Subiect: Workshop Practice-I and I!

ws-171 &172 L-T-P: 0-0-3 2 credits 1stand 2nd Semester, All Branches

Weldinq shop
GENERAL INSTRUCT(ONSTO STUDENTS
Students are required to come in proper dress while attending the Workshop practical class.
They should wear apron (available in the workshop) and full shoes. Without shoes no one
be permitted to enter into the shop.
2. Students are required to come on time as per the timetable.They shall be marked late if they do
not turn up within five minutes of the scheduled time. Those who come late are to take
permission from Prof.-in-Charge to enter into the shop. No one be allowed if they are late
by 15 minutes in any case.
3, Students are required to follow the instructions given by the teacher concerned or instructor
strictly. They should remain present in their place of working for the whole class unless
otherwise instructed.
4. Students are required to handle only those machines allowed to them by the instructors. Under
no circumstances any student should handle machines not assigned to him.
5. Students are required to fill in Workshop Card each day before entering the shop. At the time of
leaving student must ensure that it is signed by the instructor and a grade is given.
6. Students are required to complete the job within the time allotted to them. They should do the
job by themselves. Instructors would only help them in difficulty. Students should gather as
much information about the machine tools; power tools, hand tools, gauges, processes and other
details as possible from the instructors.
7. In case of any dispute, misunderstandingor difficulty,they may meet the Prof.-in-Chargeor
Head of the Central Workshop.
8. Every student is required to clean the machine and return the tools issued to them after each
day' work.
9. Students are required to appear for the Quiz Test/Viva-voce examination as and when notified
or instructions given by the Coordinator, Workshop Practice.
10. Assessment shall be done on the basis of regularityin attendance,discipline, attitude of the
student, quality of jobs done, report and performance in the Quiz Test/Viva-voce test.
After they are required to submit the record (one bound volume for entire semester)
when they.repog (QC

On completion all classes in a shop, all students are required to

!bEL Each class shop record should consist of the following:
Task to be done
'i. Raw materials used.
iii. Tools used
iv. Description of tools and instruments used with neat sketch
v. Procedure

Page 1 of 10
 Weldino ss e ana Pr Av.autions

AWays wear protective clothing i.e. Full-shoe, Apron

(available in the
workshop) and flame proof gloves before start welding to
protect
sparks and spatter. Without full-shoes no one will be permitted against
to enter into

Atways wear protective goggles during cutting, grinding and

chipping

An equipmentor machine should be use by one person at a

time (waitfor
your tum until the machine is not free).
AWays perform welding only in designated areas.
Operate welding equipment only after getting proper training
from the

During arc welding, wear specifically designed, leak-proof

helmets
with fitter plates to protect against ultraviolet, infrared, and visible equipped
radiation.
Never look at the arc with bare eye, even for an instant.
• For gas welding use black goggles.
Keep your head away from the plume by staying back and
to the side of the
work. Use your helmet and avoid inhalation of fume.
• Never touch the job with bare hand just after the welding.
Do not perform welding in wet areas, or with wet hands.
If othersare working in the area be sure they are warned and
protected
against arcs, fumes, spark'. and other welding hazards.
Check. area around you before wok-lingto be sure no flammable material
or
degreasing solvents are in the we!diißl
• Locate the nearect fire eytinguisher before welding.
Deposit all scraps and butts in proper waste container to avoidfire
and toxic v,ges,
After using aii the eq iomenw proper place.
Clean tie working area after completing your work

Page. 2 of
 Practice Schedule and Record Submission Details
I S Class
A. Introduction about different types of joining and welding process
Study of gas welding and arc welding setup

Equipment
No.
1 Arc welding system
2 Gas welding System
3 Cut-off saw
4 Band saw
5 Power saw
6 Pedestal Grinding machine
7 Drilling machine
8 4-•aw chuck Lathe
Uses
41.
To join (weld) different materials
To join (weld) different materials
To cut metal plate (cutting is done by abrasive disc cutter)
To cut metal plate, rod, bar etc.
To cut metal plate, rod, bar etc.
To remove burr from material and finishing operation
To make a hole
For turnin facin thread cuttin

B. Record Submission
Draw the schematic diagram of gas welding equipment
How heat is generating in gas welding?
Different type of flame used in gas welding

