Welding shop practice Sub Code: ES 11152

College Vision
To produce professionals with competency for pursuing excellence in Science and Technology Education,
Research, and Entrepreneurship with ethical values and social sensitivity for offering specialized services to
the society meeting the global requirements and standards in a multicultural environment.

College Mission
· Creating a niche in the field of science and technology education and research through an innovative
modular system.
· Producing globally competitive technical and scientific manpower in different disciplines with high ethical
values and with particular reference to the North Eastern region.
· Inducing in engineers/technologist and trainees a mind-set full of creativity to pursue excellence with focus
on stakeholders, accountability, environment and people.
· Developing collaborations with world class R&D organizations, industries, and educational institutions in
India and abroad for attaining excellence in teaching, research and consultancy practices.
·

Department Vision
To create a niche in the field of Mechanical Engineering through education and research to develop a sound
human resource by nurturing the young talents especially from the North Eastern States and also from other
states of India, matching the global standards and demands

Department Mission
· To create an environment for providing balance education in Mechanical Engineering through teaching,
learning and practice rendering equal weightage in all.
· To create a centre of excellence in research that will provide the students necessary impetus for future
development and life-long learning.
· To create technical manpower in different levels for the North Eastern States in particular and for the
country in general.

Central workshop ME, Deptt. Page 2

 Welding shop practice Sub Code: ES 11152

WORK SHOP AND FITTING SHOP PRACTICE

Syllabus
[AS PER BASED CREDIT SYSTEM (CBCS) SCHEME]
Semester – I

1. ES – 11152 WORKSHOP PRACTICE 4 Credits (0-0-8)

[Carpentry: 2 hrs, Fitting: 2hrs, Sheet metal/machine shop: 2hrs, welding: 2hrs]

OFFERED TO: First year 1ST Semester- CE, EC, EE, AE & ME
Prescribed syllabus: Introduction to safety aspects in workshop and different tools (functions, types and
Specifications) usedin different shops.

Welding Shop: Introduction to gas and arc welding tools, equipment and processes. Soldering, brazing
and welding Practice. Job preparation by welding.

Ø WELDING SHOP (2 hrs)

Introduction of safety in welding shop, Various welding tools etc 2 Hrs
Demonstration of arc welding equipments and welding techniques etc 2 Hrs
Arc welding Practice 10 Hrs
Practical job 1 : To make a butt joint 2 Hrs
Practical job 2 : To make a Lap Joint 2 Hrs
Practical job 3 : To make a Tee joint 2 Hrs
Practical job 4 : To make a corner joint 2 Hrs
Demonstration of gas welding equipment 2 Hrs
Test job / Practice Exam and Final Viva-Voce 4 Hrs
Total Hrs/Semester 28 Hrs

Central workshop ME, Deptt. Page 3

 Welding shop practice Sub Code: ES 11152

Welding shop

3. Use first aid box or inform the faculty for need of medicalassistance.

4. Use of safety goggles, apron, hand gloves, etc is compulsory during welding and Forging
Practice; do not touch hot jobs with bare hands.

5. Handle tools carefully. Keep distance from each other while working welding,
hammering, chiseling, forging or foundry operation.

Central workshop ME, Deptt. Page 4

 Welding shop practice Sub Code: ES 11152

WELDING
Introduction:
Welding is a fabrication process used to join materials, usually metals or thermoplastics, together. During welding, the
pieces to be joined (the workpieces) are melted at the joining interface and usually a filler material is added to form a pool
of molten material (the weld pool) that solidifies to become a strong joint.

WELDING TOOLS

Handgloves : These are used to protect the hands from

electric shocks and hot spatters

Faceshield: A face shield is used to protect the

eyes and face from the rays of the arc and from
spatter or flying particles of hot metal. It is
available either in hand or helmet or Goggles
types.

Wirebrush : A wire brush is used for cleaning

and preparing the work for welding.
Chipping hammer : A chipping hammer is used
for removing slag formation on welds.

Ground Clamp :It is connected to the end of

the ground cable and is clamped to the work or
welding table to complete the electric circuit. It
should be strong and durable and give a low
resistance connection.
Electrodeholder :
The electrode holder is connected to the end of
the welding cable and holds the electrode.

Apron: These are used to protect the front portion of

body from electric shocks and hot spatters.

Central workshop ME, Deptt. Page 5

 Welding shop practice Sub Code: ES 11152

Types of Welding

There are many different types of welding processes and in general they can be categorized as:

However, only electric arc welding (SMAW)and Gas welding (oxyacetylene welding) process is discussed in
the subject point of view.
1. Arc Welding: A welding power supply is used to create and maintain an electric arc between an electrode
and the base material to melt metals at the welding point. In such welding processes the power supply could
be AC or DC, the electrode could be consumable or non-consumable and a filler material may or may not be
added.

