Fabrication Tech

MERCHANT POLYTECHNIC COLLEGE
BASNA
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Shri ________________________________
Roll no. of class 6TH MECHANICAL
Has satisfactorily completed the course in

Febrication technology (361916)
Within four walls of merchant Polytechnic College,Basna.

Date of submission : Faculty/ Staff
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FABRICATION TECHNOLOGY- 2011
BASNA
MERCHANT POLYTECHNIC COLLEGE BASNA
Febrication technology (361916) LABORATORY PRACTICAL INDEX

Sr No. 1 Name of Experiment Introduction of fabrication Page no. Date of Start Date of Comp. Comp. Sign Marks
Interpretation of fabrication drawing Arc welding job Gas welding job
Spot welding job Mig welding job
Edge preparation
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Total Marks
Signature of Faculty
2 FABRICATION TECHNOLOGY- 2011
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Practical: 1 AIM: INTRODUCATION OF FABRICATION TECHNOLOGY
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Objectives: Understanding meaning of fabrication, difference welding processes And operational information. Advantages of fabrication in engineering field.
Define Fabrication Fabrication as an industrial term refers to building metal structures by cutting, bending, and assembling. The cutting part of fabrication is via sawing, shearing, or chiseling ,torching with handheld torches and via CNC cutters The bending is via hammering ,press brakes and similar tools. The assembling is via welding, binding with adhesives, riveting, threaded fasteners, or even yet more bending in the form of a crimped seam. Structural steel and sheet metal are the usual starting materials for fabrication, along with the welding wire, flux, and fasteners that will join the cut pieces. As with other manufacturing processes, both human labor and automation are commonly used. The product resulting from (the process of) fabrication may be called a fabrication. Shops that specialize in this type of metal work are called fab shops. Need of Fabrication:
In the past, full penetration welding involved costly back gouging, grinding, and rewelding. With non metallic weld backings you can achieve X-ray quality, full penetration welds from one side and in a single pass. The result is a finished high quality weld and a savings of labor, materials and time. Weld backings are manufactured in many different configurations and in formulas for the diverse conditions encountered when welding anything from light gauge sheet metal to heavy metal fabrication. Weld backings can be used to compensate for poor fit-ups, and is a valuable tool when welding conditions are not ideal or where the back side of a weld joint is inaccessible.
Weld backings are non metallic, non hygroscopic, neutral, and unlike metal backing bars, do not become part of the finished weld. When properly positioned and attached to the back side of a weld joint, your welds can be free of defects, eliminating rework and cleanup associated with poor root welds.
One-sided one-pass and one-sided multi-pass welds are possible with weld backings. Our backings support molten weld metal over a wide range of welding heats resulting in uniform back beads of finished quality.
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Welding is widely used by metalworkers in the fabrication, maintenance, and repair of parts and structures. While there are many methods for joining metals, welding is one of the most convenient and rapid methods available. The term welding refers to the process of joining metals by heating them to their melting temperature and causing the molten metal to flow together.
Advantage of Fabrication Technology: : Welding is a very commonly used permanent joining process. Thanks to great advancement in welding technology, it has secured a prominent place in manufacturing machine components.
. A welded joint has following advantages: Compared to other type of joints, the welded joint has higher efficiency .An efficiency > 95 % is easily possible. Since the added material is minimum, the joint has lighter weight. Welded joints have smooth appearances .Due to flexibility in the welding procedure, alteration and addition are possible. It is less expensive Forming a joint in difficult locations is possible through welding. Welding is generally the simplest, fastest, and most cost-effective method, Structural metals. welding doesn't require parts to fit exactly. Methods like bolts or screws require some type of flange or overlap of parts, so with welding, weight and material savings can be realized. A high quality weld can often be stronger than the parts to be joined, though this should not be depended on. It's probably less true than may welders might claim.
Disadvantage:
The biggest disadvantage is that welds often contain defects. In practice welding is less reliable, less predictable than other methods. Problems caused by faulty bolts are relatively rare, problems caused by bad welds are fairly common. Obviously, welding creates a permanent joint, not desirable if parts need to be fixed or replaced later.
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effective for thin sheet metal. Used of Fabrication in Various Fields: Assemblers and fabricators Boilermakers Computer control programmers and operators Jewelers and precious stone and metal workers Machine setters, operators, and tendersmetal and plastic Machinists Plumbers, pipe layers, pipefitters, and steamfitters Sheet metal workers Tool and die makers Space craft ,.Automobile ,Aircraft and Marine craft
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Welding very thin sheets is difficult, in some situation rivets or screws are more cost-
The advantages have made welding suitable for joining components in various machines and structures. Some typically welded machine components are listed below. Pressure vessels, steel structures. Flanges welded to shafts and axles. Crank shafts Heavy hydraulic turbine shafts Large gears, pulleys, flywheels Gear housing Machine frames and bases Housing and mill-stands.
While designers need some basic knowledge of welding processes, equipment, materials, and techniques, their main interest is in how to transfer forces through welded joints most effectively and efficiently. Proper joint design is the key to good weld design.
The loads in a welded-steel design are transferred from one member to another through welds placed in weld joints. Both the type of joint and the type of weld are specified by the designer.

