FACULTY OF ENGINEERING & TECHNOLOGY
LAB REPORT
WORKSHOP TECHNOLOGY
EME 1226
Experiment 2:
Electric Arc Welding
Student Name CHONG YONG XIN
Student ID 1121118097
Date of experiment 27/12/13
Objective:
To learn how to use arc welding machine in the workshop and use it to make a V-shape by using
arc welding process. It is also to study the failure of the welded component.
Abstract:
In this lab, I was given enough time to study and learn the precaution and technique to
use the arc welding machine. When I finish welding the work piece given, a test given to test the
strength of the welded part. Thanks to the guidance from lab assistant, I am able to finish welded
and pass the test.
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.
[1]
It is the
process to join two pieces of metal using an electrode that is guided along the joint between the
pieces. It use either direct (DC) or alternating (AC) current, and consumable or non-consumable
electrodes.
Electric arc welding is one of the consumable electrode arc welding. The electrode is
either a rod that simply carries current between the tip and the work, or a rod or wire that melts
and supplies filler metal to the joint. When the electrode is positioned close to the work piece, an
arc is created across the gap between the metal and the hot cable electrode. Ionized column of
gas will develops and circuit completed. Below diagram shows the process of electric arc
welding.
Theoretical Background:
Welding is the method in which metals are joined together by melting them and using a
filler to join the parts. To weld, a combination of heat and pressure is used. The earliest form of
welding is called forge welding and dates back to 2000 B.C. In this, the metals are heated and
hammered to fuse them. Nowadays this is only practiced by blacksmiths. There are various
methods that are followed after the advent of electricity. Now different sources of energy are
used for welding purposes - gas flame, electric current, laser, electronic beam, friction and ultra
sound. Some of them are arc welding, gas welding and resistance welding.
The method that is mostly used is arc welding. This is also called stick welding. In this,
inexpensive equipment is used and a continuous supply of AC or DC is required with constant
voltage. Welding is done by an electric arc between the electrode and the base materials. At the
point of welding, the metal is melted. Shielding gas protects the area. The work is done speedily.
It has a high concentration of heat and so the distortion is less. Some of the processes are
shielded metal arc, gas tungsten arc, gas metal arc, flux-cored arc and submerged arc.
Gas welding is generally used for repair work and welding of materials that cannot
withstand high temperatures. This includes repairing pipes and tubes, welding plastics and
making jewelry.
Resistance welding needs costly equipment and it cannot be used in all situations. In this
method additional sheets of metal are used to encase the pieces that have to be fused together.
The latest method is laser welding or energy beam welding. It is very fast and the
accuracy is perfect, but it is too expensive for all purposes. Electron beams are also used. This is
greatly automotive and aerospace industry.
Welding can be done only on certain metals. When it comes to alloys, it is difficult to
know its composition and hence can create a problem when it is welded. Stainless steel tends to
crack and distort when fused.
In many manufacturing units, welding has become automated and robots are used in
many areas. Welding is not only done indoors in manufacturing units, it can be done outdoors
too. It can be done underwater, where ships and pipelines underwater have to be repaired. Its use
in space is also being researched.
It is very essential to be very careful while welding. A welder requires a good welding
gear which includes a welding helmet, welding gloves and a heavy jacket. The eyes can be
damaged if you do not protect your eyes when you see the arc. The fumes from welding can also
be highly toxic. You can also get electric shock, burns, and overexposure to ultra violet rays. So,
extreme care should be taken by the welder, while welding. One should have welding hoods, eye
protection, face protection, welding gloves, first aid kit, hearing protection, respiratory protection
and any other protective gear that will be of help to the welder.
The difference in the different types of welding is the different types of energy that is
used to generate heat and the method that is used to weld the metals. With modern technology,
there are many newer and safer methods that are used.
Apparatus and Materials:
AC machine: Transformer or motor, DC machine: Transformer with DC rectifier or motor, metal
plate, welding gloves, welding mask, electrode holder, electrode, chipping hammer and wire
brush.
Procedure:
1) Two mild steel plates were cleaned by using wire brush.
2) Appropriate speed, voltage and the current of a direct current (DC) welding machine was
adjusted.
3) The earth cable was clipped to the work table while the coated electrode was clamped 90
to the holder which connected to the transformer.
4) The transformer was then switched on.
5) Both plates were placed on the working table.
6) The electrode holder was tilted to approximately 45 with respect to right side for right
handed welder and weld in the direction of left to right.
7) Small weld begins at the both end of the steel plates welding region.
8) The welding region was allowed cooling down until it is solidifies. A hammer was used
to knock out the slag.
9) Several passes were carried out and step 11 was repeated after each weld until a secure
bead line was formed.
10) Lastly, the welded work piece was undergoing a failure testing.
Results:
Discussion:
During the welding process, I faced some problem. The first one will be I don't have
much experience in welding, I bring the electrode too close and touches the surface of the metal
plate and it stick. I take more time on figuring how to handle the electrode and the correct way of
using it. Besides that, I also weld the joint too fast. As a result, the weld is not even and
inconsistency. It is hard to clean the flux in the hole.
Luckily, after practice a few times the technique of welding, I able to master it and
produce a strong weld joint and passes the strength test.
Conclusion:
In conclusion, we enjoy learning the methods to weld using electric arc welding. Apart from this,
we also learn how to protect ourselves in the workshop such as wearing safety equipment to keep
us from health hazard.
