J.C.

BOSE UNIVERSITY OF SCIENCE

AND TECHNOLOGY, YMCA, FARIDABAD
NAAC 'A' Grade Accredited State Govt. University

DEPARTMENT OF MECHANICAL ENGINEERING

WORKSHOP
MANUAL
WELDING WORKSHOP

ACADEMIC YEAR 2021-22

 Workshop Manual

B. Tech.
Mechanical Engineering

FWSMT WORKSHOP

Department of Mechanical Engineering

J.C. Bose University of Science and Technology, YMCA,
Faridabad
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 VISION of University

J.C. Bose University of Science and Technology aspires to be a nationally and

internationally acclaimed leader in technical and higher education in all spheres which
transforms the life of students through integration of teaching, research and character
building.

MISSION of University

 To contribute to the development of science and technology by synthesizing

teaching, research and creative activities.
 To provide an enviable research environment and state-of-the-art technological
exposure to its scholars.
 To develop human potential to its fullest extent and make them emerge as world
class leaders in their professions and enthuse them towards their social
responsibilities.

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 Department of Mechanical Engineering

VISION

To be a centre of excellence by producing high calibre, competent and self-reliant

mechanical engineers, who possess scientific temperament and would engage in activities
relevant to industries with ethical values and flair to research.

MISSION

 To provide efficient engineers for global requirements by imparting quality

education.
 To explore, create and develop innovations in various aspects of engineering
through industries and institutions.
 To emphasize on practical skills and socially relevant technology.

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 DEPARTMENT OF MECHANICAL ENGINEERING

Program Educational Outcomes (PEO’S): B. Tech. Mechanical Engineering

PEO-1:

To train students with practical skills and experimental practices related to core and applied areas

of mechanical engineering to expand their knowledge horizon beyond books.

PEO-2:

To enable students to design, develop and maintain mechanical equipments which are useful for

the society.

PEO-3:

To improve team building, team working and leadership skills of the students with high regard for

ethical values and social responsibilities.

PEO- 4:

To enable students to communicate effectively and demonstrate the knowledge of project

management and independent research.

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 DEPARTMENT OF MECHANICAL ENGINEERING

PROGRAMME OUTCOMES (PO)

PO Engineering Graduates will be able to:

Engineering knowledge: Apply knowledge of mathematics, science, engineering

PO1 fundamentals, and mechanical engineering to the solution of engineering problems.
Problem analysis: Identify, formulate, review literature and analyze mechanical
PO2 engineering problems to design, conduct experiments, analyze data and interpret data.
Design /development of solutions: Design solution for mechanical engineering
PO3 problems and design system component of processes that meet the desired needs with
appropriate consideration for the public health and safety, and the cultural, societal and
the environmental considerations.
Conduct investigations of complex problems: Use research based knowledge and
PO4 research methods including design of experiments, analysis and interpretation of data, and
synthesis of the information to provide valid conclusions in mechanical engineering.
Modern tool usage: Create, select, and apply appropriate techniques, resources, and
PO5 modern engineering and IT tools including prediction and modeling to mechanical
engineering activities with an understanding of the limitations.
The engineer and society: Apply reasoning informed by the contextual knowledge to
PO6 assess societal, health, safety, legal and cultural issues and the consequent responsibilities
relevant to mechanical engineering practice.
Environment and sustainability: Understand the impact of the mechanical engineering
PO7 solutions in societal and environmental contexts, and demonstrate the knowledge and
need for sustainable development.
Ethics: Apply ethical principles and commit to professional ethics and responsibilities
PO8 and norms of the mechanical engineering practice.
Individual and team work: Function affectively as an individual, and as a member or
PO9 leader in diverse teams, and in multidisciplinary settings in mechanical engineering.
Communication: Communicate effectively on complex engineering activities with the

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PO10 engineering committee and with society at large, such as, being able to comprehend and
write affective reports and design documentation, make effective presentations in
mechanical engineering.
Project Management and finance: Demonstrate knowledge & understanding of the
PO11 mechanical engineering principles and management principles and apply these to one’s
own work, as a member and leader in a team, to manage projects and in multidisciplinary
environments in mechanical engineering.
Life- long learning: Recognize the need for, and the preparation and ability to engage in
PO12 independent research and lifelong learning in the broadest contest of technological
changes in mechanical engineering.

