MECHANICAL ENGINEERING DEPARTMENT

DJF 3012 – MANUFACTURING

WORKSHOP PRACTICE 2

TITLE WELDING ( MIG )

1. Make a project using TIG and MIG welding, conventional machine, EDM,
CNC machine based on standard operational procedures. (P4, PLO 4)
COURSE
LEARNING
2. Demonstrate safety awareness in practical work procedures and practices.
OUTCOMES
(A3, PLO 5)

3. Demonstrate an understanding of professional ethics, responsibilities,

norms and practices in manufacturing processes during practical work
session. (A3, PLO8)

OBJECTIVE 1. Produce project by performing the techniques for TIG and MIG welding

1.0 INTRODUCTION / BASIC THEORY

Welding is defined as a joining process that produces penetration of material by heating them
to the welding temperature, with or without the application of pressure or by the application of
pressure alone, and with or without filler metal. The most popular welding process are oxy
acetylene welding (OAW), Shielded Metal Arc Welding (SMAW), Gas Tungsten Arc Welding
(GTAW), and Gas Metal Arc Welding (GMAW).

Gas metal arc welding (GMAW), sometimes referred to by its subtypes metal inert gas (MIG)
welding or metal active gas (MAG) welding, is a welding process in which an electric arc forms
between a consumable wire electrode and the workpiece metal(s), which heats the workpiece
metal(s), causing them to melt and join.

Along with the wire electrode, a shielding gas feeds through the welding gun, which shields the
process from contaminants in the air. The process can be semi-automatic or automatic. A
constant voltage, direct current power source is most commonly used with GMAW, but constant
current systems, as well as alternating current, can be used. There are four primary methods of
metal transfer in GMAW, called globular, short-circuiting, spray, and pulsed-spray, each of which
has distinct properties and corresponding advantages and limitations.

Originally developed for welding aluminum and other non-ferrous materials in the 1940s, GMAW
was soon applied to steels because it provided faster welding time compared to other welding
processes. The cost of inert gas limited its use in steels until several years later, when the use of
semi-inert gases such as carbon dioxide became common. Further developments during the 1950s
and 1960s gave the process more versatility and as a result, it became a highly used industrial
process. Today, GMAW is the most common industrial welding process, preferred for its
versatility, speed and the relative ease of adapting the process to robotic automation. Unlike
welding processes that do not employ a shielding gas, such as shielded metal arc welding, it is
rarely used outdoors or in other areas of moving air. A related process, flux cored arc welding,
often does not use a shielding gas, but instead employs an electrode wire that is hollow and filled

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 MECHANICAL ENGINEERING DEPARTMENT

DJF 3012 – MANUFACTURING

WORKSHOP PRACTICE 2

with flux.

Apparatus / Materials / Tool / Equipment (either one)

a) MIG Welding Machine

Figure : Metal Inert Gas welding equipment

2.0 SAFETY

i. CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury.
ii. WARNING: Indicates a potentially hazardous situation which, if not avoided, could result
in serious injury.
iii. Safety Glasses: Wear safety glasses to avoid injury to your eyes.
iv. Lifting Hazard: Lift with two or more people to avoid serious injury.
v. Recycle: Use proper recycling techniques for materials and packaging.

a) Personnel Protactive Equipments (PPE)

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 MECHANICAL ENGINEERING DEPARTMENT

DJF 3012 – MANUFACTURING

WORKSHOP PRACTICE 2

Figure : Personnel Protective Equipment

b) Safety Precaution.

The following recommendation details the standard procedure for all personnel working
within in a workshop:

i. Before any work is carried out in the workshop, permission must be obtained from
the Workshop Supervisor or Lecturer.
ii. Always wear safety equipment during welding process.
iii. Working areas and equipment are to be thoroughly cleaned after the usage.
iv. If you are last person to leave the workshop, make sure all equipment is turned off.

c) Operator Safety Checklist.

Regular checks by the operator are a good way of identifying problems as well as making
sure machinery is safe for use. Checks should be carried out at regular intervals, as a
suggestion daily or after using the machine. The table below contains the recommended
minimum checks the operator should carry out on a regular basis.

Table : Safety checklist

NO Description Yes No Remarks

1 Welding machine in a good working condition

Provided with earthing or grounding or work

2
clamp

3 Provided with Torch

4 Torch in a good condition / Complete set

5 Coolant system in a good work condition

6 Properly insulated and no exposed cables

Cables and joints are proper and in good

7
condition.
If the answer is ‘No’, action need to be taken.

