HIMALAYA COLLEGE OF ENGINEERING

(TU AFFILIATED)

Chyasal, Lalitpur

PROJECT: Welding
Project No: 03
Submitted by:
Student Name: Rohit Saud
ROLL NO: 05
Date: 2080/11/29
OBJECTIVES:

1. To Familiarize ourself with the appropriate welding equipment and tools needed for the
specific welding process.

2. Understand the fundamentals of welding, including different welding techniques and

safety precautions.

TOOLS REQUIRED:

1. Hand tools:

i. Scriber

ii. Vice

iii. Hacksaw

iv. File

v. Steel wire brush

2. Marking tools:

i) scriber

ii) tri-square

1. HAND TOOLS
An operation powered by human effort rather than machinery tends to be manual. Manual
processes typically have lower efficiency and depend greatly on the skill level of
individuals for quality outcomes.

Advantages of manual processes include:

i. Reduced risk as they are less dangerous.

ii. Flexibility in operations.

iii. Consistent work availability.

iv. Final assembly control.

DIFFERENT TYPES OF HAND TOOLS

VICE
There are different types of hand tools. One of them is a vice, which is used to hold the
workpiece during manual processes. Vices are usually made of cast iron for the body and
hardened tool steel for the jaws.

Things to be noted while using vices:

i. We should avoid hitting the vice body directly with a hammer.

ii. We can lightly hammer on the anvil part of the vice.

iii. We should Tighten the vice handle by hand to prevent over-clamping.

FILES

1.Files are tools used for the removal of material from a workpiece.

2.They are commonly made of hardened high carbon steel.

3. Files come in various shapes and sizes to suit different applications and materials.

4. Files are essential in metalworking, woodworking, and various other trades for
refining surfaces and shaping materials.
 Filing process
i. Cross filing

ii. Draw filing

Types of files according to cuts on it:

a) Single-cut file

1. single set of parallel, diagonal rows of teeth.

2. single cut files are generally used with low pressure.

3. To produce a smooth finish or to put a keen edge on knives, shears, etc.

b) Double-cut file

Two sets of diagonal rows of teeth.

1. First set of teeth is known as the overcut, second is known as upcut.
2. Second set of teeth cut in opposite diagonal direction and on top of the first
set. Upcut is finer than overcut.

Hacksaw
1. It is used for cutting a metal into pieces

2. It consists of a frame and a saw blade

3. Its frame may be of fixed type or adjustable type

4. A wing nut to adjust the tension of the blade

5. Saw blade made of high carbon steel, alloy steel.

 Steel wire Brush

It is a brush which has bristles made up of steel wire which can remove hard materials
from metal surface, used to remove excess build up weld.

2. MARKING OUT TOOLS

Tri-square

It is a tool that helps to measure perpendicularity of a workpiece.

Scriber

Scriber is a tool that is used to mark guidelines to assist in cutting or further process on a
workpiece.

3. MACHINE TOOLS:

I. Welding Machine

Arc welding:

Arc welding is a fundamental method used to join metals together through the heat
generated by an electric arc between an electrode and the workpiece. Here's a concise
overview of its key principles:

Electric Arc Formation:

Arc welding involves creating an electric arc between a welding electrode and the
workpiece. This arc is generated when an electrical current passes through the electrode
and jumps the gap to the workpiece, creating a conductive path.

Heat Generation:

The electric arc produces intense heat, melting the base metal and the electrode to form a
molten pool of metal at the weld joint.
Consumable Electrode:

Many arc welding processes use a consumable electrode that provides filler material to the
weld joint as it is consumed during welding. The composition of the electrode varies based
on the materials being welded and the welding process used.

Weld Pool Control:

Control of the weld pool's size and shape is crucial for producing strong, uniform welds.
Factors such as welding current, arc length, travel speed, and electrode angle influence the
weld pool's characteristics.

Solidification and Cooling:

After welding, the molten metal in the weld pool solidifies and cools, creating a
continuous bond between the base metals. Proper cooling is essential to prevent distortion
and ensure weld joint integrity.

Types of Arc Welding:

Various arc welding processes exist, including shielded metal arc welding (SMAW), gas
metal arc welding (GMAW), flux-cored arc welding (FCAW), and gas tungsten arc
welding (GTAW). Each process has specific advantages and applications.

In summary, arc welding employs the heat generated by an electric arc to fuse metals
together. By controlling parameters such as welding current, electrode type, and shielding
methods, arc welding processes produce high-quality welds suitable for diverse industrial
applications.