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 DEPARTMENT OF MECHANICAL ENGINEERING

PROGRAMME SPECIFIC OUTCOMES (PSO)

PSO Engineering Graduates will be able to:

To empower the students to apply practical skills, knowledge in major streams such as
thermal, design, manufacturing and industrial engineering.
PSO1

To enable the student to take-up career in industries or to pursue higher studies in mechanical
and interdisciplinary programs with high regard for ethical values, environmental and social
PSO2
issues.

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WS- 161C/WS-162C MECHNICALWORK SHOP- I/II
B.Tech I/II -Semester

No. of Credits: 2 Internal: 30Marks

L T P Total External: 70 Marks
0 0 4 4 Total : 100Marks
Duration of Exam: 3Hours

Course Outcomes (COs): After studying this course the students will be able to:

CO 1- Acquire skills on basic engineering materials and safety aspects.

CO 2- Understand the fundamental concept of various basic engineering practices namely fitting, sheet
metal, carpentry, pattern making and welding etc.
CO 3- Learn and use different marking & measuring instruments used in machine shop, fitting shop,
sheet metal shop, carpentry & pattern making shop etc.
CO 4- Practice real time job preparation using various operations related to fitting, sheet metal,
carpentry, welding & foundry etc.

List of Exercises:

Machine shop, fitting shop, sheet metal shop, carpentry & pattern making shop, welding shop,
foundry shop, forging (smith) shop and injection moulding shop.

Section (A): Machine Shop

1. To understand the layout, safety measures and fundamental concept of different engineering
materials used in the workshop.
2. To study and demonstrate the various parts, specifications & operations on lathe, milling and
shaping machine.
3. To study different types of measuring tools used in metrology and determine the least count
of vernier calipers, vernier height gauges and micrometers.

Section (B): Fitting & Sheet Metal Shop

4. To study different types of tools, equipments, devices and machines used in fitting shop.
5. To prepare a job involving filing, drilling, tapping and hacksaw cutting operations on mild
steel plate.
6. To study various types of sheet metal tools and prepare a simple sheet metal joint.

Section (C): Carpentry and Pattern Making Shop

7. To study various types of carpentry and pattern making tools and equipments.
8. To prepare a simple wooden joint (cross lap / Tee-lap/dovetail joint) using kail wood in
carpentry shop.
9. To prepare single piece pattern / split pattern using kail wood in pattern making shop.

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Section (D): Welding Shop

10. To practice striking an arc and prepare straight short bead on given M.S plate in flat position
by arc welding.
11. To prepare straight continuous bead and re start of electrode in flat position by arc welding
on given M.S. plate as per size.
12. To practice tack weld & close butt joint in flat position by arc welding on given M.S. plate as
per size.

Section (E): Foundry, Forging (Smithy) & Injection Moulding shop

13. To study various types of foundry tools and prepare a mould cavity using single/split pattern
in moulding sand.
14. To study various types of forging / black smithy tools and prepare a ring or hook by hand
forging operation.
15. To study the working of injection molding machine and prepare a simple component by
injection moulding.

NOTE: - Total twelve exercises should be performed from the above list. At least two from each
section and remaining two may either be performed from above list or designed by the concerned
institution as per the scope of the syllabus and facilities available in institute.

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 WELDING

INTRODUCTION
Welding is the process of joining similar metals by the application of heat, with or without
application of pressure or filler metal, in such a way that the joint is equivalent in composition and
characteristics of the metals joined. In the beginning, welding was mainly used for repairing all kinds of
worn or damaged parts. Now, it is extensively used in manufacturing industry, construction industry
(construction of ships, tanks, locomotives and automobiles) and maintenance work, replacing riveting
and bolting, to a greater extent.
The various welding processes are:

Methods of welding
There are two methods by which welding is performed
1. Plastic welding
2. Fusion welding

Plastic welding
In this method, the metal parts are heated to plastic state. At this stage, pressure is applied to
make a perfect joint. It is also known as pressure welding.

