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Purpose:
Equipment:
1. Welding Machine.
a) Alternating Current-AC
b) Direct Current-DC
2. Cables.
Generally, there are two cables that carry the electricity from welding machine
to work metal and back to welding machine and earth cable. These cables are
made from small copper wire coated with strong rubber so that we can hold it
without feeling the intense heat. Besides that, every cable has it own size. For
instance, size No. 2 means that the cable will be able to withstand welding
electricity up to 200 amps. These cables are connected to the welding machine
through its copper end.
3. Electrode Holder.
The electrode holder has a few functions. Firstly, it is used to provide the
electricity from welding machine to metal work. It is also used to hold the
electrode during the welding operations. One of its constructive parts is the
spring where it can hold the electrode firmly and withdrawn the electrode easily
after finish welding. A few important requirements for the electrode holder are
the electrode holder must be lightweight, has good rubber coating and easy to
handle for certain period of time. Apart from that, it must also have its own size
for the amount of electric current that it can carry.
4. Earth Holder.
The earth holder is connected to the earth cable and clamped to the work metal
or to the work table. It has a spring so that is can be easily clipped and
unclipped. Without this equipment, welding operation definitely cannot be
done.
4. Shield.
5. Chipping Hammer.
It is made from an old punch, chisel or spring metal. Shape like a chisel at one
end and has a sharpened end at the other one. Its holder is made from welded
soft metal. It is used commonly to remove the slag excess stringer from the
surface of the work metal.
6. Wire Brush.
It is used to clean the surface of the stringer bed after the slag is chipped away
and to remove dirt from the surface of metal work before welding can be done.
7. Glove.
It must be made from high quality leather. Use to protect your hand from fire-
bolt and hot metal welding.
8. Leather jacket.
Leather jacket is used to protect the user from the intense heat produced during
welding operations. It is made of high quality leather to provide greater comfort for
the user.
9. Tongs.
Procedure:
Connect the electrode cable and the earth cable to the Direct Current Welding
Machine.
i. Clip the earth cable using its holder to the work table.
ii. Clip an electrode with the holder. Make sure that the flux is not in contact with
the holder. Undesired spark may occur if the flux is in contact with any metal.
iv. Before we begin welding, we should put on our gloves and shield.
v. Take a piece of scrap metal and put it on the working table.
vi. Hold the electrode about 90o above the scrap metal. Tilt the electrode 20 o-
25odegrees to the right or left depending on which hand do you use from the
work metal.
vii. Scratch the front end of the electrode onto the work metal to start the burning.
After the electrode has started burning, hold it at 10mm above the work metal.
Try to avoid the electrode from being in contact with the surface of work
because the electrode might be stucked onto the work.
viii. Repeat the welding process for several times until you get a straight and firm
stringer bead line when welding.
xi. You must weld onto the block line by line. When you finish welding a line, use
the chipping hammer to chipped off the slag and brush it off using a wire brush.
xii. Stop when you have finished welding the side in three layers.
Safety Precautions.
c. Protect your face and body from heat radiation and molten metal.
d. Move all the flammable material off the working place or cover it up using
fireproof material.
f. Make sure that all line holder, earth clip and connection placed on good place.
h. Make sure that all electric connection is tight, clean and dry.
i. Avoid pulling the cable on top or near sharp things.
l. Avoid welding cable from be in contact with hot metal, water, oil and grease.
n. All equipment such as hammer, chisel, brush and others must be well
maintained.