Figure 16-1 cuffs (a) Work gloves may be cloth, leather palm, or all leather; (b) Welding gloves are gauntlet-type gloves with high
Figure 16-2 Welding boots should have smooth toes to prevent sparks from being trapped.
Figure 16-3 (a) The MC acetylene tank holds 10 ft 3 ; (b) The B acetylene tank holds 40 ft 3
Figure 16-4 Diagram of a cutaway section of a B acetylene tank showing the porous absorbent section
Figure 16-5 Acetylene regulator with gauges
Figure 16-6 (a) 22 ft 3 oxygen cylinder; (b) 55 ft 3 oxygen cylinder
Figure 16-7 Support the cylinder with one hand when turning on the acetylene or oxygen valves
Figure 16-8 Nonadjustable acetylene wrench
Figure 16-9 (a) Correct position for striker, off to the side of the torch tip; (b) Improper position for striker, directly in front of the torch tip
Figure 16-10 (a) Correct appearance of oxyacetylene flame for brazing; (b) Flame with too much acetylene brings heat too close to tip, and can damage it
Figure 16-11 (a) When first lit, low pressure acetylene has smoke; (b) Increase acetylene pressure until smoke disappears; (c) Turn on oxygen and slowly increase flow; (d) Increase oxygen until the outer feather forms into a very smooth uniform cone; (e) Excessive oxygen causes the flame to become purple and the inner cone becomes very small
Figure 16-12 Turn off the acetylene gas valve first; for clarity, this procedure is shown with bare hands, but welding gloves should always be used
Figure 16-13 Tip cleaning set
Figure 16-14 File the tip flat if it has been damaged
Figure 16-15 Use the round tip cleaner to ream the tip orifice
Figure 16-16 Air acetylene torch kit
Figure 16-17 Portable oxyacetylene welding and cutting rig (Courtesy Victor Equipment Company)
Figure 16-18 Copper oxide formed by excessively heating copper pipes and fittings
Figure 16-19 (a) Use aluminum oxide sand cloth to clean copper before brazing and soldering; (b) Be sure to clean all the way around the fitting
Figure 16-20 Round tubing brushes can be used to clean the inside of pipe and fittings
Figure 16-21 (a) Copper pipe before cleaning; (b) Copper pipe after cleaning; (c) Clean at least 1/2 in beyond the fitting
Figure 16-22 (a) Insert the copper pipe into the fitting; (b) Twisting the copper pipe against the stop helps seat the fitting
Figure 16-23 (a) Begin heating the pipe near the fitting; (b) Once the pipe is hot, move the flame onto the fitting and continue heating
Figure 16-24 Once brazing temperatures have been reached, use a slight downward pressure on the filler rod at the braze joint and follow the joint around the fitting
Figure 16-25 Add the filler metal straight into the joint gap
Figure 16-26 Add a small amount of braze to the joint so that there is a smooth uniform fillet to ensure a good joint seal
Figure 16-27 This horizontal refrigerant line is 1 in above the ground, making access to the bottom of the joint difficult
Figure 16-28 Use the flame to heat and bend the brazing rod approximately 2 in from the end to make reaching the bottom of the horizontal joint easier
Figure 16-29 When the fitting is completely heated, filler metal can be added from the bottom first; then follow the joint around with the tip of the filler metal ending at the top of the joint
Figure 16-30 Inward pressure of the filler metal helps in filling the joint gap completely with brazes in the vertical up position
Figure 16-31 The first step in braze joint testing is to cut the fitting just beyond where the pipe is seated
Figure 16-32 Use a hacksaw to make two cuts through the entire length of the fitting
Figure 16-33 (a) Use a pair of pliers to bend each quarter section out; (b) Flatten each section using a ball peen hammer and anvil
Figure 16-34 (a) A thin layer of brazed metal can be seen between the pipe and fitting; (b) Area not filled with brazed metal will allow the pipe and fitting to slip, slightly revealing a very small shelf between the pipe and fitting; this area was not properly filled with brazing metal
Figure 16-35 Electric resistance soldering gun
Figure 16-36 Cleaning soldering gun tip
Figure 16-37 Fluxing soldering gun tip in preparation for tinning
Figure 16-38 Tinning soldering gun tip
Figure 16-39 Loop wire through terminal lug to make a mechanical connection
Figure 16-40 Hold the soldering gun against one side of the wire and lug as the solder is introduced to the opposite side
Figure 16-41 Clip the ends of the wire as necessary to complete the job; when connecting multiple wires, have the insulation always on the inside so there is less chance of an electrical short
Figure 16-42 Air Mapp and air propane flames wrap around the pipe for more uniform heating than oxyacetylene
Figure 16-43 A variety of sanding cloths are available
Figure 16-44 Apply the flux up to approximately 1/8 in from the end of the copper pipe
Figure 16-45 Preheat the pipe before moving the flame over the fitting
Figure 16-46 Add a small amount of additional solder to create a fillet around the joint
Figure 16-46 Add a small amount of additional solder to create a fillet around the joint
Figure 16-48 (a) Begin the hacksaw cut flat across the fitting; (b) Rock the hacksaw as the cut is made
Figure 16-49 The finished cut should completely cut through only the outer fitting. A small cut into a portion of the inner fitting is OK
Figure 16-50 Place a flat head screwdriver in the hacksaw kerf and twist to begin opening up the joint; use pliers to finish the job
Figure 16-51 An acceptable solder joint is one that will have a minimum of small bubbles and flux inclusions
Figure 16-52 Excessive bubbles formed by overheating and boiling solder
Figure 16-53 From the outside, this joint looks very good; solder flowed completely across the outside face of the joint indicating that the fitting was at the proper soldering temperature
Figure 16-54 The inside of the joint from Figure 16-53; solder did not flow through the joint because the pipe had not reached the soldering temperature due to improper heating techniques
Figure 16-55 Resistance spot welding
Figure 16-56 Resistance spot welding, tip cleanup
Figure 16-57 Pedestal spot welder
Figure 16-58 Portable spot welder