Fusion welding
The metal parts are heated unto the point of melting in this method. The joint is made at this
stage and the parts are allowed to cool. On cooling, the molten metal forms a solid joint. No pressure is
applied in this method. Hence, it is also known as pressure less welding. Arc welding and gas welding
fall in this category.

Classification of welding processes

1. Arc welding
a. Carbon arc welding
b. Metal inert gas welding
c. Tungsten inert gas welding
d. Atomic hydrogen welding
e. Plasma arc welding
f. Submerged arc welding
g. Electro slag welding
2. Gas welding
a. Oxy-acetylene welding
b. Air-acetylene welding
c. Oxy hydrogen welding

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3. Resistance welding
a. Butt welding
b. Spot welding
c. Seam welding
d. Projection welding
e. Percussion welding
4. Thermit welding
5. Solid state welding
a. Friction welding
b. Explosive welding
c. Ultrasonic welding
d. Diffusion welding
6. Newer welding
a. Electron beam welding
b. Laser welding
7. Welding related processes
a. Oxy-acetylene cutting
b. Arc cutting
c. Hard facing
d. Brazing
e. Soldering
1. Electric arc welding,
2. Gas welding
3. Thermal welding
4. Electrical Resistance welding and
5. Friction welding
However, only electric arc welding process is discussed in the subject point of view.

Electric arc welding

Arc welding is the welding process, in which heat is generated by an electric arc struck between
an electrode and the work piece. Electric arc is luminous electrical discharge between two electrodes
through ionized gas.

Any arc welding method is based on an electric circuit consisting of the following parts:

a. Power supply (AC or DC);

b. Welding electrode;
c. Work piece;
d. Welding leads (electric cables) connecting the electrode and work piece to the power supply.

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 Fig: 1 Arc welding set up

Electric arc between the electrode and work piece closes the electric circuit. The arc Temperature
may reach 10000°F (5500°C), which is sufficient for fusion the work piece edges and joining them.
When a long joint is required the arc is moved along the joint line. The front edge of the weld pool melts
the welded surfaces when the rear edge of the weld pool solidifies forming the joint.
Transformers, motor generators and rectifiers’ sets are used as arc welding machines. These machines
supply high electric currents at low voltage and an electrode is used to produce the necessary arc. The
electrode serves as the filler rod and the arc melts the surface so that, the metals to be joined are actually
fixed together.
Sizes of welding machines are rated according to their approximate amperage capacity at 60% duty
cycle, such as 150,200,250,300,400,500 and 600 amperes. This amperage is the rated current output at
the working terminal.

Transformers
The transformers type of welding machine produces A.C current and is considered to be the least
expensive. It takes power directly from power supply line and transforms it to the voltage required for
welding. Transformers are available in single phase and three phases in the market.

Motor generators
These are D.C generators sets, in which electric motor and alternator are mounted on the same
shaft to produce D.C power as pert the requirement for welding. These are designed to produce D.C
current in either straight or reversed polarity. The polarity selected for welding depends upon the kind of
electrode used and the material to be welded.

Rectifiers
These are essentially transformers, containing an electrical device which changes A.C into D.C
by virtue of which the operator can use both types of power (A.C or D.C, but only one at a time).In
addition to the welding machine; certain accessories are needed for carrying out the welding work.

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Welding Currents

The three types of current used for welding are

1. Alternating Current (AC)
2. Direct Current Straight Polarity (DCSP)
3. Direct Current Reverse Polarity (DCRP)

1. Alternating Current (AC) –

 In AC, the electrons change direction every 1/120 of a second so that the electrode and work
alternate from anode to cathode.
 The rapid reversal of current flow causes the welding heat to be evenly distributed on both the
workpiece and the electrode i.e. half on the workpiece and half on the electrode.
 The even heating gives the weld bead a balance between penetration and buildup.

Fig. Alternating current (AC)

2. Direct Current Straight Polarity (DCSP)

 In DCSP electrode is negative and the workpiece is positive.

