Military Automotive Welding Course
on CD

TABLE OF CONTENTS


1. Identification and Uses of Electrodes

Factors in Selecting an Electrode.
Classification of Electrodes.

Types of Electrodes.
Bare Electrodes.
Thinly Coated Electrodes.
Shielded-arc or Heavy-coated Electrodes.

Functions of Electrode Coatings.

Polarity of Welding Current
Direct Current Arc-welding Electrodes.
Alternating Current Arc-welding Electrodes.

Electrode Defects and their Effects.


2. Automotive Welding Processes, Materials, and Identification

Determining Weldability of Equipment.
Determining the Welding Method.
Cast Iron, Cast Steel, Carbon Steel, and Forgings.
Cast Iron Engine Blocks
Heat Treated Parts
Frames
Welding and reinforcing frames
Rear Axle Housings
Drive Shafts
Machined Alloy Steel Parts
Radiators


Welding Joint Design
Types of Joints
Butt Joint
Corner Joint
Edge Joint
Lap Joint
Tee Joint

Types of Welds
Groove Weld
Surfacing Weld
Plug Weld
Slot Weld
Fillet Weld
Flash Weld
Seam Weld
Spot Weld
Upset Weld


Welding Positions
Flat Position Welding
Horizontal Position Welding
Vertical Position Welding
Overhead Position Welding



Welding Techniques
Welding Current, Voltage, and Adjustments.

Starting the Arc

Proper and Improper Arc Control
Long Arc
Short Arc
Bead Welding

Overhead Position Welding
High-Carbon Steels
Tool Steels
High Yield Strength, Low Alloy Structural Steels
Cast Iron
Electric Arc Welding of Nonferrous Metals


Welding Armor Plate
Homogeneous Armor Plate
Face Hardened Armor Plate

Cutting Armor Plate


Cutting with the Oxygen Torch
Stainless steel


Cutting with the Electric Arc
Electric arc cutting
Carbon-arc cutting
Metal-arc cutting
Oxy-arc cutting


Testing of Welds
Performance Tests
Destructive and Nondestructive Tests
Physical Tests
The free bend test
Nick Break Test
Hydrostatic Test
Magnetic Particle Test
Fluorescent Penetrant Test


Troubleshooting Welds
Poor Fusion
Poor Penetration
Undercut
Poor Weld Appearance
Warping of Thin Plates


PRACTICAL EXERCISE

PRACTICAL EXERCISE - ANSWERS