Research Activity in

TLE 275: Metal Works and Welding

1. Welding Tools and Equipment

 2. different parts of a micrometer caliper

Micrometer Parts and Their Main

Function:
As we know the micrometer has wide application in all fields of science during different
scientific experiments and in engineering to measure the values of finest objects up to higher
precision and accuracy so for better understanding and to ensure the appropriate use of
micrometer, firstly we must have to know its mechanism and basic parts, construction and main
function.
So we discuss here all the basic parts of micrometer and the main function of these parts in order
to make proper use and avoid measurement errors. The typical micrometer that‟s used normally
is called outside micrometer so following are its parts.

C-Frame:
It‟s a c shaped frame as identified in the picture, is a rigid part that has both holding points for a
job or object to be measured. Its size depends on micrometer measuring range so size of c frame
increases as range expands to bigger.
Zero adjust screw:
It‟s a screw located back end of anvil shown in figure. As name shows it is to correct or adjust
the zero error of micrometer if there is some error found before the measurement during test.
Anvil:
As discussed above it is a small stationary cylindrical part of micrometer located in far end of c-
frame and acts as one holding point for measuring objects. So we can say it‟s a one of rigid
measuring and holding point of micrometer.
Spindle:
A cylindrical long part which is mounted through all other parts sleeve, lock nut and thimble. It
is moveable part and has a connection with ratchet as we rotate the ratchet clockwise or counter
clockwise the spindle slides out or inward to adjust it with compare to measuring object size.
Anvil Face and Spindle Face:
Faces of both anvil and spindle which are opposite to each other are the measuring points of
micrometer and hold the measuring object collectively.
Lock nut:
As we know the mechanism of micrometer based on precision ground threads of spindle so the
lock nut works as stationary nut for this mechanism, so rotation of this mechanism into lock nut
controls the spindle movement.
Sleeve:
It‟s a barrel type cylindrical part which mounted on spindle and is main scale of micrometer
because main scale is engraved on the sleeve .Thimble rotates around that sleeve and spindle. Its
main function is indication of reading in millimeter in case of imperial micrometer.
Thimble:
Thimble is also mounted on spindle and a scale is engraved around it perimeter of thimble. Scale
of thimble is to show the measurement value in fraction.

3. parts of Vernier caliper

It has already been established that the Vernier caliper is one of the most widely used measuring
instruments after the measuring scale. The vernier caliper allows users to measure
distances with a far greater degree of accuracy than a measuring scale which is vital in most
engineering applications. The concept for the vernier caliper came into being way back in 1631
thanks to French scientist Pierre Vernier but it has been going strong since then.
The vernier caliper, like everything else has undergone modernization thanks to technological
advancement and developed into digital calipers which are convenient and accurate. They also
have many other useful features such as computer connectivity, the ability to compare lengths
and to convert units of measurement with ease. However, manual vernier calipers are still widely
used today and have some advantages over their digital counterparts. Firstly they are a bit
cheaper than digital calipers unless you are talking about the high end market.
Lower Jaws:
The upper jaws are the most prominent feature of a vernier caliper. These jaws are designed to
grip objects firmly between them for measurement. One of the jaws is fixed and attached to the
main scale of the caliper while the other one is attached to the vernier scale and is movable. The
lower jaws allow the vernier caliper to measure outer dimensions of objects such as the length,
width or diameter.
Upper Jaws:
The upper jaws are smaller in size and are attached to the upper portion of the vernier caliper.
Similar to the lower jaws, one of these jaws is fixed and the other is movable. The difference
between them and the lower jaws is that the upper jaws are used for measuring inside dimensions
of hollow objects such as inside diameters of pipes, lengths and widths of boxes etc. The jaws
are placed inside the place to be measured and then opened till they touch the edges and the
reading is taken at that point.
Depth Rod:
The depth rod is another useful feature of the vernier caliper which can be used to measure the
depths of holes or steps. The depth rod is a thin rod located at the end of the main scale. To
measure with the depth rod, the edge of the main scale is placed on the top surface of the hole
and then the jaws are opened. As the jaws are opened, the depth rod slides out with the main
scale. The depth rod is extended till it touches the bottom of the hole and the reading is taken as
usual.
Main Scale:
The main scale is the large scale which runs along the body of the vernier caliper. It is graduated
either in centimetres and millimetres or inches depending on the type of units it is built for. In SI
units the lowest graduation of the main scale is normally 1mm. The main scale is stationary.
 Vernier Scale:
The Vernier scale is the defining component of the caliper and what gives it its name. The
vernier caliper is a smaller scale attached to the main scale and can move along the main scale as
the jaws are opened or closed. The vernier scale provides accuracy to the reading of the main
scale by further dividing the lowest reading of the main scale into increments. In a metric caliper,
the vernier scale is divided into 50 increments each representing 0.02 mm.
Thumb Screw:
The thumb screw is located at the bottom of the vernier scale. Its purpose is to provide a grip for
the user to slide the jaws easily and adjust the position of the jaws and depth rod while
maintaining a firm grip on the object.
Lock Screw:
The lock screw is used to fix the position of the jaws once the object is positioned properly so
that readings can be taken without the fear of spoiling the position.

4. different recommended practices to identify defective and non-defective hand tools.