 DCSP has higher heat on the workpiece and lower heat on the electrode.
 The DCSP weld bead has deep penetration into base metal with little buildup.

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 Fig. Direct Current Straight Polarity (DCSP), electrode negative (DCEN)

3. Direct Current Reverse Polarity (DCRP)

 In DCSP electrode is positive and the workpiece is negative.

 DCSP has higher heat on the electrode and lower heat on the workpiece.
 The DCSP weld bead has shallow penetration into base metal with high buildup.

Fig. Direct Current Reverse Polarity (DCRP), electrode positive (DCEP)

Welding cables
Two welding cables are required, one from machine to the electrode holder and the other, from
the machine to the ground clamp. Flexible cables are usually preferred because of the case of using and
coiling the cables. Cables are specified by their current carrying capacity, say 300 A, 400 A, etc.

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Electrodes
Filler rods are used in arc welding are called electrodes. These are made of metallic wire called
core wire, having approximately the same composition as the metal to be welded. These are coated
uniformly with a protective coating called flux. While fluxing an electrode; about 20mm of length is left
at one end for holding it with the electrode holder. It helps in transmitting full current from electrode
holder to the front end of the electrode coating. Flux acts as an insulator of electricity. In general,
electrodes are classified into five main groups; mild steel, carbon steel, special alloy steel, cast iron and
non‐ferrous. The greatest range of arc welding is done with electrodes in the mild steel group. Various
constituents like titanium oxide, potassium oxide, cellulose, iron or manganese, Ferro silicates,
carbonates, gums, clays, asbestos, etc., are used as coatings on electrodes. While welding, the coating or
flux vaporizes and provides a gaseous shield to prevent atmospheric attack. The size of electrode is
measured and designated by the diameter of the core wire in SWG and length, apart from the brand and
code names; indicating the purpose for which there are most suitable

Fig :2 parts of an electrode

Electrodes may be classified on the basis of thickness of the coated flux. As

1. Dust coated or light coated
2. Semi or medium coated and
3. Heavily coated or shielded

Electrodes are also classified on the basis of materials, as

1. Metallic and
2. Non‐metallic or carbon

Metallic arc electrodes are further sub‐divided into

1. Ferrous metal arc electrode (mild steel, low/medium/high carbon steel, cast iron, stainless
steel, etc)
2. Non‐ferrous metal arc electrodes (copper, brass, bronze, aluminum, etc).
In case of non‐metallic arc electrodes, mainly carbon and graphite are used to make the electrodes.

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Functions of Electrode Coating Ingredients
The covering coating on the core wire consists of many materials which perform a number of
functions as listed below:

1. Welding electrodes are used to join various similar and dissimilar metals as plain carbon steels,
cast iron, copper, aluminum, magnesium and their alloys, stainless steels and other alloy steels.
2. Slag forming ingredients, like silicates of magnesium, aluminum, sodium, potassium, iron oxide,
china clay, mica etc., produce a slag which because of its light weight forms a layer on the
molten metal and protects the same from atmospheric contamination.
3. Arc stabilizing constituents like calcium carbonate, potassium silicate, titanates, magnesium
silicates, etc.; add to arc stability and ease of striking the same.
4. Gas shielding ingredients, like cellulose, wood, wood flour, starch, calcium carbonate etc. form a
protective gas shield around the electrode end, arc and weld pool.
5. Deoxidizing elements like ferro-manganese, and ferro-silicon, refine the molten metal.
6. It limits spatter, produces a quiet arc and easily removable slag.
7. Alloying elements like ferro alloys of manganese, molybdenum etc., may be added to impart
suitable properties and strength to the weld metal and to make good the loss of some of the
elements, which vaporize while welding.
8. Iron powder in the coating improves arc behavior, bead appearance helps increase metal
deposition rate and arc travel speed.
9. The covering improves penetration and surface finish.
10. Core wire melts faster than the covering, thus forming a sleeve of the coating which constricts
and produces an arc with high concentrated heat.
11. Coating saves the welder from the radiations otherwise emitted from a bare electrode while the
current flows through it during welding.
12. Proper coating ingredients produce weld metals resistant to hot and cold cracking. Suitable
coating will improve metal deposition rates.

