Purpose of document:

Written report describing detailed, accurate planning and production of 2 different welded joints using 2
different materials, processes and welding positions safely. Also refining the plan for the 2 joints to
make them more efficient and effective.
Contents:

1 - Purpose of document

2 - Contents

3 - P5 MIG welding carbon steel

4 - P5 GMAW aluminium

5 - P6

6-

7-

8-

9-

10 -
P5
Carbon steel Metal Inert Gas welding

Obtain the necessary carbon steel materials for the welded joint, making sure they are clean and free of
any debris or contaminants.

Assemble the MIG welder according to the manufacturer's instructions and set it to the appropriate
settings for welding carbon steel.

MIG welder:

Position the carbon steel materials for the welded joint in the desired location, making sure they are
properly aligned and clamped in place.

Perform a test weld on a scrap piece of the same material to ensure the welder is set correctly and that
the welder is comfortable with the process.

Start welding the joint, using the appropriate technique and speed. Move the MIG gun along the joint,
maintaining a consistent distance from the workpiece and keeping the gun at a 90-degree angle to the
workpiece.

Continuously monitor the weld, looking for any inconsistencies or defects, such as porosity or lack of
fusion. Make any necessary adjustments to the welder's settings or technique.
Once the joint is fully welded, allow the weld to cool before removing any clamps or fixtures. Inspect the
welded joint to ensure it meets the required specifications and quality standards.

Disassemble the MIG welder and clean up the welding area, properly disposing of any debris or used
materials.

Aluminium Gas Metal Arc welding

Prepare the materials. Make sure the aluminum pieces to be joined are clean, dry, and free of any debris
or contaminants. Use a wire brush or sandpaper to remove any rust or oxidation.

Set up the welding equipment.

Secure the materials in place. Clamp or tack-weld the aluminum pieces together to ensure they do not
move during the welding process.

Begin welding. Start by making a small tack weld in a inconspicuous area to test the settings, then begin
welding along the joint, maintaining a consistent speed and angle. Keep the gun at a 90-degree angle to
the workpiece, and maintain a distance of about 1/8 inch between the gun and the workpiece.

Inspect the weld. After finishing the weld, inspect the joint for any defects such as cracks, porosity, or
lack of fusion. If necessary, make any repairs and re-inspect the joint.

Clean the joint. Use a wire brush or sandpaper to remove any slag or other debris from the joint.

Finish the joint. Apply any surface treatment such as painting or anodizing to the joint to protect it from
corrosion.
P6
Carbon steel Metal Inert Gas welding

First clean each piece of carbon steel by removing any rust, paint, or debris that may be present. A wire
brush or grinder would be useful to remove any contaminants.

Set up the two pieces of steel in the desired location and clamp them securely in place.

Connect the welding machine to the power source and set the appropriate settings for MIG welding
carbon steel:

Wire diameter: 0.035-0.045 inches

Fast welding speed

Voltage: 18-22V

Amperage: 150-250A

Shielding gas: 100% CO2 or 75% Argon / 25% CO2

Nozzle: Small diameter

Stick-out: 0.25 inches

Some of the settings are in ranges because they depend on the thickness of steel and equipment being
used.
Always wear personal protective equipment (PPE) - welding helmet, gloves, and long sleeves for
protection from the intense heat and sparks which are created during welding.

Begin by making a tack weld at the beginning and end of the joint to hold the pieces in place. Then, use a
steady and consistent motion to fill in the joint with weld beads. Use a steady hand to ensure a smooth
and even weld.

After completing the weld, inspect it for any imperfections such as cracks, porosity, or incomplete
fusion. If any defects are found, rework the weld to ensure it is structurally sound.

Use a wire brush or grinder for removing slag or debris which may be left on the welded joint. This will
ensure there is a smooth and clean finish.

Allow the welded joint to cool completely before handling it or using the pieces of steel.

Aluminium Gas Metal Arc welding

Ensure the area for welding is clean and free of debris, and that all necessary safety equipment, such as
eye and ear protection, is available.

