Kress Welding Procedure A514 5y2s5f

WELD PROCEDURES FOR KRESS CORPORATION EQUIPMENT Kress Standard #095202, Revision A Released May 8, 2006

1.0 Purpose: To provide a method of communicating the end requirement for arc-welded ts based on the type of loading, e.g. bending, fatigue, shock, static, torsion, etc., and the resulting stress levels as determined by Kress Corporation engineering analysis and / or field experience. 2.0 WELD SAFETY & WARNINGS:

2.1

Under No Circumstances should wheel rims be welded while the tire is mounted. Dangerous fumes can form inside the tire during welding that has resulted in severe explosions causing severe injury and death.

2.2

All factory welding on Kress machines is done in accordance with Kress Engineering Weld Quality Standard #095200.

2.3

All welding personnel are qualified per Section 5.11 Method B of the AWS D14.394 specification for welding earth moving and construction equipment.

2.4

Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can kill.

2.5

Read and understand the manufacturer’s instruction and your employer’s safety practices. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing zone and the general area. Wear correct eye, ear and body protection. Do not touch live electric parts.

2.6

Refer to the American National Standard Z49.1, "Safety in Welding and Cutting" published by the American Welding Society, 2501 N.W. 7th Street, Miami, Florida 33125: OHSA Safety and Health Standards, 29 CFR 1910, available from U.S. Dept. of Labor, Washington D.C. 20210. Proper Welding Procedure on Machines and Engines with Electronic Controls

3.0 PROPER CLEANING FOR INSPECTION:

3.1

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Personal injury can result from working with cleaning solvent. Because of the volatile nature of many cleaning solvents, extreme caution must be exercised when using them. If unsure about a particular cleaning fluid, refer to the manufacturer’s 1

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instructions and directions. Always wear protective clothing and eye protection when working with cleaning solvents. 3.2

Care must be taken to ensure that fluids are contained during performance of inspections, maintenance, testing adjusting and repair of the product. Be prepared to collect the fluids with suitable containers before opening any compartments or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates.

4.0 Preparing the Area for Welding 4.1 Clean the area that will be welded. Make sure that the substances that follow are removed from the area that will be welded. • Oil • Grease • Paint • Dirt 5.0 The carrier portion of the Kress machine has approximately 80% content of quenched and tempered steel plate comparable to ASTM A514 specifications. The remaining steel in the machine is Mild SAE 1018 or 1020 material, however in most cases this mild steel material is welded to ASTM A514. Because of these conditions, all welds must be treated as if the base material meets ASTM A514 at 100,000 PSI minimum yield. 5.1 The welding material used on Kress machines is to have a published yield of 62,000 to 80,000 PSI. This is important if the fatigue life of the machine is to be maintained. 5.2

Manual welding ("Stick") electrodes MUST meet American Welding Society E7018 Grade Specifications for low hydrogen electrodes - these electrodes must be kept dry and maintained in a rod oven.

5.3

Semi-automatic wire electrode MUST meet American Welding Society E71T-1 or E70T-5 Grade Specifications.

6.0 WELD PRE-HEAT: 6.1 No welding should be done on Kress machines when the metal is below 70 degrees Fahrenheit without pre-heat.

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6.2

When welds are being made in areas where plates are 1.00 inch thick or thicker, and/or where the t is highly constrained (a flat plate crack is a good example of this), the weld area should be pre-heated to and maintained at between 250 and 400 degrees F. Do not exceed 400 degrees F. for pre-heat and inter temperature. A temperature stick, or a surface pyrometer should be used to correctly judge temperature.

6.3

When the ASTM A-514 plate thickness is more than 2.50" the preheat temperature is to be maintained throughout the welding process at the higher part of the range, but do not exceed 450 deg. F. The welding electrode is to be AWS CLASS E70T5 (Kress# T16180) which is similar to AWS A5.5-81 E7018-A1 electrode.

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6.3.1

Heat distortion of the base metal is possible when you weld. Avoid excessive heating of the base metal.

6.3.2

Attach the welding ground cable directly to the base metal. Protect machined surfaces from sparks. Protect the machined surfaces from the weld splatter.

