(1mj16me027) Internship

A Presentation on Internship Work
“WELDING PROCESS”
PRESENTED BY EXTERNAL GUIDE INTERNAL GUIDE
NAME: Harshith k NAME: Mr GAJENDRA SHARMA NAME: Mrs SHWETA AGRAWAL

USN: 1MJ16ME027 DESIGNATION: Senior Engineer DESIGNATION: ASSC. PROFESSOR
ORGANIZATION:INDO AUTOTECH Ltd DEPT: MECHANICAL
ORGANIZATION: MVJCE
Approved by AICTE |Affiliated to VTU | Recognized by UGC with 2(f) & 12(B) status |Accredited by NBA and NAAC 1
Agenda
• About the Organization

• About the Department
• Task Performed
• Conclusion
• Reference
About the Organization:
 Indo Auto-tech Limited has made the automobile industry the core of its concentration since 1974.
 Today it stands to meet the needs of the most discerning customers around the globe.
 The company is in a position to develop and supply sheet metal components and sub-assemblies conforming to
international standards.
 The company designs and assembles the chassis of different automobiles using automation(PLC, sensors, SCADA).
 Indo Auto-tech limited deals in a wide range of sheet metal components, Tubular components, Fabricated
Components, Welding Components, Assemblies and Sub Assemblies such as factories and jobs.

PRODUCTS

Indo Auto-tech limited deals in a wide range of sheet metal components, Fine blanked components, Tubular
components, Fabricated Components, Welding Components, Assemblies and Sub Assemblies Commitment to
quality and sense of innovation is deep rooted in the company. The company has the most impressive track record in
meeting stringent quality requirements and is committed to make available products of the best quality standards at
the most competitive prices. The company is certified ISO/TS 16949:2009, ISO 14001:2004 & OHSAS 18001:2007
by DNV. By exceeding our customer requirements Indo has become a valued supplier of major Sheet Metal
Components Tubular components and assemblies and Sub assemblies to leading OEM’s in the Indian as well as
global automotive Industry. Our Engineering, Production and Quality Assurance departments coordinate to
guarantee and maintain the highest quality levels. Process controls assure quality from prototype through
production.
Departments in the Industry:
• Tool Room • Furnace Brazing for MS Parts

