UNIVERSITI TUN HUSSEIN ONN MALAYSIA

Centre for Diploma Studies

DEPARTMENT OF MECHANICAL ENGINEERING

WORKSHOP REPORT

Course Code/Name:
DAM13701/Mechanical Engineering Practice 1
Workshop: Welding Section: 14

Class date: 8/12/2021 Report submission date:

15/12/2021

Student’s Name / matrix’s number:

1) Muhammad Hazeeq Hilman Bin Rosli (AA211798)
2) Muhammad Hakimie Bin Sudirman (AA210463)
Lecturer / Instructor / Tutor’s Name
1) Ts. Abdullah Bin Wagiman

Assessment Scale mark (1-5) Weightage Score mark

1. Objective (2.5%) 0.5

2. Introduction (5%) 1

3. Safety procedure (5%) 1

4. Project’s technical drawing (15%) 3

5. Equipment (15%) 1

6. Project / equipment procedure (5%) 3

7. Workpiece observation (20%) 4

8. Discussion (15%) 3

9. Conclusion (15%) 3

10 References (2.5%) 0.5

Comments:
Total
Verified stamp:
1. Objective
- Learn the basic techniques of welding.

- To know the part of welding arc.

- To know what is a true step when doing a welding.
- Give a real life experience of metal arc welding to engineering students.
- To ensure all student according to the instruction and safety.

2. Introduction
Arc welding is a type of welding that uses a welding power supply to create
an electric arc between an electrode and the base material to melt the metals at the
welding point. They can use either direct (DC) or alternating (AC) current, and
consumable or non-consumable electrodes. The welding region is usually
protected by some type of shielding gas, vapor, or slag. Arc welding processes
may be manual, semi-automatic, or fully automated. First developed in the late
part of the 19th century, arc welding became commercially important in
shipbuilding during the Second World War. Today it remains an important
process for the fabrication of steel structures and vehicles.

Arc welding is one of alternative for joining process in manufacturing. Arc

welding process had done by create an electric arc between electrode and the base
material to melt the metal at the welding point using welding power supply. The
welding region is sometimes protected by some type of inert or semi-inert gas,
known as a shielding gas and sometime adds by an evaporating filler material.
Shielded metal arc welding (SMAW), also known as manual metal arc (MMA)
welding or informally as stick welding, is a manual arc welding process that uses
a consumable electrode coated in flux to lay the weld. They can use either direct
current (DC) or alternating current (AC) from a welding power supply, used to
form an electric arc between the electrode and the metal to be joined. As the weld
is laid, the flux coating of the electrode disintegrates, giving off vapors that serve
as a shielding gas and providing a layer of slag, both of which protect the weld
area from atmospheric contamination. Gas metal arc welding (GMAW),
sometimes referred to by its sub types metal inert gas (MIG) welding or metal
active gas (MAG) welding, is a semi-automatic or automatic arc welding process
in which a continuous and consumable wire electrode and a shielding gas are fed
through a welding gun. A constant voltage, direct current power source is most
commonly used with GMAW, but constant current systems, as well as alternating
current, can be used. There are four primary methods of metal transfer in GMAW,
called globular, short-circuiting, spray, and pulsed-spray, each of which
3.Safety procedure

1. Please wear all the personal protective equipment recommended by OSHA :

- Wear Approved Eye Protection or face shield.
- Wear Flame Resistant Clothing (apron)

- Wear Long Sleeves, Pocket Flaps and No Cuffs

- Wear Approved safety boot
-Wear Approved Hand gloves
2. Always protect your eyes from arc rays.
3. Protect your face and body from heat radiation and molten metal.
3. Move all the flammable material off the working place or cover it up using fireproof
material.
4. Make sure that the welding machine is earthen.
5. Make sure that all line holder, earth clip and connection placed on a good place.
6. Make sure that your working place is clean and tidy.
7. Make sure that all electric connection is tight, clean and dry.
8. Avoid pulling the cable on top or near sharp things.
9. Turn off welding machine when not in use.
10. Avoid welding cable from be in contact with hot metal, water, oil and grease.
11. Wear all safety clothing when welding and protect it with apron.
12. All equipment such as hammer, chisel, brush and others must be well maintained.
13. A welder should not try to install or repair a welding machine has distinct properties
and corresponding advantages and limitations.
14. Clean your hand before leaving the workshop.

4. Project’s technical drawing

5.Equipment
1. Mild steel flat bar x2 (5mm x 50mm x 100mm)
-The steel that we need to weld in flat position.

2. Arc welding machine

-Use to make the welding beads on the mild steel plate.
-Consist of electrode holder, ground clamp . are welding power source.
3. Electrode
-The "E" stands for arc welding electrode. Next will be either a 4 or 5 digit number
stamped on the electrode. The first two numbers of a 4 digit number and the first 3
digits of a 5 digit number indicate the minimum tensile strength (in thousands of
pounds per square inch) of the weld that the rod will produce, stress relieved. E6013
electrode can be used with AC and DC currents.
- It produces a medium penetrating weld with a superior weld bead appearance.

4. Protected hand gloves

- To protect the hand from the heat of the plate.
- To protect the hand from the spark of the electrode when welding.
- To hold the hot steel plate when the steel is warm.
5. Plier
- To hold the mild steel plate after welding
- To lift the mild steel plate when it is hot.

5. Chipping hammer
- It is used commonly to remove the slag excess stringer from the surface of the work
metal.
- To make the beads on the workpiece look clean.
6. Wire brush
- Used to clean the surface of the stringer bed after the slag is chipped away and to
remove dirt from the surface of metal work before welding can be done.

