INTRODUCTION

Arc Welding
Electrical arc welding is the procedure used to join two metal parts. Its
take advantage of the heat developed by the electric arc that forms
between an electrode (metal filler) and the material to be welded. This
welding arc may be powered by an alternating current generator
machine. The welding machine is basically is a single-phase static
transformer suitable for melting rutile (sliding) acid electrodes. Alkaline
electrodes may also be melted by alternating current if the secondary
open-circuit voltage is greater than 70 V. The welding current is
continuously regulated (magnetic dispersion) by turning the handwheel
on the outside of the machine, which makes it possible to select the
current value, indicated on a special graded scale, with the utmost
precision. To prevent the service capacities from being exceeded, all of
our machines are fitted with an automatic overload protection which cuts
of the power supply (intermittent use) in the event of an overload. The
operator must then wait for a few minutes before returning to work. This
welding machine must be used only for the purpose described in this
manual.

Type of Arc Welding Machine

DC inverters
Unlike traditional arc welders, modern DC inverter arc welders are very small,
light and portable. Even the cheap ones available from as little as 100 function
well, though the more expensive ones (up to 500) will be much more robust
and will normally last much longer.

AC/DC inverters
These are normally aimed at TIG welding, and would not be bought for arc
welding alone, but they generally have arc welding settings.

DC transformer welders
Transformer based arc welders are normally very heavy, and are aimed at TIG
welding in a workshop rather than portability.

AC air cooled welders

Often referred to as buzz boxes. A number of companies made reasonable
quality air cooled AC welders in the past. The technology is now the reserve of
DIY stores selling welders to people who don't know any better. They are the
least usable of any type of arc welder.

Type Of Joints

Type of Electrode
Consumable Electrodes

Consumable electrodes slowly burn away as they are used,

and need to be replaced at regular intervals. These
electrodes are purchased in bulk and are much less
expensive than the permanent versions. They are generally
considered to be easier to use, but do not have many
commercial uses. While a gas may be used in addition to the
electrode to help shield the weld, it is not always necessary
with consumable electrodes because of the gases their
burning
produces.
Flux

Consumable electrodes are coated with chemicals known as

flux. Most flux coatings are designed to create a smoother,
protected weld. As the flux burns it produces a small cloud of
gas, shielding the weld from oxygen and other contaminants
that can ruin its cooling process. The metal of the
consumable electrode is also burned and added to the weld
to help with stability. There are many different kinds of flux
coatings with slightly different effects to choose between.

Nonconsumable Electrodes

Nonconsumable electrodes to not burn away as they channel

the electric current and last much longer. Nonconsumable
electrodes, such as tungsten rods, are considered more

difficult to use than consumable versions, and must be used

with a shielding gas. This gas can be one of several
compounds and is spread out at the site of the weld to
perform the same protection tasks that the flux does in
consumable models. Nonconsumable electrodes can be used
with a wider variety of metals, especially the heavier metals.

OBJECTIVES
1.To study about arc welding.
2.To study how to conduct project using arc
welding .
3.To study the safety precautions in workshop.
4.To study how to make corner joint using arc
welding.

SAFETY PRECAUTIONS

1. Use the goggle, apron and gloves before start the

operation.
2. Remove all unneeded accessories.
3. Wear a safety boots to protect leg.
4. Do not playing in workshop.
5. Avoid holding and touching a sharp tool.
6. Machine must have a safety switch.
7. Ask permission from the lecturer before start using
the machine.
8. Do not simply touch the welding product during
welding process. High temperature may cause
serious injury.

TOOL EQUIPMENT
TOOLS

FUNCTION
Supply power and
voltage.

use E6013 for this

project.

use to hold electrode.

 use to protect face.

use to protect hand.

use to hit the notch.

 use to clean the ash

after hit by the
hammer.

use to protect body.

use to protect leg.

work material use in

this project.

PROCEDURE
1. Firstly, pay attention to lecturers advice and
instruction. Do not simply touch, carry or start any
machine without lecturers permission.
2. Set a target about the process going to complete.
Discuss and separate jobs with teammates.
3. Wear the safety equipment before starts the working
steps.
4. Find an empty working space, clean up the unneeded
things and wastes.
5. Check if the machine is in function.
6. Prepare the tools and item that going to be used.

