Welding

TM 10-3930-633-34

must be made in 2 or more passes. Bead from first

available from welding suppliers in 50 in-

pass is to be chipped and work must not be

crements from 100 F through 2200 F.

allowed to cool between passes.

c. All cracks in the damaged area, or in areas

listed in paragraph 2-14 above, must be groove-

2-21. Inspection

ground the entire length of the crack, and the

a. Remove slag and spatter, and check for

entire crack removed. Any weld repair must be

conformity to paragraph 2-20 (above). Finished

made on sound material.

and cooled joints should be thoroughly inspected

d. No notches, gouges, or craters should be left

for chill cracks. If any, prepare as in paragraph 2-

in the area of weld repair, but must be weld-filled

19 (above) and reweld.

and ground to the original contour before repair

b. Joint inspection is recommended by either

welding. Preparation for weld assumes smooth

of the following methods:

surfaces and contours easily accessible to the weld

(1) Dye penetrant, wet or dry process.

arc.

( 2 ) Magnetic particle inspection. Man-

e. Finish grind marks after welding (if any) on

ufacturer's instructions included with the testing

any surface should not exceed 63 microinches,

gear should be followed as applied to the size,

and should run in the direction of the load. When

shape, or other nature of the work being tested.

required, a disc grinder with #80 grit abrasive is

In general, however, the conditions shown below

recommended.

will serve in most cases, whether the process

2-20. Welding

employs direct or rectified current.

a. Welding should be performed by ex-

(a) Distance betweeen prods shall not be

perienced/qualified welders.

less than 2 inches.

b. Voltage/amperage/speed settings should be

(b) Ratio for prod spacing/amper-

balanced to produce a well-formed bead, and to

age/section thickness:

assure proper penetration.

c. For subject component welding, the

following ranges apply for E-7018, E-8018, E-

9018 and E-10018 electrodes: Manufacturers

recommendation for arc length and amperage is to

be followed. These ranges must be balanced per b

direct method, care must be taken to provide

above.

sufficient contact area to pass the required

Size

Weld Inches Min

Amperage

amperage without overheating or burning the

(Average)

work. 100 to 400 amperes per inch of diameter

3 /32

70-120

1/8

6-8

100-150

should be used.

5 /32

120-200

8-10

c. Continuous or residual inspection may be

200-275

10-12

3/16

employed.

12-14

275-350

7/32

d. Repaired weldment should be checked for

14-16

300-400

1/4

straightness, flatness, and overall conformance to

d. On the rectifier type welders (most common

original dimensions prior to returning to service.

today) the voltage is variable and is automatically

2-22. Indemnity

keyed to the amperage. The voltage range is

It is understood by all parties that the welding

therefore omitted from the listing.

repair of any damaged fork, carriage, or upright

e. Average welding speed (inches per minute)

component on the machines of subject Govern-

is based on " fillets and on flat and horizontal

ment contract, and the compliance with the in-

joints. It will be obvious that the selection of

structions and conditions contained herein, is to

electrode sizes under 5/32" is unwise for this

be the responsibility of the agency authorizing

application.

that repair, and not the manufacturer.

f. All joints calling for 3/8" (or more) fillet

Section IV. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS AND ACCESSORIES

2-23. General

of those major components which are replaceable

only at the Direct Support or higher level of

The instructions in the following paragraphs

maintenance. Refer to TM 10-3930-633-12 for

are provided to aid in the removal and installation

2-12