 The defective and non-defective tools are easily identified through visual inspection. Defective
and non-defective tools are described by its physical appearance such as dullness, sharpness,
dismantled parts and more.
 Visual Inspection - The defective and non-defective tools are easily identified through visual
inspection. Defective and non-defective tools are described by its physical appearance such as
dullness, sharpness, dismantled parts and more.

 Functionality - Another way to determine the defective and non-defective tools is by checking
or assessing if the tool is already susceptible to wear and tear or does it exceeded its service life
already.

 Performance - Checking the performance of the tool is one way also to determine defective and
non-defective tools. Checking of the performance of a tool is not only done during the actual
use, it should also be done after to determine whether the tool is still worthy to be used.

5. different steps in mounting blade to the metal frame

How to change a hacksaw
blade

Shop for Hacksaws

Please note: How this is done may vary depending
on the make and model. One method is shown below:

How is the blade attached?

A hacksaw has a removable blade mounted in a metal

frame. Like all frame saws, the blade must be held
taut in order to cut efficiently. The blade is held in
place by two metal pins on either end of the frame.
These pins hook onto two corresponding holes on
either end of the hacksaw‟s blade.

Removing the blade

Step 1 – Loosen wingnut

Turn the wingnut in an anti-clockwise

direction. This controls the position of
a metal bar at the end of the frame‟s
arm.

This bar holds one end of the blade.

Turning the wingnut anti-clockwise
pushes the bar forward, so that it‟s no
longer stretching the blade.

Step 2 – Unhook blade from pins

Once enough tension is released, you

can remove the blade by unhooking it
from the pins.

Installing the blade

Please note: Hacksaw blades come in

two lengths: 250 or 300mm. Ensure
you select the correct one for your
hacksaw.

Step 1 – Loosen wingnut

Ensure the wingnut is loosened before

hooking the blade onto the pins.
 When installing a blade, ensure the
teeth are on the outside of the frame,
and are facing away from the handle.
This is to ensure the hack saw cuts on
the push stroke

Step 2 – Tighten wingnut

Once the blade is in place, turn the

wing nut in a clockwise direction.
This will cause the metal bar to move
back, stretching the blade tightly in
the frame.

How tight should the blade be?

If the blade is too loose, it will move

about on the pins and could even fall
off. A blade with too much movement
will also make it hard to control the
saw when working. However, stretch
the blade too much and it could snap,
potentially causing an injury.As a
general rule, you should tighten the
blade enough so that it does not move
about on the pins, but can still flex
very slightly in the centre.

6. different steps in fixing stock In metal vise and operation position

7. steps in sawing the stock

8. Expound the two steps in Bending 90 degree

with Ball Peen Hammer.
9. Discuss how circular bend in metal is done.

10. Discuss the importance of routine maintenance on welding tools and equipment.
 11. Why lubricating is important in machines?

Despite the fact that correct lubrication is one of the most crucial aspects of a reliability
programme for rotating equipment, lubrication is often perceived as a lowly job that doesn‟t
require much experience or skill.

Lubrication-related failures are probably the most preventable type of all failures of rotating
machinery, yet it‟s an area of industry that isn‟t always allocated the appropriate level of
attention.

Machine reliability relies on the right methods of lubrication, the right quantities and
formulations of lubrication and the appropriate application procedures and intervals – and a
vigilant machinery operator will be able to maximise the performance and the operating life of
the equipment by adhering to a well-planned and appropriate maintenance programme.

Most people believe that lubrication is only important because it makes the parts „slippery‟. In
reality, lubricants are substances which play a major role in bearing and machinery function and
longevity by:

 Reducing wear of moving parts

 Reducing friction between rotating parts and stationery ones
 Absorbing shock
 Reducing operating temperatures
 Minimising corrosion of metal surfaces
 Keeping contaminants out of the system
 Sealing and protecting components

The incorrect choice and application of lubricants is said to account for around 40% of all
machine failures, and so lubrication procedures are a critical factor in maximizing your
equipment‟s reliability.

To ensure optimum lubrication, it is important to use the right type and quality of lubricant, in
the right amounts, at the right place and at the right time. Once lubrication has been applied,
the equipment and the lubricant should be tested to see if:

 The correct formulation of lubricant was used for the application

 Whether the lubricant solved – or merely masked – the problem
 Whether the amount of lubrication applied was correct

The need for frequent lubrication may well be a symptom of underlying machinery damage (such
as wear or damage to bearings, shafts or seals) so the solution isn‟t simply to lubricate to stop
vibration or excessive noise. In fact, too much lubrication can be just as detrimental as too little
lubrication. Under lubrication can cause bearings to wear out before their time, whereas over-
lubrication can lead to catastrophic results to the bearings or long-term damage to motor coils
and windings.
 12. Explain why the following are important?
a. Clearly label machinery, equipment, part, jigs, tools, and their locations, so that
everything is understandable, and visible to everyone at a glance.

