1.1.

To investigate band study the effect of varying the current and

the voltage on the arc welded specimen.

1. Objective
During this experiment we shall study the arc welding, its applications, applications in
Pakistan, advantages, disadvantages and limitations of the arc welding.

2. Apparatus
 Electrode holder
 Arc
 Electrode
 Work cable
 Welding machine
 Base material

Fig. 1 Arc welding

3. Procedure
 Prepare a piece of mild steel plate 3.0mm thick.
 Use an electrode of your required needs.
 Adjust the ampere around 60 – 100 for electrode diameter 3.2mm
 Put an electrode at the electrode holder and make sure that there are no
movement of electrode at the holder.
 Hold the electrode 60’degrees work angle and 2mm – 3mm above the base
metal.
 Hold that position over a spot just inside the left edge of the base metal until a
molten pool is established.
 Welding then proceeds from left to right (for the right hand)
 Stop the process at the end of the work piece.
  The correct technique is holding an electrode at the start position for 1s or 2s
and continue until the end of the process. At the end, hold an electrode at the
last position for 1s or 2s before finishing the process.
 The frequency of this action will be determined by the size
 of the weld being deposited, and the correct action improve
 with practice

Theory
4. Arc welding
Arc welding is the process of joining the two metal by using the current that will provide the
enough heat to melt the element and the metals that are being are then allowed to cool will
result in the binding of the meatal. We can use both type of current like alternating current
and direct current. The fillers which we use can either be consumables or non-consumables.
Welding power supply will create an electric are between the metal stick and the base
material.
The welding area is usually protected by some type of shielding vapors or gas. Arc-welding
processes include shielded metal arc welding, metal inert-gas welding, tungsten inert-gas
welding, plasma arc welding, and submerged arc welding.

Fig.2 Arc welding process

5. Principle
Basic principle of the arc welding is somehow like the principle of the spot welding. In this
welding we heat up the base metal and electrode with the help of current so that they melt
and merge with each other so that on cooling they can be attached with each other. At the
same time when the metal melts the filler metal is filled so that they can be mixed with each
other rand we can get a good weld. The figure below shows the complete process:

Fig.3 Arc welding process

We can get different types of the joints based on our requirements and the needs and the
operation we choose.

Fid.4 Types of joints

6. Ohm’s law
Ohms law provides us with the relation between the voltage and current.
It states that the current that is passing through the conductor is directly proportional to the
voltage by introducing a constant of proportionality that is resistance.
V
I=
R
R shows the resistance which is the opposition to the flow of the current.
I am in amperes and V is in volts whereas R is in ohms.
According to the ohms law resistance is independent of the current. Due to this resistance
heat is produces in the fire or in any circuit path. This produced heat can be determined by
the formula:

H=I 2 Rt

7. Advantages of arc welding

 Cost-Equipment o the arc welding is affordable and not too expensive.
 Portability-Arc welding plant is compacting size and we can transport the plant
from one place to the other easily.
 Unlike other welding this type of welding can be used on the dirty metals
whereas other welding cannot be easily used on the dirty materials.
 Shielding gas-In other welding we must have to cover the surface with some type
of shielding gas.

8. Disadvantages of arc welding

Regardless of certain advantages there are some disadvantages of the arc welding:

 Lower efficiency is one of the basic disadvantages of the arc welding. The reason
of less efficiency is due to extra loss of material in the arc welding than any other
type of the welding
 To operate arc welding plant, we require operator with skills and training
 There is a disadvantage of using arc welding is that it can be used only on the thin
metal. It cannot be used on thick materials.

9. Limitations of arc welding

 Arc welding is sensitive to the contaminants like rust, mill scale, dirt and oil paint.
These can cause porosity, incomplete fusion and bad appearance
 Lack of fusion is also another limitation for the arc welding due to which we often
resist to use arc welding
 Arc welding is an open process due to which there could be a skin contact which
a cause damage to the skin.

10. Applications in Pakistan

 Miller synchro wave
  Miller maxter
 Miller Dynasty
 Miller gold star series

11. Steps of operation

Following are the steps for the arc welding:

 Clean up the face of metal

 Set up the workpiece
 Adjust your welding plant
 Turn on the plant and weld the workpiece
 Fill the remaining metal with the beads weld

12. Precautionary steps

There is certain precautionary measure which we must take before using spot welding
which are as follows:

 Helmets with shields so that it can protect bus from UV radiations which will
cause certain chemical burns
 Goggles or glasses are necessary s that there should be no damage to the eyes
 We should wear closed shoes to prevent any contact of the fire or workpiece
with our foot
 Our clothes should be skin fit, clothes not should be too losing that they can be
captured by the machine

13. Comments
At the end of this experiment:

 There are problem occurs on the arc welding process.

 To get a best result of this arc welding process, student must know the angle
that are used, concentration, and the movement of the electrode and speed of
moving the electrode.
 The thickness of the metal and type of the electrode are used are the factor in
arc welding process.
 Factor that affect result of that arc welding.