• Press Shop • Furnace Brazing for Stainless Steel Parts
• CNC Pipe Bending • Powder Coating
• Pipe End forming • Assembly Facility
• Pipe Squeezing • Laser Cutting
• Robotic Welding • Plasma Cutting
• MIG Welding • CNC Press Brake
• TIG Welding
About the Department:
WELDING PROCESS
• Robotic Welding
• MIG Welding
• TIG Welding
WELDING PROCESS:
• Welding is a process for joining different materials.
• The large bulk of materials that are welded are metals and their alloys, although the term welding is also applied to the joining of
other materials such as thermo plastics.
• Welding joins different metals/alloys with the help of a number of processes in which heat is supplied either electrically or by
means of a gas torch.
• In order to join two or more pieces of metals together by one of the welding processes, the most essential requirement is Heat.
Pressure may also be employed.
• Since a slight gap usually exists between the edges of the work pieces, a 'filler metal’ is used to supply additional material to fill
the gap. But, welding can also be carried out without the use of filler metal.
• The filler metal is melted in the gap, combines with the molten metal of the work piece and upon solidification forms an integral
part of the weld.
CLASSIFICATION OF WELDING:
Gas Welding Resistance Welding
1. Spot Welding
1. Air Acetylene Welding
2. Seam Welding
2. Oxyacetylene Welding
3. Projection Welding
3. Oxy hydrogen Welding
4. Resistance Butt Welding
4. Pressure gas Welding
5. Flash Butt Welding
Arc Welding
Solid State Welding
5. Carbon Arc Welding
6. Cold Welding
6. Shielded Metal Arc Welding 7. Diffusion Welding
7. Flux Cored Arc Welding 8. Explosive Welding
8. Submerged Arc Welding 9. Forge Welding
9. TIG (or GTAW) Welding Radiant Energy Welding Processes
10. MIG (or GMAW) Welding 10. Electron Beam Welding
11. Plasma Arc Welding 11. Laser Beam Welding.
ROBOTIC WELDING:
• Robot welding is the use of mechanized programmable tools (robots),which completely automate a welding process by both
performing the weld and handling the part.
• Robot welding is commonly used for resistance spot welding and arc welding in high production applications , such as the
automotive industry
• There are two types of robot welding:
1) arc welding
2) spot welding
ROBOTIC ARC WELDING :
• Arc welding is performed by skilled workers who are assisted by a person called fitter
• The working condition of the welder is typically unpleasant and hazardous.
• The arc from the welding process emits ultra-violet radiations which is injurious to human vision.
• Because of the hazards for human workers in continuous arc welding, it is logical to consider industrial robots for the purpose.
• The major components of arc welding robots are manipulator or mechanical unit and the controller, which acts as the robot
“brain” . The manipulator is that which makes the robot to move.
ROBOTIC SPOT WELDING :
• For larger works on spot welding the welding guns with cables attached is quite heavy and can easily exceed 100lb in weight.
• To assist the operator in manipulating the gun, the apparatus is suspended from an overhead hoist system.
• Even with this assistance, the spot-welding gun represents a heavy mass and is difficult to manipulate by a human worker at
high rates of production desired on a car body assembly line.During resistance welding process the welding electrodes are
exposed to severe heat and pressure.
• When welding with robots is that the cables and hoses used for current and air etc. tend to limit the capacity of movement of
robot wrist.
BENEFITS OF ROBOT SPOT WELDING: IMPROVED PRODUCT QUALITY
OPERATOR SAFETY
CONTROL OVER PRODUCTION OPERATION
SIX AXIS ROBOT:
• Slim, extended reach six axis MA3120 welding robot increases productivity and achieves highest robotic
welding performance. It is used for arc welding applications and carries a payload of 6kg. Horizontal reach
is 3121mm and vertical reach is 5615mm.
• Axis-1: Located at the robot base, allows the robot to rotate left to right. This axis allows the robot to spin up
to a full of 180 degrees range from the centre point.
• Axis-2: This allows the lower arm of the robot to extend forward and backward.
• Axis-3: It allows the upper arm to raise and lower . This axis gives the upper arm the better part access.
• Axis-4: It rotates the upper arm in a circular motion moving parts between horizontal and vertical
orientations.
• Axis-5: This axis allows the wrist to tilt up and down. This axis is responsible for the pitch and yaw motion.
• Axis-6: This is the wrist of the robot arm. It is usually capable of more than 360 degree rotation in either
clockwise or counter clockwise direction.
MIG Welding:
Metal Inert Gas (MIG) welding is a gas metal arc welding

(GMAW) process that uses a continuous solid wire electrode
which is heated and fed into the weld pool from a welding gun.
The two base materials are melted together which causes them
to join. The welding gun also feeds an inert shielding gas
alongside the wire electrode, which helps protect the process
from airborne contaminants . A wire of copper coated mild steel
is fed continuously from a reel through a gun with a melting rate
up to 5m/min. Current through the wire ranges from 100 to 400
A depending upon the diameter of the wire. CO2 is principally
used apart from argon or argon-helium mixture as shielding gas.
The welding machine is a dc constant voltage machine.
Manual MIG/MAG welding is often referred as a semi-automatic process, as the wire
feed rate and arc length are controlled by the power source, but the travel speed and
wire position are under manual control. The process can also be mechanised when all
the process parameters are not directly controlled by a welder, but might still require
manual adjustment during welding. When no manual intervention is needed during
welding, the process can be referred to as automatic.
The process usually operates with the wire positively charged and connected to a
power source delivering a constant voltage. Selection of wire diameter (usually
between 0.6 and 1.6mm) and wire feed speed determine the welding current, as the
burn-off rate of the wire will form an equilibrium with the feed speed.
Advantages and Dis-Advantages of MIG welding:
• Advantages of MIG welding are: • Two Disadvantages are:
• High quality welds can be produced much faster • The MIG welding cannot be used in the vertical or
overhead welding positions because of the high heat
• Since a flux is not used, there is no chance for the entrapment
input and the fluidity of the weld puddle
of slag in the weld metal resulting in high quality welds
• The equipment is complex.
• The gas shield protects the arc so that there is very little loss of
alloying elements. Only minor weld spatter is produced
• MIG welding is versatile and can be used with a wide variety of

