1.

0 Title:

Welding Process

2.0 Objective:

The goal of the welding procedure is to permanently and firmly fuse two or more metal parts
together. Construction, automotive, aerospace, and fabrication are just a few of the several
industries that heavily rely on welding as a manufacturing technique.

The main goals of welding consist of:

Joint Strength:

Stronger than the base metals being bonded, or at least as strong as them, is the fundamental
purpose of welding. To endure the projected loads and stresses encountered during the service
life of the welded structure or component, the weld must be strong and structurally sound.

Structural Integrity:

Maintaining the structural integrity of the materials being joined is the major goal of welding.
The base metals must be metallurgical bonded to each other in order for the joint to maintain
strength and integrity even under demanding operating circumstances.

Quality and Reliability:

Welding procedures aim to create welds that are both high-quality and dependable. This
entails attaining uniform and constant weld penetration, reducing flaws like cracks or voids,
and guaranteeing the weld's durability.

Efficiency and Cost-effectiveness:

Welding methods are designed to produce products in an efficient and economical manner.
This entails maximizing the welding parameters to maximize productivity while reducing
material waste and energy consumption, such as welding speed, heat input, and consumable
usage.

Safety:

Operator and environmental protection must come first in welding procedures. To reduce the
dangers associated with welding, such as exposure to dangerous gases, arc flashes, or fire
hazards, it is essential to implement adequate safety measures, including personal protective
equipment (PPE), effective ventilation, and adherence to established welding procedures.

Weld look:

Depending on the industry and application, the weld's look may also be a goal. Some welding
procedures attempt to produce smooth, aesthetically beautiful welds, especially in fields like
automobile or architectural fabrication.

Together, these goals make sure that the welding process yields sturdy, dependable, and
secure welds while maximizing output and cutting expenses.

3.0 Introduction

In the manufacturing process known as welding, two or more pieces of metal are joined
together by melting the workpieces and adding a filler material. The filler material then cools
and solidifies to form a strong bond. It enables the development of intricate structures and
assemblies and is a frequently utilized method in the manufacturing, building, and repair
sectors.

The preparation of the workpieces to be joined precedes the welding procedure. In most
cases, this entails thoroughly cleaning the surfaces to get rid of any debris, rust, or other
pollutants that can compromise the weld's integrity. The pieces are then aligned and fixed in
place using clamps, fittings, or other holding tools.

The base metals are melted when the workpieces have been appropriately prepared and
heated. Electric arcs, gas flames, lasers, and electron beams are the most frequently employed
heat sources in welding. The choice of heat source depends on a number of elements,
including the type of metal being welded, the thickness of the material, and the particular
welding application. Each heat source offers advantages.
4.0 Experimental procedure

4.1 Apparatus

Power Supply (17-40v) Arc Welding Machine Thin plate of mild steel

DCRP and DCSP. Electrode Holder

AC (120A) Welding electrodes

4.2 Apparatus Setup

How to Choose Welding Equipment

-Select the best welding technique for the job at hand, such as shielded metal arc welding
(SMAW),

-Depending on the specified method, pick the appropriate welding machine. Voltage,
amperage, and duty cycle requirements are a few things to think about.

-Make that the welding equipment is grounded properly and in good operating order.

Getting the Workpiece Ready:

-Extremely clean the surfaces to be welded, removing any debris, rust, or other pollutants that
can compromise the weld's quality.

-Make sure the workpieces to be linked are properly positioned and aligned. When necessary,
use clamps or fittings.

-If necessary, bevel or chamfer the joint's edges for greater penetration.

Welding parameters can be set.

-To determine the proper welding parameters, such as voltage, amperage, wire feed speed,
and shielding gas flow rate, refer to the welding procedure specifications (WPS) or welding
recommendations.

-Set these settings on the welding equipment in accordance with the guidelines.

Grounding:

Use a suitable grounding cable to attach the workpiece to the welding machine's ground
clamp, making sure the connection is strong and offers a reliable electrical connection.

Activate and evaluate:

-Start the welding machine as directed by the manufacturer.

-To confirm the welding parameters and make any necessary adjustments, perform a test weld
on a scrap of material.

-Before continuing, examine the weld's quality and make any required modifications.
6.0 Result and Discussion
Qurratul Nadjwa Nuraisyah binti Nadzri
2022464476

Figure 1 (welding result)

Discussion

1.As we can see the first line and second line (starting from right to left) of the result from the
picture above the line is a bit slanted and spotted because I keep lifting the electric rode too
high and the weld looks like a flattened in the middle of the line because the electrode’s
attached to workpiece.

2. During the welding process, I regularly experience flash or unintentionally see a spark.
This is glaring in my face. This event frequently happens when I try to remove the electrode
that has stuck to my metal plate.

3.The third and fourth line look better to compare from the first line and second line but still
slanted and uneven and I think if I have given more time for practice I can cope better with
the process.
7.0 Conclusion

Overall, arc welding is a versatile and frequently used welding technique that offers a quick
and easy way to combine metal parts. To produce successful and high-quality welds, it is
crucial to adhere to safety precautions, use the right technique, and take into account the
particular needs of the materials and application.