FEDERAL UNIVERSITY OF TECHNOLOGY OWERRI

SCHOOL OF ENGINEERING AND ENGINEERING TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING

A STUDENT INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)

REPORT

UNDERTAKEN AT

IRON PRODUCT INDUSTRIES LIMITED (IPI)

ONILEWURA STREET, OFF COLLEGE BUS-STOP, IKOTUN, ALIMOSHO

L.G.A, LAGOS STATE.

IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR THE AWARD

OF BACHELOR OF ENGINEERING IN MECHANICAL ENGINEERING

ENOCH CHIZARAM EMMANUEL

20171047093

PRESENTED TO THE

DEPARTMENT OF MECHANICAL ENGINEERING

FEDERAL UNIVERSITY OF TECHNOLOGY OWERRI

DECEMBER 21, 2022.

1
 DEDICATION

I dedicate this report to the Almighty God for his grace, strength and wisdom

throughout my SIWES training. This report is also dedicated to my family and

friends for their support throughout my industrial training and my instructors at

IRON PRODUCTS INDUSTRIES.

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 ACKNOWLEDGEMENT

First and foremost, my gratitude goes to God Almighty for the gift of life and

for whom without; there will be no me. My gratitude also goes to Mr.

Augustine Okwuewuna , my instructors who ensured my industrial training

were optimally educative, entertaining and successful. The entire crew at

IRON PRODUCT INDUUSTRIES were my motivation, inspiration and support

in my quest for knowledge.

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 ABSTRACT

This report is a summary of the experience i acquired during my six months’

Students Industrial Work Experience Scheme (SIWES) at IRON PRODUCT

INDUSTRIES (IPI), IKOTUN, LAGOS STATE.

The report highlights majorly on fabrication of mechanical products, giving a full

details on the equipments used in machining as well as various products made

from machining. It also gives a clear idea of the students involvement in all

operational activities carried out in the firm.

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Table of Contents
1.1 HISTORICAL BAGROUND OF SIWES.........................................................................................6
1.2 ABOUT INDUSTRIAL TRAINING FUND (ITF)...........................................................................7
1.3 MISSSION OF ITF...........................................................................................................................7
2.0 HISTORY OF IRON PRODUCT INDUSTRIES............................................................................11
2.1 IPI MISSION...................................................................................................................................12
2.2 IPI VISION......................................................................................................................................12
2.3 IPI VALUE......................................................................................................................................12
2.4 IPI PASSION...................................................................................................................................12
2.5 Health, Safety & Environment.........................................................................................................13
3.0 INTRODUCTION TO TOOLS AND WORKSHOP MACHINERIES...........................................14
3.1 Measuring tape............................................................................................................................14
3.2 Try square....................................................................................................................................14
3.3 PLIER..........................................................................................................................................16
3.4 VERNIER CALIPER..................................................................................................................16
3.5 Steel chalk and marker.................................................................................................................17
3.6 Chipping hammer........................................................................................................................17
3.7 Wire Brush...................................................................................................................................18
3.6 WRENCH....................................................................................................................................18
3.9 HAMMER...................................................................................................................................19
3.10 SLEDGE HAMMER.................................................................................................................19
3.11 ANGLE GRINDER...................................................................................................................20
3.12Concrete Drilling Machine.........................................................................................................21
3.13 Arc Welding Machine................................................................................................................22
3.14 Portable Mini CNC Plasma And Flame Cutting Machine..........................................................23
3.15 MIG WELDING MACHINE.....................................................................................................25
3.16 Straight High Speed CNC Cutting Machine..............................................................................26
3.17 Band-saw Blade.........................................................................................................................27
3.18 Ironworker.................................................................................................................................27
3.19 Crane.........................................................................................................................................28
3.20 WORKSHOP SAFETY.................................................................................................................29
3.21Health and safety guidance on Workshop Safety........................................................................29
3.22 Workshop equipment and tools..................................................................................................29
3.23 Workshop practices and personal protective equipment................................................................31

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GENERAL PROCESSES AND STEPS INVOLVED IN FABRICATION AND CONSTRUCTION. 43
STEP 1: MATERIAL SELECTIONS................................................................................................43
STEP TWO: ISSUING AND APPROVAL OF DRAWING.............................................................44
STEP FOUR: BENDING AND SHAPING.......................................................................................45
STEP FIVE: WELDING...................................................................................................................45
STEP SIX: POLISHING AND BUFFING........................................................................................46
STEP SEVEN: PAINTING...............................................................................................................47
STEP EIGHT: FINAL ASSEMBLY.................................................................................................47
6.4 Safety Considerations......................................................................................................................59
6.6 WORKSHOP MEETINGS..............................................................................................................60
RECOMMENDATIONS...................................................................................................................63
REFERENCES..................................................................................................................................63

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 CHAPTER ONE

1.0 INTRODUCTION

1.1 HISTORICAL BAGROUND OF SIWES

SIWES was established by ITF in 1973 to solve the problem of lack of
adequate practiced skills preparatory for employment in industries by Nigerian
graduates of tertiary institutions.
The scheme educates student on industrial based skills essential for a smooth
transition from the class room to the world of work. Student of tertiary institution
is given the opportunity of being familiarized and exposed to the needed
experience in handling machinery and equipment which are usually available not
available in the educational institutions. Partaking in SIWES industrial training has
become a crucial pre condition for the award diploma and degree certificates in
specific disciplines in most institutions of higher learning in Nigeria in line wwith
the government education policies. The operators are; ITF the coordinating
agencies (NUC, NCCE, MBTE), employers of labour and various institutions.
One of the primary goals of SIWES is to help students integrate leadership
development into the experimental learning process. Students are expected to learn
and develop basics nonprofit leadership skills through a monitory relationship with
innovative nonprofit leaders as a mechanical engineer.

