University of Zakho

Department of Mechanical Engineering

Manufacturing Process/ Practical

WELDING WORKSHOP

Student’s Name: Rojeen Hameed Mahmood

Stage: Third
Date of experiment: 21/9/2021
Date lab report is submitted:12/10/2021
Supervised by: Mr. Jivan
List of Content:

1. Safety

2. Introduction

3. Types of welding

4. Tools and Equipment

5. Exercise 1

6. Exercise 2

7. Exercise 3

8. References
Safety:

The most important thing and the priority in welding workshop or any
workshop is safety. The welder must work very carefully because some things
are becoming dangerous in our life.
To keep the safety the welder should take a consideration in those points:

 Identify the hazards and the limits of your welding operation such as
using the appropriate equipment in the best possible conditions and working
with less hazardous materials are three of the best advices to start welding.

 Ask for training, training in safety ofiquipment and read the welder’s
operating manual to run the machine safely and also to maximise its
performance.

 protect themselves from all the potentially harmful effects of arc welding,
always wearing the proper gear -fire-resistant personal protective clothing
such as welding jacket -, including helmets, goggles, hand gloves and High-
top leather shoes or boots provide the best foot protection

 Don’t watch to the light because eyes are the most sensitive part of our body
when it comes to welding performance and ‘arc flash’ is one of the most
common injury and clean breathing during the welding.

 Take caution against electrocution such as small electric shocks. It is better to

using high quality protective equipment is key to avoid any kind of electric
shock.

Graph (1): Welding process

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Introduction:
Welding is a fabrication process whereby two or more parts are fused together
by means of heat, pressure or both forming a join as the parts cool. Welding is
usually used on metals and thermoplastics but can also be used on wood. The
completed welded joint may be referred to as a weldment. Some materials
require the use of specific processes and techniques. A number are considered
'unweldable,' a term not usually found in dictionaries but useful and descriptive
in engineering.

The parts that are joined are known as a parent material. The material added to
help form the join is called filler or consumable. The form of these materials
may see them referred to as parent plate or pipe, filler wire, consumable
electrode (for arc welding), etc.

Welding is a dependable, efficient and economic method for permanently

joining similar metals. In other words, you can weld steel to steel or aluminum
to aluminum, but you cannot weld steel to aluminum using traditional welding
processes. Welding is used extensively in all sectors or manufacturing, from
earth moving equipment to the aerospace industry.

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 Types of welding:

There are many different types of welding process, and in general can be
categorized as:

Electric arc welding, gas welding, thermal welding, electrical resistance

welding and frictional welding.

1. Electric arc welding:

Arc welding is a welding process that is used to join metal to metal by using
electricity to create enough heat to melt metal, and the melted metals when the
cool result in a binding of the metals. Arc welding is one of several fusion
processes for joining metals. By applying intense heat, metal at the joint
between two parts is melted and caused to intermix directly, or more
commonly, with an intermediate molten filler metal. Upon cooling and
solidification, a metallurgical bond is created.

Arc Welding Advantages, the process gives high deposition rates, welding
speed is high, wire consumption is low, the consumption of electrical energy is
low, as a maximum of 97 % of heat energy can be utilized and any length can
be welded without any interruption.

Arc Welding Application:

The application of Arc welding in the various department like Industries

Construction, Shipbuilding, farm equipment, lawn and Garden, highway
Equipment, Institutional Equipment and Railways Department.

Graph (2): Electrical arc welding

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2. Gas welding:

Gas welding is a type of liquid state welding process, in which fuel gas burns to
generate heat. This heat is used to melt interface surfaces of welding plates
which are held together to form a joint. In this welding process, mostly oxy-
acetylene gas is used as working fuel gas. This process can be done with or
without the help of filler material.

Gas welding involves the use of a gas-fed flame torch to heat the metal work
piece and the filler material to create a weld. The gas is generally a mixture of a
fuel gas and oxygen to create a clean, hot flame. Many different gases can be
used as fuel for gas welding, and electricity is not needed to power the welding
system, resulting in a flexible and portable fabrication method. All gas welding
techniques require proper safety equipment for the welder and storage of the
welding gases.

Gas Welding has the following advantages (Less is versatile, adapted too many
different jobs, equipment is relative to low cost, portable, self-sufficient and
independent from the availability of external energy sources).

Arc Welding Application:

For joining thin materials, joining most ferrous and nonferrous materials, and
used in automatic and aircraft industries and sheet metal fabrication.