Electrode Size (mm) Current Range (Amp.)

Ø2.5 x 350mm 60-90Amp

Ø 3.15 x350mm 90-130Amp

Ø 4.00 x 450mm 140-180Amp

Ø 5.00 x 450mm 180-220Amp

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Welding defects are formed in a welding work due to the weak or poor technique used by the
inexperienced or untrained welders or due to structural problems in the welding operation. Or you can
say, in a welding process, the size and shape of the metal structure are varied. It is maybe due to the
incorrect welding process or the application of the incorrect welding procedure.

An ideal weld or good weld must be one that exists with good penetration with sufficient fusion between
the filler metal and the edge preparation.

Types of Welding Defects

Following are the types of welding defects:

1. Porosity and Blowholes

2. Undercut
3. Weld crack
4. Incomplete fusion
5. Slag inclusion
6. Incomplete penetration
7. Spatter
8. Distortion
9. Hot Tear

Arc Welding Equipment

1. Arc welding power source

Both direct current (DC) and alternating current (AC) are used for electric arc welding, each
having its particular applications. DC welding supply is usually obtained from generators driven by
electric motor or if no electricity is available by internal combustion engines. For AC welding supply,
transformers are predominantly used for almost all arc welding where mains electricity supply is
available. They have to step down the usual supply voltage (200-400 volts) to the normal open circuit
welding voltage (50-90 volts). The following factors influence the selection of a power source:

1. Type of electrodes to be used and metals to be welded

2. Available power source (AC or DC)
3. Required output
4. Duty cycle
5. Efficiency
6. Initial costs and running costs
7. Available floor space
8. Versatility of equipment

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2. Welding cables
Welding cables are required for conduction of current from the power source through the
electrode holder, the arc, the workpiece and back to the welding power source. These are insulated
copper or aluminium cables.

3. Electrode holder
Electrode holder is used for holding the electrode manually and conducting current to it. These
are usually matched to the size of the lead, which in turn matched to the amperage output of the arc
welder. Electrode holders are available in sizes that range from 150 to 500 Amps.

Fig: - Electrode holder

4. Earth Clamp
The earth clamp is a tool that, via the earth cable, ensures the electrical circuit to be closed
between the welding power source and the piece to be welded. The choice of cable section and length
should be based on the maximum welding current in amps.

Fig: - Earth Clamp

4. Hand Screen
Hand screen used for protection of eyes and supervision of weld bead.

Fig: - Hand Screen

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5. Chipping hammer
Chipping Hammer is used to remove the slag by striking.

Fig. Chipping hammer

6. Wire brush
Wire brush is used to clean the surface to be weld.

Fig. Wire brush

7. Protective clothing
Operator wears the protective clothing such as apron to keep away the exposure of direct heat to
the body.

Fig. Leather Apron Fig. Leather Hand Gloves

8. Chisel
Chisels are used for removing surplus metal or for cutting thin sheets. These tools are made from
0.9% to 1.0% carbon steel of octagonal or hexagonal section. Chisels are annealed, hardened and

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tempered to produce a tough shank and hard cutting edge. Annealing relieves the internal stresses in a
metal. The cutting angle of the chisel for general purpose is about 60°.

Fig:.Chisel

10. Punches
These are used for making indentations on the scribed lines, to make them visible clearly. These
are made of high carbon steel. A punch is specified by its length and diameter (say as 150’ 12.5mm). It
consists of a cylindrical knurled body, which is plain for some length at the top of it. At the other end, it
is ground to
a point. The tapered point of the punch is hardened over a length of 20 to 30mm.

(a) Dot Punch is used to lightly indent along the layout lines, to locate center of holes and to
provide a small center mark for divider point, etc. for this purpose, the punch is ground to a
conical point having 60° included angle.

Fig. Dot Punch

(b) Center Punch is similar to the dot punch, except that it is ground to a conical point having 90°
included angle. It is used to mark the location of the holes to be drilled.