1.2 ABOUT INDUSTRIAL TRAINING FUND (ITF)

Established in 1971, the Industrial Training Fund (ITF) has operated

consistently and painstakingly within the context of its enabling laws Decree 47 of
1971 as Amended in the 2011 ITF ACT. The objective for which the Fund was
established has been pursued vigorously and efficaciously. In the decades of its
existence, the ITF has not only raised training consciousness in the economy, but
has also helped in generating a corps of skilled indigenous manpower which has
been manning and managing various sectors of the national economy.
The ITF enhances manpower development through training by exposing the
students to the practical aspects of what they learn in the classroom in view to
prepare them face challenges after completion of studies.

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1.3 MISSSION OF ITF

The provision of Decree 47 of 8th October, 1971 empowers the ITF to "promote
and encourage the acquisition of skills in industry and commerce with a view to
generating a pool of indigenous trained manpower sufficient to meet the needs of
the Nigerian economy".

1.4 OBJECTIVES OF SIWES

The objective of SIWES includes: -

- SIWES will provide students the opportunity to test their interest in a

particular career before permanent commitments are made.
- SIWES students will develop skills in the application of theory to practical
work situations.
- SIWES students will acquire good work habits.

- SIWES helps the students with the opportunity to apply their knowledge in
real working situations.

- SIWES prepares and expose students towards a successful business career

by margin their analytical power with self -reliance.

- SIWES Students will be able to provide tools to use in prioritizing tasks of

an assigned project and create with staff a tentative schedule for completion
based on these tasks.

1.5 FUNCTION OF THE SIWES UNIT

By the directive of National Universities Commission (NUC) and Industrial
Training Fund (ITF), the Unit is mandated to carry out the following functions.
i. Supervision of the students placed in the industries located within our ITF
zone.

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ii. Processing of students’ logbooks, ITF forms and industrial attachment
reports upon which is based on the Federal Government funding of
supervision and students’ allowances.
iii. Fostering of close links between the university and industries participating in
SIWES programme.
iv. Provision of advisory guidance to participating students on career
employment opportunities.
v. Monitoring of compliance with the requirements of SIWES on the part of
students in eligible disciplines as a condition for graduation.

1.6 OVERVIEW OF THE STUDENTS INDUSTRIAL WORK

EXPERIENCE SCHEMES (SIWES)
Students Industrial Work Experience Scheme (SIWES) is a mandatory skills
acquisition and training programme. It is designed to expose students to the
industrial workplace environment in their respective disciplines during their course
of study. The students are also expected to develop occupational competencies
that would facilitate their fitting into the world of work after graduation.
The objectives of SIWES scheme is to:
 To make the transition from the schooling to world of work easier through
enhancing students’ contact for later job placement.
 Expose students to work methods and techniques in handling equipment and
machineries that may not be available in the university.
 Prepare students for industrial work situation they are likely to meet after
graduation.
 Provide avenues for students to acquire industrial skills and experience
during their course of study.
 Provide students with the opportunities to apply their educational knowledge
in real work situations, thereby bridging the gap between theory and
practice.

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 CHAPTER TWO

2.0 HISTORY OF IRON PRODUCT INDUSTRIES

Iron Product Industries Ltd. (IPI) has been active for more than 50 years in
Nigeria. The company started as a steel work manufacturer and has since become
the leader in steel fabrication. The group has executed major projects around the
country in all sectors with a focus on structural steel and oil and gas.

Over the years, IPI has also diversified into the Automotive assembly, Trailer
manufacturing, Paint manufacturing and Logistics. Iron Product Industries is the
contractor of choice for a large number of companies such as Total Nigeria PLC,
ExxonMobil, Coca-Cola, Flour Mills, Dangote Cement and Sugar , Novare.

We are also specialized in the assembly of trucks and buses of all types. We have
a very broad client base from the largest transporters, FMCG and logistics
companies. Being the largest trailer and truck manufacturer in the country, we
decided to start a logistics division 5 years ago. Our fleet is now 150 units strong
and we’re growing this division aggressively. We are targeting 1000 units by 2022.

2.1 IPI MISSION

To improve the Nigerian Industry by using the best fabrication techniques and
engineering technology available in the production of trailers, paints, structures,
and steel works to international standards.

2.2 IPI VISION

To be the best steel construction engineers and builders on the African Continent
by continuously putting our best into all we do.

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2.3 IPI VALUE
 Quality
 Integrity
 Professionalism
 Creativity
 Team Work
 Positive Attitude
 Passionate People

2.4 IPI PASSION

We believe that before you can truly aspire to be the best at what you do, you must
have an intense passion for it. If this is missing, you can never be the best at what
you do.

2.5 Health, Safety & Environment

At Iron Product Industries, we understand that good quality work can only be
delivered by healthy people who understand the importance of working in an
environment that is safe. The company recognizes its legal responsibility to health
& safety standards which are of international standard and we are committed to the
continuous improvement of our working environment. Our commitment to health,
safety and the environment goes beyond what we do on our sites on a daily basis; it
has become a part of our culture where ever we are.

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 CHAPTER THREE

3.0 INTRODUCTION TO TOOLS AND WORKSHOP MACHINERIES

3.1 Measuring tape

Fig.1a Fig.1b

Measuring tape is a flexible ruler and used to measure distance.It consists of a

ribbon of cloth, plastic, fibre glass, or metal strip with linear-measurement
markings. It is a common measuring tool. Its design allows for a measure of great
length to be easily carried in pocket or toolkit and permits one to measure around
curves or corners.

3.2 Try square

Fig.2

A try square is a woodworking or a metalworking tool used for marking and

measuring a piece of wood. The square refers to the tool's primary use of
measuring the accuracy of a right angle (90 degrees); to try a surface is to check its
straightness or correspondence to an adjoining surface. A piece of wood that is
rectangular.

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3.3 PLIER

Fig. 3
Pliers are made in various shapes and sizes and for many uses. Some are used for
gripping something round like a pipe or rod, some are used for twisting wires, and
others are designed to be used for a combination of tasks including cutting wire.

