Car Ramp.

I. Introduction.

Welding is a common process for joining metals using a large variety of applications.
Welding occurs in several locations, from outdoors settings to rural farms and
construction sites to inside locations, such as factories and job shops. Welding
processes are fairly simple to understand, and basic techniques can be learned quickly.
Welding is the joining of metals at a molecular level. A weld is a homogeneous bond
between two or more pieces of metal, where the strength of the welded joint exceeds
the strength of the base pieces of metal.

At the simplest level, our team has come out with a project of creating a car ramp. A
car ramp will be use to lift up the cars to repair the lower parts of the cars. So, at this
moment we need a car ramp to lift up the car. So to create, we weld at several location
to join the parts and use other tools to lift up the cars.

Our team members has bought heavy duty car ramp that stows away into a 4' x 8' x 3'
work bench. The plan was to build a ramp in sections so that when it is not being used
it can be stacked into a compact "box", place a sheet of MDF on top and use it as a 4'
by 8' work island at a comfortable 36" height. The dimensions worked out so that I
had two 8' sections, two 4' sections and four 4' up-ramp sections, each one 16" wide
and 20" high. My guess is that the load capacity of these ramps is well over 5000 lbs.
II. Mechanical Tools and Components Of Welding

Tools: Grinder, measuring tape, soap stone marker, bench grinder, clamps, welder,
table saw,powder actuated fastener gun, hammer

* We use 94' of 1.500" x 1.500" x 1/8" square steel tubing,80' of 2"x2"x1/4" angle
iron,67' of 1"x1"x1/8" angle iron,half a pack of welding electrodes,5 sheets of 3/8"
OSB,1 sheet of 5/8" MDF,1 sheet of formica/arborite.

Welders has four main components:

1. A ground lead or clamp

2. A welding lead or stinger
3. A constant amperage power source
4. The electrode or welding rod to weld with
* The process is simple! The ground clamp is attached to the car ramp to be welded.
Then the welding lead, or stinger, gets the electrode inserted in it. Finally, the
power supply is turned on and only requires the user to strike the metal to ignite it.
Once that is done. the arc starts and the electrode begins to burn. This creates a
shielding gas and deposits metal into the joint that is being welded. The slag from
the electrode needs to be cleaned or chipped off as soon as the weld is
finished.Finally,the car ramp has been weld and can be used to lift up any cars.

*Welding today is comprised of three main ingredients which are required to join
metals together:

1. An electrical power source to produce an arc.

2. Some form of shielding to protect the weld from the air.
3. Filler material to fill the weld joint.

*The ways these three ingredients work together are:

1. The weld area needs to be shielded from any air around it. This is important
because oxygen and other gasses in the air make welds brittle and porous.
2. Electricity to produce an arc. An electrical arc melts metal in fractions of a
second and is hot enough to melt any known metal!
3. Filler metal is added which is how two pieces of metal become one.

III. METHOD OF WELDING USED.

a. Stick/Arc welding (SMAW)
This common method of welding was invented in the year 1802 and involves the use
of a consumable electrode that has a flux-coated core wire that gives electric current.
When in contact with the metal being welded an electric arc is created at the gap
generating high temperatures of up to 6500o F. This heat melts the electrode and the
metal thus creating a weld. This welding method is beneficial in that it does not
require shielding gas and is effective on rusty metals. However, thin metals can
complicate the process, necessitating the presence of a skilled and experienced
operator.Arc welding is best used on heavy metals of size 4mm and above and is used
in repairing heavy equipment, steel erection, and pipeline welding as well as in the
manufacturing and construction industry.

b. Metal Inert Gas (MIG) welding or GMAW

This common type of welding was perfected in the 1960s. MIG welding uses a gun
that is continuously fed with a consumable electrode. The process uses an external gas
to shield the welded metal from environmental factors like oxygen making it
continuous and quick. This method is easy to learn, produces less welding fumes, has
high electrode efficiency and requires less heat input. However, the equipment is
costly, the process does not work effectively on thick materials and it requires an
external shielding gas.MIG welding works well with a variety of alloys like stainless
steel, aluminum, silicon bronze, magnesium, copper and nickel. It is used in
automotive repairs, construction, plumbing, robotics, fabrication and maritime repairs

c. Tungsten Inert Gas (TIG) welding or GTAW

This welding method, released in the year 1941, is a difficult and time-consuming
welding process that requires a high level of skill and focus. An autogenous weld can
be created by melting two pieces of metal together without filler metal. TIG produces
high quality and spatter free welds of various alloys that can be very thin. However, it
requires a highly skilled operator and external shielding gas and does not work on
rusty or dirty materials.TIG welding is best used in aerospace welding, vehicle,
motorcycle and bike manufacturing, tubing and in high precision welds.

d. Flux-Cored Arc Welding

This method of welding is similar to SMAW except that it uses tubular wire-filled
flux in place of a solid wire. It can be self-shielded or dual shielded with an additional
external gas. It is used in welding thick materials, heavy equipment repair, and
construction as well as in steel erection.Welding processes have highly evolved in
recent years giving rise to a variety of new and innovative methods. As such, it is
necessary that you understand these techniques so that you know which one is right
for your job. This will largely dictate who you will want to hire to complete it. Every
method of welding has distinct advantages and disadvantages, and you will want to
take the time to consider which process will be optimal for your application. No
matter what welding method is right for your project Swanton Welding can aid you
today.

