4) Arc welding

Introduction to Arc welding :-

In the year1500, forge welding was invented. In this method copper and gold were jointed together to form a joint.
Then in the year 1903, the actual welding process was invented.
At that time by using electrode, arc welding process was invented.

Manual Metal Arc Welding :- In this method an electric arc is developed between the electrode and work piece,
so that large amount of heat is generated. By using this heat, arc welding is done without application of pressure
and by using filler material. This is known as manual metal arc welding.
Arc welders can use either direct (DC) or alternating (AC) current and consumable or non consumable
electrodes. The welding area is usually protected by some type of shielding gas, vapor or slag.
Arc welding 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 ship building during the Second World War. Today it
remains an important process for the fabrication of steel structures and vehicles.

The Equipments used in Arc Welding are as given below.:-

1) Arc Welding Machine. (AC or DC)
2) Electrode Holder.
3) Welding Cable.
4) Earthing Clamp.
5) Welding Screen.
6) Electrode
7) Chipping goggle
8) Cable Lugs and wing nut.
9) Chipping Hammer.
10) Wire Brush.
11) Hand Gloves and Apron.
12) Tong
13) Water bucket or sand bucket

1) Arc Welding Machine :- The function of arc welding machine is to step down usual supply voltage to the normal
open circuit voltage. On this machine there are three types of poles such as High voltage positive pole, Low voltage
positive pole and negative pole. There is an indicator which displays current. On upper side of welding machine
there is a lever through which we can set the required current for the electrode. There are three types of welding
machines.
A) A.C. welding machine i) Air cooled transformer ii) Oil cooled transformer
B) D.C. welding machine i) Diesel generator ii) Motor generator
C) A.C./ D.C. Rectifier By using this we get A.C. or D.C. current.

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Mechanical Technology
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2) Electrode Holder :- It is used for holding the electrode and for supplying the current to the electrode. It consist
of a Bakelite handle, spring acted jaw and lever. Electrode is held in between two jaws. One end of holder cable
is attached to the handle of the electrode holder. The supply is given from handle to the electrode. This complete
construction is insulated, so that it may not cause any electrical shock to the person.

3) Welding Cable :- The welding cable carries current to the desired place. The cable is selected according to the
machines capacity and depends upon the length of a cable.
There are two types of cables such as Holder cable and Earthing cable.
A) Holder cable :- One end of holder cable is connected to the positive pole of welding machine and other end is
connected to the electrode holder.
B) Earthing Cable :- One end of earthing cable is connected to the negative pole of welding machine and other
end is connected to the welding table by using earthing clamp.

4) Earthing Clamp :- One end of earthing cable is connected to the earthing clamp. This clamp is fitted to the
welding table so that we can get negative polarity. It is made from copper or brass. It has a spring which holds the
table rigidly.

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5) Electrode :- Electrode is used to produce an arc and to fill up the gap between the joint.
Flux coating done on the metal which in the form of rod and which carries current is known as Electrode. The
electrode should be selected according to the property of the base metal. The front portion of the electrode is
known as tip. The other end is known as stub end. This stub end is held in the electrode holder. The length of the
electrode varies from 350 mm to 450 mm. The diameter of the electrode is decided according to the core diameter
of the electrode. The electrode is available in sizes as 14 gauge - 2.0 mm, 12 gauge - 2.5 mm, 10 gauge - 3.15
mm, 8 gauge - 4.0 mm.

6) Welding Screen :- It is used for protecting the eyes and face from the arc which contains ultra violet and infrared
rays. It is also used to watch the welding operation. It is made from fibre. There are two types of welding screens :-
a) Hand Screen :- It can be held in hand.
b) Head Screen :- It can be placed on to the head.
In welding screen special quality Blue color glass is fitted. In front of that plane transparent glass is fitted to protect
special glass from spatters.

7) Chipping goggle :- It is used for protecting eyes from slag while doing chipping operation after completing
welding process. It has a transparent glass.

8) Chipping Hammer :- It is used for removing the slag from the weld bead.

9) Wire Brush :- Wire brush is used for cleaning the weld bead after chipping operation.

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Mechanical Technology
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10) Cable Lugs :- Cable lugs are made from copper. It works as a cable terminal end. They are used to join one
end of holder cable and earthing cable to the welding machines positive and negative pole. It can be tightened by
using nut and bolt. It has capacity from 300 to 600 ampere.

11) Apron :- Apron is used for the protection of the body from sparks, spatters and heat while doing welding. It is
made from leather or asbestos.

12) Hand gloves :-Hand gloves are used for the protection of hands from rays, spatters and spark while doing
welding. It also provides the protection while handling the work piece. It is made from leather or asbestos.