It is a good idea to have all the equipment labeled to avoid being separated from one another and
to make the search easier especially when it is in use.

b. Don‟t pile up jigs, tools, and materials without separators (shelves). They should be
picked up easily.

it is easier and more convenient to place the equipment if they have their own containers or
shelves.

c. Rearrange machinery and equipment to make smooth production flow, when

necessary.
Welding positioner also named as welding rotating worktable, which is mainly used
for welding and assembling parts, It makes the workpiece in the best welding or
assembly position through the turning over of the mechanism for welding and
assembly. It is widely used in the welding of flange and pipe fitting joints, as well as
the inversion of construction machinery and the position conversion of various
welding structures. It can also be used as robot peripheral equipment to realize
welding automation. It greatly improve the quality of welding, at the same time can
reduce the number of work handling, reduce the labor intensity of workers, quickly
improve the labor efficiency.

The welding positioner series are side tipping type, head and tail rotation type, head
and tail lifting rotation type, head and tail inclined type and double rotation type,etc.
Special customized welding rotating worktable are available to meet clients' different
requirement.

d. Maintain the space around the fire extinguishers and evacuation passages free.
Always check the electronic wires and cables, and workplace must have fire extinguisher.

13.Explain the effects of Effects of Ergonomic Hazards

14. What are the causes of electric shock?

Discuss different safety measure to prevent electric shock during welding.
 15.. Discuss what is arc rays?

What types of radiation are associated with welding?

Welding arcs give off radiation over a broad range of wavelengths - from 200 nm (nanometres)
to 1,400 nm (or 0.2 to 1.4 µm, micrometres). These ranges include ultraviolet (UV) radiation
(200 to 400 nm), visible light (400 to 700 nm), and infrared (IR) radiation (700 to 1,400 nm).

UV-radiation is divided into three ranges - UV-A (315 to 400 nm), UV-B (280 to 315 nm) and
UV-C (100 to 280 nm). UV-C and almost all UV-B are absorbed in the cornea of the eye. UV-A
passes through cornea and is absorbed in the lens of the eye.

Some UV radiation, visible light, and IR radiation can reach the retina.

What are the symptoms of "Arc Eye"?

Certain types of UV radiation can produce an injury to the surface and mucous membrane
(conjunctiva) of the eye called "arc eye," "welders' eye" or "arc flash." These names are common
names for "conjunctivitis" - an inflammation of the mucous membrane of the front of the eye.
The symptoms include:

 pain - ranging from a mild feeling of pressure in the eyes to intense pain in severe
instances
 tearing and reddening of the eye and membranes around the eye (bloodshot)
 sensation of "sand in the eye"
 abnormal sensitivity to light
 inability to look at light sources (photophobia)

The amount of time required to cause these effects depends on several factors such as the
intensity of the radiation, the distance from the welding arc, the angle at which the radiation
enters the eye, and type of eye protection that the welder or bystander is using. However,
exposure to just a few seconds of intense UV light can cause arc eye. These symptoms may not
be felt until several hours after exposure.

Are there other possible effects to the eyes?

Long-term exposure to UV light can produce cataracts in some persons. Exposure to infrared
light can heat the lens of the eye and produce cataracts over the long term.

Visible light from welding processes is very bright and can overwhelm the ability of the iris of
the eye to close sufficiently and rapidly enough to limit the brightness of the light reaching the
retina. The result is that the light is temporarily blinding and fatiguing to the eye.

What are the skin hazards associated with welding and radiation?

Welding arcs and flames emit intense visible, ultraviolet, and infrared radiation.

 UV radiation in a welding arc will burn unprotected skin just like UV radiation in
sunlight. This hazard is true for direct exposure to UV radiation as well as
radiation that is reflected from metal surfaces, walls, and ceilings. Surface finishes
and certain paint colours can reduce the amount of UV radiation that is reflected.
 Long-term exposure to UV radiation can cause skin cancer.
 Infrared radiation and visible light normally have very little effect on the skin.

16. What are the fumes and gases present during welding?

Argon, nitrogen, carbon dioxide, carbon monoxide and hydrogen fluoride gases often are
produced during welding. Welding fumes can cause serious health problems for workers if
inhaled, according to OSHA. Short-term exposure can result in nausea, dizziness, or eye, nose
and throat irritation.
17. What are the different eye protection during welding process? Discuss each and provide
pictures)
18. Provide standard safety symbols (pictures) in a welding shop.

What are the different Classification of Safety Signs? Discuss each.

 19. What are the standards of International Safety Organization (ISO) in different safety
signs?

Safety signs are essential for preventing accidents and injury. Symbols that are internationally
agreed and globally used in safety signs ensure clarity and consistency, regardless of language,
culture or setting. The ISO standard that is a reference for safety signs has just been updated to
incorporate new safety signs that are in use around the world.

From no-go areas on construction sites to emergency exits, ISO 7010, Graphical symbols —
Safety colours and safety signs — Registered safety signs, prescribes safety signs for the
purposes of accident prevention, fire protection, health hazard information and emergency
evacuation.

It features the shape and colour of the sign as referenced in ISO 3864-1, Graphical symbols —
Safety colours and safety signs — Part 1: Design principles for safety signs and safety
markings, and the design of the symbol is according to ISO 3864-3, Graphical symbols — Safety
colours and safety signs — Part 3: Design principles for graphical symbols for use in safety
signs.

Mr Jan-Bernd Stell, Chair of the ISO technical committee that developed the standard, said lack
of harmonization and standardization in this area could lead to confusion and accidents.

