Workshop report 3 Kamil Issa

Basic arc welding

Introduction:
Arc welding is one of several methods of joining metal. In arc welding, electricity is generated to
melt metal. When the molten metal cools down, binding of metal occurs when metallic pieces
are combined through solidified molten metal between these pieces. There are 3 processes of arc
welding: stick welding, mig welding, and tig welding. Each of these processes has advantages
and disadvantages and each type is used in specific circumstances.

Materials:
tools:
 safety glasses
 auto darkening welding helmet
 chipping hammer
 wire brush
 gauntlet cuff gloves for mig welding
 tig welding gloves
 work metal piece

 welding transformer
 electrode
 electrode holder
 workpiece clamp



Measuring devices: N/A

Different processes and their advantages and disadvantages:

 MIG welding: In mig welding, a filler metal is used as the electrode and it is on a
spool of wire. It is also a shielding gas process where the arc formed between the
electrode and the metal being welded melts the electrode. This molten metal from
the electrode then deposits on the metal being welded, creating a weld
Advantages:
 Easier to learn because you preset all of your parameters
 Cleaner welding because there will be no slag process
 Great for welding indoors on a wide variety of metal thicknesses (ex in a garage
or in a shop)
  Stick welding: It uses a consumable electrode to weld metal
Advantages: Because it is a flux based process, it works well in windy outdoor
conditions.
 Also works well on thicker metals
 If your metal is dirty or rusty (ex: farm equipment, gates, etc), rust and debris
don't affect it as much as other processes

Disadvantages: There will be too much spattering, vapors, fumes and off gassing. As a
result, It is not recommended indoors
 It is not the prettiest nor the cleanest weld, so it is not the best process to work on
frames, such as automobile frame mounts.
  TIG welding: Joins metals together by heating them with an arc between a non
consumable tungsten electrode, a consumable filler wire, and metal piece
Advantages: provides highest quality welds that are aesthetically pleasing to look at.
 Works well on thin metals
 great for frames, such as motorcycle frames and automotive sheet metal.
Disadvantages: It is more difficult to control because you have to control the heat with
your leg, filler metal deposition rate with your hand, and move the tungsten electrode at
the same time.
 Slower process that requires more time and practice to master
 Recommendations:
 If you want to work outdoors on farm equipment, or any dirty, thick metal, choose
a stick welder.
 If you are working on thin metals, HVAC, or frames; choose a tig welder
 If you want to work on a wider range of metals indoors, choose mig welding
 mig welding can be used to weld steel, stainless steel, and aluminum alloys
 stick welding can be used to weld steel, stainless steel and cast iron
 tig welding can be used to weld any metal that conducts electricity, such as steel,
stainless steel, aluminum, copper, brass, chromoly, and exotic metals(magnesium
and titanium)

Safety considerations:
Conclusion:
Arc welding is a useful process to know if you wish to combine metals for
different purposes, such as automobile manufacturing. Before welding, make sure
you know what and where are you welding in order to choose one of the three arc
welding processes. Also, never forget safety precautions because light, fumes,
gases, heat and other possible hazards resulting from welding can harm your
health.