "C" 50-54) ............................................. 500-550 Brineli Hardness

DESCRIPTION

The Medium Chrome-Carbon rod is a hard-surfacing alloy steel electrode with a coating of powdered metals
and flux. When welding, this special coating combines in the arc with the steel core wire to give an
extremely hard weld-meta! deposit Deposited weld metal requires no heat treatment for maximum
strength, ductility, and wear resistance, Annealing or heat treating will not soften the metal deposit, which
is not machinable, but may be hot forged to any desired shape, Deposited metal has a very fine grain and is
free of slag and porosity The metal is tough and highly resistant to wear and impact
The rod is designed for use with either AC or DC (either polarity) Hold a medium short arc and deposit the
metal with a weaving motion Excellent welding results are obtained in either the vertical or flat position,
WELDING PROCEDURE: Gdnd the surface to clean and remove shallow cracks, rust, or other foreign
material Cracks too deep to be removed by grinding should be gouged out w_th a cutting torch or cutting
rod Use the "drag" technique to deposit weld metal, to thin edges when desirable or weave a wider bead,
or use a "free" arc,

2-3

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 WELDmNG ROD SPECmF CATmONS

AWS E-7014 CONTACT AC-DC

for welding of mild steel

GENERAL APPLICATIONS: Sheet Metal Fabrication and Repairs e Machinery

Fabrication • Construction Equipment Repairs = Storage Tanks e Shipbuilding
Fabricating Structural Shapes and Heavy Equipment = Equipment and Heavy Pipe
Welding

SIZES AND HEATS lAMPS)

Diameter .... 1/18" 3/32" 1/8" 5/32" 3/16" 1/4"

Length 12" 14" 14" 14" 18'" 18"
Amperes 70-90 90-110 130-105 190-210 200-250 250-350

SPECl FICATIONS

MEETS _k
THESE _) AmericanWelding Society ..................... Class:E-7014
REQUIREMENTS JV American Bureauof Shipping ................ C/ass:E-7014

Physical Properties of Deposited Metal: AsWelded

TensileStrength ................................................................................... 72,000 psito 78,000 psi
Yield Point ..................................................................................... 60,000 psito 69,000 psi
% Elongation in 2.inches .......................................................................................... 17%to 28%

DESCRIPTION

The AWS E-7014 is an excellent electrode for the inexperienced or experienced welder_ Starts on contact
with smooth surge-free arc, also restrikes instantly. This Craftsman electrode has powdered iron in the
coating which makes welding easier and faster_ The slag is easy to remove in most cases self-peeling as the
weld cools_

Ideal for fixture welding where weld appearance and lack of spatter is important. The amount of slag
permits use in all welding positions
WELDING PROCEDURES: Weld materials should be clean. Best results are obtained when fit-up is good.
Either AC or DC current may be used. When arc is established, deposit metal holding a short arc or place
electrode in contact with work,.

2-4
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 Jm=LDBNG ROD SPECNF CAT ONS

MACHINABLE CAST RON AC-DC

machineable welds on all cast irons

GENERAL APPLICATIONS: Cylinder Blocks o Crankcases o Valve Seats e Defective

Castings o Gears o Sprockets e Casting Repairs in General o Garages o Farms o Shops

SIZES AND HEATS (AMPS)

Diameter 3/32" 1/8" 5/32" 3/18"

Amperes 48-85 75-130 100-150 130-175

DESCRIPTION

This electrode uses a nickel core wire, and produces a fully machinable weld without
pre-he._ting the casting, Cast irons can be joined to steel, nickel alloys and copper,
This electrode operates with AC or DC (reverse polarityL It has very stable arc
characteristics
It is recommended for automotive repairs, such as cylinder blocks, crank cases, valve seats
and other cast iron parts In maintenance and repairs it is used on gears, sprockets, and
many farm machinery parts

WELDING PROCEDURE: Remove all dirt and grease from work piece before starting to
weld, A cutting electrode may be used to burn a groove along the break where the weld is
to be made This cutting electrode removes the grease and scale, and then seals in any oil
soaked into the cast iron
Use the lowest amperage that gives good fusion During cooling, peen hammer the weld to
relieve strain and stress

CUTTIING ROD AC-DC

quick, inexpensive, easy cuts through all metals

GENERAL APPLICATIONS: Cutting e Piercing _ Gouging = Scarfing o Beveling = etc

SIZES AND HEATS (AMPS)

Diameter ...... 3/32" 1/8" 3/16"

Amperes- AC 80150 75-130 100o150 130-175
5/32"
Amperes - DC 150-250 -

DESCRIPTION

For piercing, gouging, cutting, and scarfing

Excellent for removing old welds in preparation to rewelding_ Also used for beveling
cracks in castings or removing sharp edges prior to welding Needs no oxygen or special
equipment to cut carbon steels, stainless steel, manganese steel, cast iron, etc
Recommended for the owners of all arc welders_ AC or DC

