FAKULTI TEKNOLOGI KEJURUTERAAN

MEKANIKAL DAN PEMBUATAN

UNIVERSITI TEKNIKAL MALAYSIA
MELAKA

JOINING TECHNOLOGY
BMMP 3523 REV :01

LAB 1: ROBOT WELDING (CMT)

1.
NAMES OF GROUP
MEMBERS & 2.
MATRIX NUMBER
3.

4.

5.

COURSE

NAME OF 1.
INSTRUCTOR
2.

EXAMINER’S COMMENT VERIFICATION

STAMP

TOTAL MARKS :
REV NO DESCRIPTION DATE OF REVISON
01 Contents reviewed after 5 years 30/8/2018
02
03
04
 ROBOT WELDING (CMT)

1.1 OBJECTIVES
The objectives of this laboratory are;
1. Perform the butt join of Aluminum plates.
2. Investigate the effect of welding parameters such as arc current, voltage, travel speed
and feed rate on the welding conditions and strength.
3. Analyze the welding parameters against tensile strengths of the weld.

1.2 INTRODUCTION
Metal inert gas (MIG) is one of the most employed heat sources in welding
process. It melts and joins metals by heating them with an arc established between a
continuously fed filler wire. The filler wire also acts as an electrode to the welding
system. Shielding of the arc and the molten weld pool is obtained from inert gas such as
argon and helium. MIG welding is normally perform with positive direct current
electrode because it can provide a stable arc, smooth metal transfer, relatively low
spatter and good weld characteristics.
Some of the advantages of using MIG welding are as follows:
a) Very clean process due to the application of inert shielding gas
b) Higher welding rate
c) Can weld thick plates at high speed

This modern joining method satisfies increasingly stringent demands, some of

the most important of which are process stability, reproducibility and cost effectiveness.
The bundling together of specific material properties opens up a number of interesting
possibilities. Material compounds impart to a component or product the desirable
properties of the constituent materials. Previously, such results could only be achieved
by mechanical means or by bonding. Of much greater interest, however, is the ability to
use heat to join materials with differing properties. The main focus in this respect is on
the joining of steel and aluminum, as this will be of particular interest to the automotive
sector, where it could spawn a whole range of previously undreamt of innovations.
 Figure 1: Schematic illustration of the MIG welding process

1.3 SETUP
1. Robotic MIG Welding Machine (Model: KUKA KRC-6)

2. Tensile test machine

3. Aluminum Plates dimension of 50 x 150 x 0.5 mm

4. Mild Steel wire of 0.1 mm

5. Hand Notcher Machine

6. Vernier Caliper

1.4 EXPERIMENTAL PROCEDURE

1. Each group should consist of 4 or 5 person.
2. Each group is given a raw material of 2 aluminum plates with size of 50 mm x
150 mm and thickness 0.5 mm.
3. By referring to the machine operation manual, identify the suitable
welding parameters.
4. Fill in the selected process parameters together with their values in Table 1.
5. Perform butt joint of the aluminum plates using the selected parameter
and variables.
6. Observe for defects on the weld if any and record the result.
 7. Measure the width of the weld using a Vernier Caliper and record the result in
Table 1.

1.5 SAMPLE PREPARATION FOR TENSILE TESTING

After the samples have been welded, it needs to cut off using Hand Notcer
Machine and the size of each specimen is equally divided into 7 pieces. 5 pieces
from one completed weld plate were taken for tensile testing as shown in Figure 2.
The start and stop points were cut off, is not included in the evaluation.

Figure 2: Specimen cutting for Hand Notcher machine

1.6 TENSILE TEST

1. Locate the welded plate in the midway between the jaws of the testing machine.
2. The width thickness of the test specimen is measured before testing, and the area in
square inches is calculated by multiplying these before testing.
3. The tensile test specimen is then mounted in a machine that will exert enough pull
on the piece to break the specimen.
4. The specimen is being tested in this machine; the load in pounds is registered on the
gauge.
5. In the stationary types, the load applied may be registered on a balancing beam. In
either case, the load at the point of breaking is recorded.
6. Record result of Yield Strength and Tensile Strength in Table 2 below.
 Figure 3 : Tensile test
1.7 RESULT AND DISCUSSION

Complete the following data/table 1.

Size of wire (mm):

Table 1: The effect of selected parameter and variables on the width of the weldment
WELDING PARAMETERS
NO. OF EXPERIMENT
Remarks (for defects,
WIDTH (MM)
if any)

Table 2: Mechanical properties of welded material

SPECIMENT NO. Yield Strength(Mpa) Tensile Strength (Mpa)
1.8 SAFETY PROCEDURES

1) Always keep safety in mind.

2) Wear eye protection and safety shoes at all times.
3) Do not wear neckties, wristwatches, rings jewellery, etc. when operating the
machine. Long sleeve shirts will be rolled above the elbows.
4) The area surround the machine should be free of oil or coolant spills (avoid a
slippery floor) and as free as possible from obstruction. Keep the area clean at all
times.