3.4 VERNIER CALIPER

Fig. 4
A vernier scale is a visual aid that allows the user to measure more precisely than
could be done unaided when reading a uniformly divided straight or circular
measurement scale. It is a scale that indicates where the measurement lies in
between two of the graduations on the main scale.

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3.5 Steel chalk and marker

Fig. 5a Fig. 5b

The engineers Chalk is specifically suited for metal, specifically steel. Chalk line
refills, for use with the SCCS Chalk line, come in three differentcolour options and
perfect for drawing straight lines on concrete, plaster, metal.

3.6 Chipping hammer

Fig. 6
A chipping hammer is a tool used to remove welding slag from a weld and welding
spatter from along side welds.

3.7 Wire Brush

Fig. 7

A wire brush is a tool consisting of a brush whose bristles are made of wire, most
often steel wire. The steel used is generally a medium- to high-carbon variety and
very hard and springy. Other wire brushes feature bristles made from brass or
stainless steel, depending on application.

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3.6 WRENCH

Fig. 8
A wrench (or spanner outside of North America) is a tool used to provide grip and
mechanical advantage in applying torque to turn objects usually rotary fasteners,
such as nuts and bolts or keep them from turning. In Commonwealth English
(excluding Canada), spanner is the standard term.Monkey wrench, Socket wrench,
Torque wrench, Lug wrench.

3.9 HAMMER

Fig. 9
A hammer is a tool or device that delivers a blow (a sudden impact) to an object.
Most hammers are hand tools used to drive nails, fit parts, forge metal, and break
apart objects. Hammers vary in shape, size, and structure, depending on their
purposes. Hammers are basic tools in many trades.

3.10 SLEDGE HAMMER

15
Fig. 10
A sledge hammer is a tool with a large, flat, often metal head, attached to a lever
(or handle). The size of its head allows a sledgehammer to apply more force than
other hammers of similar size. Along with the mallet, it shares the ability to
distribute force over a wide area.

3.11 ANGLE GRINDER

Fig.11
Angle grinders can be used for several functions including sanding, grinding and
cutting processes, depending on the type of disc used.

Disc Selection: The disc must be suitable for the material (example steel,
masonry), the correct size for the grinder (this includes Centre hole size), and
capable of being used at the maximum r.p.m. of the grinder. If any doubt exists, the
disc should not be attached to the grinder. Cutting discs should never be used for
grinding and vice versa.

Operation:
1. Newly mounted discs should run free for one minute before cutting or grinding.
2. Never apply pressure to stop a disc spinning.
3. The work item should be rigidly supported.
4. Eye/face and hearing protection appropriate to the task must be worn.
5. Flange and flange nuts must suit the disc and be in good condition.
6. Discs should be stored and handled carefully to avoid damage.

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3.12Concrete Drilling Machine

Fig. 12
A hammer drill, also known as a "roto-drill" or "hammering drill", (see also rotary
drill) is a rotary drill with a hammering action. The hammering action provides a
short, rapid hammer thrust to pulverize relatively brittle material and provide
quicker drilling with less effort. .

3.13 Arc Welding Machine

Fig. 13
Arc welding machine is a machine that is used to join metal to metal by using
electricity to create enough heat to melt metal, and the melted metals when cool
result in a binding of the metals. It is a type of welding that uses a welding power
supply to create an electric arc between an electrode and the base material to melt
the metals at the welding point. They can use either direct (DC) or alternating (AC)
current, and consumable or non-consumable electrodes. The welding region is
usually protected by some type of shielding gas, vapor, or slag. Arc welding
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processes may be manual, semi-automatic, or fully automated. First developed in
the late part of the 19th century, arc welding became commercially important in
shipbuilding during the Second World War. Today it remains an important process
for the fabrication of steel structures and vehicles.

3.14 Portable Mini CNC Plasma And Flame Cutting Machine

Fig. 14a

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Fig. 14b
The cutting machine is modern cutting equipment with digital program control. In
addition to automated cutting, it has high cutting precision, high material
utilization and high production efficiency. Along with the mechanical electronic
technology and computer technology progress, the CNC cutting machine with its
good man-machine dialogue operation interface, powerful auxiliary support
function and relative low equipment investment, is being valued by more and more
enterprises and more widely used in the production.

It can be widely used in automobile, shipbuilding, petrochemical, boiler and

pressure vessel, engineering machinery, light industrial machinery and other
industries. Suitable for cutting metal sheets, such as the carbon steel (flame
cutting), stainless steel, aluminum, copper (plasma). It particularly applies to a
single piece with abnormity surface and the mass production.

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3.15 MIG WELDING MACHINE

Fig. 15
Metal Inert gas (MIG) welding is generally used for large and thick materials. It
employs a consumable wire that acts as the electrode and filler material. Compared
to TIG welding, it is much faster, resulting in shorter lead times and lower
production costs. The consumable wire moves continuously and is fed through a
welding gun and into the weld pool, joining the two base materials together.
3.16 Straight High Speed CNC Cutting Machine

Fig. 16
This machine adopts new material, which improves the serviceability, durability
and heat-insulating property. This machine can be matched with plasma torch to
cut stainless steel and non-ferrous metals. It is equipped with interface of arcing. It

20
can control the arcing of plasma easily. The machine is suitable for straight cutting.
It also can do circle cutting (＞ø200mm). The speed of it is the 3-4 times of
general carriage. It meets with the need of plasma sheet cutting. The machine can
be used on the fields of shipbuilding, bridge, metallurgy, heavy machinery and so
on.

3.17 Band-saw Blade

Fig. 17
Bandsaw blades used for cutting metal have bent teeth. The bend in the teeth
creates a cut slightly wider than the thickness of the blade, which is important to
prevent the blade from getting stuck from being pinched by the metal.

21
3.18 Ironworker

Fig. 18
Ironworker is a class of machines that can shear, notch, and punch holes in steel
plate. There may have been a brand name called Ironworker.

3.19 Crane

Fig.19
A crane is a type of machine, generally equipped with a hoist rope, wire ropes or
chains, and sheaves, that can be used both to lift and lower materials and to move
them horizontally. It is mainly used for lifting heavy things and transporting them
to other places.