“International standardization of safety signs means everyone speaks the same language when it
comes to safety. This provides a simple solution for everyone, both in workplaces and public
areas like airports where many nationalities converge.

Examples of safety signs documented in the standard include everything from warnings around
deep water, electricity or barbed wire to instructions such as „do not walk or stand here‟, or to not
use lifts in the event of a fire.”
 20.What are the different Classification of Safety Signs? Discuss each.

Attached answer on number 18.

21. Discuss the different Responsibilities of Employers and Employees under OSHS.
22. Justify the following:

a. Welding or cutting operations shall not be permitted in rooms or areas containing

combustible materials or in proximity to explosives or flammable liquids, dusts,
gases, or vapors, until all fire and explosion hazards are eliminated.

b. Welding or cutting operations on containers filled with explosives or flammable

substance is prohibited. Welding closed containers that have held explosive or
flammable substance shall only be undertaken after the containers have been
thoroughly cleaned and found completely free of combustible gases or vapors of
the containers are filled with inert gas or with water.
c. Welding and cutting operations carried out or done in places where persons other
than the welders work or pass shall be enclosed by means of suitable stationary or
portable screens. Screens shall be opaque, of sturdy construction to withstand
rough usage of a material which will not readily be set on fire by sparks or hot
metal at least 2 meters (6.5 feet) high, and

d. A portable fire extinguisher shall be provided at the place where welding and
cutting operations are being undertaken.

e. Before welding and cutting operations are allowed in large establishments, the
area shall be inspected by the safety man. He shall issue a written permit or
authorization for welding and cutting, indicating there in the precautions to be
followed to avoid fire or accidents.
GAS AND ELECTRIC WELDING AND CUTTING OPERATIONS

1100.01: General Provisions:

(1) Welding or cutting operations shall not be permitted in rooms or areas containing
combustible materials or in proximity to explosives or flammable liquids, dusts, gases or vapors,
until all fire and explosion hazards are eliminated.

(2) Welding or cutting operations on containers filled with explosives or flammable substance is
prohibited. Welding closed containers that have held explosive or flammable substance shall
only be undertaken after the containers have been thoroughly cleaned and found completely free
of combustible gases or vapors or the containers are filled with inert gas or with water.

(3) Welding and cutting operations carried out or done in places where persons other than the
welders work or pass shall be enclosed by means of suitable stationary or portable screens.
Screens shall be opaque, of sturdy construction to withstand rough usage of a material which will
not readily be set on fire by sparks or hot metal, at least 2 m. (6.5 ft.) high, and preferably
painted with light flat paint.

(4) A portable fire extinguisher shall be provided at the place where welding and cutting
operations are being undertaken.

(5) Authorization, before welding and cutting operations are allowed in large establishments, the
area shall be inspected by the safetyman. He shall issue a written permit or authorization for
welding and cutting, indicating therein the precautions to be followed to avoid fire or accidents.

1100.02: Personal Protective Equipment:

(1) All workers or persons directly engaged in welding or cutting operations shall be provided
with the following personal protective equipment:

a. goggles, helmets or head shields fitted with suitable filter lenses and hand shields; and

b. suitable aprons.

REPORT THIS AD
(2) all persons directly assisting in welding or cutting operations shall be provided with gloves,
goggles or other protective clothings, as may be necessary.
1100.03: Welding or Cutting in Confined Spaces:

The inhalation of any fumes, gases or dusts by persons welding or cutting in confined spaces
shall be prevented by the provision of:

(1) Local exhaust and general ventilation system to keep fumes, gases or dusts within allowable
concentrations or threshold limit values;

(2) Approved types of respiratory protective equipment.

23. Draw the alphabet of lines in a separate bond paper. And define each lines.
24. Using a Ven diagram differentiate weld symbol and welding symbol

WELDING SYMBOL WELD SYMBOL

Difference
is “A graphical is “A graphic
between
character
representation of Weld connected to the
the specifications Symbol reference line of a
for producing a and brazing or welding
welded joint.” Welding symbol specifying
Symbol the joint geometry
or weld type.”
25. Discuss and illustrate complete welding symbol. Use 1 bond paper for it)
Welding cannot take its proper place as an engineering tool unless means
are provided for conveying the information from the designer to the
workmen.
Welding symbols provide the means of placing complete welding information on
drawings.

The scheme for the symbolic representation of welds on engineering drawings

used in this manual is consistent with the “third angle” method of projection.

This is the method predominantly used in the United States.

The joint is the basis of reference for welding symbols.

The reference line of the welding symbol (fig. 3-2) is used to designate the type
of weld to be made, its location, dimensions, extent, contour, and other
supplementary information.

Any welded joint indicated by a symbol will always have an arrow side and an
other side. Accordingly, the terms arrow side, other side, and both sides are used
herein to locate the weld with respect to the joint.

The tail of the welding symbol is used for designating the welding and cutting
processes as well as the welding specifications, procedures, or the
supplementary information to be used in making the weld.

If a welder knows the size and type of weld, he has only part of the information
necessary for making the weld. The process, identification of filler metal that is to
be used, whether or not peening or root chipping is required, and other pertinent
data must be related to the welder.