The most common types of arc welding are:

A. Shielded Metal Arc Welding (SMAW): A process that uses a coated consumable electrode to lay the
weld. As the electrode melts, the (flux) coating disintegrates, giving off shielding gases that protect the
weld area from atmospheric gases and provides molten slag which covers the filler metal as it travels
from the electrode to the weld pool. Once part of the weld pool, the slag floats to the surface and protects
the weld from contamination as it solidifies. Once hardened, the slag must be chipped away to reveal the
finished weld.

Central workshop ME, Deptt. Page 6

 Welding shop practice Sub Code: ES 11152

The equipment used for SMAW consists of a step-down transformer and for direct current models a rectifier,
which converts alternating current into direct current. Because the power normally supplied to the welding
machine is high-voltage alternating current, the welding transformer is used to reduce the voltage and increase the
current. As a result, instead of 220 V at 50 A, for example, the power supplied by the transformer is around 17–
45 V at currents up to 600 A. A number of different types of transformers can be used to produce this effect,
including multiple coil and inverter machines, with each using a different method to manipulate the welding
current.
Direct current with a negatively charged electrode (DCEN) causes heat to build up on the electrode, increasing
the electrode melting rate and decreasing the depth of the weld. Reversing the polarity so that the electrode is
positively charged (DCEP) and the workpiece is negatively charged increases the weld penetration. With
alternating current the polarity changes over 100 times per second, creating an even heat distribution and
providing a balance between electrode melting rate and penetration.

The choice of electrode for SMAW depends on a number of factors, including the weld material, welding position
and the desired weld properties. The electrode is coated in a metal mixture called flux, which gives off gases as it
decomposes to prevent weld contamination, introduces deoxidizers to purify the weld, causes weld-protecting
slag to form, improves the arc stability, and provides alloying elements to improve the weld quality.
Tools:

B. Gas Metal Arc Welding (GMAW): A process in which a continuous and consumable wire electrode
and a shielding gas (usually an argon and carbon dioxide mixture) are fed through a welding gun.
C. Gas Tungsten Arc Welding (GTAW): A process that uses a nonconsumable tungsten electrode to
produce the weld. The weld area is protected from atmospheric contamination by a shielding gas, and a
filler metal that is fed manually is usually used.

2. Gas Welding:
Gas welding is a welding process that melts and joins metals by heating them with a flame caused by a
reaction of fuel gas and oxygen. The most commonly used method is oxyacetylene welding, due to its high
flame temperature. The flux may be used to deoxidize and cleanse the weld metal. The flux melts, solidifies
and forms a slag skin on the resultant weld metal.
Oxy-acetylene Welding:
CaC2 + 2H2O = Ca (OH) 2 + C2H2 C2H2+2.5O2= 2CO2+H2O(vapour)+ 306.800 cal /mol

Central workshop ME, Deptt. Page 7

 Welding shop practice Sub Code: ES 11152

Oxyacetylene welding, commonly referred to as gas welding, is a process which relies on combustion of oxygen and
acetylene. When mixed together in correct proportions within a hand-held torch or blowpipe, a relatively hot flame is
produced with a temperature of about 3,200 deg.C. The chemical action of the oxyacetylene flame can be adjusted by
changing the ratio of the volume of oxygen to acetylene.
Three distinct flame settings are used, neutral, oxidising and carburising.

Neutral flame Oxidising flame Carburising flame

Welding is generally carried out using the neutral flame setting which has equal quantities of oxygen and
acetylene. The oxidising flame is obtained by increasing just the oxygen flow rate while the carburising flame is
achieved by increasing acetylene flow in relation to oxygen flow. Because steel melts at a temperature above
1,500 deg.C, the mixture of oxygen and acetylene is used as it is the only gas combination with enough heat to
weld steel. However, other gases such as propane, hydrogen and coal gas can be used for joining lower melting
point non-ferrous metals, and for brazing and silver soldering.

Oxyacetylene equipment is portable and easy to use. It comprises oxygen and acetylene gases stored under
pressure in steel cylinders. The cylinders are fitted with regulators and flexible hoses which lead to the blowpipe.
Specially designed safety devices such as flame traps are fitted between the hoses and the cylinder regulators. The
flame trap prevents flames generated by a 'flashback' from reaching the cylinders; principal causes of flashbacks
are the failure to purge the hoses and overheating of the blowpipe nozzle.

