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FIELD WELDING PROCEDURE METHOD

Process Sheet No. FW0061 Part No. Ver 01, 07-03

DESCRIPTION: This welding method is to repair rack

frame crack (ES4186).
The area shown is at the front of the trackframe between the front idler and the first lower roller.
PROCEDURE NO: FW0061 DRAWING NO:

AUTHORIZED BY: L. Gunnell DATE: 4-18-01

BASE METAL: P&H 50 & 106A WELD JOINT DETAIL:

WELDING PROCESS: FCAW, SMAW

FILLER METAL SPECIFICATION: AWS A5.20, A5.1

FILLER METAL CLASSIFICATION: E71T-1, E7018-M

AWS E7018-M, ESAB Atom Arc or Equivalent, Low Hydrogen

ESAB Dual Shield II 70 Ultra,

MANUAL OR Manual

MACHINE

SHIELDING GAS: 75 Ar/25C02

FLOW RATE: 45-55 CFH

FLUX: NA

SINGLE OR MULTIPLE PASS: Multiple

WELDING CURRENT & POLARITY: DCRP,DCEP

PREHEAT TEMPERATURE INTERPASS TEMPERATURE

THICKNESS MINIMUM OF PREHEAT F MIN: Based on thickness F MAX: 600 F

ASTM A 633 Grade C&D P&H 106A P&H 50 POST HEAT TREATMENT: Cover after welding with a thermal blanket

TO 70 70 TIME: NA

OVER TO 1-1/2 70 70 TEMPERATURE: NA

OVER 1-1/2 TO 2-1/2 150 150 TECHNIQUE Weld with stringer passes with a slight weave

OVER 2-1/2 225 225 STRINGER X WEAVE ( )

IF NONE, AND BASE METAL IS BELOW 32 F PREHEAT TO 70 F BACKING MATERIAL: Base Plates

ADDITIONAL NOTES: INSPECTION:

This process sheet is FOR REFERENCE ONLY. Actual dimension to be taken from part print.
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FIELD WELDING PROCEDURE METHOD
Process Sheet No. FW0061 Part No. Ver 01, 07-03

METHOD: Visual and magnetic particle or dye penetrant

WELDING PARAMETERS
PASS PROCESS ELEC- ELEC- AMPS VOLTS WIRE TRAVEL CURRENT OTHER
OR TRODE TRODE SPEED SPEED TYPE &
LAYER DIA. TYPE IPM IPM POLARITY
All FCAW .045, 1.2mm E71T-1 250-290 27-30 400-450 11-14 DCRP FL,HZ

All FCAW .045, 1.2mm E71T-1 190-222 23-25 259-304 4-9 DCRP VT,OH

All FCAW 1/16 ,1.6mm E71T-1 300-400 27-30 244-360 14-16 DCRP FL,HZ

All FCAW 1/16 ,1.6mm E71T-1 170-210 21-25 135-160 4-10 DCRP VT,OH

ALL SMAW 1/8 7018 90-160 N/A N/A 8-12 DCEP All

ALL SMAW 5/32 7018 130-220 N/A N/A 8-12 DCEP All

Welding Instructions:

1. Use the dye penetrant or magnetic particle to outline the crack and to show any hidden areas.

2. Use the air carbon arc process to remove the crack from the top approximately 2/3 rds of the plate thickness
at the same time forming a single-v-groove with a 30-degree angle. After use a hand grinder to grind the
gouged area to clean smooth base material.

3. Re-check the ground areas to make sure that there are no more cracks.

4. Proceed to tack welding runoff tabs on the open end for the stop and starts.

5. Preheat based upon the plate thickness listed on page 1.

6. Proceed to weld the groove to to 2/3rds of the groove depth.

This process sheet is FOR REFERENCE ONLY. Actual dimension to be taken from part print.
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FIELD WELDING PROCEDURE METHOD
Process Sheet No. FW0061 Part No. Ver 01, 07-03

7. Then move to the bottom side and use the air carbon arc process to remove the crack until it cannot be seen
visually.

8. Grind smooth the gouged area and check with the dye penetrant or magnetic particle inspection to verify
that the crack is removed.

