Safety and Scheduled Maintenance Protect Your Welding Assets

Safety and Scheduled Maintenance Protect Your Welding Assets By Mike Pankratz, Miller Electric Manufacturing Company October 2000 You are faced with the task of removing the engine from your customer's aircraft. It might be routine, scheduled...

Finishing details
Following the preceding procedures, we now have an engine mount assembly worthy of supporting that new engine. Although a fairly simple looking structure, the engine mount plays a very important part in the overall airworthiness of the aircraft. Any maintenance organization contemplating the return of an aircraft engine mount to service under their facility's signature must give seriously consideration to ensuring they have:
• Trained personnel with experience in TIG welding Chromaloy 4130
• The facilities to:
a) Sandblast
b) Perform dye penetrant inspection
c) Painting
• Possess the tooling and fixtures required to perform a detailed inspection and undertake the necessary repairs
If not, you may want to consider sending the mount to an FAA licensed repair station staffed with trained personnel and the facilities to do the job correctly. When considering the overall cost of a major engine replacement, using the services of a licensed repair station can be a cheap form of insurance. With the repair station signing off on the return to status authorization, you can be confident of having an engine mount that won't fail in its assigned task. AMT

The following is a series of questions and answers regarding safety for welding personnel as well as and procedures for the maintenance of welding equipment.
Q: What can I do to avoid electrical shocks?
A: Wet working conditions must be avoided, because water is an excellent conductor and electricity will always follow the path of least resistance. Even a person's perspiration can lower the body's resistance to electrical shock. Poor connections and bare spots on cables further increase the possibility of electrical shock, and therefore, daily inspection of these items is recommended. Equipment operators should also routinely inspect for proper ground connections.
Q: How can I inspect and maintain my wire feeder?
A: Periodically inspect the electrode wire drive rolls. If dirty, remove the drive rolls and clean with a wire brush. Deformed drive rolls should be replaced. Drive rolls should be changed, adjusted or cleaned only when the wire feeder is shut off. In addition, check the inlet and outlet guides and replace if they are deformed from wire wear. Remember that when power is applied to a wire feeder, fingers should be kept away from the drive roll area.
Q: What are some important electrode safety considerations?
A: Welding power sources for use with MIG and TIG welding normally are equipped with devices that permit on/off control of the welding power output. If so, the electrode becomes electrically hot when the power source switch is ON and the welding gun switch is closed. Never touch the electrode wire or any conducting object in contact with the electrode circuit, unless the welding power source is off. Welding power sources used for shielded metal arc welding (SMAW or Stick welding) may not be equipped with welding power output on/off control devices. With such equipment, the electrode is electrically hot when the power switch is turned ON.
Q: How should I store my gas cylinders?
A: Cylinders should be securely fastened at all times. Chains are usually used to secure a cylinder to a wall or cylinder cart. When moving or storing a cylinder, a threaded protector cap must be fastened to the top of the cylinder. This protects the valve system should it be bumped or dropped.
Cylinders should not be stored or used in a horizontal position. This is because some cylinders contain a liquid which would leak out or be forced out if the cylinder was laid in a flat position. Also, welding guns and other cables should not be hung on or near cylinders. A gun could cause an arc against the cylinder wall or valve assembly, possibly resulting in a weakened cylinder or even a rupture.

Q: How can I tell if my regulator is faulty?
A: The following symptoms indicate a faulty regulator:

• Leaks - if gas leaks externally.
• Excessive Creep - if delivery pressure continues to rise with the downstream valve closed.
• Faulty Gauge - if gauge pointer does not move off the stop pin when pressurized, nor returns to the stop pin after pressure release. Do not attempt to repair a faulty regulator. It should be sent to your designated repair center, where special techniques and tools are used by trained personnel.

We Recommend