2n Class
A. Task
a) Practice —melting a welding track by gas welding on 3 mm thick MS plate
b) Bead formation .using filler rod on the opposite side of the plate

B. Record Submission
Raw material, Equipments used and prqcedure for doing the job
 oj i,' welding
PtØdic.O Ouict

B, Record Submission

Rawjnatcrial. Equipmcntg used and p/ocedurc for doing the job

4 Class

Practice - corner Joint using gas welding

B. Record Submission
thejob
Re,' material, Equipments uwd and procedure for doing
the connnon defcctg occur during gøg welding
Whgt4te advantages and disadVøntages orgøs wcjding
 Class
A. Task
Practice- Lap joint of two plates (5 mm thick) using arc welding

150 mm

25 mm
B. Record Submission

Draw the schematic diagram ofarc welding equipment

Raw material, Equipments used and procedure for doing the job
-TyÖe,ofebctrodes, fiMction of electrode coating
What is the function of flux? What is-slag?

6 Class
A. Task
Practice- T joint üåing arc welding

23 mm

ISO rnm

B. Record Submission
Raw material, Equipments used and procedure for doing the job
What are the common defects occur during arc welding
What are the advantages and disadvantages of arc welding
 INTORDUCTIONABOUT WELDING

Weldingis a process of metallurgicaljoining of two pieces of metals by the

application of heat with or without the application of pressure and addition of
fillet
metal. Thejoint formed is a permanent joint.

Varioustypes of welding process:

Arc welding Gas Welding Resistance Solid State Advanced

Weldin Weldin
C&bon arc Oxy-acetylene
weldin
Spot Friction
Meal rc Air-acetylene Seam Electron beam
Mæl inat Ultrasonic Laser beam
(MIG) Oxy-hydrogen Projection Diffusion
T.stn inertgas(TIG)
Explosive
arc

Differenttypes of joint:

Butt joint
Lap joint

Tæ joint Edge joint

 Oxy-acetylene Gas Weldinq
In oxy-fuel gas welding the heat is obtained from the combustion of
a fuel gas such as
acetylene in combination with oxygen
The process is a fusion welding process wherein the joint is
completely melted to obtain the
fusion.
The heat produced by the combustion of gas is sufficient to melt
any metal and as such is
universally applicable
The fuel gas generally used is acetylene because of the high
temperature generated in the
flame. This process is called oxy-acetylene welding

Equipment
Regulator
Oxygen
control
valve Torch f.
Regulator
Acetylene
control
valve

Acetylene hose

Acetylene
cylinder Oxygen cylinder

Oxy-acetyleneGas Welding Equipment

1. Welding torch & tip
2. An acetylene cylinder— 15.5 bar, red or maroon
3. An oxygen cylinder —125 bar. Blue or black
4. Pressure regulator —C linder pressure to deliverypressure
5. Pressure gauge- One Shows cylinder pressure & the other shows the workingor
delivery pressure
6. Rubber hoses - black/green hose for oxygen & red/orange hose for acetylene
7. Safety devices —Goggle, hand gloves, helmet,apron. sleeves, shoes etc
 GAS WELDING FLAMES (Based on Gas Ratio)
The maximum temperature of the oxy-acetylene flame is 3
100-3500oc
Centre o: heat concentration is near the extreme tip of the white
cone.
mner Cone:
2C2H2+ 202 (cylinder) 4 CO+ 2H24 heat
Outer envelope:
4C0+2H2+302 - 4 C02 + 2H20 + heat

1. Neutral Flame: (Gas ratio is 1:1)

Inner white cone
(3100'C)

Torch tip
Outer blue flame
(1275•c)
2. Carburizing or Reducing Flame: ( Gas ratio 0.95 to
1)
Mixtureof acetylene
and oxygen

2900•c Intermediate
name feather

3. Oxidizing Flame: (Gas ratio 1.15 tb 1.5)

o
3300 c

Advantages of Oxy-acetylene Gas Welding:

The equipment is inexpensive, simple and is easily
portable.
Useful for welding light metals such as automobile
bodies and repair works.
A large variety of material can be welded.
Welds can be produced at reasonable-cost.
Compared to electric arc welding this provides greater flexibility
with respect to heat impact
and cooling rates.

