Students Note

8/11/2019 Students Note

1/19

MALAYSIAN INSTITUTE OF AVIATION TECHNOLOGY

NOTES

AIRCRAFT WELDING

GAV 1751

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AMENDMENTS

LIST OF EFFECTIVE PAGE

ISSUESNo Date

of issueEnte e!

"#1 15$%&$%' S(ED IDRUS

REVISIONSNo Issue

NoPa)e Ente e!

"#

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TA*LE OF CONTENTS

PageO*+ECTIVES , LEARNING OUTCOMES 5

C-a.te 1 WELDING FUNDAMENTAL

1/ T#.es of 0e !in)1-1-Gas .e/&ing1- -E/e$% i$ a $ .e/&ing

1- -1-1- S2ie/&e& 3e%a/ a $ .e/&ing1- -1- - Gas 3e%a/ a $ .e/&ing1- -1-4- Gas %!ngs%en a $ .e/&ing

1-4-E/e$% i$ esis%an$e .e/&ing1-4-1-1- S5o% .e/&ing1-4-1- - Sea3 .e/&ing

1-6-7 a8ing an& so/&e ing 1-6-1-1- To $2 " a8ing of s%ee/ 1-6-1- - To $2 " a8ing of a/!3in!3 1-6-1-4- To $2 so/&e ing

2/ T#.e of 3oints -1 7!%% #oin%s - Tee #oin%s -4 La5 #oin%s -6 Co ne #oin%s -( E&ges #oin%s

'

7&&

&

4

1%

11

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C-a.te 2 A! an6e! 0e !in) an! e.ai s

1/ A! an6e! 0e !in)1-1- Gas .e/&ing a/!3in!31- - TIG .e/&ing a/!3in!31-4 TIG .e/&ing Magnesi!31-6 TIG .e/&ing %i%ani!31-( TIG .e/&ing s%ain/ess s%ee/

2 Re.ai of ai 6 aft st u6tu e "# 0e !in) S5e$ifi$ .e/&e& e5ai s )en%s a% a $/!s%e .e/& )en%s "e%.een $/!s%e s

T!"e s5/i$ing .i%2 an inne s/eeve einfo $e3en% T!"e s5/i$ing .i%2 an o!%e s/eeve einfo $e3en% E95ansion an& $on% a$%ion Lan&ing gea an& Engine 3o!n% e5ai s

12

12

1

C-a.te *asi6 Gas We !in) an! Cuttin)/1- *asi6 )as 0e !in)

1-1-1- E !i53en%i; Gases o9=gen> ni% ogen> 2e/i!3

ii; P ess! e eg!/a%o siii; Hosesiv; To $2esv; ?e/&ing gogg/esvi; To $2 /ig2%e svii;Fi//e o&sviii; Hig2 f e !en$= a%%a$23en%

1-1- - E !i53en% se%

2/ Safet# . e6aution-1-1- Oi/> g eases an& a&2esive--1- - .o @s2o5 safe%=-

18

15

1'

17

1&14

14

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O*+ECTIVE , LEARNING OUTCOMES

O7 ECTIVES

To i35a % %2e a55/i$a"/e @no./e&ge on ai $ af% ?e/&ing so %2a% %2e !n&e s%an&ing an& $o35/ian$e of.2i$2 s2a// $on% i"!%e %o goo& an& safe 5 a$%i$es in es5e$% of ai $ af% 3ain%enan$e o5e a%ions-

LEARNING OUTCOMES

A% %2e en& of %2is /esson> %2e % ainees .i// "e a"/e %o:1; Un&e s%an& %2e gene a/ fo!n&a%ion of ai $ af% .e/&ing %e$2ni !e an& Re5ai on %2e

$ivi/ ai $ af% 3ain%enan$e-

; Un&e s%an& %2e safe%= 5 e$a!%ion 2an&/ing %2e .e/&ing e !i53en%s-

?HAT YOU ?ILL LEARN

1- ?EL)ING FUN)AMENTAL- A)VANCE) ?EL)ING AN) REPAIRS

4- 7ASIC GAS ?EL)ING AN) CUTTING-

WELDING FUNDAMENTAL

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?e/&ing 3eans a 3e%2o& of #oining 3a%e ia/s in .2i$2 a 5o %ion of ea$2 5ie$e is3e/%e& an& $o3"ine& in i%s 3o/%en s%a%e-

Have %=5e ai $ af% .e/&ing :,00 %o ,>400 F B Mos% &one on anges a"o!% 0-0 ' %o 0-0(0 %2i$@ness of 3e%a/

E e6t i6 A 6/1-S2ie/&e& Me%a/ A $ ?e/&ing SMA?;