The notation to be placed in the tail of the symbol indicating these data is to be
established by each user. If notations are not used, the tail of the symbol may be
omitted.
Welding Symbols
26. Draw and define the different weld symbols in a bond paper

Deciphering Weld Symbols

Deciphering Weld Symbols
Print Article

Weld symbols are often used among welders and engineers. Learn how to read common welding
symbols and their meaning.

Common weld symbols and their meanings

When welds are specified on engineering and fabrication drawings, a cryptic set of symbols is used
as a sort of shorthand for describing the type of weld, its size and other processing and finishing
information. Here we will introduce you to the common symbols and their meaning. The complete set
of symbols is given in a standard published by the American National Standards Institute (ANSI) and
the American Welding Society (AWS): ANSI/AWS A2.4, Symbols for Welding and Nondestructive
Testing

The structure of the welding symbol

The tail of the weld symbol is the place for supplementary information on the weld. It may contain a
reference to the welding process, the electrode, a detail drawing or any information that aids in the
making of the weld that does not have its own special place on the symbol.

Types of welds and their symbols

Each welding position has its own basic symbol, which is typically placed near the center of the
reference line (and above or below it, depending on which side of the joint it's on). The symbol is a
small drawing that can usually be interpreted as a simplified cross-section of the weld. In the
descriptions below, the symbol is shown in both its arrow-side and other-side positions.
The perpendicular leg of the triangle is always drawn on the left side of the symbol, regardless of the
orientation of the weld itself. The leg size is written to the left of the weld symbol. If the two legs of
the weld are to be the same size, only one dimension is given; if the weld is to have unequal legs
(much less common than the equal-legged weld), both dimensions are given and there is an
indication on the drawing as to which leg is longer.
If no length is given, then the weld is to be placed between specified dimension lines (if given) or
between those points where an abrupt change in the weld direction would occur (like at the end of
the plates in the example above).
For intermittent welds, the length of each portion of the weld and the spacing of the welds are
separated by a dash (length first, spacing second) and placed to the right of the fillet weld symbol.

The groove weld is commonly used to make edge-to-edge joints, although it is also often used in
corner joints, T joints, and joints between curved and flat pieces. As suggested by the variety of
groove weld symbols, there are many ways to make a groove weld, the differences depending
primarily on the geometry of the parts to be joined and the preparation of their edges. Weld metal is
deposited within the groove and penetrates and fuses with the base metal to form the joint. (Note: for
the sake of graphical clarity, the drawings below generally do not show the penetration of the weld
metal. Recognize, however, that the degree of penetration is important in determining the quality of
the weld.)
The various types of groove weld are:

Square groove welds

The groove is created by either a tight fit or a slight separation of the edges. The amount of
separation, if any, is given on the weld symbol.
Flare bevel groove weld
Commonly used to join a round or curved piece to a flat piece. As with the flare-V, the depth of the
groove formed by the two curved surfaces and the intended depth of the weld itself are given to the
left of the symbol, with the weld depth shown in parentheses. The symbol's perpendicular line is
always drawn on the left side, regardless of the orientation of the weld itself.
Plug and slot welds

Plug welds and slot welds are used to join overlapping members, one of which has holes (round
for plug welds, elongated for slot welds) in it. Weld metal is deposited in the holes and penetrates
and fuses with the base metal of the two members to form the joint. (Note: for the sake of graphical
clarity, the drawings below do not show the penetration of the weld metal. Recognize, however, that
the degree of penetration is important in determining the quality of the weld.) For plug welds, the
diameter of each plug is given to the left of the symbol and the plug-to-plug spacing (pitch) is given
to the right. For slot welds, the width of each slot is given to the left of the symbol, the length and
pitch (separated by a dash) are given to the right of the symbol, and a detail drawing is referenced in
the tail. The number of plugs or slots is given in parentheses above or below the weld symbol. The
arrow-side and other-side designations indicate which piece contains the hole(s). If the hole is not to
be completely filled with weld metal, the depth to which it is to be filled is given within the weld
symbol.
27. Discuss the brief history of welding.

The History of Welding

Print Article

Welding has been around since ancient times. Read this article for a brief overview of welding
history throughout the years.

Middle Ages
Welding can trace its historic development back to ancient times. The earliest examples of
welding come from the Bronze Age. Small gold circular boxes were made by pressure welding lap
joints together. It is estimated that these boxes were made more than 2,000 years ago. During the
Iron Age the Egyptians and people in the eastern Mediterranean area learned to weld pieces of iron
together. Many tools were found that were made in approximately 1000 B.C.
During the Middle Ages, the art of blacksmithing was developed and many items of iron were
produced that were welded by hammering. It was not until the 19th century that welding as we know
it today was invented.

1800
Edmund Davy of England is credited with the discovery of acetylene in 1836. The production of an
arc between two carbon electrodes using a battery is credited to Sir Humphry Davy in 1800. In the
mid-19th century, the electric generator was invented and arc lighting became popular. During the
late 1800s, gas welding and cutting was developed. Arc welding with the carbon arc and metal arc
was developed and resistance welding became a practical joining process.

1880
Auguste De Meritens, working in the Cabot Laboratory in France, used the heat of an arc for joining
lead plates for storage batteries in the year 1881. It was his pupil, a Russian, Nikolai N. Benardos,
working in the French laboratory, who was granted a patent for welding. He, with a fellow Russian,
Stanislaus Olszewski, secured a British patent in 1885 and an American patent in 1887. The patents
show an early electrode holder. This was the beginning of carbon arc welding. Benardos' efforts
were restricted to carbon arc welding, although he was able to weld iron as well as lead. Carbon arc
welding became popular during the late 1890s and early 1900s.