O%advantages of Oxy-acetylene Gas Welding:

Equipment must always be handled carefully as in certain circumstances acetylene is
exp:osive as oxygen when used in an oily atmosphere (such as
an old dirty garage floorpit).
high temperatere flame from a hand held torch is dangerous
when handled carelessly.
It is much slower than electric arc welding and does not
concentrate the heat close to the
weld. Thos, the heat treated area is larger, which
causes more distortion.
Highly skilled operators are required to produce a good
weld.
If electric arc welding is available gas welding
is seldom used for work over 3.2mm thick.
The process is not satisfactory for heavy sections

Page 8 of 10
 i,

Arc weldinq
An electric arc is a discharge of electric current across a gap in a circuit
It is sustained by an ionized column of gas (plasma) through •which the current flows
To initiate the arc electrode is brought into contact with work and then quickly separated from
it by a short distance
The arc-must be shielded because as it hardens the molten metal combines with oxygen
and
nitrogen to form impurities that weaken the weld.
The electrodes are usually coated with a flux. This coating forms a gaseous cloud that shields
the molten metal from the atmosphere.
The coating also forms a protective slag. The slag floats on the molten pool and hardens
as
the weld cools. This keeps impurities out of the weld.

Electrode
holder
Source of Electrode
electric
current a.c. Insulated cables
or d.c. Arc
Workpiece

Metal table

Arc welding setup

ARC WELDING MACHINE:

RACArc Welding Machine:

A step down transformer receives the AC supply between 200 to 440volts and transforms it
to the required low welding voltage in the range of 80 to 100volts.
A high current of 100 to 400A will be suitable for general arc welding work.
In AC arc welding, there is no choice of polarity since they change in every cycle.

DC Arc Welding Machine;

In DC welding, the work-piece is connected to the positive pole of a DC generator and the
electr&de to the negative pole in order to melt greater mass of the metal in the base material.
This is called straight polarity."
When the less heatis required at the base material, the polarity is reversed. This is called
reversed polarity.
We can select the polarity depending upon the type of the job, Hence, in PC arc welding, it is
possible to melt many metals which require more heat to melt.
ARC WELDING ELECTRODES
work-pieces & fills the joint (Bare or Coated)
Consumable Electrodes: Melt along with the
globules of the molten metal while passing from the
When the bare electrodes are used, the
air to form non-metallic constituents
electrodesabsorb oxygen and nitrogen from the atmospheric
thereby decreasing the strength of the Joint.
which gets trapped in the solidifying weld metal and
Coated Electrodes facilitate:
Protection of molten metal from oxygen and nitrogen of the air by providing a gaseous shield
around the arc and the moltennetal pool
To establish & maintain the arc throughout welding
The formation of slag over the joint, thus protects from rapid cooling
Addition of alloying elements'

Advantages of Arc Welding:

l. Applicableto an infinite variety of work & can be executed in any position.
2. There is less buckling and warping of the work.
3. It produces strong sound and ductile welds.
4. Satisfactory welds can be produced in heavy & light sections.
5. Low cost process & Low accuracy in setting up required,
6. Excellentjoint properties can be obtained in mild, low alloy and stainless steels. nickel and
copper-base alloys.

GENERAL WELDING PROCEDURE

l. Marking and cutting: mark the work-piece as per requirement and cut it with Cut-off saw.
2. Edge Preparation: Edges preparationof the pieces to be joined should be done by grinding
wheel. It may involve beveling or grooving. This is done in order to get the fusion or
penetration through the entire thickness ofthe member.
3. Checking and setting of welding machine: check the welding machine and do proper
current setting (for arc welding); check the cylinder regulator pressure, hose pipe and blow
pipe (for gas welding).
Safety Devices: Goggles & shields to protect the eyes, Apron to prevent the sparks and flying
globules of molten metal, shoes, hand gloves etc.
5. Initial Weld: Initial welding spot are done at the opposite corners of the joint to secure the
pieces together.
6. Intermediate and Final Welding: The weldjoint is formed through various weaving
movements (weld beads), During this process, filler metal and a suitable flux are used, After
the intennediate run of welding, final run is taken.
7. Removnt of Excess Material: Extra materialon the weld surface can be removed using tongs
and chipping hanuner. The weld is allowed to cool and then cleaned.

Reference Book:
1. Manufacturing Volume 1 (Foundry, Forming and Welding), P. N, Roo
2. Elements of workshop technology Vol-l Manufacturing
process, Hajra & Choudhury