Group No: G 01

Module Name: ME1071

Semester: 2

Familiarisation with metal welding

By

Index No. Name Marks

200509X RANASINGHA S.M.

Group members

Index No. Name

200354P LOKUGALAPPATHTHI V.H.
200009N ABILAASH A.
200414C NAOTUNNA I.H.
200221G HEWAWASAM H.S.S.M.
200649B THILAKARATHNA A.W.G.T.N.
200527B RASHMINA I.D.D.P.
200756B DE SILVA T.D.H.
200025J AMARASINGHA D.A.
200167U FERNANDO P.S.M.
200509X RANASINGHA S.M.

Date of practical session 04/08/2022

Date of submission 18/08/2022

Instructor’s name

Mr. H.A.P. BIMSARA

Department of Mechanical Engineering

University of Moratuwa
Sri Lanka
PART 01

description of the steps followed in performing welding operations

using oxy-fuel, arc, and spot-welding methods

oxy-fuel welding

Oxy-fuel welding and oxy-fuel cutting are processes that use fuel acetylene
and oxygen to weld or cut metals. We can make a hot flame is about 3200℃
of temperature by mixing oxygen and acetylene together in correct
proportions. The flame can be adjusted by changing the ratio of the volume
of oxygen to acetylene. Generally, three type flame used. Those types are
neutral (1:1), oxidising (excess of oxygen), and carburising (excess of
acetylene).

we can see black coloured cylinder is oxygen cylinder and the red one is
acetylene cylinder. First, we should open valves of gas cylinders. After that
open valve on the welding torch (respectively first oxygen valves, next
acetylene cylinder). We neutral flame use to weld and oxidising flame use to
cutting.

For weld adjust valves until to neutral flame and keep the 70ᵒ angle in touch.
After place the filler rod to have a welding point by about 30ᵒ and press
lightly with thumb. After heat until the heat bubble is formed at the starting
point and after it, move the bubble along the path to be soldered. We can
weld like this without filler rod. After welding close the acetylene valve and
oxygen valve respectively for stop flame.
For cutting adjust valves until to neutral flame and keep the 30ᵒ angle in
touch. Keep the touch close to the cut line. Then keep cutting until the plate
separates. After welding, similarly, stop the flame.

Arc welding

Electric arc is used for the arc welding to create heat to melt and join metals.
A power supply creates an electric arc between a consumable or non-
consumable electrode and the base material using either direct DC or AC
currents.

First, we should keep two metal plates, get as close as possible but not touch
in the edges of each of them. After attached one electrode for welding table.
Welding rod and current are selected by considering about the metal
material and the thickness of metal plates for proper welding. Then switch
on the welding machine and use a hand shield before starting. Welding rod
set to touch. First rub and bring the welding rod towards the solder line in
such a way that it is ready for welding. Now weld the towards us slowly. After
weld remove the slag using a hammer and wire brush.

Spot welding

This process uses only for weld thin metals or metal sheets (0.5-3mm). first
place the two plates to be soldered on top of each other. Then keep the joint
between electrodes and press the little time of foot paddle.
Part 02

Describe general safety precautions followed in a welding shop.

• Wear safety shoes and goggle because hot parts or tools (hammers,
tongs, and heavy tools) can fall on your body.
• dressing dress properly for your work. Wearing a workshop apron.
• Long hair should be tied back away from face and not allowed to fall
into your work.
• Remover all rings, bracelets, necklaces.
• Be careful when handling work piece as it may be hot. Use tools
whenever possible.
• Definitely, use face shield for arc welding. The light emitted there is
harmful to the eyes.

Compare and contrast characteristics of oxy-fuel welding, arc welding and

spot welding.

Oxy-fuel welding Arc welding Spot welding

No such power supply electrical power supply electrical power supply

cheap costly costly

Welding rods are used Filler rod are used Not use filler metals

think metal sheet weld think metal sheet weld Only thin metal sheet
and cutting weld

Can be used from place Can be used from place Cannot be used from
to place to place place to place

Difficult to use Difficult to use Operation is simple

slowly slowly very quickly.

Part 03

literature survey performed on the applications of oxy-fuel

welding/cutting, arc welding and spot welding in the Sri Lankan
manufacturing industry.

The welding process is widely used in many industrial applications in globally.

Below are some of the manufacturing industries in Sri Lanka that use welding
processes

• Aircraft and aerospace industries

• Construction industries
• Automobile and vehicle industries
• Shipbuilding and marine industries
• Land transportation and automotive industries.
• Automotive
Applications
• Battery & Battery Pack
Application
• Electronics Application

Oxy-fuel Welding/Cutting

The oxy-acetylene welding process is mainly used to weld thin metal sheet and
cut the think metal. this process can use to make items which are used in many
industries. So oxy-fuel process is used to weld tubes, sheet, and pipes.

Meanwhile, oxy-fuel cutting is still vastly

used in heavy industry as well as light
industrial and including the automotive
industry.

In Sri Lanka, this process is more useful

process when electricity is inaccessible.
Arc Welding

ARC welding is the most popular and

common welding in Sri Lanka. it is very
cost effective. The prime uses in the
industry are for the construction works. And
in the ship, building, vehicle and repairing
industry, building constructions, machine
designing and large items etc. of arc
welding is performed.

Spot welding

Spot welding is the most economical welding

process for sheet metals. The most commonly
spot welding is used in the automobile
manufacturing industry and many type of
vehicle body making and repairing industry. Due
to spot welding can also be automated, most
manufacturing processes use spot welding in Sri
Lanka as well as other countries.

Spot welding is also used is in the orthodontist's clinic. Also spot-welding straps
cell together for made hydride battery pack. The cells are joined by spot welding
thin nickel straps to the battery terminals. Spot welding can protect the battery
from getting too hot. The advantage of this
welding method is that it does not heat up a lot.
hance it can use for many sensitive applications.