Use a wire brush or grinder to remove any dirt, rust, or other contaminants from the aluminum.

Ensure that the welding machine is properly grounded, and that the correct welding wire and shielding
gas are being used.

Set the welding current, voltage, and wire feed speed to match the thickness and composition of the
aluminum.

Settings for GMAW aluminium:

Wire diameter: 0.035 inches (0.9mm)

Welding wire type: 4043 or 5356

Welding gun angle: 15-20 degrees

Welding current: DCEN (direct current electrode negative)

Welding voltage: 19-26 volts

Amperage: 150-250 amps

Travel speed: 3-5 inches per minute (7.6-12.7 cm/min)

Shielding gas: 100% Argon

The settings which are with ranges are dependent on thickness of the aluminium and equipment being
used.
Start the weld by striking an arc and maintaining a consistent distance between the electrode and the
workpiece. Keep the electrode angle consistent and move the torch in a steady, fluid motion.

After completing the weld, inspect it for any defects such as porosity, cracking, or lack of fusion.

Example of porous weld:

Use a wire brush or grinder to remove any slag or spatter from the weld.

Repeat the process as many times as necessary to achieve the desired quality of the final product,
following appropriate safety measures.
M3
Carbon steel Metal Inert Gas welding

Obtain the necessary carbon steel materials for the welded joint, making sure they are clean and free of
any debris or contaminants.

Equipment needed for MIG welding:

MIG welder

Welding helmet and gloves

Wire electrode

Welding pliers, clamps and magnets

Workspace without flammable materials

Assemble the MIG welder according to the manufacturer's instructions and set it to the appropriate
settings for welding carbon steel.

Position the carbon steel materials for the welded joint in the desired location, making sure they are
properly aligned and clamped in place.

Perform a test weld on a scrap piece of the same material to ensure the welder is set correctly and that
the welder is comfortable with the process.

Start welding the joint, using the appropriate technique and speed. Move the MIG gun along the joint,
maintaining a consistent distance from the workpiece and keeping the gun at a 90-degree angle to the
workpiece.

Continuously monitor the weld, looking for any inconsistencies or defects, such as porosity or lack of
fusion. Make any necessary adjustments to the welder's settings or technique.

Once the joint is fully welded, allow the weld to cool before removing any clamps or fixtures. Inspect the
welded joint to ensure it meets the required specifications and quality standards.

Disassemble the MIG welder and clean up the welding area, properly disposing of any debris or used
materials.

Aluminium Gas Metal Arc welding

Prepare the materials. Make sure the aluminum pieces to be joined are clean, dry, and free of any debris
or contaminants. Use a wire brush or sandpaper to remove any rust or oxidation.

Set up the welding equipment. GMAW welding, also known as MIG welding, requires a welding
machine, a wire feeder, a welding gun, and a shielding gas. Set the machine to the appropriate settings
for welding aluminum, such as a wire feed speed of around 400 to 450 inches per minute, and a voltage
of around 18 to 22 volts.

Secure the materials in place. Clamp or tack-weld the aluminum pieces together to ensure they do not
move during the welding process.

Begin welding. Start by making a small tack weld in a inconspicuous area to test the settings, then begin
welding along the joint, maintaining a consistent speed and angle. Keep the gun at a 90-degree angle to
the workpiece, and maintain a distance of about 1/8 inch between the gun and the workpiece.

Inspect the weld. After finishing the weld, inspect the joint for any defects such as cracks, porosity, or
lack of fusion. If necessary, make any repairs and re-inspect the joint.

Clean the joint. Use a wire brush or sandpaper to remove any slag or other debris from the joint.

Finish the joint. Apply any surface treatment such as painting or anodizing to the joint to protect it from
corrosion.
M4
Carbon steel Metal Inert Gas welding

First clean each piece of carbon steel by removing any rust, paint, or debris that may be present. A wire
brush or grinder would be useful to remove any contaminants.