Fig. Center Punch

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11. Try Square
It is measuring and marking tool for 90 angle .In practice, it is used for checking the squareness
of many types of small works when extreme accuracy is not required .The blade of the Try square is
made of hardened steel and the stock of cast Iron or steel. The size of the Try square is specified by the
length of the blade.

Fig: Try Square

12. Scriber
A Scriber is a slender steel tool, used to scribe or mark lines on metal work pieces. It is made of
hardened and tempered High Carbon Steel. The Tip of the scriber is generally ground at 12 o to 15o . It
is generally available in lengths, ranging from 125mm to 250mm .It has two pointed ends the bent end is
used for marking lines where the straight end cannot real.

Fig: Scriber
13. Files
Filing is one of the methods of removing small amounts of material from the surface of a metal
part. A file is hardened steel too, having small parallel rows of cutting edges or teeth on its surfaces. On
the faces, the teeth are usually diagonal to the edge. One end of the file is shaped to fit into a wooden
handle. The figure shows various parts of a hand file. The hand file is parallel in width and tapering
slightly in thickness, towards the tip. It is provided with double cut teeth. On the faces, single cut on one
edge and no teeth on the other edge, which is known as a safe edge. Files are classified according to
their shape, cutting teeth and pitch or grade of the teeth. The figure shows the various types of files
based on their shape.

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 Fig: Parts of a Hand File
14. Mallet:
It is generally made of wood or plastic. It is used whenever slight blows are required. Wooden
hammer (mallet) is most commonly used because it does not damage the work surface.

Fig: Mallet
15. Marking and Measuring Tools:
Accurate marking and measurement is very essential in carpentry work, to produce parts to exact
size. To transfer dimensions onto the work; the following are the marking and measuring tools that are
required in a carpentry shop.

16. Steel Rule and Steel Tape

Steel rule is a simple measuring instrument consisting of a long, thin metal strip with a marked
scale of unit divisions. It is an important tool for linear measurement.
Steel tape is used for large measurements, such as marking on boards and checking the overall
dimensions of the work.

Fig: Steel Rule

Fig: Steel Tape

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17. BENCH VICE:
It is firmly fixed to the bench with the help of nuts and bolts. It consists of a cast Iron body and
cast iron jaws. Two jaw plates are fitted on both the jaws. The holding surface of the jaw plates is
knurled in order to increase the gipping. Jaw plates are made up of carbon steel and are wear resistant.
One jaw is fixed to the body and the second slides on a square threaded screw with the help of a handle.
The jaws are opened upto required length; job is placed in the two jaws and is fully tightened with the
help of handle. Handle is used to move the movable jaw

TECHNIQUES OF WELDING

A welding arc is maintained when the welding current is forced across a gap between the electrode tip
and the base metal. A welder must be able to strike and establish the correct arc easily and quickly.

There are two general methods of striking the arc:

1. Scratching
2. Tapping

The scratching method is easier for beginners and when using an AC machine. The electrode is moved
across the plate inclined at an angle, as you would strike a match. As the electrode scratches the plate an
arc is struck. When the arc has formed, withdraw the electrode momentarily to form an excessively long
arc, then return to normal arc length.

Preparation of work
Before welding, the work pieces must be thoroughly cleaned of rust, scale and other foreign
material. The piece for metal generally welded without beveling the edges, however, thick work piece
should be beveled or veed out to ensure adequate penetration and fusion of all parts of the weld. But, in

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either case, the parts to be welded must be separated slightly to allow better penetration of the weld.
Before commencing the welding process, the following must be considered
a) Ensure that the welding cables are connected to proper power source.
b) Set the electrode, as per the thickness of the plate to be welded.
c) Set the welding current, as per the size of the electrode to be used.

Types of Joints

The joints used in welding are

1. Butt joint 2. Lap joint 3. Edge joint
4. T – joint 5. Corner joint

1. Butt joint

It is used to join the ends or edges of plates lying in the same plane. Plates having thickness less than
5mm do not require edge preparation but plates having thickness more than 5mm require edge
preparation on both sides.