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3.20 WORKSHOP SAFETY

3.21Health and safety guidance on Workshop Safety.

Safety in the workshops is subject to a number of various risk assessments and safe
codes of working practices which have to be observed and adhered to by all
workshop users and enforced by the person in charge of these areas. Due to high
risk activities taking place in the workshops access to these areas is restricted to
authorised personnel only. No other person may enter the workshops without
permission.

3.22 Workshop equipment and tools

1. No machine may be used or work undertaken unless the technician-in-
charge is satisfied that the person is capable of doing so safely. If equipment
is fitted with guards these must be used. Equipment must never be used if
the safety guards have been removed.
2. Any person working in the mechanical and electronic workshop must have
read and signed the appropriate risk assessment if the work or equipment
they are using has been risk assessed. Risk assessments are kept in a filing
cabinet within the mechanical workshop (B.128).
3. No person shall mount any abrasive wheel unless he/she has been trained in
accordance with the Provision and Use of Work Equipment Regulations
1998. Grinding machines shall only be operated by technical staff and eye
protection must be worn.
4. Service records of all machine tools, plant and equipment must be kept.
They must list the date of any service/repair and name of the person
responsible for carrying out that service/repair. Faults which cannot be
repaired immediately should be reported to the technician-in-charge and a
note should be attached to the machine where it is clearly visible indicating
that the equipment is out of order.
5. All Portable Electrical Equipment must be regularly inspected and tested for
electrical safety.
6. Lifting equipment must be registered with the University’s Engineering
Insurers and be subject to annual inspection.
7. All air receivers must be subject to a thorough examination at the statutorily
required intervals.

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 8. Where applicable suitable Local Exhaust Ventilation (LEV) must be used.
The LEV systems must be subjected to a thorough inspection and test at
least once every 14 months.
9. Ladders/stepladders should be individually identified and formal inspections
carried out.
10.No welding may be undertaken unless the technician-in-charge is satisfied
that the person is capable of doing so safely. During any welding operation
the fume extraction system must be used.
11.When using woodworking machines the dust extractor and face masks must
be used.
12.Equipment must be cleaned after use. Any materials, tools or equipment
used must be tidied away.
13.Precision measuring equipment, drills, etc. must be replaced in their
appropriate cabinets after each working day.
14.Tools and equipment must not be removed from the workshop without
permission from the technician-in-charge.

3.23 Workshop practices and personal protective equipment

1. Eating and drinking in the mechanical workshop areas are strictly prohibited.
2. When working with machine tools or other equipment with rotating
spindles, jewellery, loose clothing etc. are prohibited and long hair must be
completely covered.
3. Personal Protective Equipment (PPE) is supplied and must be used where
necessary. Barrier cream, lab coats/overalls, eye and hearing protection, dust
masks and safety shoes must be used as the work/risk assessment dictates.
4. Lab coats/overalls and safety boots must be worn by technicians operating
the machines.
5. The gangway through the workshop must be kept clear. Any oil spillage,
grease etc. must be cleaned up immediately.
6. Do not carry loads such that the weight may be dangerous or vision
obscured.
7. No hazardous substance to health can be used before a COSHH risk
assessment is undertaken and a safe system of work issued to the users.

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 CHAPTER FOUR

INTRODUCTION TO WELDING

4.1 CONCEPT OF WELDING

Welding is a fabrication process whereby two or more parts are fused together by
means of heat, pressure or both forming a join as the parts cool. Welding is
usually used on metals and thermoplastics but can also be used on wood. The
completed welded joint is referred to as a weldment. Some materials require the
use of specific processes and techniques. A number are considered ‘unwelldable’, a
term not usually found in dictionaries but useful and descriptive in engineering.

The parts that are joined are called parent material. The materials added to help
form the joint is called filler or consumable. The form of these materials may see
them referred to as parent pate or pipe, filler wire, consumable electrode (for arc
welding), etc.

4.2 HOW WELDING WORKS

- JOINING METALS

As opposed to brazing and soldering, which do not melt the base metal, welding is
a high heat process which melts the base material. Typically with the addition of a
filler material. Heat at a high temperature causes a weld pool of molten material
which cools to form the joint, which can be stronger than the parent metal.
Pressure can also be used to produce a weld, either alongside the heat or by itself.
It can also be used as a shielding gas to protect the melted and filler metals from
becoming contaminated or oxidized.

- JOINING PLASTICS

Plastics welding also uses heat to join the materials (although not in the case of
solvent welding) and is achieved in three stages. Firstly, the surfaces are preared
before heat and pressure is applied and the materials are allowed to cool to create
fusion. Joining methods for plastics can be separated into external or internal
heating methods, depending on the exact process used.

- JOINING WOOD

25
Wood welding uses heat generated from friction to join the materials. The
materials to be joined are subjected to a great deal of pressure before a linear
friction movement creates heat to bond the workpiece together. This is a fast
process which allows wood to be joined without adhesives or nails in a matter of
seconds.

4.3 COMMON JOINT CONFIGURATIONS

- BUTT JOINT

A connection between the ends or edges of two parts making an angle to one
another of 1350 to 1800 inclusive in the reoin of the joint.

- T JOINT

A connection between the end or edge of one part and the face of the other part, the
parts making an angle to one another of more than 50 up to and including 900 in the
region of the joint.

- CORNER JOINT

A connection between the ends or edges of two parts making an angle to one
another of more than 300 but less than 1350 in the region of the joint.

- EDGE JOINT

26
A connection between the edges of two parts making an angle to one another of 00
to 300 inclusive in the region of the joint.

- CRUCIFORM JOINT

A connection in which two flat plates or two bars are welded to another flat plate at
right angles and on the same axis.

- LAP JOINT

A connection between two overlapping parts making an angle to one another of 00

to 50 inclusive in the region of the weld or welds.