metals and alloys
• The MIG process can be operated several ways, including semi

and fully automatic
TIG WELDING
Gas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG) welding, uses the heat generated by an electric arc
struck between a non-consumable tungsten electrode and the workpiece to fuse metal in the joint area and produce a molten weld pool.
The arc area is shrouded in an inert or reducing gas shield to protect the weld pool and the non-consumable electrode. The process may
be operated autogenously, that is, without filler, or filler may be added by feeding a consumable wire or rod into the established weld
pool. TIG produces very high quality welds across a wide range of materials with thicknesses up to about 8 or 10mm. It is particularly
well suited to sheet material.
WORKING PRINCIPLE OF TUNGSTEN INERT GAS WELDING:
• First, a low voltage high current supply supplied by the power source to the welding electrode or tungsten electrode. Mostly, the
electrode is connected to the negative terminal of power source and work piece to positive terminal.This current supplied form a spark
between tungsten electrode and work piece. Tungsten is a non –consumable electrode, which give a highly intense arc. This arc produced
heat which melts the base metals to form welding joint.
• The shielded gases like argon, helium is supplied through pressure valve and regulating valve to the welding torch. These gases form a
shield which does not allow any oxygen and other reactive gases into the weld zone. These gases also create plasma which increases heat
capacity of electric arc thus increases welding ability. For welding thin material no filler metal is required but for making thick joint some
filler material used in form of rods which fed manually by the welder into welding zone.
Advantages and Dis-Advantages of TIG welding:
• Advantages: • Disadvantages:
• TIG provides stronger joint compare to shield arc • Metal thickness to be weld is limited about 5 mm.
welding.
• It required high skill labor.
• The joint is more corrosion resistant and ductile.
• Initial or setup cost is high compare to arc welding.
• Wide verity of joint design can form.
• It is a slow welding process.
• It doesn’t required flux.
• It can be easily automated.
• This welding is well suited for thin sheets.
• It provides good surface finish because negligible metal
splatter or weld sparks that damage the surface.
• Flawless joint can be created due to non-consumable
electrode.
• More control on welding parameter compare to other
welding.
• Both AC and DC current can be used as power supply.
Applications of TIG welding:
• Mostly used to weld aluminum and aluminum alloys.
• It is used to weld stainless steel, carbon base alloy, copper base alloy, nickel base alloy etc.
• It is used to welding dissimilar metals.
• It is mostly used in aerospace industries.
COMPARING MIG AND TIG WELDING:
• Based on Material Thickness
• Because MIG welding employs a consumable filler material to make welds, it can often complete welds of thicker metal objects in
less time than a TIG weld.
• For the TIG welding procedure to be successful without a filler material, the pieces of metal being welded need to be hot enough to
form a bond with each other. Typically, this is easier with thinner pieces of metal than with thicker ones. Using this process on
thicker pieces of metal can create heat stress cracking and other issues.
• Overall, for really thick, heavy-duty welds, MIG welding is the go-to option. For thinner pieces of metal, TIG welding tends to be
the more effective solution.
• MIG Vs TIG Welding: Ease of Control
• Generally speaking, MIG welding is more often recommended for ease of use. The process tends to be a bit more forgiving of
mistakes than TIG welding is—so it’s often recommended for first-time operators and non-professionals.
• TIG welding, on the other hand, requires very strict control over the timing, pressure, and electric current used in the weld. In most
cases, TIG welding is best done using an automated, computer numerically-controlled (CNC) welding machine. Machines can
reliably perform identical welds over and over much more easily than a manual welder could.
• When using an automated welder (whether it’s MIG or TIG), it’s important to get the weld settings and controls just right—
otherwise, you risk repeating the same mistake over and over.
• Which is Better: MIG or TIG Welding?
• The answer depends on the job in question. As noted earlier, MIG welding is typically better for heavy-duty welding work where
larger, thicker pieces of metal are being joined because it uses filler material.
• However, TIG welding can work wonders for joining smaller pieces of metal, such as the wires for a custom steel wire basket. Also,
because the TIG process directly joins two pieces of metal, there’s no filler material to fail—meaning less money spent on welding
supplies.
• With robotic welding equipment, TIG welding can be a bit lower-maintenance, since the welding electrode isn’t being constantly
consumed by the welding process. However, TIG welder parts, such as the welding electrode, still need to be properly cleaned and
polished between uses—especially when welding stainless steel.
• In short, choosing one welding solution as the best should be done on a case-by-case basis, which is why Marlin Steel is dedicated to
having a range of tools and technologies for completing welds.
When Should You Use MIG vs. TIG Welding?
• A basic rule of thumb when choosing between MIG and TIG welding is to consider the following:
• How thick are the two pieces of metal being joined?
• Thicker pieces of sheet metal are very difficult to weld by simply heating them up until they fuse—the thicker they are, the more
energy it takes to heat them to the melting point and the less efficient TIG welding becomes. If metals are especially thick, then MIG
welding may be more effective.
• What is the electrical conductivity of the metal being joined?
• Another variable to consider is how ductile the metal being joined is. The heat used to fuse metal in an electric arc welding process
is generated by the metal’s inherent electrical resistance as the electric arc tries to pass through the weld site. If metal is highly
ductile, it will take more time to heat up, which consumes more energy. Electrically-resistant metal will heat up faster, making it
easier to weld without filler material.
Am I welding dissimilar metals?
While it isn’t usually a good idea to weld dissimilar metals since it could cause numerous issues (weak bonds, weld corrosion,
etc.), there are times where it may be unavoidable. If two dissimilar metals are being welded, it’s usually better to use a weld
technique that supplies a filler material to create a bond. However, this filler material needs to be carefully chosen.
Is surface condition/smoothness important?
Filler materials increase the risk of weld spatter being left on the surface of a workpiece, requiring extra work to smooth out if the
elimination of surface flaws is important. Direct metal-to-metal welds sidestep this issue to create welds that are typically much
cleaner than filler-dependent ones.
INTERNSHIP OUTCOMES:
During the course of the internship, I learnt :
o Basics of robotic welding and how it works.
o How to analyze a problem and work efficiently with connections.
o How MIG and TIG welding works .
o Comparision between MIG and TIG welding.
o When you should use MIG or TIG welding.
o Identifying the different problems one may encounter during welding.
o I learned how to adjust myself in the work environment, how to deal with people at work.
o It’s a good and quality experience, the necessary kind of experience as it helps you realize what you want in future. Also
got the opportunity to evaluate myself under these stressful conditions.
CONCLUSION:
• It was a nice learning experience at INDO AUTOTECH PVT.LTD for four weeks in NARSAPURA, KOLAR DISTRICT.
• I was given exposure in almost all the department at the plant. The knowledge gained from the employees is appreciating,
sharing the experience which they have gained in their time of working in the company.
• I am very much thankful for the wonderful facility from INDO AUTOTECH.
• The knowledge I gained during my time here will surely help me in my future and shaping my career.
MVJ College of Engineering
Near ITPB, Whitefield
Bangalore-560 067
M: principalengg@mvjce.edu.in
Thank You
P: +91 80 4299 1040