7. Face shield
- It is used to protect the user from fire-bolt and harmful rays during welding work.
- Protect the face skin from the arc rays and the mild steel chips.
- Protect the eyes from the arc rays.
7 Apron
-To protect the clothes from the dust of the steel plate.
-To protect the clothes from electrode spark.
- To protect the clothes from caught on fire.
6. Project / equipment procedure
1. Prepare a piece of mild steel plate 3.0mm thick.
2. Bring all the equipment and material to the welding bay.

3. Use an electrode code E6013with diameter 2.6mm .

4. Adjust the ampere around 50 - 60 for electrode diameter 2.6 mm.
5. Take a wire brush and clean the surface of the 2 pieces of mild steel plate from rust.
6. Turn on the switch for the main power source and turn on the arc welding machine.
7. Put an electrode at the electrode holder and make sure that there are no movement of
electrode at the holder.
8. Hold the electrode 60’degrees work angle and 2mm – 3mm above the mild steel plate.
9. Hold that position over a spot just inside the left edge of the base metal until a molten
pool is established.
10. Welding then proceeds from left to right(for the right hand).
11. Stop the process at the end of the work piece.
12. The correct technique is hold an electrode at the start position for 1s or 2s and
continue until the end of the process. At the end, hold an electrode at the last position
for 1s or 2s before finishing the process.
13. The frequency of this action will be determined by the size of the weld being
deposited, and the correct action improve with practice.
14. After finished all the lesson practice project, get a piece of paper and wraps it the
workpiece after the workpiece become warm form hot.
15. Turn off the arc welding machine and it’s switch.
16. Put back all the equipment that was borrowed and clean the welding bay.

7. Workpiece observation /result

Hazeeq’s welding project :

MUHAMMAD HAZEEQ HILMAN BIN ROSLI (AA211798)

-
- The types of welding used in this project is the fusion welding of Shielded Metal Arc
Welding.
-The instruction for the first project was to make a straight bead on flat plate and to fill
the crater.
-The result of the first project was not entirely perfect.
-Almost all the weld have some visible defects where the weld insert are not equall in
width and uneven.
-One of the weld does not have enough width because the travel speed of the arc was too
fast.
-Thus, a ropey weld happen and the bead was not too perfect.
- One of the bead was not in a straight line but instead curved.
- This happen because when wearing the face shield, I cannot see clearly the white chaclk
line even though the arc light was emitting.
-One of the other bead was formed incomplete because the electrode was not enough.
- I overcome this problem by put another layer on top the unfinished bead.

- For the second lesson practice, the instruction was to make a butt weld in flat position
CAWS position 2F.
- The result was one side of the butt weld was not straight and moving too fast.
- This happen because I did not draw a white line using the chaclk at the edge of the
workpiece.
- The width pf the bead was also not enough and not good.
-On the other side, the butt weld have enough width but not full in the line.
-There have put another layer or continue weld because the electrode have stick when
doing a welding.
- This happen because the distance between the workpiece and the electrode was too near
and another part is too far.
-The problem is I don’t have the consistent distance between workpiece and electrode.
-Thus, result in spatter will formed on top of the butt weld.
-Other that that, the travel angle when controlling the arc was not consistent.
-This happen because my arm was not used on holding the electrode holder in the right
angle.
-My arm cannot do the right control the electrode holder because ooff the wyre that make
the electrode holder become heavy and hard to consistent the travel angle and movemnet.
8.Discussion

Welding is easy to understand the concept of it but it is hard to do. Based on the result
from the project, there is still many flaw in my welding.I have to get used to stay at one
travel angle so that the bead is formed is the same from start to finish. I also have to
control the travel speed of the arc when moving along the base material while welding.
We can conclude that there are some problems that happened in arc welding process. The
thickness of the arc line on the metal plate is the first issue that arises during the arc
welding process. We can overcome it by improving our skills and reducing the speed at
which we move when arc welding. The second issue is that the metal plate combination is
not very sturdy. It could cause the work to crack or be of poor quality. We need to
increase the number of electrodes at work to solve this problem.
The third issue is that the arc welding work is not up to par. When welding, it could be
caused by the improper angle and position on the plate. This difficulty can be solved by
welding at a 30o angle with at least 3mm between the electrode and the plate. We can
figure out the major reason why our welding work isn't up to par once we do some
welding work. The main cause is a student's lack of ability. As a result, we must develop
ourselves by welding properly and using the suitable welding process.

9.Conclusion

  From this experiment, we have demonstrated mostly on how to use SMAW. We also
have been performing with build a pad technique at on the mild steel. The defect and the
quality of the welding bead is due to several factors which are the change of voltage,
current, welding speed and welding angle. The skill of each student for getting a good
welding result can be enhancing through everyday practice. So, the objective of this
experiment is occur as we have achieved this purpose of doing Shielded Metal Arc
Welding (SMAW).     
10.References

1. J.E.Linnert(1994) “Welding Metallurgy”, 4th Edition., vol 1, American Welding

Society.

2. Tool and Manufacturing Engineering Handbook, (1986)Vol 4:Quality Control and

Assembly, Society of Manufacturing Enginees.

3. W.A.Bowditch.,K.E.Bowditch(1997), “Welding Technology Fundamental”,

Goodheart-Willcox.

4.https://weldguru.com/smaw-tips-techniques/

5.https://www.fabtechexpo.com/blog/2018/01/04/shielded-metal-arc-welding-basics