B @no.n as s%i$@ .e/&ing B !sef!/ fa" i$a%ing %oo/s o s2o5 e !i53en%s B Uses a $ons!3a"/e e/e$% o&e $/a35e& in %2e #a.s of a 2an& 2e/& #a.- B Main/= fo /o. $a "on*/o. a//o= s%ee/s B E/e$% o&e $oa%e& .i%2 f/!9 is %o $ ea%es an ine % gas %2a% 2e/5s %o f/oa%s o

%2e i35! i%ies an& fo 3 ai %ig2% sea/ ove %2e .e/& s/ag ; B T2e s/ag 3!s% $2i55e& a.a= B Using /o. vo/%age*2ig2 $! en% AC*)C- B T2e %e35e a%! e is a55 o9i3a%e/= 100000F

- Gas Me%a/ ?e/&ing GMA? ; B Fo 3a//= $a//e& MIG Me%a/ Ine % gas ; B Use& fo 5 i3a i/= in /a ge vo/!3e 5 o&!$%ion .o @ B A&van%ages ove s%i$@ a e no s/ag- B Un$oa%e& fi//e o& as an e/e$% o&e %2a% is fe& %2 o!g2 a 2an&/e> .2en % igge is

&e5 esse& .i%2 ine % gas f/o. o!% %o 5 o%e$% %2e .e/& f o3 o9i&a%ion fo 3s- B T2e $ons!3a"/e e/e$% o&e of %2e sa3e 3a%e ia/ as %2e "ase 3e%a/ "eing !se&

no 3a//=-

B Ine % gas !se& s!$2 as a gon * 2e/i!3 * $a "on &io9i&e-

Gas T!ngs%en A $ ?e/&ing GTA? ;

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B Co33on/= $a//e& TIG %!ngs%en Ine % Gas; o % a&e3a @s as He/ia $ *He/i.e/&-

B Can "e !sing ei%2e AC o )C $! en%-

B Fo !sing )C $! en% %2e e 2ave 3e%2o& fo TIGS% aig2% 5o/a i%=-Reve se 5o/a i%=-

B Fi//e o& is fe& in%o 3o/%en 3e%a/ %2a% $a!se "= %2e a $ "e%.een e/e$% o&e an&%2e .o @-

B Ine % gas f/o.s a o!n& %2e .e/& %o 5 even% %2e fo 3a%ion of o9i&e in %2e 5!&&/e- B TIG*GTA? no 3a//= 5 efe e& ove o9=a$e%=/ene as $an s%a"i/i8e %2e

%e35e a%! e of %2e .e/&e& a ea*2ea% $on$en% a%e a% %2e .e/& a ea on/=- B Te35e a%! e ange as 2ig2 as 11>000 F

B T!ngs%en e/e$% o&es 3!s% se/e$% a$$o &ing %o %2e si8e an& %=5e of 3e%a/ %o "e.e/&e&-

B 7asi$a//= 2ave 4 %=5e of e/e$% o&e !se& B P! e %!ngs%en B Less e95ensive an& $ons!3e& so fas% %2an o%2e B i $oni!3 %!ngs%en B Las% /onge an& 5 ovi&es 3o e s%a"/e a $- B T2o i!3 %!ngs%en B P o&!$e $/eane .e/& an& a $ easies% %o s%a %-

B )ia3e%e s of e/e$% o&es %2a% a e !se !se& fo A*C .e/& a e 0-060 in$2> 1*1, in$2an& 4*4 in$2 "!% .2en $2oose %2e ig2% si8e 3!s% fo//o. %2e 3an!fa$%! e3an!a/ fo 5a %i$!/a e !i53en% !se&-

E e6t i6 Resistant We !in) B T2 ee "asi$ i%e3s e !i e& a e $! en%> 5 ess! e an& &.e// %i3e- B T2in s2ee% 3e%a/s es5e$ia//= s%ain/ess s%ee/-

1- S5o% .e/&ing- B Use %.o $oo5e e/e$% o&es 2e/& in #a.s an& %2e .o @ $/a35 "e%.een %2e3- B C! en% f/o. %2 o!g2 e/e$% o&e an& 3e%a/ B Resis%an$e of 3e%a/ is 2ig2e %2an e/e$% o&e %2an %2e 3e%a/ 3e/%s an& .e/&ing

i%se/f-

- Sea3 ?e/&ing B A 3e%a/ is o//e& "e%.een %.o $o55e .2ee/s as %2e e/e$% o&e- B No 3a//= !se& on f!e/ %an@ %o 5 ovi&e $on%in!es ai %ig2% B La5 .e/& is a .e/&e& sea3 in .2i$2 %.o 5ie$es of 3e%a/ ove /a5 an& a e .e/&e&