When everything was ready, we starts the welding

process with the following steps:

1. Ready with metal plates, including four side plates

and a base plate.
2. Ensure that all metal plates are having the same
length and width.
3. Taking two side plates, connecting them corner by
corner.
4. Ensure that the angle between the plates is
accurately 90 degree, measure by using L-shape
rule.
5. Locate a block beside the plates to prevent the
plates from dislocation during welding process.

6. Place a base plate on the welding area to cover up

the gap on the table, to prevent fall of object during
welding process.
7. Clamp the E6013 electrode and part of table using
the clamps from machine to complete the circuit for
the welding process to begin.
8. Ensure that the correct end of electrode is clamped.
9. Switch on the machine and set the current value to
75 ampere.
10. Start the welding process. Touch the metal plates
corner first.
11. Repeat step 3 to 10 by replacing the other two
pieces of metal side plates.
12. After both set of metal plates is completely
touched, carefully connect them corner by corner
and insert the base plate.
13. Measure the angle between each plate by using Lshape rule. Make sure it is accurately at 90 degree. If
not, adjust it to a proper angle of 90 degree by using
hammer.
14. Check if there is any visible gap between the
plates, if it exists, it means that there is an error in
measurement.
15. Touch the other corners of metal plates.
16. After all corners has been successfully touched,
Ensure again that every side of metal plate are in
correct dimension.
17. The welding process is completed after all (four)
corners are successfully welded.

ANALYSIS
To get a good notch, move the electrode to the top the
welding part, but not contact the electrode with the
welding surface. During welding process, move the
electrode across the welding surface with a constant
and medium speed and a angle of 45 degree between
the electrode and welding surface.

Initially, do not fully weld the corner. Touch at both ends

of corner first. This step is mainly to lock the location of
the metal plates. If there is an error in measurement,
such as the angle between the plates is not exactly 90
degree, we can correct it by using tools such as
hammer and L-rule. After all corners has been
successfully touched and correctly dimensioned, the
welding process can be proceed completely.

If the end of electrode stick on the welding surface

during the welding process, switch off the machine
immediately and separate them by hammer. Do not
touch any part of welding product since it is still in
extremely high temperature. After that, check if there is
any dislocation and relocate the metal plates to their
original location if necessary.

There are some mistake in our welding process. The

metal plates is displaced during the welding step and
we did not realize. This results an incorrect angle
between the plates. Besides, we did not weld the corner
with constant speed, this results a bad notch after
welding.

DISCUSSION
Before start the project, we have been exposed about
arc welding. After that, we have been given a task and
been explained about the procedure of the project by
our lecturer. We also have to use the safety equipment
such as safety boots, workshop jacket, goggle, gloves
and the others.

The task that we had been given for this project is to

weld the corner joint. We followed the procedure step
by step. There are some problems while conducting the
project such as how to weld with good notch. We have
to set the value of voltage depend on the comfortibility
of ourselves. So, we have study how to set the voltage
and make a good notch for this project.

At the end of the week, we have complete the project

successfully and we have study how to use the arc
welding with equipments.

CONCLUSION
At the end of the project, we know about arc welding
machine that we use in this project. We also know how
to conduct the arc welding machine. Besides, we have
been exposed the safety precautions in workshop and
we have study how to make corner joint using the arc
welding machine. Lastly, we study the precautions
during welding process. The product is successfully
completed by following the procedures step by step.

REFFERENCE
http://en.wikipedia.org/wiki/Arc_welding
http://en.wikipedia.org/wiki/Electrode
http://www.weldcraft.com/education/joint-types/
http://engineeringhut.blogspot.com/2010/11/safetyprecautions.html

ATTACHMENT

SKILL

: WELDING

NO
ELEMENTS
A Part length 75mm 0.4
B Part length 75mm 0.4
FINISHING
C MATCHING OF PART

READING*
72.7
74.32

TOTAL

SECTION:
NO. OF GROUP:
SUB GROUP:

CHECKED BY:
SIGNATURE:

MARK
/2
/2
/5
/5
/14