each type of weld.
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So its important for a designer to know what are the types and edge preparations are possible in
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welding defects In the welding time there are some weld defects are found, which is may cause of damaging the job or reducing the job life. If we take some awareness of welding then it may be prevented. The welding defects are

Lack of Penetration. Porosity. Slag Inclusions. Undercuts. Cracking. Incomplete fusion Overlap Extra spatter deposition Crater
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The major welding defects are describing bellow. Lack of Penetration: The lack of penetration is one kind of welding faults. If the molten base metal does not fill the correct design depth of base metal it is called lack of penetration. Whether that penetration can be obtained depends upon the accessibility of the heat source and filler rod to the face area. The lack of joint penetration may result from improper technique, insufficient welding heat, improper fit-up, or improper joint design. If all other factors are correct, proper fusion depends on the skill and technique of the welder, the technique of welder mostly depends on the type and position of the joint. The lack of penetration may also depends of too long arc, always keep the arc as short as possible. Porosity or Blow Holes: If air trap inside the molten metal or trapping air comes out through the molten metal it makes the small holes it caused porosity or blow holes. The entrapped gas comes from either the gas used in the welding process or the gas released from chemical reaction occurring during the welding process. Proper welding technique avoids gas formation and entrapment. One o the main factors contributing to this fault is the condition of the electrode, particularly the moisture content of the coating. The essential factor depends upon electrodes design which should be base metal related. The current is the essential part for the porosity, too low a welding current is generally more frequent cause of porosity than too high current. Rust, scale, galvanizing, oil or dampness on the work surface promote porosity.

Slag Inclusion: Slag or other non-metallic foreign matter entrapped in the weld joint its called slag inclusion. The usual source is the slag formed by the electrode coating and dirty surface is also other cause. The correct weld joint design is can play very important part. The another most cause of slag inclusions is inadequate removal of
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the slag between the deposition of successive runs in which is associated with undercutting or unevenness of surface. Cracks: Cracks are occur in the weld and /or base metal when localized stress is exceed. The crack generally associated with notches, discontinuity welding and base metal, with high residual stresses and sometimes with hydrogen embrittlement. Where the metal were harden there are generally observed cracks. Cracks are generally divided into two major parts, which is hot cracks and cold cracks. The hot cracks are formed in high temperature and cold cracks are formed after solidification is completed. To avoiding the cracks the welder should avoid rapid cooling the weld.

Practical: 2 AIM: INTERPREATION OF FABRICATION DRAWING
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Objectives: Understanding different types of joints with its symbol in fabrication engineering drawing And also learn about standard location of elements of a welding symbol and representation, types of welding and welding joints.
Weld joints and its Symbols: Weld symbol is indicated the type of weld joint. Weld joints are classified according to the method of joining as butt joint, lap joint, strapped joint, tee joint and corner joints. In butt joint, the two plates to be welded are placed in the same plane face to face before welding Name of joint Fillet joint Joint drawing Symbol Name of joint Square butt joint Single V butt joint Single U butt joint Double V butt joint Double U butt joint Joint drawing Symbol
Single bevel butt joint
Double bevel butt joint
Single J butt joint
Double J butt joint
Edge joint
Backing strip
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Spot welding
Seam welding
In figure notice there are designated locations for the size, length, pitch (center-to-center spacing), groove angle, and root opening of a weld. These locations are determined by the side of the reference line on which the weld symbol is placed. Figure shows how dimensions are applied to symbols.
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Practical: 3 AIM: ARC WELDING