WELDING PROCEDURE: Place etectrode in holders so that it's positioned like a lance in
the direction of travel The angle between the electrode and work metal should not
exceed 15° Strike arc at starting point, Push electrode along the line of cut, forcing the
molten metal ahead and away If deeper gouge is required, repeat procedure untg the
desired depth has been reached

2_5

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 REPAIR PARTS
PARTS LIST FOR CRAFTSMAN 230 AMP WELDER MODEL 113o201372

42 43 27 45 45 15

34
41 27

\
\ 44
\

19
/

35

11 10

23 24

32 \
\
\

12
27 13

= Transformer not replaceable°

29
28

2-6
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 PARTS LIST FOR CRAFTSMAN 230 AMP WELDER MODEL 113.201372

Always Order by Part Number - not by Key Number

Key Part I(ey J Part

No. No., Description No.. i No_ Description
r
1 61331 Plate, Selector 28 130284 +Holder, Electrode
2 61276 Spacer 29 51439 +Clamp, Work
3 61277 Pointer 30 _STD 522507 *Screw, Hex Hd, 1/4-20 x 3/4
4 STD 511110 *Screw, Pan Hd 10-32 x 7/8 31 61234 Cable Assembly, Work
5 61278 Knob Assembly 32 6TD 601105 *Screw, Ty T Pan Hd 10-32 x 1/2
6 61279 Bushing 33 60314 *Screw, Truss Hd.. I/4-20 x 5/8
7 !60325 Washer, 3/8 x 1-3/8 x 3/64 34 STD 510607 *Screw, Pan Hd 6-32 x 3/4
8 61280 Cabinet, ]'op 35 61295 Cable Assembly, Electrode
9 STD 611005 *Screw, Type AB Pan Hd No 10 x 1/2 36 30332 insulator, Plug
10 STD 541025 *Nut, Hex 1/4-20 37 61171 Plug, Selector
11 STD 551225 *Lockwasher, 1/4 int.. 36 61086 Relief, Strain
12 STD 551025 *Washer, 17/64 x 47/64 x 1/16 39 61329 Cabinet, Bottom
13 STD 541006 *Nut, Hex 6-32 40 STD 510692 *Screw, Pan Hd. 6-32 x 3/16
14 30307 Connector, Cable 41 STD 600805 *Screw, Pan Hd. 8-32 x 1/2
15 61143 Cord 42 30254 Switch
16 61332 Slide, Shunt 43 STD 551008 *Washer, 3/16 x 3/8 x 1/32
17 61335 Bracket, Guide 44 STD 551010 *Washer, 13/64 x 5/8 x 1/32
18 STD 601103 *Screw, Ty T Pan Hd 10-32 x 3/8 45 STD 541008 *Nut, Hex 8-32
19 61333 Guide, Shunt 46 60309 Washer, 1-1/64 x 1-1/2 x 1/64
20 61334 Spring 47 61115 Block, Contact Mounting
21 61384 Core Assembly, Moving 48 61116 Contact, Selector Plug
22 o
Transformer Assembly 49 61117 B_ock, Contact Mounting
23 61314 Motor 50 6TD 541110 *Nut, Hex 10-32
24 61302 Bracket, Fan 51 STD 551110 *Lockwasher, No 10
25 STD 501102 *Screw, Socket Set 10-32 x 1/4 52 61186 +Helmet
26 61315 Blade Assembly, Fan - 61298 Bag Assembly, Loose Parts
27 STD 551108 Lockwasher, #8 - 61337 Owners Manual (not illustrated)

*Standard Hardware Item - May be Purchased Locally,

+Stock Item - May be secured through the hardware department of most
Sears Retail Stores or Catalog Order Houses,
OTransformer not replaceable,

_7

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 ISears I
230 AMP DUAL RANGE
ARC WELDER

SERVICE Now that you have purchased your 230 amp arc welder, should
a need ever' exist for' repair parts or service, simply contact any
Sears Service Center and most Sears, Roebuck and Co. stores.
Be sure to provide all pertinent facts when you call or visit

MODEL NO. The model number' of your 230 amp arc welder will be found
on a plate attached to your' welder, at the rear' of the cabinet.
113.20137 2

HOW TO ORDER WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE

FOLLOWING INFORMATION:
REPAIR PARTS
PART NUMBER PART DESCRIPTION

MODEL NUMBER NAME OF ITEM

113,201372 230 AMP ARC WELDER

All parts listed may be ordered from any Sears Service Center
and most Sears stores. If the parts you need are not stocked
locally, your order will be electronically transmitted to a Sears
Repair Parts Distribution Center for handling.

Sold by SEARS, ROEBUCK AND CO., Chicago, IL 60684 U.S.A.

Part No 61337 Form No SP4271-4 Printed in USA 6/81
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