POLITEKNIK MUADZAM SHAH JABATAN

KEJURUTERAAN MEKANIKAL WORKSHOP

WORKSHEET
DIPLOMA IN MECHANICAL ENGINEERING (MANUFACTURING)

MIG/TIG WELDING WORKSHOP

CODE & COURSE : DJF 21012 MANUFACTURING PRACTICE 1

CLASS: GROUP: DATE SUBMISSION:
LECTURER 1 :
LECTURER 2 :

STUDENT INFORMATION:
NO. NAME REGISTRATION NO
1

PREPARED BY: RECEIVED / CHECKED BY:

(STUDENT ) ( LECTURER)
Report and Practical Task Evaluation by Lecturer ( refer rubric)

MINI PROJECT EVALUATION ( CLO 1 )

PROJECT OUTPUT MARKS
SKILLS / ASPECT CLO MARKS
1. Apply safety procedures when operating TIG welding machines
1 5/4/3/2/1

2. Select nozzle size, wire feeder, current and voltage and adjust correct gas
1 5/4/3/2/1
flowrate.
3. Prepare welding process, determine speed, angle and current polarity
1 5/4/3/2/1
4. prepare material and welding process for Butt Joint
1 5/4/3/2/1

5. weld workpieces on various positions (Lap and T-Joint) 1 5/4/3/2/1

6. Ensure the finishing of workpiece 1 5/4/3/2/1
7. Keep the workplace clean and safe 1 5/4/3/2/1

REPORT EVALUATION( CLO1) MINI PROJECT EVALUATION ( CLO3)

SKILLS / ASPECT CLO MARKS SKILLS / ASPECT CLO MARKS
A. Introduction 1 5/4/3/2/1 A. Accountability 3 5/4/3/2/
B. Tools /equipment /
1 5/4/3/2/1 B. Integrity/ Honesty 3 5/4/3/2/
materials
C. Safety Precaution 1 5/4/3/2/1 C. Social Responsibility 3 5/4/3/2/
D. Procedures 1 5/4/3/2/1 D. Self-Discipline 3 5/4/3/2/
E. Result & Discussion E. Safety, Health and
2 5/4/3/2/1 3 5/4/3/2/
Environment
F. Conclusion 2 5/4/3/2/1
G. References 2 5/4/3/2/1

TOTAL MARKS
 POLITEKNIK MUADZAM SHAH JABATAN
KEJURUTERAAN MEKANIKAL WORKSHOP

WORKSHEET
EVALUATION TOTAL MARKS
REPORT CLO 1 ( /35 ) x 30 =
MINI PROJECT CLO1 ( /35 ) x 30 =
MINI PROJECT CLO3 ( /25 ) x 10 =

TITLE : TIG WELDING – FLAT POSITION

 POLITEKNIK MUADZAM SHAH JABATAN
KEJURUTERAAN MEKANIKAL WORKSHOP

WORKSHEET
1.0 COURSE LEARNING OUTCOMES
Upon completion of this workshop, students should be able to :
1.1 practice safety procedures regulation correctly in the workshop according to the
workshop safety.
1.2 Perform correctly TIG welding work in various types of metal, metal thickness and
joining.

2.0 OBJECTIVES
2.1 Welding workpieces on Flat Position (Butt Joint)

3.0 APPARATUS/EQUIPMENT
3.1 TIG welding equipment
3.2 Face shield
3.3 Leather hand glove
3.4 Plier
3.5 Wire brush
3.6 Tungsten Electrode (φ1.6mm or 2.4mm)

4.0 MATERIAL
4.1 Mild steel metal (190mm x 65mm x 4mm)
4.2 Angle Bar (25mm x 25mm)

List out the apparatus/equipment and material Draw the apparatus/equipment and material
 POLITEKNIK MUADZAM SHAH JABATAN
KEJURUTERAAN MEKANIKAL WORKSHOP

WORKSHEET

5.0 SAFETY AND HEALTH

 POLITEKNIK MUADZAM SHAH JABATAN
KEJURUTERAAN MEKANIKAL WORKSHOP

WORKSHEET
It is the individual’s responsibility to practice the following general safety guidelines at all times and
keep your workspace reasonably tidy.
5.1 Always know the hazards associated with the equipment/materials that are being utilized
in the workshop.
5.2 Always wear appropriate protective clothing and equipment.
5.3 Confine long hair and loose clothing. Do not wear high-heeled shoes, open-toed shoes,
sandals or shoes made of woven material.
5.4 Be familiar with the location of emergency equipment such as fire alarm and fire
extinguisher. Know the appropriate emergency response procedures.

5.5 __________________________________________________________________________
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6.0 INTRODUCTION
 POLITEKNIK MUADZAM SHAH JABATAN
KEJURUTERAAN MEKANIKAL WORKSHOP

WORKSHEET
6.1 Theory

Gas tungsten arc welding is a process in which the joining of metals is produced
by heating therewith an arc between a tungsten (non consumable) electrode and the
work. A shielding gas is used, normally argon. Normally done with a pure tungsten or
tungsten alloy rod, but multiple electrodes are sometimes used.

Figure 1 : TIG Welding Working Principle

The heated weld zone, molten metal, and tungsten electrode are shielded from
the atmosphere by a covering of inert gas fed through the electrode holder. Filler metal
may or may not be added. A weld is made by applying the arc so that the touching
workpiece and filler metal are melted and joined as the weld metal solidifies. This
process is similar to other arc welding processes in that the heat is generated by an arc
between a nonconsumable electrode and the workpiece, but the equipment and
electrode type distinguish itfrom other arc welding processes.

7.0 PROCEDURES
 POLITEKNIK MUADZAM SHAH JABATAN
KEJURUTERAAN MEKANIKAL WORKSHOP

WORKSHEET
7.1 Cut the stainless steel sheet metal to the specified size.
7.2 Clean the workpieces from oil, grease, paint, rust, dirt, and other contaminants.
7.3 Prepare the TIG welding equipment and make sure it is tightly installed.
7.4 Switch on theT IG welding machine to warmup/calibrating process.
7.5 Set the workpiece on the flat position.
7.6 Strike the arc and start the welding process.
7.7 After completion, clean the workpieces with wire brush or buffing machine.

PROCEDURES DIAGRAM (with label)

PROCEDURES DIAGRAM (with label)

 POLITEKNIK MUADZAM SHAH JABATAN
KEJURUTERAAN MEKANIKAL WORKSHOP

WORKSHEET

8.0 RESULT
 POLITEKNIK MUADZAM SHAH JABATAN
KEJURUTERAAN MEKANIKAL WORKSHOP

WORKSHEET
Draw the work piece with the dimension.

9.0 DISCUSSION

9.1 Why must we follows the safety procedures in workshop?

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9.2 GTAW is stand for ?

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9.3 What type of electrode is use in TIG weld?

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9.4 What is crater current and start current?

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10.0 CONCLUSION
 POLITEKNIK MUADZAM SHAH JABATAN
KEJURUTERAAN MEKANIKAL WORKSHOP

WORKSHEET

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11.0 REFERENCES

11.1 B.J Moniz and R.T. Miller (2010).Welding Skills Fourth Edition. American Technical
Publishers. Orland Park, Illinois.

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