For an arc welder, the components typically include:

1. Power Source:

Provides the electrical energy necessary to create the welding arc between the electrode
and the workpiece.
2. Welding Cables:

Conduct electrical current from the power source to the electrode holder and from the
workpiece back to the power source.

3. Electrode Holder:

Holds the welding electrode and provides a connection to the welding cable, allowing
current to pass through the electrode and create the welding arc.

4. Ground Clamp:

Connects the welding machine to the workpiece, completing the electrical circuit and
providing a path for the welding current to return to the power source.

5. Transformer or Inverter:

Converts the input electrical power into the appropriate voltage and current for welding.
Inverters are increasingly common due to their efficiency and portability.

6. Controls and Settings:

Allow the welder to adjust welding parameters such as amperage, voltage, and electrode
polarity to suit the specific welding process and material thickness.

7. Safety Features: Include thermal overload protection, which shuts down the machine if
it becomes too hot, as well as ground fault circuit interrupters (GFCIs) to prevent electric
shock hazards. These components work together to provide the necessary electrical power
and control for creating high-quality welds in arc welding processes. Understanding how
each component functions enables welders to operate the machine safely and effectively
while achieving desired weld results.
4. SAFETY EQUIPMENT’S:

1. Welding Helmet: Protects the welder's face and eyes from sparks, intense light,
and ultraviolet (UV) and infrared (IR) radiation emitted during welding.

2. Welding Gloves: Made of heat-resistant materials such as leather, welding gloves

shield the hands and wrists from burns, sparks, and molten metal.

3. Welding Jacket or Apron: Provides additional protection for the upper body from
sparks, heat, and UV radiation. Made of flame-resistant materials like leather or
treated cotton.

4. Welding Sleeves: Protects the arms from sparks, heat, and UV radiation. Often
worn in addition to a welding jacket or apron.

5. Safety Glasses or Goggles: Protects the eyes from flying debris, sparks, and
radiation. For welding operations, use safety glasses with side shields or goggles
that provide full eye coverage.

PROCEDURE:
1. Measure and Mark:

Using a metal scale to measure and mark the desired length on the metal bar and scribe a
mark using scriber.

2. Cutting the Metal Bar:

Secure the metal bar firmly in a vice or clamp to prevent movement during cutting.

Use the cutting tool (hacksaw) to cut the metal bar along the marked line. Ensure the cut is
straight and clean.

3. Filing to Remove Unwanted Material:

After cutting we inspected the cut edges for any roughness or unevenness.

We used the metal file to remove any burrs, sharp edges, or unwanted material from the
cut edges to ensure they are smooth and uniform.

4. Preparing for Welding:

We Ensured the two cut pieces of metal bar are clean and free from any contaminants,
rust, or grease. We positioned the pieces to be welded together in the desired
configuration, ensuring proper alignment and fit.

5. Welding the Metal Pieces Together:

We put on the appropriate safety gear, including welding helmet and gloves.

Weld the metal pieces together using arc welder ensuring consistent bead formation and
proper penetration.

6. Cooling the Welded Metal:

The welded metal is hot and can’t be worked with so we cooled the hot welded bar with
water.

7. Removing Excess Weld Residue:

Once the welded metal has cooled, inspect the weld joints for any excess weld residue or
spatter. Use a metal wire brush to remove the excess weld residue, ensuring the weld area
is clean and smooth.

PHOTOS
DISCUSSION

During our welding process with the arc welder, we encountered various challenges that
required quick solutions for effective work. We had to deal with weld spatter, which
occurred when molten metal splashed outside the welding area. To fix this, we
experimented with our welding technique and used special sprays to prevent it.
Sometimes, our welds had tiny holes called porosity due to trapped air bubbles. We
learned to clean the metal better and adjust our technique to reduce this issue. Weld cracks
were another challenge. They occurred when joints weren't prepared well or there was too
much stress. We learned to prepare joints better and pay attention to stress points to
prevent cracks. Sometimes, our welds didn't fuse together properly, so we had to ensure
that our joints were clean and free of contaminants. Lastly, welding could make metal
bend or warp. To stop this, we used clamps and sometimes heat treatment after welding.
By solving these problems, we ensured that our welding jobs with the arc welder were
strong, reliable, and successful.

CONCLUSION

In conclusion, our arc welding experience taught us to tackle challenges head-on and
refine our skills. Despite encountering issues like weld spatter and cracks, we learned to
adapt and improve our techniques. By focusing on cleanliness and preparation, we
achieved better welds and gained valuable insights. Moving forward, we'll continue to
refine our approach, ensuring success in our future welding projects.