Set up the two pieces of steel in the desired location and clamp them securely in place. Connect the
welding machine to the power source and set the appropriate settings for MIG welding carbon steel:

Wire diameter: 0.035-0.045 inches

Fast welding speed

Voltage: 18-22V

Amperage: 150-250A

Shielding gas: 100% CO2 or 75% Argon / 25% CO2

Nozzle: Small diameter

Stick-out: 0.25 inches

Some of the settings are in ranges because they depend on the thickness of steel and equipment being
used.

Always wear personal protective equipment (PPE) - welding helmet, gloves, and long sleeves for
protection from the intense heat and sparks which are created during welding.

Begin by making a tack weld at the beginning and end of the joint to hold the pieces in place. Then, use a
steady and consistent motion to fill in the joint with weld beads. Use a steady hand to ensure a smooth
and even weld.

After completing the weld, inspect it for any imperfections such as cracks, porosity, or incomplete
fusion. If any defects are found, rework the weld to ensure it is structurally sound.

Use a wire brush or grinder for removing slag or debris which may be left on the welded joint. This will
ensure there is a smooth and clean finish.

Allow the welded joint to cool completely before handling it or using the pieces of steel.

Aluminium Gas Metal Arc welding

Ensure the area for welding is clean and free of debris, and that all necessary safety equipment, such as
eye and ear protection, is available.
Use a wire brush or grinder to remove any dirt, rust, or other contaminants from the aluminum.

Ensure that the welding machine is properly grounded, and that the correct welding wire and shielding
gas are being used.

Set the welding current, voltage, and wire feed speed to match the thickness and composition of the
aluminum.

Settings for GMAW aluminium:

Wire diameter: 0.035 inches (0.9mm)

Welding wire type: 4043 or 5356

Welding gun angle: 15-20 degrees

Welding current: DCEN (direct current electrode negative)

Welding voltage: 19-26 volts

Amperage: 150-250 amps

Travel speed: 3-5 inches per minute (7.6-12.7 cm/min)

Shielding gas: 100% Argon

The settings which are with ranges are dependant on thickness of the aluminium and equipment being
used.

Start the weld by striking an arc and maintaining a consistent distance between the electrode and the
workpiece. Keep the electrode angle consistent and move the torch in a steady, fluid motion.

After completing the weld, inspect it for any defects such as porosity, cracking, or lack of fusion.

Use a wire brush or grinder to remove any slag or spatter from the weld.

Repeat the process as many times as necessary to achieve the desired quality of the final product,
following appropriate safety measures.
D3
Carbon steel Metal Inert Gas welding

For securing the pieces for welding any clamps used should not be tightened in a way that puts pressure
on any other recently created joints on the materials because this could lead to them breaking.

The speed of the welding gun movement should be maintained as constant as possible during the weld
to ensure the strength of the weld is even along the whole length of the joint.

A fast welding speed would ensure less build up of slag along the welded joint which creates even
strength of the whole joint and less grinding work to smooth out the weld after it has been completed.

The wire electrode needs to be cut with pliers when it gets long as it will start bending making the weld
more difficult to be done accurately.

Aluminium Gas Metal Arc welding

A faster travel speed of 12-18 inches/min would reduce the risk of burn through or warping of the base
metal while still being slow enough to allow the aluminium and filler wire at a consistent rate.

For welding aluminium a specific filler metal needs to be used which should have high silicon content.
High silicone content helps to prevent the formation of hydrogen gas which can make the weld weaker
by increasing its porosity.

A backing gas like helium can be used to shield the back of the weld which can prevent contaminations.
References:

MIG welder:

https://images.app.goo.gl/5mM3cEEnVg2Hqotu7 (Accessed 20/12/2022)

GMAW system:

https://images.app.goo.gl/6mSXh24sPV82MECL7 (Accessed 20/12/2022)

MIG welding setup:

https://images.app.goo.gl/th6WnJuX3zmtVPHv6 (Accessed 20/12/2022)

Example of porous weld:

https://images.app.goo.gl/ok3wKK2gU97yzek88 (Accessed 20/12/2022)