The Welding Handbook - Wilh. Wilhelmsen

1 The Welding HandbookWelding and Related Processes for Repair and Maintenance Onboard14th edition2nd revisionNotice: All Welding is carried out on the welder s own risk and account. Welding should be executed by a qualified and experienced welder and adequate safety measures should always be adhered to. The information and guidelines in this Welding Handbook are based on general information and knowledge at hand and are believed to be accurate and reliable, but the information and guidelines are not to be taken as a guarantee or warranty for a special purpose. The information and guidelines are provided to the welder solely for his own consideration, and Wilhelmsen Ships Service AS assumes no legal responsibility or liability for eventual damages and/or losses should the information and/or guidelines turn out to be incorrect or un-suitable.

2 Wilhelmsen Ships Service AS is not liable for any loss or damages whatsoever and howsoever arising which is due to force majeure, other events beyond the reasonable control of Wilhelmsen Ships Service AS or events that could not reasonably be foreseen by Wilhelmsen Ships Service AS when this Welding Handbook was made. Wilhelmsen Ships Service AS is in no event liable for indirect, incidental or consequential damages or losses, including dam-ages for loss of profits, resulting from lack of conformity, including but not limited to loss resulting from goods or software not working when connected to other goods/software or for any related cause thereto.

3 Wilhelmsen Ships Service AS s liability shall in any event not exceed the total purchase price of theWilhelmsen Ships Service AS goods used during the Welding operations. These conditions are automatically accepted by anybody using the information and guidelines in this Welding ship at sea depends upon the knowledge, skills and self-reliance of the crew to carry out necessary maintenance and repair work. One of the important skills required is a good command of modern Welding purpose of the Welding Handbook for maritime welders is to provide guidance in modern Welding and related processes and to provide the welder with a source of practical information on the right solution to specific onboard Welding gained from user contact and Welding training of crewmembers showed that documentation aimed specifically at on board Welding solutions was needed.

4 This led to the development of the first Welding Handbook for on-board repair and maintenance Welding already the edition of the UNITOR Welding Handbook builds upon all the earlier editions and on Wilhelmsen Ships Service s business Ships Service AS enjoys close co-operation with its customers and would like to thank the many who have taken the effort to contribute with examples of successful solutions to real life maintenance situations. Unitor s business activity traces back to 1905 and the company NAG with Acetylene production as a basic activity. The first maritime deliveries from this period were supply of Acetylene as fuel gas for the guiding light beams from numerous lighthouses along the long and weather-beaten coast of focus changed towards gas and arc Welding techniques when these were developed to useful production and repair methods through the main objective became to develop and maintain a range of Welding equipment that is suitable for onboard Welding , backed by a worldwide service network, training and 1943 the company name was changed to UNITOR.

5 Mergers and increasing activity in the department for sales to ships led to the establishment of this department as a separate company; Unitor Ships Service AS in 1968. In 2005 the company was bought by ASA and the brand Unitor is now incorporated in Wilhelmsen Ships Service AS, a part of Wilhelmsen Maritime Services AS, a company in the Wilh. Wilhelmsen Welding Handbook Introduction & quick guides to processes Filler material consumption Metal identification Unalloyed / low alloyed steel Problem steels Stainless steels Cast iron Copper and copper alloys Aluminium Evaluation of welds Coated Electrodes TIG Welding rods & Fluxes Wires for Wire Welding Gas Welding rods & Fluxes Brazing rods & Fluces Cold Repair Compounds electrode Welding & gouging TIG Welding Wire Welding Plasma Cutting Current Distribution System AC/OX

6 Cutting, Welding , brazing Gas Supplies and gas distribution system 517 5351 SAFETY IN WELDING2 SOLUTIONS3 CONSUMABLES4 ARC Welding AND CUTTING PROCESS & EQUIPMENT5 GAS Welding AND CUTTING PROCESS & MISCELLANEOUS INFORMATION Welding HANDBOOK41 SAFETY IN Welding .. 9 1 .01 Introduction .. 10 1 .02 How to use the Handbook .. 11 1 .03 Welding instructions and training .. 12 1 .04 Personal protection .. 13 Arc Welding face shields .. 14 Protective goggles .. 18 Welder's protective clothing .. 20 1 .05 Work site protection.

7 22 Welding curtain .. 22 Welding blanket .. 22 Fire extinguisher .. 23 1 .06 Welding fumes .. 24 Welding fumes .. 26 Fume extraction .. 27 1 .07 Safety check list .. 30 Equipment .. 30 Work place .. 31 Hot work procedure .. 32 Operator protection .. 322 SOLUTIONS .. 35 2 .01 Introduction .. 36 Quick reference for cutting .. 37 Quick reference for joining .. 38 Quick reference for rebuilding, hardfacing and coating .. 41 Quick reference to cold repairs.

8 43 2 .02 Filler material consumption .. 45 2 .03 Metal identification .. 48 2 .04 Unalloyed / low alloyed steel .. 53 Introduction .. 53 Unalloyed steel .. 53 Low alloyed steel .. 53 Heat resistant steel .. 53 Low temperature steel .. 54 Weathering steel .. 54 2 .05 Problem steels .. 62 2 .06 Stainless steels .. 65 Introduction .. 65 Austenitic Stainless Steel .. 66 Ferritic Stainless Steel .. 68 Martensitic Stainless Steel .. 69 Duplex Stainless Steel.

9 70 Clad Steel .. 71 Stainless Steel corrosion types 72 Storing and handling of Stainless Steel onboard .. 74 Grinding/cutting consumables for Stainless Steel .. 75 Unitor Safety Grinder .. 77 2 .07 Cast iron .. 78 Introduction .. 78 Grey cast iron .. 79 White cast iron .. 80 Malleable cast iron .. 80 Ductile cast iron .. 81 High alloy cast iron .. 82 Identification of cast iron .. 83 Preparation of the work piece .. 84 Arc Welding of cast iron.

10 87 Braze Welding of cast iron .. 95 Cold repair on cast iron .. 97 2 .08 Copper and copper alloys .. 104 Introduction .. 104 Brass .. 104 Aluminium brass (Yorcalbro) .. 105 Bronze .. 106 Nickel bronses (Cunifer) .. 107 2 .09 Aluminium .. 112 2 .10 Evaluation of welds .. 114 Typical Welding faults .. 114 Inspection of welded joints .. 118 Crack detection .. 1233 CONSUMABLES .. 125 3 .01 Coated Electrodes .. 126 Introduction .. 127 Types of electrodes .. 128 Storing and re-drying.