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Manufacturing Laboratory-I (ME207) Report

Date of submission: 17/08/2021 Name: Md Athar Hassan

Group: G10 Entry No: 2019meb1278

Experiment No -07

Experiment title
To perform the experiment by welding the work piece by using MAG welding and
Spot welding.

Objective of the Experiment

Using the Arc Welding Process, create a V-Butt Joint and by using spot welding
equipment, create a lap joint on the given work components.

Material and apparatus used I the Experiment

 In MAG welding
 Mild steel flat of 150 x 50 x 6 mm3 – 2 No‟s.
 Welding Transformer,Electrodes, MIG welding torch, consumable welding wire.
 Wire Brush, Grinding Machine, Tong, Chipping Hammer.
 Protective Equipment(Helmet, thermally and electrically resistant gloves,
apparent body cover).

 In Spot welding
 Two sheets of galavanised iron having dimension(75X50X0.8mm3)
 Spot Welding Equipment, Snips and Gloves

Experimental procedure

 For MAG welding

 Using a grinding machine, the given material's edge is prepared to the
appropriate V-shape.
 The welding current (90 amps) and welding voltage(22.5V) are set on the
equipment.
 Using a wire brush, clean the mild steel flats that will be attached.
 Place the two work pieces on the table in the necessary position, leaving enough
space for the butt joint to fully penetrate (2mm).
 To hold the metal parts together throughout the welding process, strike the arc
and make tacks at both ends.
 The first run of welding is used to fill the gap and penetrate the weldment by
uniformly advancing the electrode from one end to the other.
 Then filling the weldment's root side.
 Chipping hammer is used to chip the scale that has been produced.
 Filing is used to remove any spatter that may have formed around the weld.
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 Then repeat the process with different welding currents of 100Amp and 110Amp.
 Then, using a Rockwell Hardness Testing Machine, we checked the hardness of
the three specimens that correspond to the welding current at (90amp, 100amp,
110amp) and recorded the results.

 For Spot welding

 The two components that will be spot welded together are put in the proper
position between the two electrodes.
 Set the timer (150ms) for the current to flow through the electrodes with the
thickness of the plates as a reference.
 60 percent of the heat input should be set.
 Press the foot lever to provide pressure to the movable electrode, causing it to
move towards the fixed electrode.
 After that, the pressure is released, and the process is repeated until the task is
finished.

Observation

Welding Welding Average

Specimen Hardness(HRA)
Current(A) Voltage(V) Hardness(HRA)
65.4
1 90 22.5 63.4 64.73
65.4
60.5
2 100 22.5 59.1 59.53
59.0
42.2
3 110 22.5 34.8 38.83
39.5

Question/Answer
Q1 What is the role of active gas in MAG welding?
Ans The active gas has an impact on several aspects of the welding process. The
heat transfer is the most significant. The heat from the welding arc must be delivered
as efficiently as possible to the work item. The thermal conductivity of different gases
varies greatly. As a result, a gas with a high thermal conductivity will efficiently
transmit heat to the work piece and will also provide a most stable arc.

Q2 Write any two ways by which you can minimize weld spatter in MAG welding?
Ans Follow proper welder training and best practices and clean the metal sheets
from dirt.
Adjust wire and welding parameters like proper balance between current and voltage
.
Q3 Why pressure is applied during spot welding?
Ans The mechanical force required to hold the two or more surfaces together
throughout the welding cycle is provided by pressure. This ensures a good current
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channel and prevents ejection by containing any molten metal that may occur.

Results and discussion

 We discovered that as welding current increases, bead width also increases.

 We observed the hardness value 64.73HRA at 90Amp welding current, 59.53

HRA at 100 Amp, 38.83 HRA at 110Amp.

Graph of Hardness(HRA)
vsWelding current(Amp)
80
HARDNESS(HRA)

60

40

20

0
0 20 40 60 80 100 120

Welding current(Amp)

 Above graph shows that when we increase the welding current hardness of the
work piece will decreases.
 Excessive current causes the electrode wire to overheat causing instability in
the welding.

 When the welding current is increased, the heat input increases as well,
resulting in reduced spattering and better weld quality.

Learning from the experiments

 Learn basic welding techniques and improve our skills at MAG welding and
spot welding.
 Learn how changing parameters affects welding quality and gain a sense of what
parameters will result in a good weld.
 Learn why active gas is used in MAG welding.
 Learn when and how to employ spot welding and MAG welding, as well as the
distinctions between the two.
 We investigate the impact of welding current on bead width, weld spatters, heat
input, and welded plate hardness.

Safety concern
 Never use a machine unless you've had proper training and supervision.
 We need to wear a helmet to protect our eyes from high-intensity electric
arc/UV rays, as well as to shield the welder's face from the heat generated by the
arc.
 To avoid electric shock and fire, we must wear thermal and electrical gloves,
as well as body cover and totally covered rubber soled shoes.

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