Weld Joint
Butt joint: A butt joint is a joint where two pieces of metal are placed together in the same plane, and the side of each
metal is joined by welding.
Butt welds are made in a variety of ways, and each one
serves a different purpose. Varying factors include the
shape of the groove, layering and width of the gap. Listed
below are some typical examples of butt weld joints.
· Square
· Single bevel
· Double bevel
· Single J
· Double J
· Single V
· Double V
· Single U
· Double U grooves

Central workshop ME, Deptt. Page 8

 Welding shop practice Sub Code: ES 11152

Corner Joint : Corner joints have similarities to tee welding joints. However, the difference is the location of where
the metal is positioned. In the tee joint, it’s placed in the middle, whereas corner joints meet in the ‘corner’ in either an
open or closed manner—forming an ‘L’ shape.

These types of joints are among some of the most common

in the sheet metal industry, such as in the construction of
frames, boxes and other applications. There are two ways
of fitting up an outside corner joint—either it forms a V-
groove (A) or forms a square butt joint (B), as seen in the
diagram.

The styles used for creating corner joints include V-

groove, J-groove, U-groove, spot, edge, fillet, corner-
flange, bevel-groove, flare-V-groove and square-groove or
butt.

Lap Joint: Lap welding joints are essentially a modified version of the butt joint. They are formed when two pieces of
metal are placed in an overlapping pattern on top of each other. They are most commonly used to joint two pieces with
differing thicknesses together. Welds can be made on one or both sides.
Lap joints are rarely used on thicker materials, and are
commonly used for sheet metal. Potential drawbacks to
this type of welding joint include lamellar tearing or
corrosion due to overlapping materials. However, as with
anything, this can be prevented by using correct technique
and modifying variables as necessary.

Central workshop ME, Deptt. Page 9

 Welding shop practice Sub Code: ES 11152

Edge Joint: In an edge joint, the metal surfaces are placed together so that the edges are even. One or both plates may
be formed by bending them at an angle.
The purpose of a weld joint is to join parts together so that
the stresses are distributed. The forces causing stresses in
welded joints are tensile, compression, bending, torsion
and shear. The following styles are applicable for edge
joints:
· U-groove
· V-groove
· J-groove
· Corner-flange
· Bevel-groove
· Square-groove
· Edge-flange
EDGE JOINT

Tee joint:
Tee welding joints are formed when two pieces intersect at a 90° angle. This results in the edges coming together in the
center of a plate or component in a ‘T’ shape. Tee joints are considered to be a type of fillet weld, and they can also be
formed when a tube or pipe is welded onto a base plate.

With this type of weld, it’s important to always ensure there is effective penetration into the roof of the weld. There are a
handful of welding styles that can be used to create a tee joint:

· Plug weld
· Slot weld
· Bevel-groove weld
· Fillet weld
· J-groove weld
· Melt-through weld
· Flare-bevel-groove weld

A Fillet weld is triangular in shape and this weld is used to join two surfaces that are at approximately right
angles to each other in a lap, tee, or comer joint.

Plug and Slot welds are welds made through holes or slots in one member of a lap joint. These welds are used to
join that member to the surface of another member that has been exposed through the hole.

Central workshop ME, Deptt. Page 10

 Welding shop practice Sub Code: ES 11152

Groove welds (also may be referred to as Butt welds) are simply welds made in the groove between two
members to be joined. The weld is adaptable to a variety of butt joints, as seen in the figure.

Welding Symbols
Welding symbols are used on drawings to indicate the type and specifications of the weld.
The figure shows the American Welding Society (AWS) standard welding symbol. The most important
features of the welding symbol are illustrated below:

· The table shows the Basic weld symbol for the different types of welds.

Central workshop ME, Deptt. Page 11

 Welding shop practice Sub Code: ES 11152

Types of Welding Defect:

There are several types of weld defects which may fall under different classifications depending on their location,
size and shape in a particular consideration. We can break down weld defects into the following main categories.
· Inclusions
· Lack of fusion
· Porosity
· Undercut
· Under-fill
· Cracks
· Excess reinforcement and excess penetration
· Over-roll/Overlap
· Mechanical damage

Central workshop ME, Deptt. Page 12

 Welding shop practice Sub Code: ES 11152

Central workshop ME, Deptt. Page 13

 Welding shop practice Sub Code: ES 11152

GRINDING :
Grinding is the most common form of abrasive machining. It is a material cutting process that
engages an abrasive tool whose cutting elements are grains of abrasive material known as grit.
These grits are characterized by sharp cutting points, high hot hardness, and chemical stability
and wear resistance. The grits are held together by a suitable bonding material to give shape
of an abrasive tool.
Practical applications
Surface finishing, slitting and parting, descaling, deburring, stock removal (abrasive milling)
finishing of flat as well as cylindrical surface and grinding of tools and cutters and re
sharpening of the same.