9. Preheat and weld the bottom side complete.

10. Then move back to the topside and weld this side complete.

11. After welding grind the weld smooth to the original base material and remove the runoff tabs.

12. Listed below are some general guidelines for the repairs on the fillet welds and groove.

General Information on repairing cracks

If the crack has progressed completely through the plate thickness and can be accessed from both sides. Then
repair as shown in the (figures 8-8,8-9.8-10,8-11,8-12).

FILLET WELD PLATE CRACK REPAIR METHODS

FIGURE. 8-5

Inspect with magnetic particle or dye penetrant testing to highlight the crack and to find the starting and end
points to the crack.

This process sheet is FOR REFERENCE ONLY. Actual dimension to be taken from part print.
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FIELD WELDING PROCEDURE METHOD
Process Sheet No. FW0061 Part No. Ver 01, 07-03

FIGURE. 8-6

Refer to MOP 5.10 for the steel type and preheat temperature prior to air carbon arc gouging. Begin to remove
the crack with the air carbon arc process or with a grinder. Start 2 inches ahead and behind the crack in to clean
steel to keep the crack from chasing during the gouging process. Use a grinder to clean the gouged areas to a
smooth surface. Check with the magnetic particle or dye penertant to make sure that the crack is removed

FILLET WELD CRACK REPAIR METHODS

FIGURE 8-7

Preheat according to MOP 5.10 regarding the steel type and thickness. Use the recommended welding
consumables listed in the tables per this document. Apply weld improvement techniques on highly restraint or
repeatable cracked areas on the weld toes.

THROUGH THICKNESS PLATE CRACK REPAIR METHODS

This process sheet is FOR REFERENCE ONLY. Actual dimension to be taken from part print.
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FIELD WELDING PROCEDURE METHOD
Process Sheet No. FW0061 Part No. Ver 01, 07-03

FIGURE 8-8

Inspect with magnetic particle or dye penetrant testing to highlight the crack and to find the starting and end
points to the crack.

THROUGH THICKNESS PLATE CRACK REPAIR METHODS

FIGURE 8-9
Refer to MOP 5.10 for the steel type and preheat temperature prior to air carbon arc gouging. Begin to remove
the crack with the air carbon arc process or with a grinder. Start 2 inches ahead and behind the crack in to clean
steel to keep the crack from chasing during the gouging process.
On plate remove approximately 1/2 thickness of the plate material.
Use a grinder to clean the gouged areas to a smooth surface. Check with the magnetic particle or dye penertant
to make sure that the crack is removed

This process sheet is FOR REFERENCE ONLY. Actual dimension to be taken from part print.
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FIELD WELDING PROCEDURE METHOD
Process Sheet No. FW0061 Part No. Ver 01, 07-03

FIGURE 8-10
Preheat according to MOP 5.10 regarding the steel type and thickness. Use the recommended welding
consumables listed in the tables per this document. Use weld run off tabs on the open ends for the stop and
starts. Peen the intermediate weld passes with a dull rounded chipping hammer. Placement of the welding
passes would be working from the sides to the center of the joint on each weld pass layer.

Through Thickness Plate Crack Repair Methods

FIGURE 8-11
This process sheet is FOR REFERENCE ONLY. Actual dimension to be taken from part print.
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FIELD WELDING PROCEDURE METHOD
Process Sheet No. FW0061 Part No. Ver 01, 07-03

Preheat the steel on the second or other side and use the air carbon arc process to remove the crack from the
back or other side and into clean weld metal that was welded from the first side. Start ahead and behind the
crack when gouging. Grind smooth the gouged areas. Then check the ground areas to verify that the cracks are
removed with the dye penetrant or magnetic particle testing.

FIGURE 8-12
Preheat according to MOP 5.10 regarding the steel type and thickness. Use the recommended welding
consumables listed in the tables per this document. Use weld run off tabs on the open ends for the stop and
starts. Peen the intermediate weld passes with a dull rounded chipping hammer. Placement of the welding
passes would be working from the sides to the center of the joint on each weld pass layer.

This process sheet is FOR REFERENCE ONLY. Actual dimension to be taken from part print.