Marks: 4.

75
Suggestions: ​Write the advantages, disadvantages, applications of welding.
List a few welding defects, ways to avoid them.
Write the meanings of technical terms like flux, slag, filler etc.
Describe the processes in your own words only. Do not copy directly.

Date: 13/09/2019
Enrollment No : 2019EEB1160
Name: Gurjot Singh
Session No: 6

Session Report

Objective of the Session:

To Perform Welding to Weld the side walls and metal barricade to the Base of the medical centre.

Prerequisite Knowledge-:
Welding
● Welding is a sculptural process in which materials (usually metals or thermoplastics) are
melted at high temperatures and allowed to cool which results in their fusion and they
become a single entity.
● The welded joint can be stronger than the parent materials if a filler metal is used that has
strength properties superior to those of the parents, and if proper welding techniques are
used.
● Different energy sources are used for welding such as gas flame, electric arc, laser,
electron beam, friction and ultrasound.
● Depending on the process, equipment cost can vary, from inexpensive for methods like
shielded​ ​ ​metal arc welding and , to extremely expensive for methods like laser beam
welding and electron beam welding.
● Alternative mechanical methods of assembly require more complex shape alterations (e.g.,
drilling of holes) and addition of fasteners (e.g., rivets or bolts).

Source-www.miat.edu
Types of welding-:
1. Fusion Welding
2. Solid State Welding
Fusion welding:​ ​Fusion-welding processes use heat to melt the base metals. In many fusion
welding operations, a filler metal is added to the molten pool to facilitate the process and provide
bulk and strength to the welded joint.
Some ​Types​ of fusion welding:-

Source of theory- ​www.wikipedia.org​ ; ​www.brighthubengineering.com​ ; ​www.welderstation.com

1. ​ Arc welding-: refers to a group of welding processes in which heating of the metals is
accomplished by an electric arc. ​This was Done in the Workshop

www.slideshare.com
● Resistance welding-​ Achieves coalescence using heat from electrical resistance to the
flow of a current passing between the faying surfaces of two parts held together under
pressure.

● Oxyfuel gas welding-​ These joining processes use an oxyfuel gas, such as a mixture of
oxygen and acetylene, to produce a hot flame for melting the base metal and filler metal, if
one is used.
Source of theory- ​www.wikipedia.org​ ; ​www.brighthubengineering.com​ ; ​www.welderstation.com

www.mech4study.com

Solid-State Welding:​ Solid-state welding refers to joining processes in which coalescence

results from application of pressure alone or a combination of heat and pressure. If heat is used,
the temperature in the process is below the melting point of the metals being welded. No filler
metal is utilized. Some types of solid state welding.
Write in your own words.

● Diffusion welding-​ Two surfaces are held together under pressure at an elevated
temperature and the parts coalesce by solid-state diffusion.

​www.researchgate.net
Source of theory- ​www.wikipedia.org​ ; ​www.brighthubengineering.com​ ; ​www.welderstation.com

● Friction welding- ​ Coalescence is achieved by the heat of friction between two surfaces

www.slideplayer.com

● ​ ltrasonic welding- ​Moderate pressure is applied between the two parts and an
U
oscillating motion at ultrasonic frequencies is used in a direction parallel to the contacting
surfaces. The combination of normal and vibratory forces results in shear stresses that
remove surface films and achieve atomic bonding of the surfaces.

www.mech4study.com
Types of Joints:
(a)​ ​Butt
​(b)​ Corner
(c) ​Lap
(d)​ Tee
(e)​ Edge
Source of theory- ​www.wikipedia.org​ ; ​www.brighthubengineering.com​ ; ​www.welderstation.com

www.weldingworld.com
Work Performed:
1.​ First we cut the mild steel rod that we had prepared by forging in the previous session into 5 equal
pieces of 50 mm each.

2.​ After cutting, we filed them to give them final finishing and proper dimensions.We also filed the 300 mm
rod a bit to give smoothness.
3.​ After that, We went to the welding workshop with base plate, side walls( that were prepared in the
plasma arc cutting session) and the (5) 50 mm pieces and (1) 300 mm piece of rod.
4.​ We put the protective mask, protective apron and started first practicing welding on sample metal sheet.
5.​ After practicing, welding was performed under the guidance of our instructor and first we welded the side
walls after which a metal barricade was made with the help of welding between the side walls.

6.​ First, the 50 mm pieces were welded vertically after which the 300 mm rod was welded horizontally on
the welded 50 mm pieces.

Tools Used:
1.​ ​Hacksaw- For cutting the mild steel rod into smaller pieces
 www.bunning.com.au

2.​ ​Filer- For giving smooth finish to the cut pieces

www.wonkeedonkeetools.co.uk
3.​ ​Arc-Welding Machine- To weld side walls and metal barricade to the base plate

www.indiamart.com
4.​ ​Welding shield Helmet- To protect our face and eyes while welding
 www.indiamart.com

Difficulties Faced:
1.​ It was difficult to give the rod pieces the exact required dimensions.
2.​ We faced difficulty while maintaining the speed at which we moved the welding machine as we were
unable to see the joint due to the protection mask that we wore to protect ourselves while performing
welding.

Plan for next session:

To prepare for Mid-Sem Viva
We will also be making pillars of our medical centre using lathe machines and performing turning
operations.