2. Lap joint

It is used to join two over lapping pieces so that the edges of each piece are welded to the surface of
the other. It is used on plates less than 3mm thickness. Common types are single lap and double lap
joint. Edge preparation is not required for these joints.

3. Edge joint

It is used to weld two parallel plates. This is economical for joining thin plates up to 6mm. This joint
is often used in sheet metal work. It is suitable for severe loading.

4. T – joint

It is used to weld two perpendicular plates. This is economical for joining thin plates up to 3mm.
This joint is often used in structures.

5. Corner joint

It is used to join the edges of two pieces whose surfaces are approximately at right angles to each
other. It is common in the construction of boxes, tanks, frames and other similar items. Edge
preparation is not necessary for these joints.

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 Fig: Types of Joints

WELDING POSITIONS
Depending upon the location of the welding joints, appropriate position of the electrode and hand
movement is selected. The figure shows different welding positions.

Flat position welding

In this position, the welding is performed from the upper side of the joint, and the face of the
weld is approximately horizontal. Flat welding is the preferred term; however, the same position is
sometimes called down hand.

Horizontal position welding

In this position, welding is performed on the upper side of an approximately horizontal surface
and against an approximately vertical surface.

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Vertical position welding
In this position, the axis of the weld is approximately vertical as shown in figure.

Overhead position welding

In this welding position, the welding is performed from the underside of a joint

Fig: Weld positions

Advantages
1. Shielded Metal Arc Welding (SMAW) can be carried out in any position with highest weld
quality.
2. MMAW is the simplest of all the arc welding processes.
3. This welding process finds innumerable applications, because of the availability of a wide
variety of electrodes.
4. Big range of metals and their alloys can be welded easily.
5. The process can be very well employed for hard facing and metal resistance etc.
6. Joints (e.g., between nozzles and shell in a pressure vessel) which because of their position are
difficult to be welded by automatic welding machines can be easily accomplished by flux
shielded metal arc welding.
7. The MMAW welding equipment is portable and the cost is fairly low.

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Limitations
1. Due to flux coated electrodes, the chances of slag entrapment and other related defects are more
as compared to MIG and TIG welding.
2. Due to fumes and particles of slag, the arc and metal transfer is not very clear and thus welding
control in this process is a bit difficult as compared to MIG welding.
3. Due to limited length of each electrode and brittle flux coating on it, mechanization is difficult.
4. In welding long joints (e.g., in pressure vessels), as one electrode finishes, the weld is to be
progressed with the next electrode. Unless properly cared, a defect (like slag inclusion or
insufficient penetration) may occur at the place where welding is restarted with the new electrode
5. The process uses stick electrodes and thus it is slower as compared to MIG welding.

Applications
1. Today, almost all the commonly employed metals and their alloys can be welded by this process.
2. Shielded metal arc welding is used both as a fabrication process and for maintenance and repair
jobs.
3. The process finds applications in
(a) Building and Bridge construction
(b) Automotive and aircraft industry, etc.
(c) Air receiver, tank, boiler and pressure vessel fabrication
(d) Ship building
(e) Pipes and
(f) Penstock joining

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 Fabrication Welding & Sheet Metal

Workshop

Exercises
1st & 2nd Semester

1. To practice striking an arc and prepare straight short bead on given M.S plate in flat position
by arc welding.
2. To prepare straight continuous bead and re start of electrode in flat position by arc welding on
given M.S. plate as per size.
3. To practice tack weld & close butt joint in flat position by arc welding on given M.S. plate as
per size.

FWSMT WORKSHOP Page 28

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 J.C. BOSE UNIVERSITY OF SCIENCE
AND TECHNOLOGY, YMCA, FARIDABAD
NAAC 'A' Grade Accredited State Govt. University
(Established by Haryana State Legislative Act No. 21 of 2009,
Recognized by U.G.C. u/s 2 (f) and 12(B) of U.G.C. Act 1956)
NH- 2, SECTOR-6, MATHURA ROAD
FARIDABAD, HARYANA-121006

LAST UPDATED - OCTOBER 2021

jcboseust.ac.in /JCBoseUST