Bench Grinding Machine

A bench grinder is manually operated and normally has two wheels of different grain sizes
that are fixed on a floor stand or work bench; to perform roughing and finishing operations. It
is mainly used to shape tool bits; and repair or make various tools.

Bench Grinding Machine

Principle parts of a Bench Grinder

1. On/off switch: Starting and stopping of mainmotor.

2. Coarse grain wheel: It is generally used for roughingpurposes
3. Fine grain wheel: It is generally used for finishingpurposes.
4. Wheel guards: The operator is protected against flying abrasive particles and
ground material by the wheelguards.
5. Eye shield: Safety glass shields are provided for additional protection against glares and
flyingparticles.
6. Tool rest: A tool rest is provided for each wheel so that tools may be held or
steadied while being ground

Central workshop ME, Deptt. Page 14

 Welding shop practice Sub Code: ES 11152

DRILLING:

Drilling is an operation through which cylindrical holes are in a solid material by using
revolving tool.
1. Sensitive drilling machine 2. Radial drilling machine

Sensitive drilling machine:

This type of drilling machine is designed for drilling small holes (3mm to 15mm) at high speed
in light work piece. It is small machine having simple construction and operations. Fig no.
shows principle parts of a sensitive drilling machine.

Sensitive Drilling Machines

Central workshop ME, Deptt. Page 15

 Welding shop practice Sub Code: ES 11152

BUTJOINT

EXPERIMENT No:1 DATE:

Aim: Preparation of butt joint as shown in figure using shielded metal arc welding process.

Material required: 2m.s flat pieces of given size. (70mm x40mm x 6mm)

Tools required:
 welding transformer,
2. connecting cables,
3. Electrode holder,
4. ground clamp,
5. electrodes,
6. hipping hammer,
7. Welding shield etc.

V BUTT JOINT

Procedure:
1. The given metallic pieces filled or cut to the desired size.
2. On both pieces beveled in order to have V groove.
3. The metallic pieces are thoroughly cleaned from rust grease, oil, etc.
4. The metallic pieces are connected to terminals of Transformer.
5. Select electrode dia…….based on thickness of work piece and hold it on the
electrode holder. Select suitable range of current for selected dia.
6. The ground clamp is fastened to the welding table.
7. Switch on the power supply and initiates the arc by either striking arc method or
touch and drag method.
8. Take welding to be done before full welding.
9. In full welding process after completion one part before going to second part. Slag is
removed from the weldbed. With the metal wire brush or chipping hammer.
10.Then the above process will be repeated until to fill the groove with weld bed or weld
metal.
11.Check the whole piece once to identify any welding defect if any.

Precautions:
1. Use goggles, gloves in order to protect the human body.
2. Maintain the constant arc length.
Result: Butt joint is prepared as shown in figure by using arc-welding process.

Central workshop ME, Deptt. Page 16

 Welding shop practice Sub Code: ES 11152

Lap joint
EXPERIMENT No: DATE:

Aim: To make a double lap joint, using the given mild steel pieces and by arc welding.
Material used: Two mild steel pieces of 100mm X 40mm X 6mm.
Tools and equipment used:

1. Arc welding machine 9. Metallic work Table

2. Mild steel electrodes 10. Bench vice
3. Electrode holder 11. Rough flat file
4. Ground clamp 12. Try square
5. flat nose Tong 13. Steel rule
6. Face shield 14. Wire brush
7. Apron 15. Ball peen hammer
8. Hand gloves 16. Chipping hammer
Operations to be carried out:
1. Cleaning the work pieces
2. Tack welding
3. Full welding
4. Cooling
5. Chipping
6. Finishing

Procedure
1. Take the two mild steel pieces of given dimensions and clean the surfaces thoroughly from
rust, dust particles, oil and grease.
2. Remove the sharp corners and burrs by filing or grinding and prepare the work pieces.
3. The work pieces are positioned on the welding table, to form a lap joint with the required over
Lapping.
4. The electrode is fitted in to the electrode holder and the welding current is set to a proper
value.

