CONTENTS

1.0 Objectives
2.0 Additional theory
3.0 Observations / safety
4.0 Apparatus
5.0 Procedure
6.0 Workpiece
7.0 Discussion
8.0 Conclusion
9.0 References
1.0 OBJECTIVES

1. To learn how to use the SMAW and GMAW welding correctly.

2. To know the uses of welding tool and other hardware tool that involve in
this workshop.

3. To find out if it is possible to weld different materials based on current

and voltage that has been set.
2.0 ADDITIONAL THEORY

Shielded Metal Arc Welding (SMAW) and Gas Metal Arc Welding
(GMAW) stand as two prominent welding techniques utilized across various
industries. Each method possesses distinct characteristics, catering to different
welding requirements and scenarios. SMAW, commonly known as stick
welding, relies on a consumable electrode coated in flux. This electrode,
manually fed into the weld joint, melts and forms the weld. The flux coating
plays a pivotal role, serving to shield the weld from atmospheric contamination.
This welding technique finds its versatility and portability advantageous, often
being chosen for outdoor or on-site applications. Conversely, GMAW, also
referred to as MIG welding, involves a continuous wire electrode fed through a
welding gun, along with a shielding gas, typically inert, like argon or a gas
mixture. The welding arc melts the wire, creating the weld, while the shielding
gas safeguards the molten metal from atmospheric impurities. Renowned for its
speed, efficiency, and user-friendly nature, GMAW finds widespread use across
industries, particularly in automotive, fabrication, and construction. SMAW and
GMAW differ not only in their application methods but also in their equipment
requirements. SMAW necessitates a welding power supply, welding electrode,
and machine, whereas GMAW calls for a welding power supply, welding gun,
shielding gas supply, and wire feeder. These disparities in equipment and
methodology influence factors such as the type of materials welded, the
working environment, and the level of skill required to execute the welding
process effectively. The choice between SMAW and GMAW often hinges upon
several considerations. Material type, thickness, desired finish, working
conditions, and the skill level of the welder all contribute to determining the
most suitable technique for a particular welding task. SMAW's versatility and
ability to function in adverse conditions make it a preferred choice for certain
outdoor applications, while GMAW's speed, efficiency, and ease of use make it
more suitable for industries requiring faster, automated welding processes. In
essence, both SMAW and GMAW have their unique strengths and weaknesses,
making them invaluable tools in the realm of welding. Their applications span
various industries and scenarios, offering flexibility and efficiency in joining
metals together while meeting the specific demands of diverse welding projects.
3.0 OBSERVATION / SAFETY

There are two different type of welding which is shielded metal arc
welding (SMAW) and gas metal arc welding (GMAW).
SMAW, also called stick welding, uses an electrode covered in a substance to
protect the weld from dirt. It's versatile and used in construction and repairs.
GMAW, known as MIG welding, involves a wire fed through a welding gun. It
uses gas to protect the weld area.

Safety equipment and safety step is mandatory in this workshop. Neglecting

safety equipment while engaged in welding poses significant risks and hazards
to individuals performing this task. The consequences of forgoing proper
protective gear can encompass a range of health issues and potential dangers.

Firstly, the intense light generated during welding exposes the eyes to a high
risk of injury. Arc eye, also known as welder's flash, can occur, leading to
painful inflammation, blurred vision, and in severe cases, permanent damage to
the eyes. This highlights the critical importance of wearing a welding helmet
with a darkened lens to shield the eyes from harmful light. Moreover, the high
temperatures involved in welding create a substantial risk of skin burns.
Exposed skin is vulnerable to burns due to the extreme heat generated during
the welding process. Such burns can cause considerable pain, potential scarring,
and require immediate medical attention.

The inhalation of welding fumes poses is a critical hazard. These fumes contain
harmful substances such as metal oxides and ozone, which, if breathed in, can
lead to respiratory problems, lung damage, and long-term health issues.
Utilizing a respirator or a welding mask equipped with a fume extractor is
crucial to minimize exposure to these harmful particles. Additionally, the
absence of proper safety gear increases the risk of electrical hazards. Accidental
contact with the welding circuit can result in electrical shock or arc burns,
emphasizing the necessity of protective clothing that insulates against these
potential dangers.
It is true that wearing adequate safety gear is mandatory in welding to safeguard
against the multitude of potential risks. A welding helmet with a darkened lens,
flame-resistant clothing, gloves, and proper footwear are essential elements in
mitigating these dangers, ensuring the welder's safety, and preventing long-term
health issues and workplace accidents.

___safety step____

1. Wear workshop attire while managing the welding works.

2. Do not wear slippers in the welding shop and instead use safety shoes.
3. Always wear gloves and welding shields when welding the workpiece.
4. Do not open the helmet lenses and keep concentrating on the welding part.
5. Make sure to weld on a table welding instead of welding on a concrete floor
to prevent the heat from arc.
6. Always clip the welding clamp holder with the welding table for MMA
welding parts to prevent the voltage leakage from the output leads.
7. Ensure to know the emergency rescue plan and the location of the
extinguisher when having an excess of flammable material.
8. Do not smell the fumes of the welding metal as it is bad for our respiratory
system.
9. When having a serious fire risk, do not use oxygen supplies as it will make it
worse.
10. Make sure that the shielding gas hoses and connectors are tightly sealed
4.0 APPARATUS

1. SMAW welding (Shielded Metal Arc Welding):

This equipment uses a consumable electrode coated in flux to create an electric
arc for welding.