1890
In 1890, C.L. Coffin of Detroit was awarded the first U.S. patent for an arc welding process using a
metal electrode. This was the first record of the metal melted from the electrode carried across the
arc to deposit filler metal in the joint to make a weld. About the same time, N.G. Slavianoff, a
Russian, presented the same idea of transferring metal across an arc, but to cast metal in a mold.

1900
Approximately 1900, Strohmenger introduced a coated metal electrode in Great Britain. There was a
thin coating of clay or lime, but it provided a more stable arc. Oscar Kjellberg of Sweden invented a
covered or coated electrode during the period of 1907 to 1914. Stick electrodes were produced by
dipping short lengths of bare iron wire in thick mixtures of carbonates and silicates and allowing the
coating to dry.
Meanwhile, resistance welding processes were developed, including spot welding, seam welding,
projection welding and flash butt welding. Elihu Thompson originated resistance welding. His patents
were dated 1885-1900. In 1903, a German named Goldschmidt invented thermite welding that was
first used to weld railroad rails.
Gas welding and cutting were perfected during this period as well. The production of oxygen and
later the liquefying of air, along with the introduction of a blow pipe or torch in 1887, helped the
development of both welding and cutting. Before 1900, hydrogen and coal gas were used with
oxygen. However, in about 1900 a torch suitable for use with low-pressure acetylene was
developed.
World War I brought a tremendous demand for armament production and welding was pressed into
service. Many companies sprang up in America and in Europe to manufacture welding machines
and electrodes to meet the requirements.

1919
Immediately after the war in 1919, 20 members of the Wartime Welding Committee of the
Emergency Fleet Corporation, under the leadership of Comfort Avery Adams, founded the American
Welding Society as a nonprofit organization dedicated to the advancement of welding and allied
processes.
Alternating current was invented in 1919 by C.J. Holslag; however, it did not become popular until
the 1930s when the heavy-coated electrode found widespread use.

1920
In 1920, automatic welding was introduced. It utilized bare electrode wire operated on direct current
and used arc voltage as the basis of regulating the feed rate. Automatic welding was invented by
P.O. Nobel of the General Electric Company. It was used to build up worn motor shafts and worn
crane wheels. It was also used by the automobile industry to produce rear axle housings.
During the 1920s, various types of welding electrodes were developed. There was considerable
controversy during the 1920s about the advantage of the heavy-coated rods versus light-coated
rods. The heavy-coated electrodes, which were made by extruding, were developed by Langstroth
and Wunder of the A.O. Smith Company and were used by that company in 1927. In 1929, Lincoln
Electric Company produced extruded electrode rods that were sold to the public. By 1930, covered
electrodes were widely used. Welding codes appeared that required higher-quality weld metal, which
increased the use of covered electrodes.
During the 1920s there was considerable research in shielding the arc and weld area by externally
applied gases. The atmosphere of oxygen and nitrogen in contact with the molten weld metal
caused brittle and sometimes porous welds. Research was done utilizing gas shielding techniques.
Alexander and Langmuir did work in chambers using hydrogen as a welding atmosphere. They
utilized two electrodes, starting with carbon electrodes but later changing to tungsten electrodes.
The hydrogen was changed to atomic hydrogen in the arc. It was then blown out of the arc forming
an intensely hot flame of atomic hydrogen turning to the molecular form and liberating heat. This arc
produced half again as much heat as an oxyacetylene flame. This became the atomic hydrogen
welding process. Atomic hydrogen never became popular but was used during the 1930s and 1940s
for special applications of welding and later on for welding of tool steels.
H.M. Hobart and P.K. Devers were doing similar work but using atmospheres of argon and helium.
In their patents applied for in 1926, arc welding utilizing gas supplied around the arc was a
forerunner of the gas tungsten arc welding process. They also showed welding with a concentric
nozzle and with the electrode being fed as a wire through the nozzle. This was the forerunner of the
gas metal arc welding process. These processes were developed much later.

1930
Stud welding was developed in 1930 at the New York Navy Yard, specifically for attaching wood
decking over a metal surface. Stud welding became popular in the shipbuilding and construction
industries.
The automatic process that became popular was the submerged arc welding process. This under
powder or smothered arc welding process was developed by the National Tube Company for a pipe
mill at McKeesport, Pennsylvania. It was designed to make the longitudinal seams in the pipe. The
process was patented by Robinoff in 1930 and was later sold to Linde Air Products Company, where
it was renamed Unionmelt welding. Submerged arc welding was used during the defense buildup in
1938 in shipyards and ordnance factories. It is one of the most productive welding processes and
remains popular today.