4.4 FEATURES OF COMPLETEG WELDS

27
- PARENT METAL

Metal to be joined or surfaced by welding, brazing or soldering

- FILLER METAL

Metal added during the making of a weld and retained in the weld.

- WELD METAL

All metal melted during the making of a weld and retained in the weld’

- HEAT AFFECTED ZONE (HAZ)

The part of the parent metal metallurgically affected by the weld or thermal cutting
heat, but not melted.

- FUSION LINE

Boundary between the weld metal and the HAZ in a fusion weld. This is a non-
standard term for weld junction.

- WELD ZONE

The surface of a fusion weld exposed on the side on which the weld has been
made.

- WELD ROOT

Zone on the side of the first run furthest from the welder.

- WELD TOE

Boundary between a weld face and the parent metal or between the runs. They are
very important due to their high concentrations and they are often initiation points
for cracks.

- EXCESS WELD METAL

Weld metal lying outside the plane joining the toes. It is sometimes called
reinforcements or overfill’

- RUN (PASS)

The metal melted or deposited during one passage of an electrode, torch or

blowpipe.

28
- LAYER

Stratum of weld metal consisting of one or more runs.

4.4 TYPES OF WELDING

- ARC WELDING

This category includes a number of common manual, semi-automatic and

automatic processes. These include:

I) Metal Inert Gas (MIG) Welding

II) Stick Welding
III) Tungsten Inert Gas (TIG) welding or Gas Tungsten Arc Welding
(GTAW)
IV) Gas welding
V) Metal active gas (MAG) welding
VI) Flux Cored Arc Welding (FCAW)
VII) Gas Metal Arc Welding (GMAW)
VIII) Submerged Arc Welding (SAW)
IX) Shielded Metal Arc Welding (SMAW)
X) Plasma Arc Welding (PAW)

These techniques usually use a filler material and are primarily used for joining
metals including stainless steel, aluminium, nickel and copper alloys, cobalt and
titanium. Arc welding processes are widely used across industries such as oil
and gas, power, aerospace, automotive and more.

- FRICTION WELDING

This technique joins materials with mechanical friction. This can be performed
in a variety of ways on different welding materials including steel, aluminium
or even wood. Heat generated by friction softens the materials which mix to
create a bond as they cool.

- ELECTRON BEAM WELDING (EBW)

This fusion joining process uses a beam of high velocity electrons to join
materials. The kinetic energy of the electrons transforms into heat pobn impact
with the workpiece causing the materials to melt together. Electron beam
welding is performed in a vacuum (with the use of a vacuum chamber) to
prevent the beam from dissipating. It has many applications and can be applied

29
across a number of industries from aerospace to nuclear power and automotive
to rail.

- LASER WELDING

It is used to join thermoplastics or pieces of metals. This process uses laser to

provide a concentrated heat ideal for barrow, deep welds and high joining rates.
Being easily automated, the high welding speed at which this process can be
performed makes it perfect for high volume applications, such as within the
automotive industry. Unlike EBW it can be performed in air rather than in
vacuum.

- RESISTANCE WELDING

This is a fast commonly used in the automotive industry. This process can be
split into two types, resistance spot welding and resistance seam welding. Spot
welding uses heat delivered between two electrodes which is applied to a small
area as the workpiece are clamped together. Seam welding is similar to spot
welding but the electrodes are replaced with rotating wheels to deliver a
continuous leak-free weld.

4.5 WELDING RODS COMPARED (E6013 & E7018)

Choosing the correct welding electrode, often called a rod or stick is a

challenging part of stick welding. Using the wrong electrode can lead to a bad
weld and potential part rejection. Inexperienced welders often make this
mistake and suffer the consequences.

The American Welding Society (AWS) has developed the popular “E” code to
help classify electrodes. Each alphanumeric character in this code provides
specific information about the electrode. A brief rundown is as follows:

30
 . E – stands for “Electrode”.

. The first two digits – represent the resulting weld’s minimum tensile strength
(in thousands of psi). For example, the E6010 electrode produces welds with at
least 60,000 psi strength.

. The third digit – indicates the positions in which the rod can be used and 1 is
for all positions, 2 for flat and horizontal surfaces only, and 3 for flat positions
only.

. The fourth (and the third) digit – specifies information lie welding polarity,
power supply (AC/DC), and flux composition.

- E6013 WELDING ELECTRODE

This rod is suitable for AC and DC power supplies and may be used in any position.
It is coated with a retile flux made of titanium dioxide and potassium. It is suitable
for mild intensity jobs. It has a soft arc with shallow penetration that runs smoothly.
It also produces minimal spatter and easy to remove slag.

- E7018 WELDING ELECTRODE

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This electrode is an all position, low hydrogen electrode. It is suitable for both
AC/DC supplies but is mainly used with a DC input. It runs very smoothly and
quietly with low amounts of spatter. It is a fill-freeze rod with shallow to moderate
penetration and medium fill. The arc is stable and easily controlled as well. It’s low
hydrogen content prevents cold cracking and these makes it ideal for metals like
structural and high carbon steel although the flux produces heavy slag and it reuires
more effort to chip off from joint completely.

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 CHAPTER FIVE

GENERAL PROCESSES AND STEPS INVOLVED IN FABRICATION

AND CONSTRUCTION

STEP 1: MATERIAL SELECTIONS

Sheet metal, universal column, universal beam, U channel, pipe, and angle iron
manufacturing requires quality material that will endure the life cycle of any
product that is produced. The main goal of material selection is to minimize cost
while meeting product performance goals. Systematic selection process of the best
material for a giving application begins with properties and cost of candidate
materials. Cost of materials in sheet metal manufacturing plays a very significant
role in material selection, however, other factors such as product life cycle and
weight, continue to grow in importance. Increases in freight and shipping costs
have highlighted the factor of product weight in transport. Material selection will
ensure that all this issues are addressed before production. For an example,
Thickness: one of the most important decisions when working with sheet metal is
deciding what thickness you will need. Similar to wire, sheet metal thickness is
measured in gauges, with a higher number indicating a thinner sheet. To measure
the thickness, you can use a sheet metal gauge, which will show you thickness in
both gauge number and thousands of an inch.one important note however, is that
ferrous and non-ferrous sheet metals of the same gauge have different thicknesses,
so you will need one gauge for ferrous metals, and one for non-ferrous.