Central workshop ME, Deptt. Page 17

 Welding shop practice Sub Code: ES 11152

5. The ground clamp is fastened to the welding table.

6. Wearing the apron, hand gloves, using the face shield and holding the over lapped pieces the
arc is struck and the work pieces are tack-welded at the ends of both the sides
7. The alignment of the lap joint is checked and the tack-welded pieces are reset, if required.
8. Welding is then carried out throughout the length of the lap joint, on both the sides.
9. Remove the slag, spatters and clean the joint.
10.Check the whole piece once to identify any welding defect if any.

Precautions:
2. Use goggles, gloves in order to protect the human body.
3. Maintain the constant arc length.

Result: The lap joint is thus made, using the tools and equipment as mentioned above.

Central workshop ME, Deptt. Page 18

 Welding shop practice Sub Code: ES 11152

Corner joint
EXPERIMENT No: DATE:
Aim: To make a corner joint, using the given mild steel pieces and by arc welding.
Material used: Two mild steel pieces of 100mm X 40mm X 6mm.
Tools and equipment used:

1. Arc welding machine 9. Metallic work Table

2. Mild steel electrodes 10. Bench vice
3. Electrode holder 11. Rough flat file
4. Ground clamp 12. Try square
5. Flat nose Tong 13. Steel rule
6. Face shield 14. Wire brush
7. Apron 15. Ball peen hammer
8. Hand gloves 16. Chipping hammer
Operations to be carried out:
1. Cleaning the work pieces
2. Tack welding
3. Full welding
4. Cooling
5. Chipping
6. Finishing

Procedure
1. Take the two mild steel pieces of given dimensions and clean the surfaces thoroughly from
rust, dust particles, oil and grease.
2. Remove the sharp corners and burrs by filing or grinding and prepare the work pieces.
3. The work pieces are positioned on the welding table such that, the L shape is formed.
4. The electrode is fitted in to the electrode holder and the welding current is set to a proper
value.
5. The ground clamp is fastened to the welding table.
6. Wearing the apron, hand gloves, using the face shield and holding the over lapped pieces
the arc is struck and the work pieces are tack-welded at the ends of both the sides
7. The alignment of the corner joint is checked and the tack-welded pieces are reset, if required.
8. Welding is then carried out throughout the length of the corner joint.
9. Remove the slag, spatters and clean the joint.
10. Check the whole piece once to identify any welding defect if any.

Central workshop ME, Deptt. Page 19

 Welding shop practice Sub Code: ES 11152

Precautions:
4. Use goggles, gloves in order to protect the human body.
5. Maintain the constant arc length.

Result: The lap joint is thus made, using the tools and equipment as mentioned above.

Central workshop ME, Deptt. Page 20

 Welding shop practice Sub Code: ES 11152

Tee joint
EXPERIMENT No: DATE:
Aim: To make a Tee joint, using the given mild steel pieces and by arc welding.
Material used: Two mild steel pieces of 100mm X 40mm X 6mm.
Tools and equipment used:
1. Arc welding machine 9. Metallic work Table
2. Mild steel electrodes 10. Bench vice
3. Electrode holder 11. Rough flat file
4. Ground clamp 12. Try square
5. flat nose Tong 13. Steel rule
6. Face shield 14. Wire brush
7. Apron 15. Ball peen hammer
8. Hand gloves 16. Chipping hammer

Operations to be carried out:

1. Cleaning the work pieces
2. Tack welding
3. Full welding
4. Cooling
5. Chipping
6. Finishing

Central workshop ME, Deptt. Page 21

 Welding shop practice Sub Code: ES 11152

Procedure
1. Take the two mild steel pieces of given dimensions and clean the surfaces thoroughly from
rust, dust particles, oil and grease.
2. Remove the sharp corners and burrs by filing or grinding and prepare the work pieces.
3. The work pieces are positioned on the welding table such that, T shape is formed.
4. The electrode is fitted in to the electrode holder and the welding current is set to a proper
value.
5. The ground clamp is fastened to the welding table.
6. Wearing the apron, hand gloves, using the face shield and holding the over lapped pieces
the arc is struck and the work pieces are tack-welded at the ends of both the sides.

7. The alignment of the corner joint is checked and the tack-welded pieces are reset, if required.
8. Welding is then carried out throughout the length of the T joint.
9. Remove the slag, spatters and clean the joint.
10. Check the whole piece once to identify any welding defect if any.

Precautions:
1. Use goggles, gloves in order to protect the human body.
2. Maintain the constant arc length.

Result: The lap joint is thus made, using the tools and equipment as mentioned above.

Central workshop ME, Deptt. Page 22

 Welding shop practice Sub Code: ES 11152

Central workshop ME, Deptt. Page 23