%oge%2e -

NON;FUSION WELDING

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*RA f!e/ an& 2=& a!/i$ fi%%ings an& 3an= o%2e

/o. s% ess a55/i$a%ion 7 a8ing

B Fo 3 of 3e%a/ #oining in .2i$2 an i on f ee 3e%a/ is !se& as $o2esive 3a%e ia/ B Fi//e 3a%e ia/ 3e/%s a"ove +000F "!% "e/o. "ase 3e%a/ %o "e #oine& B Have o5e a%ion

7 a8e .e/&ing

oine& sa3e 3anne as f!sion e95e$% fi//e no% f!se in%o %2e "ase3e%a/-Se/&o3 !se& in A*C s% !$%! e-Use& %o #oin &issi3i/a 3e%a/ %2a% $anno% #oine& "= f!sion

7 a8ingOn$e 3e/%e&> f/o. "e%.een $/ose fi%%ing 3e%a/ s! fa$es "= $a5i//a =a$%ion7 a8ing f/!9 2as a $a!s%i$ "ase Bi% .as2es a.a= o9i&es an&i35! i%ies on s! fa$e-

To $2 " a8ing of s%ee/ B Me$2ani$a//= $/ean &i %* !s%- B P e 2ea% .i%2 a 3i/& f/a3e !n%i/ a &!// e&- B Hea& o& %i5 a"o!% !n%i/ &a @*5! 5/e an& &i5 in%o "o a9


10/19


B A; Soft So !e in)Is a 3e%a/ #oining 5 o$e&! e 3e/%s a% %2e /o.es% %e35e a%! e !sing sof%f/a3e-

So/&e 5!//e& in "= $a5i//a = a$%ion-P o&!$es a e/a%ive .ea@ #oin% "!% !sef!/ fo ai %ig2% .i%2o!% 3!$2 5!//o vi" a%ion-F/!9 %=5e !se& is e$o33en&e& fo %2e 3e%a/-Unifo 3 2ea%ing %o %2e #oin% %o a e& $o/o an& 5!% %2e so/&e on%o !n%i/3e/%s-T2e so/&e o& !sing 3i9%! e of TIN an& LEA)-

I&en%ifi$a%ion fi//e *so/&e o& ;

B T.o n!3"e in 5e $en%age- B 1s% %.o a3o!n% of %in B Las% %.o a3o!n% of /ea&

E9a35/e :< B 60


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B La5 #oin%s B Co ne #oin%s B E&ges #oin%s

B *utt 3oints

B Use& %o #oin 3e%a/ fo 3s s!$2 as s2ee%> "a > 5/a%e> %!"e an& 5i5e- B In a*$ a55/i$a%ion> gene a//= a e no% !se& fo #oining %!"ing "e$a!se %2e= a e %oo

.ea@ fo a*$ s% !$%! e- B A %=5i$a/ "!%% .e/& s2o!/& 5ene% a%e 100 of %2i$@ness of %2e "ase 3e%a/-

Tee 3oint B J!i%e $o33on in ai $ af% .o @> 5a %i$!/a /= in %!"!/a s% !$%! e

B T2e 5/ain %ee #oin% is s!i%a"/e fo 3os% ai $ af% 3e%a/ %2i$@ness- B T2i$@e 3e%a/ e !i e %2e ve %i$a/ 3e3"e %o "e ei%2e sing/e o &o!"/e "eve/e&%o 5e 3i% %2e 2ea% %o 5ene% a%e &ee5/= eno!g2-

La. 3oints B Se/&o3 !se& in a*$ s% !$%! es .2en .e/&ing .i%2 gas> "!% $o33on/= !se& s5o%

.e/&ing- B Sing/e /a5 2as ve = /i%%/e esis%an$e %o "en&ing an& .i// no% .i%2s%an& s2ea ing

s% esses- B )o!"/e /a5 #oin%s a e s% onge > "!% e !i e %.i$e %2e .e/&ing of %2e si35/e >

3o e effi$ien%-

Co ne 3oints/ B ?2en %.o 5ie$es of 3e%a/ a e " o!g2% %oge%2e so %2ei e&ges fo 3s a $o ne of

a "o9 o e$%ang/e- B Use& .2e e /oa& s% esses is no% signifi$an%-

E!)es 3oints B ?2e e /oa& s% esses a e no% signifi$an%> e&ge #oin%s 3a= "e !se& %o #oin% %.o