STEP TWO: ISSUING AND APPROVAL OF DRAWING

This process is essential in fabrication and construction of steel, the drawing of a
given project must be issued and approved before the commencement of any
project.
STEP THREE: MARKING OUT, CUTTING AND SETTING
Marking out or layout is the process of transferring a design or pattern to a work
piece, as the first step in manufacturing process. It is performed in many industries
or hobbies although in the repetition industries the machine’s initial setup is
designed to remove the need to mark out every individual piece.
Marking out consist of transferring the dimensions from the plan to the work piece
in preparation for the next step, machining or manufacture. Some of the tools used
to carry out marking are illustrated in the beginning of this chapter

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However, in cutting, many different tools cut metal and each has its own strengths
and weakness. Some of the common cutting tools are also illustrated in the
beginning of this chapter, seting is also important in fabrication. Is a process of
bringing together the marked and cut material before it is being weld together, it’s
also called fitting.

STEP FOUR: BENDING AND SHAPING

Bending sheet metal can be tricky, but with the right tool it is easy. Those who
work with it regularly are likely to have a sheet metal bending brake in their
workshop, but this two can be bit expensive for the hobbyist. Thankfully, there are
a couple wallet-friendly options that can help you get the job done.
Using the edge of your workbench, a length of wood, two clamps, and a mallet,
you can fashion a rudimentary bending brake. Mark a bend line and place the sheet
metal on the edge of your bench. Next place the wood parallel and slightly behind
the bending line. Clamp the wood on top of the metal to the workbench. Finally,
bend the sheet up by hand to the angle desired. If you want a sharp 900 bend, tap
along the crease with a mallet.

STEP FIVE: WELDING

Welding is the main focus of steel fabrication. The formed and machined parts will
be assembled and tack welded into place then rechecked for accuracy. A fixture
may be used to locate parts for welding if multiple weldments have been ordered.
The welder then completes welding as per the engineering drawings if welding is
detailed or as per his or her own judgment if no welding detail are provided.
Special precautions may be needed to prevent warping of the weldment due to
heat. These may include re-designing the weldment to use fewer welds, welding is
staggered fashion, using a stout fixture, covering the weldment in sand during
cooling, the straightening operations after welding.
Straightening of warped steel weldments is done with an oxy-acetylene tourch and
is somewhat of an art. Heat is selectively applied to the steel in slow, linear sweep.
The steel will have net contraction upon cooling, in the direction of the sweep. A
highly skilled welder can remove significant warping using this technique.
Steel weldments are occasionally annealed in a low temperature oven to relieve
residual stresses. Such weldments, particularly those employed for engine blocks,
may be line-bored after heat treatment.

STEP SIX: POLISHING AND BUFFING

Polishing and buffing are finishing processes for smoothing a work piece’s surface
using an abrasive and a work wheel or a leather strop. Technically polishing refers

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to processes that use an abrasive that is glued to the work wheel, while buffering
uses a loose abrasive applied to the work wheel. Polishing is a more aggressive
process while buffering is less harsh, which leads to a smoother, brighter finish.
Common misconception is that a polished surface has a mirror bright finish,
however most mirror bright finishes are actually buffed.
Polishing is often used to enhance the appearance of an item, prevent
contamination of instruments, remove oxidation, and create a reflective surface, or
prevent corrosion in pipes. In metallography and metallurgy, polishing is used to
create a flat, defect-free surface for examination of a metal’s microstructure under
a microscope. Polishing stainless steel can also increase the sanitary benefits of
stainless steel.

STEP SEVEN: PAINTING

Painting is a more straightforward process and most people are familiar with it. A
primer is first applied to the base metal, followed by multiple layers of liquid paint
and finally, a protective coating such as lacquer is added to protect the underlying
paint.
The most obvious advantage of painting is that fabricators have a much greater
degree of control over how the finished product will look. Paint comes in just any
color imaginable, meaning that there are endless options for how the final product
will look. Furthermore, company and products logos can also be added to the
surface to further increase its cosmetic value.

STEP EIGHT: FINAL ASSEMBLY

After the weldment has cooled it is generally sand blasted, primed and painted.
Any additional manufacturing specified by the customer is then completed. The
finished product is then inspected and shipped.

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 CHAPTER SIX

PROJECTS I PARTICIPATED IN DURING MY INTERNSHIP AT IRON

PRODUCT INDUSTRIES

6.1 FABRICATION OF SUB-FRAME FOR TURNTABLE/SADDLE

The turntable of the truck is a swinging horseshoe shaped wear-resistant steel late
(usually coated with grease). In the centre of the plate is a semi-circular hole with a
notch. The hole wall is made of impact resistant forged steel. With the help of a
traction pin, trailers and tankers can be attached to the turntable of trucks and it
aids them when turning.

Fig 1: A saddle

After sometime due to excessive loading the frame on the chassis of the truck on
which the turntable rests becomes weak and so we construct a sub-frame on which
the turntable rests.

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MATERIALS NEEDED

- U – shaped channel (140x60x12)mm

- Cutting disc

- Grinding disc

- Electrodes (Guage 8 Low Hydrogen)

- Bolts and Nuts

- Paint (Black)

STEPS INVOLVED IN THE FABRICATION OF THE SUB-FRAME

The first thing we did was to get quality control unit to unmount the turntable so
we could get a better view for measurement

1) With our measuring tape we took our measurements. Special concentration

was given to the length of the turntable, the position of the turntable in the
chassis since there is need for bracing that section of the subframe.
2) Next we procured the necessary materials needed to fabricate the subframe.
3) With the measurement already gotten the U-channel is cut to the required
size (the length and width of the sub-frame)and they are welded completely
in and out with high quality guage 12 low hydrogen electrodes. Low
hydrogen is used due to its high resistance to cracking .