13) Tong :- It is made from steel. Tong is a type of tool used to grip and lift objects instead of holding them directly
with hands. It is used for holding hot objects and for doing job setting work. Tongs that have long arms terminating
in small flat circular ends of tongs and are pivoted at a joint close to the handle used to handle delicate objects.

14) Welding table :-Welding table is made from mild steel. For setting the work piece at the required position, the
welding table has a positioner.

15) Water bucket or sand bucket :- It is to prevent a fire produced during welding operation which may cause
accident.

While doing Arc welding operation, the following points must be taken into consideration.
1) Heat 2) Electrode angle 3) Distance 4) Speed

1) Heat :- The percentage of heat must be high, so that while coming in contact with the metal melting of the metal
must takes place.

2) Electrode angle :- While doing arc welding, the electrode must be held at convenient angle to perform proper
welding.

3) Distance :- It is necessary to maintain the distance between the tip of the electrode and the surface of the work
piece which is known as arc length.

4) Speed :- It is also necessary to move the electrode at constant speed to perform proper welding.

For getting good quality of welding the following factors must be taken into consideration.
1) Type of base metal
2) Method of joining
3) Welding machine’s current
4) Skill of welder
5) Welding position
6) Depth of penetration
7) Melting rate of metal
8) Generated weld beads.

Advantages of Arc welding :-

The advantages of welding are as follows.
1) It is easy for joining and learning.
2) According to other welding methods, welding can be done at faster rate.
3) It provides 100 % strength.
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4) It saves time.
5) There is no wastage of material.
6) Light section and heavy section parts can be welded.
7) Welding can be performed on various types of shapes.
8) It produces more penetration.
9) It creates more efficiency.

Disadvantages of Arc Welding :-

1) It is very difficult to join non ferrous metals, by using this method.
2) As flux coated electrodes are used, welding defects such slag inclusion, porosity etc are formed.
3) A sub weld portion of the electrode gets wasted.
4) Welded joints cannot be separated.
5) It is very difficult to join thin metal sheets.

Arc Welding Procedure :-

1) Maintain the dimensions of the work piece by filling the edges.
2) Wear hand gloves, apron and safety shoes before starting the welding operation.
3) Select the correct type of electrode and set the required current for the electrode.
4) Check the connections of welding machine.
5) Fix the electrode in the electrode holder.
6) Switch on the welding machine.
7) Hold the hand screen in left hand and electrode holder in right hand.
8) Strike the electrode on the work piece and produce the arc.
9) Maintain the arc length carefully and hold the electrode holder at certain required angle.
10) Move the electrode in a straight line at constant speed.
11) At the end increase the arc length so that arc will not be developed.
12) By using the chipping hammer remove the slag and clean the weld bead by using wire brush.
13) Finally switched off the welding machine.

Safety Precautions used while performing Arc welding.

1) Wear apron, hand gloves and safety shoes.
2) Select proper type of electrode according to the thickness of work piece.
3) Set the required current of the electrode.
4) Check the connections of welding cables.
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 5) Don’t performed welding on full filled and air tight containers.
6) Hold the electrode at required angle.
7) Maintain proper arc length and maintain constant speed while doing arc welding.
8) For removing the slag use chipping hammer and wire brush.
9) Use tongs for lifting hot work pieces.
10) Don’t operate the welding machine, without any knowledge.

Exercise :-

1) Choose the correct option from the bracket and rewrite the following sentences.
a) ______ is used for holding the electrode and for supplying the current to the electrode.
(arc welding machine, electrode holder, welding cable)
b) _______ is used to protect the weld from the contamination of air.
(flux, slag, graphite)
c) ______ is to step down usual supply voltage to the normal open circuit voltage.
(arc welding machine, electrode holder, welding cable)
d) ______ is used for cleaning the weld bead after chipping operation.
(chipping hammer, wire brush, mallet)
e) ______ is used for removing the slag from the weld bead. (chipping hammer, wire brush, mallet)

2) Answer the following in brief.

a) What is arc welding?
b) Which points should be taken in to consideration while doing arc welding? Explain it.
c) State the advantages of welding.
d) State the disadvantages of welding.
e) State the Equipment used in Arc Welding.

3) Answer the following questions in detail.

a) Explain the tools and equipment used for arc welding in detail.
b) Write a note on Arc welding machine & draw a labelled diagram of it.
c) Write a note on Electrode holder & draw a labelled diagram of it.
d) Write a note on Electrode & draw a labelled diagram of it.
e) Draw a labelled diagram of an arc welding plant.
c) Write down the procedure used for arc welding.
d) What safety precautions will you obey while doing Arc welding?

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Udayachal High School

Mechanical Technology
Std 9 th Welding
16