THERMODYNAMICS

MANUFACTURING RESOURCE CENTER (MRC)

LAB REPORT 5: WELDING

Submitted by: Hamna Anwaar Registration no: 335763

TITLE: Welding

OBJECTIVE:

1. The objective is for the students to experience and do the arc welding works on mild steel plates
using the right welding techniques.
2. Become familiar with basic welding operations.

APPARATUS:

1. Gloves
2. Coverall
3. Head shield
4. Steel brush
5. Chipping hammer
6. Power supply (generator)
7. Electrode holder
8. Work piece clamp
9. Electrode
10. MS Plate size 100 x 50 x 2 (mm)
11. Acetylene and Oxygen gas cylinders with gases and regulators
12. Gas welding torch with hoses connected up to the cylinders

THEORY:

Welding is a fabrication process that joins materials, usually metals or thermoplastics, by using high heat
to melt the parts together and allowing them to cool, causing fusion. Welding is distinct from lower
temperature techniques such as brazing and soldering, which do not melt the base metal (parent metal).

In addition to melting the base metal, a filler material is typically added to the joint to form a pool of
molten material (the weld pool) that cools to form a joint that, based on weld configuration (butt, full
penetration, fillet, etc.), can be stronger than the base material. Pressure may also be used in
conjunction with heat or by itself to produce a weld. Welding also requires a form of shield to protect
the filler metals or melted metals from being contaminated or oxidized.

Many different energy sources can be used for welding, including a gas flame (chemical), an electric arc
(electrical), a laser, an electron beam, friction, and ultrasound. While often an industrial process,
welding may be performed in many different environments, including in open air, under water, and in
outer space. Welding is a hazardous undertaking and precautions are required to avoid burns, electric
shock, vision damage, inhalation of poisonous gases and fumes, and exposure to intense ultraviolet
radiation.
Types of Welding:

MIG – GAS METAL ARC WELDING (GMAW)

MIG welding is used in the auto industry for repairing vehicle exhausts and is also used in creating
homes and buildings. It is one of the most common types of welding. This is a type of arc welding that
uses a continuous wire called an electrode. You will also use a shielding gas that travels through the
welding gun and protects against contamination.

TIG – GAS TUNGSTEN ARC WELDING (GTAW)

TIG welding also uses electric arc like MIG. When working with TIG welding, you use an electrode made
of tungsten. Tungsten is one of the toughest metal materials. It will not dissolve or burn off. Welding can
be done through a process known as fusion which is using or not using a filler metal. TIG also uses an
external gas supply, such as argon or helium.

Aerospace and auto also use TIG welding as well as other industrial markets. This is also a great type of
welding for Iowa as it can be very useful for farmers to use welding wagon frames, fenders and other
important equipment.

STICK – SHIELDED METAL ARC WELDING (SMAW)

Want to take your welding to go? One big positive about Stick welding is that it’s portable. Stick welding
is used in construction, maintenance and repair, underwater pipelines, and industrial fabrication.

For this type of welding, you will use a shielded metal art welding or more commonly known as Stick
welding. You will use a consumable and protected electrode, or stick. The stick softens and combines
metals by heating with an arc between a covered metal electrode and the base metal workpiece. As the
stick melts, its protective cover also melts and shields the weld area from oxygen and other gases that
may be in the air.

Welding Joints:

PROCEDURE:

1. The parent pieces are inspected for any kind of cracks or impregnated impurity like grease/ oil,
paint etc. if necessary clean them. The pieces should also be straight.
2. Cut the pieces according to the drawing with shear cutter.
3. Set the pressure of both cylinders. The pressure of oxygen gas cylinder is kept twice that of
acetylene gas cylinder to produce a natural flame.
4. Open the valve of oxygen cylinder.
5. Hold the pieces of parent metal in fixture working bench to heat them by flame and use filler
rod for filling the gap between two pieces.
6. Maintain the angle 60 degree approximately between filler rod and holder flame / torch while
gas welding.
7. After welding has been completed, first of all close the acetylene valve and then oxygen valve.
8. Neatly take away the holder/hoses and roll the hoses.
9. Inspect the joint, if necessary the opposite side of the job is also weld and file the joint.
10. Use chipping hammer and steel brush to remove the slag after the metal cools down.
ENVIRONMENTAL SIGNIFICANCE:

1. MMAW (manual metal arc welding) contributes higher environmental impacts in global
warming potential, acidification potential, photochemical ozone creation, and eutrophication
potential, and leads to higher potential health risk of welders than other selected processes.
2. Different gases like ozone, nitrogen oxides and carbon oxides produced in the various welding
methods, and all of these gases are among the pollutants, which can cause environmental
problems as released into the atmosphere.

OBSERVATIONS:

The plates were superbly welded.

SAFTY PRECAUTIONS:

1. Select the right pressure of both gas cylinders oxygen around 1 bar and acetylene 0.5 bars. Job
must be fixed properly in position for welding.
2. Open the valve of acetylene gas first then oxygen gas and when welding is completed then close
the acetylene gas valve first then oxygen.
3. Job must be fixed properly in position for Gas Welding.
4. Always wear apron shoulders, goggles and gloves during the work.
5. Keep cylinders as far as possible from the work area.
6. Do not leave torch lighted while you attend to some other work. Acetylene is dangerous above 1
atm (155Pi) pressure.

CONCLUSION:

Welding is an essential component of many industries such as the automotive industry, the construction
industry, the aviation industry, and more. Without this form of metal work, so many things, including
many buildings, gates, and fences, small kitchen appliances, vehicles - and even space travel - would not
exist.