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Copper Shoe Writeup

The document discusses a new method for repairing pin holes in thin sheet welding using a copper shoe developed by AWTI. This tool helps absorb excess heat during welding, preventing hole enlargement and improving the aesthetic finish of repairs. The technique addresses common challenges in thin sheet welding, particularly in roof and side wall assemblies, leading to better quality and reduced water leakage risks.

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39 views2 pages

Copper Shoe Writeup

The document discusses a new method for repairing pin holes in thin sheet welding using a copper shoe developed by AWTI. This tool helps absorb excess heat during welding, preventing hole enlargement and improving the aesthetic finish of repairs. The technique addresses common challenges in thin sheet welding, particularly in roof and side wall assemblies, leading to better quality and reduced water leakage risks.

Uploaded by

dselvakuu
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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QUALITY IMPROVEMENT BY USING COPPER SHOE FOR WELDING PIN HOLES IN THIN SHEET

(By: T.S.Ravichandran, CCC / AWTI, D.Selvakumaran, CD / AWTI and

K.Chandrasekaran, Lecturer / AWTI)

Thin sheet welding has always been challenging even for experienced and skilled welders.
Welding stiffeners with roof sheet in roof assembly and welding roof sheet with side wall sheet in
body assembly jig lead to hole formation due to burn through. If not attended, this results in water
leakage at later stage while testing for the same.

Repairing the holes, if any, in side wall and roof sheets is carried out with a greater difficulty
as it may lead to the enlargement of the already formed hole. However, in present day practice, it is
carried out by plugging the hole with a short piece of electrode stub and then welding around which
ends up with a shabby look.

A small copper shoe with a suitable handle has been developed in AWTI which can be easily
used in the hole repairing activity. One can support the other side of the hole with the copper shoe
which will absorb the excess heat of welding thereby preventing the enlargement of hole while
welding. Besides, the usage of copper shoe gives a better finish in the repaired location thereby
ensuring good aesthetics.

Fig.1 – Copper Shoe Fig.2 – Hole in Roof Sheet

Fig.3 – Hole in side wall near roof flange Fig.4 – Hole after welding (Backside)
Fig.5 – Hole in sheet metal Fig.6 – Set up to repair

Fig.7 – Welding with copper shoe backup Fig.8 –Filled hole (Welding side)

Fig.9 –Filled hole (Back side)

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