1940
Gas tungsten arc welding (GTAW) had its beginnings from an idea by C.L. Coffin to weld in a
nonoxidizing gas atmosphere, which he patented in 1890. The concept was further refined in the late
1920s by H.M.Hobart, who used helium for shielding, and P.K. Devers, who used argon. This
process was ideal for welding magnesium and also for welding stainless and aluminum. It was
perfected in 1941, patented by Meredith, and named Heliarc welding. It was later licensed to Linde
Air Products, where the water-cooled torch was developed. The gas tungsten arc welding process
has become one of the most important.
The gas metal arc welding (GMAW) process was successfully developed at Battelle Memorial
Institute in 1948 under the sponsorship of the Air Reduction Company. This development utilized the
gas shielded arc similar to the gas tungsten arc but replaced the tungsten electrode with a
continuously fed electrode wire. One of the basic changes that made the process more usable was
the small-diameter electrode wires and the constant-voltage power source. This principle had been
patented earlier by H.E. Kennedy. The initial introduction of GMAW was for welding nonferrous
metals. The high deposition rate led users to try the process on steel. The cost of inert gas was
relatively high, and the cost savings were not immediately available.

1950
In 1953, Lyubavskii and Novoshilov announced the use of welding with consumable electrodes in an
atmosphere of carbon dioxide gas. The CO2 welding process immediately gained favor since it
utilized equipment developed for inert gas metal arc welding but could now be used for economically
welding steels. The CO2 arc is a hot arc and the larger electrode wires required fairly high currents.
The process became widely used with the introduction of smaller-diameter electrode wires and
refined power supplies. This development was the short-circuit arc variation that was known as
Micro-wire, short-arc and dip transfer welding, all of which appeared late in 1958 and early in 1959.
This variation allowed all-position welding on thin materials and soon became the most popular of
the gas metal arc welding process variations.

1960
Another variation was the use of inert gas with small amounts of oxygen that provided the spray-type
arc transfer. It became popular in the early 1960s. A recent variation is the use of pulsed current.
The current is switched from a high to a low value at a rate of once or twice the line frequency.
Soon after the introduction of CO2 welding, a variation utilizing a special electrode wire was
developed. This wire, described as an inside-outside electrode, was tubular in cross section with the
fluxing agents on the inside. The process was called Dualshield, which indicated that external
shielding gas was utilized as well as the gas produced by the flux in the core of the wire for arc
shielding. This process, invented by Bernard, was announced in 1954, but was patented in 1957,
when the National Cylinder Gas Company reintroduced it.
In 1959, an inside-outside electrode was produced that did not require external gas shielding. The
absence of shielding gas gave the process popularity for noncritical work. This process was named
Innershield®.
The electroslag welding process was announced by the Soviets at the Brussels World Fair in
Belgium in 1958. It had been used in the Soviet Union since 1951 but was based on work done in
the United States by R.K. Hopkins, who was granted patents in 1940. The Hopkins process was
never used to a very great degree for joining. The process was perfected, and equipment was
developed at the Paton Institute Laboratory in Kiev, Ukraine, and also at the Welding Research
Laboratory in Bratislava, Czechoslovakia. The first production use in the U.S. was at the
Electromotive Division of General Motors Corporation in Chicago, where it was called the Electro-
molding process. It was announced in December 1959 for the fabrication of welded diesel engine
blocks. The process and its variation, using a consumable guide tube, is used for welding thicker
materials.
The Arcos Corporation introduced another vertical welding method, called Electrogas, in 1961. It
utilized equipment developed for electroslag welding but employed a flux-cored electrode wire and
an externally supplied gas shield. It is an open arc process since a slag bath is not involved. A newer
development uses self-shielding electrode wires and a variation uses solid wire but with gas
shielding. These methods allow the welding of thinner materials than can be welded with the
electroslag process.
Gage invented plasma arc welding in 1957. This process uses a constricted arc or an arc through an
orifice, which creates an arc plasma that has a higher temperature than the tungsten arc. It is also
used for metal spraying, gouging and cutting.
The electron beam welding process, which uses a focused beam of electrons as a heat source in a
vacuum chamber, was developed in France. J.A. Stohr of the French Atomic Energy Commission
made the first public disclosure of the process on Nov. 23, 1957. In the United States, the
automotive and aircraft engine industries are the major users of electron beam welding.

Most recent
Friction welding, which uses rotational speed and upset pressure to provide friction heat, was
developed in the Soviet Union. It is a specialized process and has applications only where a
sufficient volume of similar parts is to be welded because of the initial expense for equipment and
tooling. This process is called inertia welding.
Laser welding is one of the newest processes. The laser was originally developed at the Bell
Telephone Laboratories as a communications device. Because of the tremendous concentration of
energy in a small space, it proved to be a powerful heat source. It has been used for cutting metals
and nonmetals. Continuous pulse equipment is available. The laser is finding welding applications in
automotive metalworking operations.
28. Enumerate and define the different parts of welding.

29. What are the different parts of a welding machine?

The Shielded Metal Arc Welding process has three type of polarity, the first is Alternating Current (AC),
Direct Current Revers Polarity (DCRP), and Direct Current Straight Polarity (DCSP). For machine type,
SMAW has three kinds current that is machine direct current (DC), the machine with alternating current
(AC), machines with a combination of direct current (DC) and alternating current (AC). You can look
processing melt the electrode in this picture.