5ie$es of s2ee% 3e%a/- B To fo 3> "en& %2e e&ges of one o "o%2 5a % !5.a &> 5/a$e %2e %.o en&s 5a a//e/

%o ea$2 o%2e an& .e/& a/ong o!%si&e of %2e sea3 fo 3 "= %.o e&ges

A! an6e! 0e !in) an! e.ai s

Gas 0e !in) a u>inu>/

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B Mos% a/!3in!3 .e/&ing &one .i%2 SMA? "!% %2e e a e %i3es .2en a/!3in!3is .e/&e& .i%2 ei%2e a$e%=/ene o 2=& ogen gas-

B P efe e& 2=& ogen gas "e$a!se of i%s $/eane f/a3e an& /ess is@ of o9i&i8ing

%2e #oin% B P e5a e& %2e 3e%a/ "= $/eaning %2e .i%2 a/!3in!3 " !s2- B Hea% %2e 3e%a/ an& a55/= f/!9 %o %2e 5ie$es an& o& %2a% .i// #oine& B Use /ig2% "/!e .e/&ing gogg/e- B F/a3e s2o!/& "e ne!% a/ o s/ig2%/= $a "! i8ing %o e&!$e 5ossi"i/i%= of %2e 3e%a/

o9i&i8e& &! ing .e/&ing- B P o5e fo 3 "ea& .i// "e !nifo 3 in .i&%2> 2eig2%> an& " ig2% s2inn= s! fa$e- B If o9i&i8e&> 2ave 5o.&e = .2i%e a55ea an$e an& o!g2 s! fa$e- B

TIG 0e !in) a u>inu> B T2e a"i/i%= !sing AC %o @ee5 %2e o9i&es off %2e 2ea%e& 3e%a/ B C/ean .i%2 s%ain/ess s%ee/ " !s2 %o e3ove& o9i&es %en !ses MEK o o%2e

e$o33en&e& so/ven%- B Use e/e$% o&es s5e$ifie& "= 3an!fa$%! e - B S%a %s a $ .i%2 Hig2 F e !en$= Signa/ s!5e i35ose& s%a"i/i8a%ion; .i%2o!%

%o!$2ing %2e e/e$% o&e %o %2e .o @- B ?2en /oo@s f os%=> %2en /if% #!s% a /i%%/e an& "e ea&= %o a&& fi//e o&-

TIG 0e !in) >a)nesiu> B AC 2ig2 f e !en$= %o "/as% o9i&es B C/ean .i%2 s%ain/ess s%ee/*MEK- B Fi//e o& as sa3e as 3a%e ia/ B

TIG 0e !in) titaniu> B ?e/& in a%3os52e e .2e e no o9=gen*ni% ogen $on%a$%s .i%2 2o% 3e%a/- B Mino i35! i%ies in 3e%a/ $an $a!se " i%%/e- B Use /a ge no88/e* % ai/ing s2ie/& %o @ee5 ai a.a= B Use& %2o ia%e& %!ngs%en e/e$% o&e an& s% aig2% 5o/a i%= )C $! en% B

TIG 0e !in) stain ess stee B E92a!s% esi&!e %o "e e3ove "= a" asive "/as%ing- B Using s% aig2% 5o/a i%= )C B Fi//e o& e$o33en&e& "= 3a%e ia/ 3an!fa$%! e -

Re.ai of ai 6 aft st u6tu e "# 0e !in)

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T=5e of 3e%a/ * &esign * e5ai efe %o MFG- se vi$e 3an!a/ o s% !$%! a/ e5ai3an!a/-

Dent at 6 uste 0e ! B Reinfo $e& .i%2 a 5a%$2 ove %2e &en% B Sa3e %2i$@ness an& 3a%e ia/ B E9%en& 1 &ia3e%e of %2e %!"e "e=on& %2e &a3age&

Dents "et0een 6 uste s B ?e/&ing a s/eeve ove %2e &a3age a ea B S%o5 & i// an= $ a$@ B Sa3e .a// %2i$@ness an& 3a%e ia/ %2e I) sa3e as O) of %2e &a3age %!"e ;

B S$a fe& .i%2 40 &eg ee> s5/i% %2e %!"e> "!%% an& /a5 .e/&- B )en% no% &ee5e %2an 1*10 of %!"e &ia3e%e an& /ess %!"e $i $!3fe en$e .i%2no $ a$@ o s2a 5 e&ge 3a= "e 5a%$2 e5ai -

B Inne s ee e tu"e s. i6in)

