WELDING MACHINE

An electrical welding machine applies the principle of arc welding to join two pieces of metal. Arc
welding applies an electric arc to create heat used to melt the metals. This creates a pool of molten
metal, which is then able to mix and join the two pieces (called the base metal). To create an electric
arc, an electric current is passed from a DC/AC power source through an electrode into an air gap of
relatively small thickness separating the electrode and the base metal to be welded, which, to complete
the circuit, is usually electrically grounded. The electrical energy in the electric current is converted to
heat energy because of the resistance to flow of electrons in the air gap. The heat created is hot enough
to melt the base metals and sometimes a filler wire. The resulting pool of metal then solidifies to fuse
the edges creating a weld.

A protective or shielding gas is used to minimize the contact of the hot molten metal with atmospheric
nitrogen and oxygen which would otherwise react with the hot metal. Due to difference in the material
used for the electrode and the means of supplying the shielding gas, for main types of welding are used.
These are;

a) Shielded metal arc or stick welding (SMAW).

This method uses an electrode coated with flux to create the electric arc. The flux decomposes in the
heat of the arc to produce the shielding gas.

b) Gas metal arc welding or metal inert gas (MIG) welding.

The shielding gas used is supplied externally. A solid wire filler is used as an electrode.

c) Flux coated arc welding.

Applies a hollow wire as the electrode with the flux filled in the inside.

d) Gas tungsten arc welding.

Uses an electrode made of alloyed tungsten. A filler material can be added externally. An inert gas is
used to shield the hot electrode and weld from atmospheric oxygen and nitrogen.

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 PARTS OF A WELDING MACHINE

APPLICATION OF MACHINE TO THE PROJECT

The machine was used in the following cases during the fabrication of the drawing table;

a) Fabrication of jigs.

A jig is a structure of predetermined shape and dimensions on which the various parts that, when
assembled, make up a component while ensuring accuracy of dimensions and intended shape. It is
particularly useful in the bulk/mass assembly of the same components. For this particular project,
jigs were used in the assembly by welding of the main support frames, top frames, and
hoisting/adjusting mechanisms.

The jigs were fabricated by welding, on a perfectly flat thick sheet of metal to form a base, ‘’holder
sections’’ of either angle lines or square hollow steel sections. In these holders, the parts making up
the component could fit in their most accurate dimensions and required shape.

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 b) Assembly of the main support frames.

To assemble the main support frames, square hollow sections were welded together in a jig of the
required structure and dimensions. Shielded metal arc or stick welding was applied. For a strong weld, at
least two sides of the joint were welded

c) Assembly of the top frames.

Similar to the assembly of the main support frames, square hollow sections were welded in a jig to make
the top frame. Shielded metal arc welding (SMAW) or stick welding was applied.

d) Assembly of angle line to the main support frame.

The angle lines that were to form part of the top frame’s adjusting or hoisting mechanism were welded
to the main support frame by shielded metal arc welding. The angle lines were manually held in place
during the welding.

e) Assembly of hinges.

Hinges were to be used in the assembly of the top frames to the main support frames. A particular
hinge would consist of a wire rod stud held between two hollow steel cylindrical sections, each of 1
inch length. One cylindrical section, that was to be welded to the main support frame, was welded
to the stud such that the other cylindrical section, that was to be welded to the top frame, was free
to rotate relative to the other cylindrical section and about the stud.

f) Assembly of the top frames to the main support frames using hinges.

For the task, the top frames were first held in place on top of the main support frames using G-clamps.
Hinges which comprised of a stud held between two hollow or bored cylindrical sections were placed on
the cleft between the adjoining faces of the top and main support frames. One bored cylindrical section
was welded to the main support frame and the other to the top frame.

g) Assembly of the adjusting/hoisting/tiling mechanisms.

The hoisting mechanisms were made of wire rod sections. The wire rods were assembled by welding on
a jig with the necessary dimensions and structure of the hoisting mechanisms.

h) Assembly of the hinges for the hoisting mechanisms to the top frames.

These hinges comprised of a bored cylindrical section in which the wire rod hoisting mechanisms would
be free to rotate. For the assembly, the hoisting mechanisms were first fitted in the bored cylindrical

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sections for the two sides required. They were then held in place and the top frame closed on the main
support frame. The sections were then welded on the main support frame.

MAINTENANCE OF THE WELDING MACHINE

i. The welding machine was used at the required voltage and amperage.
ii. The welding machine was properly stored at the end of each work day.

SAFETY PRECAUTIONS IN THE USE OF THE WELDING MACHINE

i. The base metal being welded was always electrically grounded to provide a path of minimum
resistance of current to flow back through. This ensured that the user did not form this path
which meant he/she would be electrocuted.
ii. All welding was done in a ventilated environment , full of free flowing air for fast exit of the
welding fumes which usually affect the skin.
iii. Welding shield glasses were always used to shield the user’s and on lookers’ eyes from the
extreme amount of lights produced by the electric arc.
iv. The welding machine was always placed on dry and non-humid location to isolate the welder
flowing in the electric leads or electrodes.
v. The welding machine was always switched off when not in use. The welding electrode was also
separated from any grounding to completely open the welding circuit.
vi. Hot parts were always carefully handled using gloves and hot welds allowed to cool before
handling of the parts or handled far away from the body when handling was a necessity before
the welds could cool.
vii. Welding was done far away from other trainees and activities and away from paths.

References

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1. https://www.twi-global.com/technical-knowledge/faqs/what-is-arc-welding
2. https://science.howstuffworks.com/welding3.htm
3. https://technoweld.com.au/2019/05/30/the-basics-of-electricity-in-welding/

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