4) Next we fabricate the side angle plates and flat plates for holding the sub-
frame to the chassis. Most times they are drilled holes on the chassis already
to attach the flat plate but in the absence of any, a hole is made with a
plasma cutting machine. A hole is also made on the sub-frame and the
10mm thick flat plate is then used to join both the sub-frame and the chassis
(two on opposite sides of the subframe).

5) An angle plate is made to the same dimension as the older one attached to
the chassis and holes are also drilled to the same size as the other one and
with the help of these angle plates the turntable is mounted back on the
subframe and screwed tightly by quality control section.

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Fig 2: Sub-frame for saddle

6.2 CONSTRUCTION OF A 24-PALLET BOTTLE CARRIER FOR

COCA-COLA COMPANY.

A 24-pallet bottle carrier is a trailer used by coca-cola company in transporting

their beverages and IPI contractors are the ones in charge of its fabrication. It
usually takes a minimum of 6 days and a maximum of 9 days to finish the project
and all sections of the factory are involved in its production.

Firstly a job order which contains a list of all materials is made and signed by both
the contractor and the company.

6.2.1 MATERIALS NEEDED

PRODUCTS QUANTITY
12X1500X6000MM PLATE (SHEET) 2
BOLT M16X50 GALV 2
10X1500X6000 PLATE(SHEET) 0.5
BOLT M16X80 GALV 4
FLAT WASHER M16 GALV 4
BOLT M24X100 GALV 4
NUT M24 GALV 4

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NUT M16 GALV 30
BOLT M8X30 BRASS 12
BOLT M8X100 6
LOCK NUT M8 18
8X1500X6000 SHEET PLATE 15
6X1500X5850 SHEET PLATE 2
4X1220X2440 SHEET PLATE 9
2.4X1220X2440 SHEET PLATE 25
2X1220X2440 SHEET PLATE 11
EXTRA TYRE WINER 2
1.5X1220X2440MM 13.5
H-BEAM 457X191X12MM 2.65
U-CHANNEL 140X60X12M 3
U-CHANNEL 80X40X6M 2.5
SQUARE PIPE 80X40X6M(4MM THICK) 2
SQUARE PIPE 100X50X6M(4MM THICK) 5.3
SQUARE PIPE 100X100X6M(4MM THICK) 1
ROUND PIPE 1”X6M(3MM THICK) 2
TARPAULIN 2
TARPAULIN ACCESSORIES 1 SET
RIVET PIN 0.6 Pkt
CO2 COIL1.2MM (ROLL) 2 Pkt
ELECTRODE GUAGE 8 (LOW HYDROGEN) 4 PkT
ELECTRODE GUAGE 8 (MILD STEEL) 1 Pkt
ELECTRODE GUAGE 10 (MILD STEEL) 4 Pkt
GRINDING DISC 9” 3 Pcs
CUTTING DISC 9” 3 Pcs
BREAK/ELECTRICAL SYSTEM (SET) 1 Set
TYRE 18 Pcs
RIM 9 Pcs
A-FRAME 11 Pcs
CORNER PLATE (1.2 MTRS) 22 Pcs
PAINT GRAY PRIMER(NC)LTRS 15 Ltrs
PAINT BLACK (GLOSS) 1 Ltr
PAINT WHITE (GLOSS) 1 Ltr
PAINT RED (POKI) LTRS 2 Ltr
THINNER (LTR) 12 Ltr

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BODY FILLER (TIN) O.5 Pcs
SAND DISC SHARP P60 4 Pcs
SAND PAPER SHARP P60 6 Pcs
SAND PAPER SMOOTH P150 3 Pcs
FLASH BAND (COALTAR TAPE) 8 Pcs
SILICON SEALANT WHITE 10 Pcs

6.2.2 STEPS INVOLVED IN THE FABRICATION OF A 24-PALLET

BOTTLE CARRIER

1) The chassis is moved from the chassis section to the production section by the
forklift.
2) The arms are cut to size by a CNC laser cutting machine and they are bent to the
required dimension by a bending machine in the cutting and bending section.
The arms are 900mm long and 15mm thick. The arms are 24 pairs in total (24 on
the right and 24 on the left). They are attached to the beam and we ensure that
the distance between the chassis and the end of the arm is 90mm.
3) A channel of 3mm thickness is used to brace both the left and right arms
(800mm x 60mm x 3mm)
4) A U-channel is attached across the entire length of both sides to cover the entire
length of the arm. It is 15m long.
5) The surface of the arms, chassis and side U-channel are painted before welding
the floor plates.
6) The floor plates are attached and welded with guage 10 E6013 electrodes. The
floor plates are 12 in number and 2 halves at the end.
7) The side guards are fabricated and attached to the side U-channel. They are 4 in
number (2 on each side). The first is smaller and its dimension is (700 x 1800 x
50)mm while the second is (700 x 3140 x 50)mm
8) The landing gear and extra tyre support are welded and attached to the chassis.
9) The front and back panel are fabricated . Each is made of corrugated iron sheet
as covering, a square pipe is used for the top and drilled pillars for the sides.

10) A U-channel is used to hold the side channel firmly to the chassis (100 x 80 x
5)mm. There are 4 each on both sides of the chassis.

11) With the help of a mobile crane the front and back channel are attached to the
chassis and are welded firmly while ensuring that they are straight.

40
12) The triaxle is braced with 12mm thick plates and they are 425mm long and
90mm wide.

13) The U-shaped from for housing the extra fuel tank is attached to the chassis.

14) The tarpaulin rollers and engines are attached to the side channel and panel
pillars respectively.

15) Next, we fabricate the side railings for the roof. It consists of a thick square
rectangular pipe and a lighter square rectangular pipe made of two light U-channel
welded together. The light square channel are welded onto the thicker one and the
mobile crane mounts the side railing on both sides of the top of the front and back
panels.