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 MECHANICAL ENGINEERING DEPARTMENT

DJF 3012 – MANUFACTURING

WORKSHOP PRACTICE 2

3.1 PROJECT / TASK

Project 1 : Plate Weld in 3G Position

Objectives:

At the end of the session the students will be able to;

i. Demonstrate MIG plate weld in 3G position
ii. Keep the workshop clean and safe.

Equipment/Tools Required:

i. Mild Steel plate

ii. Brush
iii. MIG Welding machine
iv. Safety Wear

Procedures:

General Procedure

1. Turn on the power supply.

2. Switch on welding machine
3. Set the Carbon Dioxide (CO2) gas pressure by turning the gas regulator and nozzle.
4. Set the types of current
a) DC – Steel, mild steel and copper.
b) AC – Alloy
5. Adjust the current to 70 A for mild steel.
6. Clamp the earth cable to the work piece.
7. Touch the electrode at 45o to the work piece.
8. Press the electrode wire trigger until spark appears and welding pool produced.
9. Make sure both gas regulator and nozzle is fully closed after working.
10. Ensure the gas pressure is set to zero.
11. Press the electrode wire trigger to release all the gas in the pipe.
12. Switch off the welding machine and power supply.

Plate Weld in 3G Procedure

1. Arrange the work pieces side by side orientations as shown in figure.

2. Start at the bottom end and straight up to the top.
3. Move the electrode in a circular pattern and keep the size of the molten weld pool, if the
Size changes adjust the speed and distance of electrode.
4. Repeat this practice until you can keep the width of the molten weld pool uniform and the
Direction of travel in a straight line.
5. After completion of the welding process, switch off the welding machine. Clean the work
Piece using brush.

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 MECHANICAL ENGINEERING DEPARTMENT

DJF 3012 – MANUFACTURING

WORKSHOP PRACTICE 2

Figure: Workpiece position.

Project 2 : Pipe Weld in 1G & 2G Position

Objectives:

At the end of the session the students will be able to;

i. Demonstrate MIG plate weld in 3G position
ii. Keep the workshop clean and safe.

Equipment/Tools Required:

i. Mild Steel plate

ii. Brush
iii. MIG Welding machine
iv. Safety Wear

Procedures:

General Procedure

1. Turn on the power supply.

2. Switch on welding machine
3. Set the Carbon Dioxide (CO2) gas pressure by turning the gas regulator and nozzle.
4. Set the types of current
c) DC – Steel, mild steel and copper.
d) AC – Alloy
5. Adjust the current to 70 A for mild steel.
6. Clamp the earth cable to the work piece.
7. Touch the electrode at 45o to the work piece.
8. Press the electrode wire trigger until spark appears and welding pool produced.
9. Make sure both gas regulator and nozzle is fully closed after working.
10. Ensure the gas pressure is set to zero.
11. Press the electrode wire trigger to release all the gas in the pipe.
12. Switch off the welding machine and power supply.

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 MECHANICAL ENGINEERING DEPARTMENT

DJF 3012 – MANUFACTURING

WORKSHOP PRACTICE 2

Pipe Weld in 1G & 2G Procedure

1. Arrange the work pieces side by side orientations as shown in figure (1G or 2G).
2. Start Point the electrode so that the flame is distributed equally on both pieces.
3. The melting pool is produced, if the size of pool suitable enough to move the torch.
4. Move the electrode in a circular pattern and keep the size of the molten weld pool, if the
Size changes adjust the speed and distance of electrode.
5. Repeat this practice until you can keep the width of the molten weld pool uniform and the
Direction of travel in a straight line.
6. After completion of the welding process, switch off the welding machine. Clean the work
Piece using brush.

Figure: 1G and 2G pipe welding

PROJECT 3: TIG/MIG PROJECT

Objectives:
At the end of the session the students should be able to;
i. Produce project using TIG/MIG.
ii. Keep the workshop clean and safe.

Procedure :
i. Draw or sketch a project to be produce.
ii. Prepare materials to be weld base on type and size.
iii. Apply the suitable procedure to join/ weld.
iv. For finishing, polish and painting might be applied.

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 MECHANICAL ENGINEERING DEPARTMENT

DJF 3012 – MANUFACTURING

WORKSHOP PRACTICE 2

RESULT, ANALYSIS AND DISCUSSION

Discuss according to the completed model from the lathe machine.

CONCLUSION

Draw the conclusion based on the model of the experiment.

REFERENCES

List out all the sources of references

Prepared by: Verified by:

---------------------------------------------------- -----------------------------------------------------
Course Coordinator / Lecturer Program Leader / Head of Department
Date: Date: