MECHANICAL ENGINEERING DEPARTMENT

DJJ 20042
MECHANICAL WORKSHOP PRACTICE 2

NAME NICOLLE AIREEN KALONG

MATRIC 05DKM19F2038 CLASS DKM4A
GROUP NO. GROUP C SESSION 1
LECTURER ENCIK SAIFULDIN

REPORT *Tick ()

Welding (Arc) Welding (Gas) Foundry Machining (Lathe)
Weightage

Marks

ASPECT 1 2 3 4 SCORE
REPORT 2 (CLO2) REPORT 1 (CLO1)

A. Introduction 2
B. Safety precautions 3 ____ x 100%
40
5

C. Equipment =_________

D. Procedures 5
E. Discussion 3 ____ x 100%
40
2

F. Conclusion =_________

Contents of Report

1. Introduction
 Title
 Objective stated ( depends on the practical task)
 Theory explained clearly related to the workshop respectively
1.0 INTRODUCTION (WELDING ARC REPORT)
Arc welding is a welding process used to join metals. An electric arc from an AC or DC power

supply creates an intense heat of around 6500°F which melts the metal at the join between two work

pieces. The arc can be either manually or mechanically guided along the line of the join, while the

electrode either simply carries the current or conducts the current and melts into the weld pool at the

same time to supply filler metal to the join. Because the metals react chemically to oxygen and

nitrogen in the air when heated to high temperatures by the arc, a protective shielding gas or slag is

used to minimise the contact of the molten metal with the air. Once cooled, the molten metals

solidify to form a metallurgical bond.

2.0 Safety Precautions According to OSHA

 Be sure the welder is properly installed and grounded.

 Never weld without adequate ventilation.

 Take proper precautions to prevent fires.

 Protect your entire body with fire retardant clothing, shoes, and gloves.

 Wear eye protection at all times.

 Weld only in a firesafe area.

 Never do any welding, cutting, or hot work on used drums, barrels, tanks, or other
containers.

 Mark metal "HOT" with a soapstone.

 Keep a well stocked first aid kit handy.

Personal protection

 Wear Approved Eye Protection

 Wear Flame Resistant Clothing

 Wear Long Sleeves, Pocket Flaps and No Cuffs

 Wear Approved safety boot -Wear Approved Hand Protect

3.0 Equipment

Mild steel bar

Electrode

-Electrode that use is E6013

-Size 3.2mm

-The "E" stands for arc welding electrode. Next will be either a 4 or 5 digit

number stamped on the electrode. The first two numbers of a 4 digit number

and the first 3 digits of a 5 digit number indicate the minimum tensile strength

(in thousands of pounds per square inch) of the weld that the rod will produce, stress relieved.

E6013 electrode can be used with AC and DC currents. It

produces a medium penetrating weld with a superior weld bead appearance.

DC Arc Welding Machine

-Current that use for mild steel arc welding are between 90 - 120 amp. The

best current use for this arc welding is 110 amp.

Face Shield
-Made from inflammable material. In the middle of the shield there is a

bright rectangular glass coated with dark colored glass. It is used to protect the user from fire-bolt

and harmful rays during welding work. There are two types of shield, one is the helmet type and the

other one is the hand held type.

Leather Hand Glove

-It must be made from high quality leather. Use to protect your hand from fire- bolt and hot metal

welding.

Chipping Hammer
-Made from an old punch, chisel or spring metal. -Shape like a chisel at one end and has a sharpened

end at the other one. -Its holder is made from welded soft metal. -It is used commonly to remove the

slag excess stringer from the surface of

the work metal.

Wire Brush

-Used to clean the surface of the stringer bed after the slag is chipped away

and to remove dirt from the surface of metal work before welding can be done.

3.8 Leather Jacket

-Leather jacket is used to protect the user from the intense heat produced

during welding operations.

-It is made of high quality leather to provide greater comfort for the user

Procedures

1. Make sure work piece is clean before welding.

2. Place as close to the weld as possible.

3. Before striking an arc, insert an electrode in the electrode holder. A small diameter electrode
requires less current than a large one. Follow recommendations of the electrode manufacturer
when setting weld amperage (see Section 3-2).

4. Insulated Electrode Holder

5. Electrode Holder Position

6. Arc Length. Arc length is the distance from the electrode to the work piece. A short arc with
correct amperage will give a sharp, crackling sound. Correct arc length is related to electrode
diameter. Examine the weld bead to determine if the arc length is correct. Arc length for 1/16 and
3/32 inch diameter electrodes should be about 1/16 in (1.6mm); arc length for 1/8 and 5/32 in.
electrodes should be about 1/8 in. (3 mm).

7. Use a chipping hammer and wire brush to remove slag. Remove slag and check weld bead before
making another well pass.

Discussion
1) Arc welding process is slow process.

2) It require a practical skill and experience.

3) It may cause arc length too short or too long

4) It is an extreme high temperature process. safety procedure must be taken.

Conclusion

In conclusion, we can conclude that there are some problems that happened in arc welding process.

The first problem that happened in arc welding process is the thicknesses of arc line on metal plate.

We can overcome it such as we can improve our skill with we can reduce the movement of speed

when doing arc welding. Second problem is combination of the metal plate is not too strong. It may

cause the work be crack or don’t have enough quality. To overcome this problem is we need to add

more electrodes at the work. Third problem is the work of arc welding not good enough. It may

cause from the wrong angle and wrong position on plate when doing welding. This problem can

solve if we use 58 in angle and at least 5mm between electrode and plate when welding.