Shielded metal arc welding machine parts and

procedure:
SMAW machine parts:

1. Machine
Shielded Metal Arc Welding machine is the main parts of this process, because without machine
certainly, we can not do welding process.
2. Electrode Cable
The function Electrode cable connects the current from welding machine to electrode which we
use to weld the base metal.
3. Massa Cable
Massa Cable has a function for connecting current from machine to base metal, after that base
metal and electrode touch then will welding process is happening.
4. Welding Power Source
Have to function for supply current from electrical source to welding machine.
5. Current Control
For control current output which uses for the welding process, big or little the current dependent
form type or thickness of material (base metal).
6. Electrode Holder
For hold the electrode so we can do welding process easily. Otherside holder too has a function
for an electric current to the electrodes.
 7. Earth Cramp
To connect the machine to the base metal.
8. Switch
For on or off the welding machine.
9. Electrode
As a filler metal, after the welding process finish then the electrode will change be weld metal.
The electrode has a flux which the function is to protect steel melting when the welding process
takes place.

Shielded
Metal Arc Welding Machine Parts (abuv.tk)
SMAW Welding can use for anything weld joint or welding position. Otherside we use this process for
underwater welding, but the tools must be complete again suitable for underwater welding procedure. If
we do not follow the procedure then can cause our accident, for example, electric shock or other accident
types.

See: TIG Welding Machine

Advantages and Disadvantages SMAW Welding:

Advantages Shielded Metal Arc Welding:

 Can use to welding for all type joint.

 SMAW can use all welding position.
 We do not need gas for shielding the molten weld metal.
 Do not need much preparation before welding.

Disadvantages Shielded Metal Arc Welding:

 We must clean the slag after welding process is done.

 There are spatters.
 One electrode just can produce weld metal around ten to fifteen centimeters.
 The speed can not fast because we must change the electrode.
30. Discuss the different types of welded joints.

31. Enumerate and define the different parts of a welded joints.

There are many different types of welds, which are best described by their shape
when shown in cross section.

The most popular weld is the fillet weld, named after its cross-sectional shape.

Other types of welds include flange welds, plug welds, slot welds, seam welds,
surfacing welds, and backing welds.

Joints are combined with welds to make weld joints.

Types Of Joints
There are 5 main joints used in welding. These are:

 Butt joint
 Corner joint
 Edge joint
 Lap joint
 Tee joint
Types Of Welds
Fillet Welds
A fillet weld joins two surfaces at an approximate right angle to each other. There
are several types of fillet weld:

 Full fillet weld – is a weld where the size of the weld is the same as the
thickness of the thinner object joined together.
 Staggered intermittent fillet weld – refers to two lines of intermittent
welding on a joint. An example is a tee joint (see below) where the fillet
increments that are in one line are staggered in comparison to the other
line.
 Chain Intermittent fillet weld – refers to two lines of intermittent fillet
welds in a lap joint or T where the welds in one line are approximately
opposite those in the other line.
Other terms associated with fillet welds include:

 Boxing: which refers to the continuation of a fillet weld around a corner of

a member. It is an extension of the principal weld.
 Convexity: Refers to the maximum perpendicular distance from the face
of a convex fillet weld to a line joining the toes.

Illustrations Depicting Types of

Fillet Welds

Groove Welds
The second most popular type of weld is the groove weld. There are seven basic
types of groove welds, which are shown in figure 6-25.

The groove weld refers to beads that are deposited in a groove between two
members to be joined.
 Illustrations of Basic
Groove Welds

More examples are shown in figure 6-26 above.

The type of weld used will determine the manner in which the seam, joint, or
surface is prepared.
 Illustrations of Types of
Groove Welds

Surfacing Weld
These are welds composed of one or more strings or weave beads deposited on
an unbroken surface to obtain desired properties or dimensions.

This type of weld is used to build up surfaces or replace metal on worn surfaces.
It is also used with square butt joints.

See figure 6-28 below for examples.

Plug Weld
Plug welds are circular welds made through one member of a lap or tee joint
joining that member to the other.

The weld may or may not be made through a hole in the first member; if a hole is
used, the walls may or may not be parallel and the hole may be partially or
completely filled with weld metal.

Such welds are often used in place of rivets.

NOTE: A fillet welded hole or a spot weld does not conform to this definition.

Slot Weld
This is a weld made in an elongated hole in one member of a lap or tee joint
joining that member to the surface of the other member that is exposed through
the hole.

This hole may be open at one end and may be partially or completely filled with
weld metal.

NOTE: A fillet welded slot does not conform to this definition.

Illustrations of Surfacing, Plug and Slot

Welds

Flash Weld
Flash welding is referred to as a resistance welding process where fusion is
produced over the entire abutting surface.

Heat is created by the resistance to the current flow between two surfaces and
by the application of pressure after heating is mostly complete.

Flashing is accompanied by the expulsion of metal from the joint.

See Figure 6-29 below for an example of a flash weld.

Seam Weld
A weld made by arc seam or resistance seam welding where the welding
process is not specified.

This term infers resistance seam welding.

Spot Weld
A spot weld is a weld made by arc spot or resistance spot welding where the
welding process is not specified.

This term infers a resistance spot weld.

Read more: Spot Seam and Arc Weld Symbols

Upset Weld
An upset weld is a resistance welding process where fusion occurs progressively
along a joint of over the entire abutting surface.

The application of pressure before heating is required and occurs during the
heating period.

Heat comes from the resistance to the flow of electric current in the area of
contact between the surfaces.