16) Next, we take the roofing channel to the tank section where they are rolled to
the required angle. The side plates are attached to the roofing channel and they are
welded to the roof railing making the skeleton for the roof complete.

17) The roofing sheets (2mm thick) are then welded on the skeleton and the
butterfly plates are also attached to aid in directing rainfall away from the trailer
body.

18) Next we weld the standing pillars connecting the roof to the floor.

19) The angle plates for demarcating the inner section into two halves are drilled
and welded to the floor, they are 26 in number.

20) The rubber boards are attached to demarcate the trailer into two equal opposite
halves and they are held down to the roof by channels (2400 x 65 x 2)mm in
dimension.

21) All weldment are ground with a grinding disc to give fine finish.

22) Quality control fastens all bolts and nuts tightly

23) The welds are checked by quality control for errors before the project is
handed over to paint section for finishing.

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42
Fig 3: Images of various stages in the fabrication of the 24-Pallet bottle
carrier.

6.3 WELDING EQUIPMENT

Besides the welding machines and suitable electrodes, the accessories necessary
for a welder are:
1. A substantial work table with a fairly heavy mild steel plate for a top.
2. Leads. Two are required — one from the machine to the electrode holder,
called the electrode lead, and one from the job or work table back to the
machine to complete the circuit, called the work or earth lead. These leads
should be heavy enough to carry the required current without overheating.
They must be kept in good condition and in close electrical contact with the
holder and the work for the best utilization of current.

3. Electrode Holders. These should be heavy enough not to overheat and have
well-insulated handles to avoid electric shocks and accidental arcing.
Holders are available that are designed for continuous welding at high
amperages. These are fully insulated and the jaws are made of metals having
high heat conductivity.

4. Shields. These are necessary for protecting the eyes and face from glare and
ultra-violet radiation from the arc, and spatter from the weld pool. Special
tinted glass is used in the shields to absorb ultra-violet rays. A clear piece of

43
 replaceable glass is used in front of the coloured glass to protect it from
spatter and smoke.

5. Clothing. Leather gauntlets and apron should be worn, and clothes should
be of material that will deflect spatter and sparks.
6. Chipping Hammer. Used for deslagging of welds.
7. Wire Brush. Used for removing rust, cleaning slag off welds, etc.

6.4 Safety Considerations

The immediate area should be well marked or sectioned off in the shop prior to
welding. This is necessary as others may be unaware the possible hazards of
welding.
The workshop should contain adequate safety devices such as fire extinguishers.
The locations of these items should be clearly marked. Equipment should be
properly installed with all ground wires intact. Any loose or frayed wires should be
reported immediately. The floor should be clear and dry, free from flammable
materials such as oily rags or sawdust.
The operator should wear protective clothing to include:
- Boots – not sandals or open toed shoes;
- Welding mask;
- Safety glasses;
- Jeans or heavy pants, not frayed or torn;
- Welding apron and jacket are recommended; and welding gloves.

6.5 SAFETY FACTORS

Safety is an important consideration at any construction site, but I was made to
understand that on a site with a high rise building, extra safety is of crucial
importance and should be everyone's primary concern because construction of
trailers such as the 24-Pallet bottle carrier can be a dangerous activity. Safety is
based on knowledge, skill, and an attitude of care and concern .Thus safety factors
includes all the measures carried out to protect both the worker, consultants,
contractors and all persons present on the site at every given time from fatalities
and injuries, and as well as minimize or eliminate all possible construction hazards.
This safety measures can also be applied to the safety of the building and building
materials from damage of any kind.

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6.6 WORKSHOP MEETINGS

During my training, site meetings were held every weeks on a Thursday. The
essence of the site meetings is dissipating instructions to the contractors and to
assess the progress of the project. The site meeting is chaired by the project
architect who gives out all instructions. During the meetings, all the consultants are
expected to be present in order to obtain an update of a weekly report on each of
their jurisdictions as regards the project from the contractors. Issues from what
material should be used to the ordering of materials and expenses made are
discussed in full length and all issues or problems encountered are presented to the
architect for instructions. The site meeting for the building project is expected to be
held till the project is completed and handed over to the clients.

CHAPTER SEVEN
SUMMARY
Student Industrial Work Experience Scheme (SIWES) is a mandatory exercise for
all students in the Department of mechanical engineering in the Federal University
of Technology, Owerri (FUTO). It’s a six months mandatory exercise (training) for
all students undergoing five year degree program in the second semester
400level.Chapter one of this report covers brief history about ITF, the purpose of
its establishment and its functions. Chapter two gave a brief introduction about the
organization where i did my industrial training, Chapter three it also talked about
some measuring tools, workshop tools, machineries and their applications, also
gave a detailed note about the steps and processing involved in fabrication and
construction. Chapter four was an introduction to welding, its types, various weld
joints and also the E7018 and E6013 electrodes. Chapter five talked about the
general processes involved in fabrication and construction. Chapter six talked
about the two major projects I was involved during my period of attachment.
Chapter seven rounded up everything by giving brief explanation about workshop

45
meting; it also contains the summary of the whole work, conclusions,
recommendation and references
CONCLUSIONS

This six months industrial training has enabled me to see how the standard working
environment looks like and the pains and gains of being in the labour market and
also made me understand more about the theories taught in class and how they can
be applied in the practical world

RECOMMENDATIONS
The industrial training should be encouraged because it is a way to bridge the gap
between theory taught in class and the practical world. The industrial training
program should be closely monitored because some employers use students to do
odd jobs not in line with their main task, yet they expect optimum performance
from students.

The supervisors could not visit the students due to the ASUU strikke, it would have
been more encouraging if they take their time and evaluate students very carefully.
The industrial training coordinating centre should try and build more friendly
relationship with big establishments so as to provide a balance level of training for
students who do not really have the opportunity to get placement in such
establishments.

REFERENCES
1. www.google.com
2. www.wikipedia.com
3. My training log book
4. Machines and laboratory manuals
5. Iron Product Industries ltd.
6. www.ipi.ng

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