Marks: 5

Date: 18th October 2019

Enrollment No.: 2019EEB1147
Name: AYUSH VERMA
Session No: 9

Session Report

Objective of the Session: ​To perform​ ​welding​ process to weld the base plate with the boundary plates
and also weld rods made by forging in earlier session to make metal barricades.

THEORY
● Welding is a joining process in which two or more parts are joined at their contacting surfaces using
heat and/or pressure.
● Types of welding​ :
1. ​Fusion welding​ : Fusion-welding process uses heat to melt the base metal.
● Types of fusion welding-
● Arc welding - In this process, electricity is used to create enough heat to melt metal and thus join
them.
● Resistance welding
● Oxyfuel gas welding - It is a type of welding in which fuels like ​oxygen-acetylene​ are burned to form
a concentrated flame of high temperature.
2.​ Solid - state welding​ :Solid-state welding refers to joining processes in which joining results from
application of pressure alone or a combination of heat and pressure.
● Types of solid- state welding-
● Diffusion welding
● Friction welding
● Ultrasonic welding
 Source- ​https://mechanicallyinfo.com/different-types-of-welding-processes/
● Types of electrode​s-
● Consumable electrode - It provides the source of the filler metal in arc welding
● Non consumable electrode -nonconsumable electrode is gradually depleted during the welding
process.
● Types of joints​-
● Butt joint
● Lap joint
● Tee joint
● Cross joint
● Edge joint
● SOME TERMS
Flux​ - A Flux is a substance used to prevent the formation of oxides and other unwanted
contaminants.In our electrode,flux used was ​aluminium oxide
Slag​:-Slag is the waste material which is separated from the flux after the welding has been done.
Filler material:​- It helps in bonding the metals during welding.
Shielding gases:​ ​are inert or semi-inert gases that are commonly used in several welding
processes.It prevents oxidation.
● Straight Polarity​—occurs when electrode is made negative and base plates are made
positive. Thus electrons flow from the electrode tip to base plates.
● Reverse Polarity​—occurs when electrode is made positive and base plates are made
negative.
● We used straight polarity​(electrode was made cathode)
● Advantages
1. It is the most economical way to join materials.
2. The time consumed in welding is less.
3. Welding is not restricted to factory environment
● Disadvantage​s
 1. It gives harmful radiation and can damage our eyes.
2. It does not allow convenient disassembly.
3. Skilled person is required.
● Applications
1. Aircraft Construction
2. Bridges
3. Railroad Equipment
4. Repair of broken parts​.
● Defects of welding​.
1. Incomplete Fusion
2. Undercutting
3. Cracks
4. Porosity
5. Slag Inclusions
6. Flux Inclusions

WORK DONE
● The rods made during forging process were cut into 5 pieces of 50mm each using a hacksaw

● The ends of the obtained pieces were filled .

● The earthing was connected to the table

● Electrode used was torch(cathode).
● The two small plates were welded with the base plate and the five pieces were welded
subsequently . A rod was then welded in horizontal manner across the pieces (tee joint).
 (corner joint)

● The current used was ​80-110 Amperes​.

● The welding machine was ​DC
● The final work piece obtained after welding is as follows
Tools Used:​ The following tools have been used by us:-
● Hacksaw ​- used for cutting mild steel rod

​ ttps://www.amazon.in/VISKO-235-Hacksaw-Plastic-Handle/dp/B016OMEXEQ
Source​-h

● Electrodes. ​-Attached with the holder which completes the circuit and helps in welding operation.
● Electric Arc welding machine -​ Used for welding

● ​Bench vice​ - Used for holding the rod while cutting.

 Source ​https://www.indiamart.com/proddetail/bench-vice-swivel-base-5749454591.html
● Filer-​ For giving smooth finish to the cut pieces

Source ​https://www.digopaul.com/english-word/filer.html
● Welding mask​- To protect our face and eyes while welding

Source ​http://weldstation.com/product/weldzone-protective-gear-ordinary-welding-mask/

Difficulties Faced:
1. Welding was a bit difficult work because we were not able to see clearly through the helmet so the
welding joints produced were a bit untidy.
2. We faced difficult to maintain proper distance from the workpiece as the electrode started sticking to
it.
3. Also it was difficult to cut the rod using hacksaw.
Precautions
● We used hand held helmets / hand shield for protecting our eyes from the harmful rays generated
during welding
● Gloves were used for protection of hands while performing welding
● We wore leather shoes for protection purposes

Plan for next session: ​our plan for next session is to perform turning operations (TO) to make pillars using
lathe machines.