- - AGRICULTURE CORE CURRICULUM - -

(CLF2000) Advanced Core Cluster: AGRICULTURE MECHANICS

 (CLF2300)  Unit Title: ARC WELDING

___________________________________________________________________________
 (CLF2305)    Topic: CONTROLLING DISTORTION       Time            Years
                      IN ARC WELDING             2 Hours   1 / 2 / 3 / 4
___________________________________________________________________________

          Topic Objectives: Upon completion of this lesson, the student
                            will be able to:

          Learning Outcome: #:

             (G-6) - Control distortion in arc welding.

          Special Material and Equipment: Various pieces of metal showing 
                       weld distortion, clamps, hammers, furnace or other 
                       device to heat metal, welding apparatus, safety gear

          References: Burke, Stanley R., & Wakeman, T. J. (1990). MODERN
                         AGRICULTURAL MECHANICS (2nd ed.). Danville, IL:
                         Interstate Publishers.
                       Cooper, Elmer L. (1987). AGRICULTURAL MECHANICS:
                          FUNDAMENTALS AND APPLICATIONS. Albany, NY: Delmar
                          Publishers.
                       Phipps, Lloyd J., & Reynolds, Carl L. (1990).
                         MECHANICS IN AGRICULTURE (4th ed.). Danville, IL:
                         Interstate Publishers.

          Resources:  Deere & Company. (1987). WELDING (6th ed.) 
                         (Fundamentals of Service (FOS) Series). Available 
                         from: John Deere Technical Services, Dept. F, John 
                         Deere Road, Moline, IL 61265 (Available in
                         Spanish)
                       Giachino, Joseph W., & Weeks, William  (1976). 
                         WELDING SKILLS AND PRACTICES (5th ed.). Available 
                         from: American Technical Society, Chicago, IL 60637
                       Hobart Brothers Company. (1978). TECHNICAL GUIDE FOR 
                         SHIELDED METAL ARC WELDING. Available from: Hobart 
                         Brothers Company, Troy, OH 45373

          Evaluation: Quiz by the instructor and satisfactory completion of 
                       projects related to weld distortion.

TOPIC PRESENTATION: CONTROLLING DISTORTION IN ARC WELDING

A. Distortion - Distortion is a warping of the metal due to rapid heating 
   and slow cooling.

   1. As the metal is heated, it expands. During the cooling period the 
       metal changes shape by a shrinkage of the weld metal.
   2. The expansion and contraction of the metal do not counterbalance
       each other. During long welds, one section of the metal is being 
       heated and expanded while the previously welded sections are cooling
       and contracting. The result is a warping of the metal.

B. Preventing Metal Distortion

   1. Clamp the base metal to a backing plate when performing short welds.
       Clamping is not recommended for longer welds because the clamps
       provide no outlet for the pressure created through the expansion and
       contraction of the metal due to heating and cooling. This may result
       in residual stresses which weaken both the base metal and the weld.

   2. Use a back-step welding method. The back-step weld provides for a
       more uniform heating and cooling of the metal which reduces 
       distortion.

       a. Begin several inches from one end and weld back to the end.

       b. Start several inches in front of the previous weld and weld back
           to the beginning point of the first weld.

       c. Continue this process until the weld is complete.

   3. Space the base metal plates in such a way that they are drawn together
       during the cooling process.

   4. Avoid using too much weld material because this creates excessive
       heat which warps the metal.

   5. Use a light hammer to peen the base metal, both before and after
       the weld. Peening expands the metal and relieves the pressure that
       causes distortion.

   6. Use intermittent welds or tack welds when the strength of a full-
       length weld is not needed.

   7. Make as few passes as possible to avoid overheating the metal.

   8. Weld beads alternately on each side. This helps to distribute the 
       heat more evenly throughout the metal.

   9. Preheat the metal in order to keep the overall metal temperature more
       uniform. Preheating is especially important when welding brittle
       metals such as cast iron.

  10. Tack the ends of the weld path to minimize heat expansion.

  11. Select the appropriate electrode for the job. Different electrodes
       require different amperage and consequently there is a large 
       variation in the heat produced, depending on the particular electrode
       used.

  12. Use a skip weld method in which a series of short welds at intervals
       is followed by a second bead which fills in the gaps. Again, this
       evenly distributes the heat throughout the metal.

  13. Weld as rapidly as possible on thin gauge metal to avoid overheating.

         _________________________________________________________
         ACTIVITY:
 
         1. Practice clamping material to welding table or other
             positioning fixture.

         2. Practice welding on thin plates, some clamped down, 
             others not clamped down.

         3. Demonstrate proper peening technique, using the peening 
             end of a ball peen hammer.
         _________________________________________________________










7/24/91 RRE/DF/tf


#%&C