B C!% %!"e 40 ang/e an& e3ove &a3age- B P e5a e e5/a$e3en% sa3e &ia3e%e *.a// %2i$@ness B P e5a e s/eeve sa3e o igina/ %!"e* ( 9 ) /ong $en%e e& eve s$a f $!%- ?i%2 1*+

ga5 "e%.een en& B Rose%%e .e/& * /a5 #oin%

*ASIC GAS WELDING

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E?ui.>ents

WELDING GASES B A6et# ene

F/a33a"/e *$o/o /ess* &is%in$%ive o&o P o&!$es =e//o. s3o@= f/a3e * % ans5a en% "/!e .2en a&&e& %o o9=gen-A$e%=/ene "e$o3e !ns%a"/e a% 1( PSI &ange o!s ; an& .i// e95/o&e a% 40PSICo33on/= s%o e& in s%ee/ $=/in&e "o%%/e; an& 5 o%e$%e& f o3 e95/o&ing&! ing a s2o5 f/a3e "= a 5/!g safe%= f!se 5/!g; in %2e "o%%o3 of %2e %an@%2a% 3e/%s if o!%si&e*insi&e %e35e a%! e e9$ee& 1 0F an& /e%s %2e gases$a5e-C=/in&e $o/o e& e&* 3a oon-A3o!n% of a$e%=/ene in $=/in&e &e%e 3ine& "= %2e .eig2%-A$$e5% va/!e fo a$e%=/ene /ine 5 ess! e is ( PSI- no 3a/ 6 %o + PSI ;

Cautions@ B Neve o5en $=/in&e va/ve 3o e %2an %o %! n an& neve e3ove %2e . en$2

"o%%/e @e= f o3 $=/in&e ; B Neve !se a// %2e gas %o 5 even% /oss of a$e%one an& %2e fi//e 5 a$%i$a//= (0 PSI B Neve 3ove $=/in&e .i%2o!% 5 o%e$%ive $a5-

O:#)en B Co/o /ess* o&o /ess* %as%e/ess a"o!% 1 in a%3os52e e B Canno% !se& as avia%ion " ea%2ing o9=gen- B S%o e& in g een sea3/ess s%ee/ $=/in&e a% 000 PSI o a"ove B O9=gen "o%%/e is 5 o%e$%e& f o3 e95/o&ing &!e %o 5 ess! e "!i/% !5; "= safe%=

&is$ in %2e %o5 va/ve- B 7ees.a9 is a55 ove& /!" i$a%ion on %2 ea&s an& o9=gen fi%%ings- B Ca!%ions:

Neve !se* $on%a$% 5e% o/e!3 "ase 5 o&!$%> .2i$2 $an gene a%e s!ffi$ien%2ea% %o igni%e-?2en 3oving a.a= a/.a=s ins%a// s%ee/ 5 o%e$%ive $a5C=/in&e va/ve s2o!/& o5en f!//=-

=#! o)en

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15/19


Hig2/= f/a33a"/e* $o/o /ess No 3a//= !se& fo gases .e/&ing a/!3in!3* 3agnesi!3-Using 2=& ogen ins%ea& of a$e%=/ene %2a% .i// 5 o&!$e $/eane f/a3e %o

3ini3i8e o9i&a%ionHea% %e35e a%! e /o.e %2an a$e%=/ene

A )on$ =e iu> Co/o /ess* o&o /ess a"o!% /ess 1 in a%3os52e eAs ine % gas s2ie/&ing gas; %o enve/o5e %2e .e/&ing a ea %2a% 5 even% o9i&a%ion%o fo 3

E?ui.>ent

P essu e e)u atoT.o s%age %=5e-T2e fi s% s%age .i%2 2ig2 5 ess! e ga!ge is %o & o5 $=/in&e 5 ess! e %o a$ons%an% of in%e 3e&ia%e 5 ess! e-T2e se$on& s%age .i%2 /o. 5 ess! e ga!ge is %o give s5e$ifi$ va/!e nee&e&fo .e/&ing .o @ing * o5e a%ing 5 ess! e

A6et# eneHas a /ef% 2an& %2 ea&s an%i $/[email protected] ;T2e 2ig2 5 ess! e "e%.een 600


16/19


B T.o va/ve fo a!s%ing %2e f/o. of o9=gen*a$e%=/ene %2 o!g2 3i9ing $2a3"e%o %2e %i5-

B In%e $2angea"/e %i5 no88/e o ifi$e; 3a&e of 2a & $o55e * a//o=-

B T2e si8e of %2e %o $2 s %i5 o5ening &e%e 3ines a3o!n% of 2ea% a55/ie& %o %2e.o @ * %2e %2i$@ness of %2e 3e%a/-

B T.o %=5e of o9=a$e%=/ene %o $2es :

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