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A Presentation on Internship Work

PRESENTED BY EXTERNAL GUIDE INTERNAL GUIDE

NAME: Harshith k NAME: Mr GAJENDRA SHARMA NAME: Mrs SHWETA AGRAWAL

• About the Organization

• Tool Room • Furnace Brazing for MS Parts

• There are two types of robot welding:

• The working condition of the welder is typically unpleasant and hazardous.

BENEFITS OF ROBOT SPOT WELDING: IMPROVED PRODUCT QUALITY

CONTROL OVER PRODUCTION OPERATION

Metal Inert Gas (MIG) welding is a gas metal arc welding

• Advantages of MIG welding are: • Two Disadvantages are:

• MIG welding is versatile and can be used with a wide variety of

• The MIG process can be operated several ways, including semi

• Mostly used to weld aluminum and aluminum alloys.

• It is used to welding dissimilar metals.

• It is mostly used in aerospace industries.

• How thick are the two pieces of metal being joined?

• What is the electrical conductivity of the metal being joined?

Is surface condition/smoothness important?

During the course of the internship, I learnt :

o Basics of robotic welding and how it works.

o How to analyze a problem and work efficiently with connections.

o How MIG and TIG welding works .

o Comparision between MIG and TIG welding.

o When you should use MIG or TIG welding.

o Identifying the different problems one may encounter during welding.

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