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TOPIC : WELDING-OAW PROCESS TITLE : T FILLER JOINT OXY ACETYLENE PROCESS FLAT POSITION AND BRAZING (LAP JOINT)

) FLAT POSITION

INTRODUCTION Oxyacetylene welding, commonly referred to as gas welding, is a process which relies on combustion of oxygen and acetylene. Oxyacetylene equipment is portable and easy to use. It comprises oxygen and acetylene gases stored under pressure in steel cylinders.

TASK OUTCOME By the end of this task, student should be able to: Apply safety procedures when operating oxy acetylene welding equipment. Set up oxy acetylene welding equipment, obtain and adjust the correct flame required. Prepare and choose the correct welding nozzle size, filler rods, gas working pressure and welding speed. Weld work piece on flat position. Keep the workshop clean and safe.

Qualification and knowledge basic. Adjust to correct flame neutral. Working position. Torch angle. Terminating the molten pool. Deposition of filler rod Definitions for point and grades. Detecting weld defects.

EQUIPMENT/WORKING TOOLS HAMMER

enforce a crooked iron

GOGGLE

protect the face from the light

GLOVE

protect hands from debris welding materials PLIERS

pick up hot objects

ROD

to add to the crater during welding

WIREW BRUSH

to brush the dirt

SET WELDING

set to weld

SAFTEY PRECAUTIONS Before we entered the workshop or laboratory then we need to know about safety in the workshop or laboratory said. In early stage, the lecturer will explain the safety rules to students. Safety rules in the workshop to be learned from time-to time. This is because we will start working with electrical appliances and electronic equipment. When we work then we need vigilance to prevent an event want not happen. The causes of safety-related electronic devices, the need is known and good work habits and safe should be practiced regularly. Similarly, in order for all the work or equipment is in good condition.

WELDING PROCEDURES T joint project Practice welding safety procedures. Prepare and clean work piece and place work piece flat on table. Set to neutral flame. Prepare welding goggle in welding position. Start welding by preheating base work piece. Locate point of start and start melting the work piece to obtain the molten pool. Maintain 3-5 mm inner cone length from molten pool and proceed to direction of travel forehand technique. Make sure torch angle is 60o 70o to the direction of travel and inclination torch angle is 45o. Make sure the filler rod angle is 30o 40o to the directional of travel. Clean weld bead and check for irregular bead formation. Clean work piece and submit for evaluation.

Lap joint project Practice welding safety procedures. Prepare and clean work piece and place work piece flat on table. Set to very slight carburizing flame. Prepare welding goggle in welding position and preheat work piece. Deposit flux on joint and reheat again until flux liquefies. Deposit brass rod and push forward by using the flame. Maintain 3 5 mm inner cone length and proceed to direction of travel forehand technique. Make sure torch angle is 60o 70o to the direction of travel and inclination torch angle is 45o. Make sure the filler rod angle is 30o 40o to the directional of travel. Clean brazed joint. Check for bead irregularities. Clean work piece and submit for evaluation.

DISCUSSIONS

CONCLUSION A good welding shows the perfect running beads as nothing happened in the joining process. But if there any defect that is too large, the welding process should to be done again.

REFERENCES www.google.com www.yahoo.com www.scribd.com

TOPIC : WELDING OAW PROCESS TITLE : REESTABLISHING RUNNING BEADS AND T FILLET JOINT FLAT POSITIONS

INTRODUCTION Shield metal arc welding(SMAW) is performed by striking an arc between a coated-metal electrode and the base metal. Once the arc has been established, the molten metal from the tip of the electrode flows together with the molten metal from the edges of the base metal to forma sound joint. This process is known as fusion.

TASK OUTCOME By the end of this task, student should be able to: Apply safety procedures when operating SMAW welding machines and oxy acetylene welding equipment. Select correct electrode size and types, welding current, welding amperage and polarity. Set up oxy acetylene welding equipment, obtain and adjust the correct flame required. Prepare welding process, determine welding speed, electrode angle and arc length. Prepare and chose the correct welding nozzle size, filler rods, gas working pressure and welding speed. Prepare material, correct type and size of electrode and welding process for joints. Weld work piece on flat position. Keep the workshop clean and safe.

QUALIFICATION AND KNOWLEDGE BASIC Adjust welding current. Working positions. Electrode angle. Terminating the arc. Detecting arc blow. Controlling slag flow. Definitions for point and grades. Detecting weld defect.

EQUIPMENT/WORKING TOOLS

PROTECTIVE SHIELD

Provides full facial protection from: Sparks and flying metals. HEAD SHILD Intense light from arc .

GLOVE To protect hand from: GLOVE Spark and flying metals. Hot metal during and after

PLIER PLIERS Hand tool used to hold objects firmly or for cutting and bending tough materials.

enhancer for mewelding rod material ROD

WIRE BRUSH WIRE BRUSH Wire brush is used for cleaning rust and removing paint.

It is also used to clean surfaces and to create a better conductive area to remove debris slag HAMMER

to protect from welding debris

APRON

Two types of supply:

Alternating current (AC) welders.

Direct current (DC) welder. MESHINE WELDING Wider variety of electrode available. Better for welding thin metals. DC straight polarity (DC-EP) haselectrode negative and workpiece positive. Produce high electrodemeltin rate.

ELECTRODE HOLDER

TABLE WELDING

Grips the electrode.

Handles and clamp are insulated.

Grooves in the clamp enable changing the

WORKPIECE CLAMP ROD CLAMP Complete the electric circuit from power supply, through the electrode across thearc through the workpiece and back to the power supply.

SAFETY PRECAUTIONS Never weld without a proper face shield. Closed shoes must be worn. Long-sleeved, non-flammable shirt must be worn. Wear proper welding gloves. Never weld on or near anything that's been cleaned with a chlorinated hydrocarbon like brakecleaner. Combined with UV light it can create phosgene gas. THIS CAN KILL YOU OR PEOPLE NEARBY or hurt you really badly. Ventilation will not prevent poisoning. Always wear ear protection (earplugs or muffs) if there's any chance at all a spark could bounce or fall into your ear canal. An eardrum punctured by a spark will instantly cauterize and never heal. If you burn yourself, immediately douse with cold water.

WELDING PROCEDURES Reestablishing running beads Practice welding safety procedures. Prepare and clean work piece and place work piece flat on table. Set the desired welding current and welding current amperage is 70 90 amps. Choose correct electrode size 12 and place electrode in electrode holder. Prepare welding helmet in welding position. Strike arc and start welding. Make sure arc length between 3-5 mm and electrode angle is 65o 75o to the direction of travel. Make sure that electrode inclination angle is 45o. Remove slag and observe weld bead and check for irregular bead formation. Continue until all 3 beads have been laid down. Remove all slag on work piece and submit for evaluation.

Tee fillet joint Practice welding safety procedures. Prepare and clean work piece and place work piece flat on table. Set the desired welding current and welding current amperage is 70 90 amps. Choose correct electrode size 12 and place electrode in electrode holder. Prepare welding helmet in welding position. Strike arc and start welding. Make sure arc length between 3-5 mm and electrode angle is 65o 75o to the direction of travel. Make sure that electrode inclination angle is 45o. Remove slag and observe weld bead. Check for irregular bead formation. Remove all slag on work piece and submit for evaluation.

DISCUSSIONS

CONCLUSION A good welding shows the perfect running beads as nothing happened in the joining process. But if there any defect that is too large, the welding need to be done again.

REFERENCES www.google.com www.yahoo.com www.scribd.com

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