7.0 WELD POST HEAT: 7.1 Weld post heat is not required unless the ambient temperature is less than 50º F. If the ambient temperature is less than 50º F then a weld blanket should be used to allow the welds and adjacent material to cool slowly. 8.0 CRACK REPAIR: 8.1 All cracks are to be gouged out to their full depth with an air-carbon arc. If possible the arc gouge should be followed by grinding to a depth of 1/32 to 1/16 inch to remove any carbon deposits that may have been introduced by the carbon arc. 8.2

The gouge should always be at least twice as wide on top as it is deep. In areas where both sides of a crack are available for repair, the gouging should be done from both sides leaving a minimal area in the middle for a 100% penetration weld. In areas where the back side of the crack is not exposed, the gouge should extend almost, but not quite, through the plate for a 100% penetration weld.

8.3

In cases where a complete break has occurred, the broken parts should be scarfed (beveled on the broken edge) to allow a full depth weld, and welded from both sides if possible.

9.0 WELD FILLET SIZE: 9.1 With manual (stick) electrodes, the single fillet size should not exceed 2 rod diameters. Under no circumstances should any single weld, either manual or semi-automatic, exceed 3/8 inch. Larger welds should be built up with multiple es, no one exceeding 3/8 inch. Each should be de-slagged and wire brushed before successive es are made. Check weld temperature before each to make sure that the inter temperature does not exceed 400 degrees F. Rod Diameter (inches)

Weld Fillet Size (inches)

1/8

1/4

5/32

5/16

3/16

3/8

Table 1

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Table 2. Fillet Weld – Minimum Number of Weld es Specified Fillet Weld Leg

Minimum Number Weld es to Make Weld

Minimum Number Weld es Showing On Finished Weld

.12 thru .38

1

1

0.5

2

1

0.75

4

2

1

6

3

10.0

PROPER WELDING PROCEDURE ON MACHINES AND ENGINES WITH ELECTRONIC CONTROLS 10.1 Proper precautions are necessary to prevent damage to electronic controls. When you weld on a machine with electronic controls, use the steps that follow: 10.1.1 Turn off the engine. Put the key start switch in the OFF position. 10.1.2 If the machine has a battery disconnect switch, open the switch. If the machine does not have a battery disconnect switch, disconnect the negative battery cable at the battery. 10.1.3 Connect the ground cable for the welder directly to the actual machine component that will be welded. Place the clamp for the ground cable as close as possible to the area that will be welded. This will reduce the chance of damage from welding current to the components that follow: bearings, hydraulic components, and electrical components.

10.1.4 DO NOT use electrical components as a ground point for the welder. DO NOT use ground points for electronic components as a ground point for the welder.

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10.1.5 Protect the wiring harnesses from the weld splatter. 11.0 WELD SPECIFICATIONS 11.1 Low Hydrogen Electrodes for the SMAW Process 11.1.1 The tables that follow list the mechanical properties of welds that are deposited by low hydrogen electrodes. Mechanical Properties of Welds from Low Hydrogen Electrodes That are Classified as “ANSI/AWS A5.1 E7018” Tensile Strength

480 MPa (69618 PSI)

Yield Strength

400 MPa (58015 PSI)

Elongation

22%

Impact Toughness

27 J @ -18° C (20ft lbs @ -20° F)

Table 3 11.1.2 Low hydrogen electrodes must be stored in an electrode oven at 120° C (248° F). If low hydrogen electrodes get damp, scrap the low hydrogen electrodes or recondition the low hydrogen electrodes to the manufacturer’s specifications. 11.1.3 Table 4 shows setting for the welding current for the electrode diameter. Welding Current for Low Hydrogen Electrodes Diameter

Amperage Rating

3.2 mm (0.13 in)

70-140

4.0 mm (0.16 in)

110-180

4.8 mm (0.19 in)

190-270

Table 4 11.1.4 Use a polarity setting of DC reverse polarity. Remove the slag after each of the welding electrode. The width of the weld should not exceed two times the electrode diameter 11.2

Flux Cored Welding Electrode for the FCAW Process 11.2.1 Table 5 lists the mechanical properties of welds that are deposited by the flux cored welding electrode.