2. GMAW welding (Gas Metal Arc Welding):

It utilizes a continuous solid wire electrode and a shielding gas to create a weld.
3. Fixed angle grinder:
Used for grinding, cutting, and polishing metal surfaces and preparing them for
welding.

4. Wire brush:
Used to remove dirt, rust, and unwanted materials from the welding surface to
ensure better weld quality.

5. Bench grinder:
Primarily used for sharpening and shaping metal tools and for preparing
welding materials.
6. Chipping hammer:
Helps in removing slag and unwanted materials after welding.

7. Gloves:
Protect the hands of the welder from heat, sparks, and potential burns during
welding.

8. Magnetic angle holder:

Assists in holding metal pieces at specific angles during welding for precise
joining.
9. Welding head shield:
Provides protection to the face and eyes from the intense light and heat
generated during welding.
5.0 PROCEDURE

1. prepare the metal workpiece. mark them with measurement 10 cm lenght and
5 cm width

2. Cut the metal using grinder machine slowly. Repeat procedure 1-2 until you
get 3 pieces of metal.

3. Remove the spiky edges of the metal pieces with bench grinder. Set the
grinder with polishing wheel.

4. Measure and mark 2 lines on the pieces with chalk and ruler.

5. make 2 line of shielded metal arch welding, SMAW following the marking as
shown below.

6. Place another metal piece on top of the welded pieces closely.

7. weld with SMAW on the gap of two pieces until it stick together.

8. Repeat procedure 7 at the back of metal piece.

9. Remove the welding slag by striking them with welder chipping hammer.

10. Take one more metal piece and place it vertically using L magnet on the
unwelded area. Make sure it stands 90 degree.

11. weld at the 2 bottom edge of standing metal using gas metal arch welding,
GMAW to stick it and keep it stand vertically.
12. remove the L magnet.

13. Apply GMAW welding to the entire inner edge to stick the vertical metal.

14. wait until the workpiece cool down into room temperature.

15. Polish and clean the work piece with wire bush.
6.0 WORKPIECE
7.0 DISCUSSION

Base on the workpiece, the result is not too perfect because of lack of skill
and experiences. There are several splash of molten metal that couldn't be
removed because the metal has become solid. Improvement should be done to
get better performance in welding to get better quality of the workpiece result.
The workpiece also not too straight because the workpiece didn't placed on flat
surface during welding as there are several metal powder on the welding table.
The table should be clean nicely before applying welding to get the accurate and
straight product. The welding line too, didn't apply in a straight line because I
didn't do it calmly.

Base on this workshop, when doing welding on the workpiece, it require correct
posture, distance and position of the workpiece.
1. The correct posture when doing welding is you need to stand up straight.
2. The elbow position when holding the welding is 45 degree.
3. SMAW electrode need to be clip perpendicularly or 90 degree at the electrode
holder.
4. The distance between welding nozzle and the workpiece must be 0.3 cm to
get perfect result.
5. The workpiece need to be place on flat surface.
6. Apply the welding horizontally following the straight line.
7. Don't weld too fast and don't be too slow too.
8. Practice welding on different metal first before welding on the real workpiece
to sharpen the skill.
9. Lower the voltage or current on the power source if the firepower is too much
and vice versa.
8.0 CONCLUSION

When this workshop done, we know that SMAW and GMAW welding need
to be use properly to get a good results of metal workpiece. To increase the
welding skill and techniques, its require proper training, safety gear, and an
understanding of materials for successful welding. The choice depends on the
job and materials being used.

Which means, welding should be done correctly and properly. When welding
isn't done in a proper way, it can cause a lot of problems. For instance, the
things being welded might not stick together properly, making them weak and
likely to break. This can be really dangerous, especially if these things are
supposed to hold heavy stuff or keep people safe. Bad welding can also make
cracks or holes in the welded parts, which can break apart easily when they're
under pressure. These kinds of mistakes not only make things not work properly
but can also be really unsafe, causing accidents or making machines stop
working. Fixing bad welds costs a lot of money and takes a long time. It means
redoing the work and throwing away materials that were used wrongly, making
everything more expensive and wasting materials.

To avoid these problems, it's essential to do welding the right way. Following
the correct steps and being careful during welding helps make things strong and
safe. This ensures that the stuff being welded works well and keeps everyone
safe without costing too much or wasting materials.
9.0 REFERENCES

1. https://en.wikipedia.org/wiki/Shielded_metal_arc_welding

2. https://www.safetyaction.com.au/blog/safe-workplace-touching-temperatures

3.https://www.ccohs.ca/oshanswers/safety_haz/welding/ppe.html?
=undefined&wbdisable=true#:~:text=Wear%20a%20welder's%20face
%20shield,from%20radiation%20and%20flying%20particles.

4. https://www.sciencedirect.com/topics/engineering/shielded-metal-arc-
welding

5. https://en.wikipedia.org/wiki/Angle_grinder