JABATAN KEJURUTERAAN MEKANIKAL MECHANICAL WORKSYOP PRACTICE ARC WELDING NUR HALIZA BINTI AHMAD SUHAIMI 02DKM12F2011 DKM

1A ENCIK AZMIN BIN ABIT

INTRODUCTION The basic principal of arc welding involves heating or melting of the base metal using electric arc. The electric arc is formed when there is a voltage difference between the metal coating at the end of the electrode and the surface of the metal. The Arc will produce enough to the melt the base metal and the end of the electrode to form a pool of molten metal. Arc welding is one of alternative for joining process in manufacturing. Arcwelding process had done by create an electric arc between electrode and thebase material to melt the metal at the welding point using welding power supply.The welding region is sometimes protected by some type of inert or semi-inertgas, known as a shielding gas and sometime adds by an evaporating filler material.Shielded metal arc welding (SMAW), also known as manual metal arc(MMA) welding or informally as stick welding, is a manual arc welding process that uses a consumable electrode coated influx to lay the weld. They can useeither direct current (DC) or alternating current (AC) from awelding power supply, used to form an electric arc between the electrode and the metals to be joined. As the weld is laid, the flux coating of the electrode disintegrates, giving off vapors that serve as a shielding gas and providing a layer of slag, both of which protect the weld area from atmospheric contamination

LEARNING OUT COMES At the end of this lab work, student able to: -Understand of arc welding in joining process -Type of metal and electrode that are used in arc welding. -Know the angles that are used in arc welding

EQUIPMENTS 1)Electrodes 2) Glove. 3) Wire brush .4) Chipping hammer r 5) Apron. 6) Head shield. 7) Electrode holder. 8) Pieces of metal 9) SMAW main apparatus (electrode, power supply, etc.) 10)welding leads 11)ventilation system

SAFETY PRECAUTIONS Welding is a process involving with electricity and high temperature (heat), so we must take precaution in doing this process to as precaution. 1) Wear safety equipment such as head shield, glove and apron (safety jacket)before start welding. 2) Do not watch the ultraviolet rays spatter when welding using eye without a head Shield. 3) Carry Out at a comfortable area and where the is good welding will be doneaway from the flammable materials 4) Do not disturb other student that are still work. 5) Do not use tools that we do not recognise

PROCEDURES Firstly, make sure to wear protective clothing and Then ground the workpiece by clamping to the table. Suitable electrode was selected and inserted it in the electrode holder. After that, the proper welding was setting that range from 105A After choosing the desire welding setting, then turn on the welder. Be careful not to touch the electrode to the workpiece or worktable until ready to strikean arc. Then, strike an arc with long scratching motion of the electrode across the workpiece. Finally of the weld, quickly lift the electrode away from the workpiece. The electrode was dropped from the holder and put down the electrode holder. Wearing clear shield on the welding helmet, chip away the slag on the weld bead. After completed all the above process, make sure to tidy up your worktable

PROCEDURE DEPOSITING A BEAD 1) 2) 3) 4) 5) Obtain a piece of mild steel Postion the workpiece in flat position Deposit beads along the lines Start from the left edge and work to the right After each line has been filled .removes the slag and examine the weld bead

WELDING A BUTT JOINT IN A FLAT POSITION Obtain two pieces of 3/16 or 1/4' mild steel Form a butt join with aroot opening for expansion and tack together Position the workpiece so the weld join is in flat position Hold the electrodes at a work angle 90 and a travel angle 15 and 30.deposit a bead along the butt joint 5) Let the workpiece cool. 1) 2) 3) 4)

WELDING AN OUTSIDE CORNER JOINT IN FLAT POSITION Obtain two pieces of 3/16 or 1/4 mild steel Form a corner joint with the pieces at a 90 angles and tack together Position the workpices so the weld joint is in a flat position Hold the electrodes at a work angles of 45 and a travel angle of 30.deposit a bead along the outside of a the joint 5) For the most corner joints,one bead is sufficient.thick metals may require additional passes to fill the corne 1) 2) 3) 4)

DISCUSSION As a result, a welded joint may develop various discontinuities. Welding discontinuities also can be cause by an inadequate or careless application of proper welding or by poor operator training. The major discontinuities that affect weld quality are described here. 1)Porosity Porosity in welds may be caused by: -Gases released during melting of the weld area, but trapped during solidification. -Chemical reactions during welding.Contaminants. Porosity can be reduced by: -Proper selection of electrodes and filler metals -Improved welding techniques, such as preheating the weld area or increasing therate of heat input. -Proper cleaning and the prevention of contaminants from entering the weld zone. -Reduced welding speed allow time for gas to escape. 2) Incomplete Fusion and Penetration Incomplete fusion produces poor weld beads. A better weld can be obtained by the use of the following practices: -Raising the temperature of the based metal. -Cleaning the weld area before welding. -Changing the type of electrode used. -Providing sufficient shielding gas. Incomplete penetration occurs when the depth of the welded is insufficient. Penetrationcan be improved by: -Increasing the heat input. -Reducing the travel speed during welding. -Modifying the design. -Ensuring that the surfaces to be fit each other properly. 3) High amperage

-The electrode will melt faster and molten puddle will be excessively large and irregular. -Excessive spatter will occur due to high amperage. Its a scattering of molten metal particles that cool to solid from near weld bead. Low amperage -Not enough heat to melt the base metal and molten pool will be too small. -Lead to incomplete fusion -as both metals are not completely joined by the weld. -The correction for this problem would be to increase heat, slow travel speed and increase arc length.

CONCLUSION As conclusion, the objective can achievable to do the practical welding. The student musthave skill to do the welding, used the knowledge and understanding of the theories, and alsowelding techniques are applied in the practical welding. The practical task have been completeand the report will accomplished to prove the student can be do the practical task of Shielded metal arc-welding (SMAW). To get a best result of this arc welding process, student must know the angle that are used, concentration, and the movement of the electrode and speed of moving the electrode.The thickness of the metal and type of the electrode are used are the factor in arc welding .

REFERENCES
-http://en.wikipedia.org/wiki/Arc_welding

-Buku teks kejuruteraan mekanikal tingkatan 4. Mohd. Nasir Bin Tamin, Nawawi -Mohd Jan,Kaharrudin Bin Ismail. 2005 Dewan Bahasa dan Pustaka http://www.aee.vt.edu/teacher-resources/lab-safetyresources/arcwelder.pdf -welding skills 3rd edition B.J.MONIZ AND R.T.MILLER 2004 by AMERICAN TECHNICAL PUBLISHER