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Mechanical Properties from Flux Cored Welding Electrode that is Classified as “ANSI/AWS A5.20 E71T-1 or E70T-5” Tensile Strength

480 MPa (69618 PSI)

Yield Strength

400 MPa (58015 PSI)

Elongation

22%

Impact Toughness

27 J @ -18° C (20 ft lbs. @ -20° F)

Table 5 11.2.2 Table 6 shows setting for the welding current for the flux cored welding electrode that has a diameter of 1.3 mm (0.05 inch). Welding Current for Flux Cored Welding Electrode that is Classified as “ANSI/AWS A5.20 E71T-1 or E70T-5” Wire Feed Speed

Voltage

Amperage

Minimum 5080 mm (200 in) per Minute

24

210

Optimum 6985 mm (275 in) per Minute

28

250

Maximum 8255 mm (325 in) per Minute

29

300

Table 6

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11.3

The settings for the welding current can vary due to the position of the weld. Also, the settings for the welding current can vary with the manufacturer of the welding electrode.

11.4

Use a polarity setting of DC reverse polarity. Remove the slag after each of the welding electrode. The fast freezing characteristics of flux cored welding electrode increases the possibility of evolving gas that is trapped in the weld. Control the size of the weld in order to reduce the possibility of evolving gas that is trapped in the weld. The volume of the fillet weld should not exceed 8.0 mm (0.32 inch).

11.5

The following are acceptable weld shielding gasses: 100% Carbon Dioxide 75% Carbon Dioxide – 25% Argon 90% Carbon Dioxide – 10% Argon 6

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12.0 WELDING ON FUEL TANKS

12.1

Personal injury or death can result from an explosion. Applying heat to a tank which has held flammable liquids, even when empty, can result in residual flammable liquid or vapor igniting with explosive force. Do not weld or flame cut on any tank that has held flammable liquid without taking the proper precautions such as filling the tank with either carbon dioxide or water.

12.2

Do Not Weld an Empty Fuel Tank.

12.3

12.2.1 An empty fuel tank can not be cleaned sufficiently in order to ensure that all the flammable vapors have been removed. Vapors remain even after cleaning with steam or washing with a caustic solution. Also, when caustic solutions are heated, caustic solutions can also be explosive. In order to prepare a fuel tank for welding, use one of the following procedures: • Fill the tank with carbon dioxide. • Fill the tank with water. Filling the Fuel Tank with Carbon Dioxide: Use the following procedure in order to prepare the tank for welding: 1. Cover all openings or plug all openings, except for the filler hole. 2. Fill the tank with carbon dioxide from a CO2 fire extinguisher. 3. Put a board, or some other object with a flat surface, over the filler hole in order to keep the carbon dioxide in the tank. 4. Weld the tank by using the welding practices that are detailed in this document.

12.4 Filling the Fuel Tank with Water Use the following procedure in order to prepare the tank for welding: 1. Cover all openings or plug all openings, except for the filler hole. 2. Fill the tank with water. Note: The water must be kept at the very top of the filler hole at all times. This will ensure that there are no vapors that have collected in empty cavities. 3. Weld the tank by using the welding practices that are detailed in this document. Note: After welding on the tank, the fuel tank must be drained. Fill the fuel tank with a mixture of fuel and methyl alcohol (methanol). A ratio of 0.5 L (0.13 US gal) methanol to 38 L (10.04 US gal) of fuel is satisfactory. The methanol will mix with the water. The methanol and water will burn with the fuel.

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13.0 WELDING ON HYDRAULIC TANKS 13.1 Do not weld on a closed hydraulic tank. Use the following procedure in order to prepare the tank for welding: 1. Remove the cover. 2. Position the tank so that the welding area is at the highest point. This position makes sure that any oil that is left in the tank flows away from the welding area. With no cover on the hydraulic tank, there is little danger of a buildup of explosive vapors. Note: Do not put water in a hydraulic tank. Water can damage the valves in the hydraulic system. If necessary, carbon dioxide can also be used in hydraulic tanks. Refer to ""Fill the Fuel Tank with Carbon Dioxide" " for the correct procedure. 14.0 WELDING OF CASTINGS 14.1 Castings on Kress equipment should be treated just as ASTM A-514 and the same parameters used on both. Also, the same Preheat requirements apply. (see Section 6.0 Weld Preheat) 15.0 WELD INSPECTION 15.1 The weld should not have any of the conditions that follow: • Cracks • Porosity • Undercut • Incomplete Fusion 15.2 In order to the quality of the weld, refer to “American National Standards Institute (ANSI)/American Welding Society (AWS) Specification D14.3”

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