CarTech®, Inc.
39966 Grand Avenue
North Branch, MN 55056
Phone: 651-277-1200 or 800-551-4754
Fax: 651-277-1203
© 2015 by Jerry Uttrachi
All rights reserved. No part of this publication may be reproduced or utilized in any form or by any means, electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without prior permission from the Publisher. All text, photographs, and artwork are the property of the Author unless otherwise noted or credited.
The information in this work is true and complete to the best of our knowledge. However, all information is presented without any guarantee on the part of the Author or Publisher, who also disclaim any liability incurred in connection with the use of the information and any implied warranties of merchantability or fitness for a particular purpose. Readers are responsible for taking suitable and appropriate safety measures when performing any of the operations or activities described in this work.
All trademarks, trade names, model names and numbers, and other product designations referred to herein are the property of their respective owners and are used solely for identification purposes. This work is a publication of CarTech, Inc., and has not been licensed, approved, sponsored, or endorsed by any other person or entity. The Publisher is not associated with any product, service, or vendor mentioned in this book, and does not endorse the products or services of any vendor mentioned in this book.
Edit by Paul Johnson
Layout by Monica Seiberlich
ISBN 978-1-61325-264-2
Item No. SA365
Library of Congress Cataloging-in-Publication Data Available
Written, edited, and designed in the U.S.A.
10 9 8 7 6 5 4 3 2 1
Front Cover Photo: Courtesy Pat Stanton, Year One.
Title Page: Here, a weldor demonstrates stick welding. Developed in the early 1900s, stick welding is very versatile and is widely used in industry. A major advantage of stick welding is that it generates its own shield to protect the weld deposit from atmospheric contamination. It can be used in wind up to about 20 mph.
Back Cover Photos
Top: Repairing cast iron requires a specific approach and technique. Cracks should be opened at a sufficiently wide angle to keep the amount of melted cast iron in the weld deposit to less than 30 percent. After preheating the cast manifold, welding progresses in this simulated crack repair. Preheating helps reduce the stresses as the weld cools and is particularly useful for the cast-iron heat-affected zone, which is crack sensitive.
Middle: Sheet-metal fabrication projects, such as this inner wheel well and shock tower, require careful spot welding before the seams are filled in with the weld beads. Unibody drift cars require a very rigid chassis so they can respond instantaneously to driver input. Hundreds of spot welds make a single rigid assembly from the many internal body parts. (Jim Harvey Photo, Courtesy Harvey Racing Engines)
Bottom Left: This corner TIG weld is made of 1/8-inch-thick magnesium at 130 amps AC with a 65-percent DCSP using argon shielding gas. The DCSP/DCRP balance was altered from the test welds to see if additional cleaning action could be achieved and to reduce the chance of burn-through. The cleaning action was about the same. This autogenous weld (meaning no filler added) wet very well and is porosity free.
Bottom Right: This yard gate latch was MIG welded. It required mounting holes that were wider than the 1.25-inch gate frame so it could not be attached as designed. The solution was to narrow the mounting and weld the latch to the gate frame. To make it easier to bring the MIG welder to the fence and because it was welded outdoors, self-shielded wire was used.
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CONTENTS
Chapter 1: Welding Processes and Equipment
Chapter 3: Oxyacetylene Welding
Project: Welding Plate Practice