Graph (3): Gas welding

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Tool and Equipment:

Welding Machine (Power Supply): Electric or Power is supplying from Direct

Board to Welding Machine to Electrode cable to Electrode Holder.

Cable: The main function is to deliver the current to the electrode holder from
the machine.

Holder: The function is to hold the Electrode.

Electrode: This electrode creates a spark when contacting the work.

Hand Gloves: While performing welding operation safety comes first so for the
hand we use here Hand gloves.

Goggles: As the welding operation temperature is too high we can see the
operation with the naked eye but after some time the eye gets damaged.

Chipping Hammers: This instrument is for holding the workpiece whenever

required.

Wire Brush: To remove unwanted material from the welded workpiece that is
slag we use a wire brush.

Graph (4): Require tools and equipment for arc welding

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Cylinders: Oxygen and acetylene are stored under pressure in a steel
cylinder. They are seized by the amount of oxygen or acetylene that they hold. 

Pressure Regulator: Both oxygen and fuel gases are filled in the cylinder at
high pressure. These gases cannot use at this high pressure for welding
works, so a pressure regulator is used between the flow. 

Torches: The torch assembly consists of the handle Oxygen and fuel gas valves
and the mixing chamber. Welding tips or cutting attachments with the handles
can be used, for welding, heating, and cutting operations. 

Acetylene Cylinders: These cylinders contain acetylene under pressure are

painted black made of steel and have cylinder valves.

Oxygen Cylinders: These cylinders are made of steel and are usually painted
green. They contain compressed oxygen at presses that can be as high as 2200
PSI. 

Graph (4): Require tools and equipment for gas welding

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Exercise 1:

Three types of line:

The purpose of the exercise is make 3 types of line on a part of metal by

welding.

Procedure:

First we cut a small part of metal by a cutter and get ride from unwanted object.
Then clean it by wire brush and we selected three line. Then generating the
electrical power at specific voltage and current and make three line by welding
that are ( straight line, zig zag line and circular line).

The result of this exercise we make three lines by electrode filler rod.

Discussion:

In this experiment we learned the types of line and how to make lines by
electrode of welding. The tools and equipment are working well. The teacher
explain every step and training us to make a good work with keeping the safety
of humans and workshop. During the experiment, I felt some of fear from a
welding a I complete my exercise as possible I can do it well. The result of this
experiment we make three lines on a part of metal and the line aren’t perfect
because the movement of electrode wasn’t enough slow to make correct line.

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Exercise 2:
Corner joint:

The purpose of the exercise is join two part of metal in angle (90°) by welding.

Procedure:

First we cut a two small parts of metal by a cutter and get ride from unwanted
object. Then clean it by wire brush. Then put one of them on welding table to
weld it by electrical arc and put another part on it with angle (90°) and weld in
two point in order to connect with each other. Then weld back of them in a
circular line. Also we join another part of metal with back of workpiece in
(exercise 1) by weld their sides.

Discussion:

In this experiment we learned how to join two parts of metal together with
angle and how to weld two different parts of metal. During the work, at
welding 2 points, the two parts were not in degree (90). So, I use hummer to be
(90°). Also at welding the sides of another part there have some holes on it
because the metal wasn’t too thick. So, we welded in again to repair it.

Result:

Graph (5): Result of exercise 2

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Exercise 3:

Cut and join of metal by gas welding:

The purpose of the exercise is cutting the metal by gas welding also join to part
by using gas welding.

Procedure:

First we open the Acetylene cylinder then set a fire and open oxygen cylinder.

Then, gradually open them more unit we know that it will cut the metal. We
use a part of metal on ground to cut it. After cutting we close the oxygen then
acetylene. Also in this exercise we cut two parts be hand cutter metal and
bending 1 mm in side of each one then welding them by gas welding.

Discussion:

In this experiment we learned how to use gas welding for cutting and hoe to
joining two parts with each other. During the exercise the two part welded
together correctly without cores or separating parts. Welding work shop learn
me many things, how to weld , how be expert in working, choose type of
welding that is identical with type of material, use different technique and the
importance of welding our daily life.

Results:

Graph (6): Result of exercise 3

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 References:

 https://learnmechanical.com/arc-welding/
 https://learnmechanical.com/gas-welding/
 https://zerohourparts.com/what-is-arc-welding/
 https://www.theengineerspost.com/gas-welding-types/
 https://mae.ufl.edu/designlab/Lab%20Assignments/EML2322L-Welding.pdf

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