IV. Best practices

a) Basic elements to improve results
For many people, especially those who are new to it or perhaps don’t weld every
day, stick welding, otherwise known as shielded metal arc welding (SMAW), is one
of the more difficult processes to learn. Experienced welders who can pick up a
stinger, pop an electrode in and lay down great welds time after time can inspire great
awe in the rest of us. They make it look easy. The rest of us may struggle with it,
though. And we don’t have to, not if we pay attention to five basic elements of our
technique: current setting, length of arc, angle of electrode, manipulation of electrode
and speed of travel — or CLAMS, for short. Properly addressing these five basic
areas can improve your results.

b) Prepare
While stick welding may be the most forgiving process on dirty or rusty metal, don’t
use that as an excuse for not properly cleaning the material. Use a wire brush or
grinder to remove dirt, grime or rust from the area to be welded. Ignoring these steps
hurt your chances to make a good weld the first time. Unclean conditions can lead to
cracking, porosity, lack of fusion or inclusions. While you’re at it, make sure you
have a clean spot for the work clamp. A good, solid electrical connection is important
to maintain arc quality.
Position yourself so you have a good view of the weld puddle. For the best view, keep
your head off to the side and out of the weld fumes to ensure you’re welding in the
joint and keeping the arc on the leading edge of the puddle. Make sure your stance
allows you to comfortably support and manipulate the electrode.

c) CLAMS
Bringing all the CLAMS points (current setting, length of arc, angle of electrode,
manipulation of the electrode, and speed of travel) together may seem like a lot to
think about while welding, but it becomes second nature with practice. Don’t get
discouraged! There is a learning curve with stick welding, which many believe got its
name because when learning how to weld, everyone sticks the electrode to the
workpiece.

V. Conclusion

i. There is substantial opportunity in transforming welding technology in

industry from an experience- based technology to a science-based
technology. Fundamental work needs to be done in the thermophysical and
kinetic properties of gases and metal alloys in both the liquid and solid
state. Lack of such data is severely limiting advanced analysis. Modelling
plays an important role in the basics analyses of the various
processes discussed in this product. Models of separate effects, including
are physic, heat, and fluid flow, solidification and solid-state transformation,
need to be integrated into fully descriptive process models. Existing two-
dimensional models need to be extended to three dimensions to represent most
realistic welding conditions.

ii. Historic research on basic welding technology has generated data of limited
utility in advancing to control oriented research and development. Fundamental
research targeted at generating control-oriented data bases needs to be supported.
Such research should provide physical model verification by experimental data,
extendable to various base materials, electrical parameters, consumables, gases,
and flux materials. A common approach is needed so that data can be transferred
to models; this approach should include process identification, model formats,
experimental procedures, numerical procedures, and welding system
specification.

iii. The application of adaptive control is in its infancy in the field of welding.
Although a few systems are in commercial use, there is widespread agreement
that they are limited to special situations and lack generic understanding and
applicability. A greater understanding of control strategies and theory is needed
as a part of welding research.

iv. The development of solid -state technology has opened the door to new control
techniques and integrated sensor devices that show promise for higher levels of
control of the process.

v. Improved productivity and quality of welded structure will depend on cultural or

institutional and procedural changes in the industry as well as on applying
technological control theory. Concepts of design for producibility, the application
of group technology, and data bases for optional welding designs need to be
developed and wisely publicized. It must be recognized that more sophisticated
control and reduction of skilled labour in the manufacturing process will require
higher levels of design engineering and process planning.

vi. Pre-welding processing control is important to the total manufacturing system.

Although adaptive control can accommodate in process changes. It should not be
considered a means of totally eliminating approaches engineering practices and
procedure, which should always consider preparation of the workpieces as part of
the total process. Improved joint design, fixturing, and can reduce the burden.
VI. References
1. https://www.team-bhp.com › forumDIY: Inexpensive home-made Car
Ramps - Team-BHP

2.www.welding-fabrication.com › saWeb results Sample Welded Products

Welding Fabrication Welding Fabrication

3.https://en.m.wikipedia.org › wikiWeb results Welding - Wikipedia

VII. Appendix

diagram in Auto Cad

 MODEL OF CAR RAMP

Reported By,

Yugenthiran A/L Gunasegaran (08DKM19F1054)