Objectives: Understanding the various component of arc welding machine and application of various accessories and can perform arc welding process where ever it required.
In electric arc welding is only a electrical spark, otherwise it is nothing. It is fusion welding process. It is work in a closed electrical circuit in which current flows. If a small gap formed in the circuit then there an electrical spark is occurred, which is called electrical arc. In this spark or arc are contain a huge amount of temperature like 34000C-40000C. Due to this huge temperature, the weld metal can be fuse in arc welding process. Principle of Arc welding
In the arc welding the heat is produced through an electrode or arc welding rods. The electric arc is produced between consumable electrode and the work piece. The current is continuously supplied through the consumable electrode and fillet deposited on work piece. Thus the electric arc welding process is carried out. The electrode which is passing the current is made with flux coated, these types of electrode is called bar electrode. The coating flux are melt at the time of welding and deposited upper level of filler metal as a slag, which is removed by chipping or grinding process after normal cooling. The filler metal is called electrode in arc welding practice. The carbon-arc welding is the another type of arc welding. Where carbon or graphite are used as a electrode. There are two methods used for produced an arcs, the single-carbon process and another
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is the twin-carbon process. The main difference is, the twin-carbon arc welding carried electrically independent torch. The carbon-arc welding is invariably carried out with direct current. The heat is produced between carbon electrode and work piece, base metal melts with this heat and additional filler metal can be added where extra metal needed. The essential point of this carbon-arc welding is that the filler rod quite difference from the ordinary filler rod. Because it can not be connected with current source.
Advantages:

Work piece distortion is less. Process is suitable for any kind of joint. Weld heat can be controlled very easily through changing of arc length. Welders are made skilled in short time. It is simple welding process. Big range of metals and their alloys can be welded.
General safety in arc welding
The operator should wear anti-flame clothes to prevent burning and he should also protect himself from hot metals.
The hand screen must be used for preventing the ultra-violet ray and infrared ray. Avoid the spatter fire hazardous from the welding area and there cover up with asbestos cloth if possible.
Connection for welding should be made proper care and do direct ground if feasible. The connecting cable must be super insulated.
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The wok should not placed on combustible material. During chipping or slag removing the proper goggles should be wear. A fire extinguisher should always kept in hand. Helmets should be used. Proper ventilation must be provided in welding area. The black paint may be provided inside of the wall for killing the reflection rays. In general condition there is main four types of weld used for solid material with intermediate or combination types for special cases.
The four types of welds are- 1) Roller Weld, 2) Plain Weld, 3) Ring Weld, 4) Wire Weld.
In roller welds, the weld metals like plates, foils, strips, sheets etc. are passed between several rollers which exert the required pressure for the weld. In some special cases the device combination roller is used which can make form of tube shape from a metal strip and then welded the edge by the seam welding process. Trim away the excess material with some kind of process so that there is practically no kind of projection indicates.
The plain welds are most common used in general cases. In this welds the two pieces of metal made face to face where they are meet, overlapping condition and weld them spot to spot or continuous seam. For the example, the boxes are made by this plain welds.
The ring welds are generally welded for desired perimeter welding shape like circle, square, pentagon or hexagon sizes; these are joining at the edge. This weld is very suitably for edge sealing containers. The hollow floats made by joining hemispheres provide one examples of the use of this type of welds.
For the wire weld the special type of welding technique is used called wire weld and the particular form is overlapping process. Enough strength is getting and electrical resistance is same as parent material, because due to weld joint portion diameter slightly increased. This type of weld joint is used for manufacturing of electrical grids and screens.
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Practical: 4 AIM: GAS WELDING

Objectives: Understand about various gas flames and maintain about flame temperature according to different types of material and advantages of gas welding.
Oxy-acetylene welding is one of the flame welding or gas weld process, because the flame is produced of mixture of gasses in a combustion chamber for heat provided to the job. Oxyacetylene mixture of gasses most commonly used for producing high temperature 32600C. It is oldest development fusion welding process. No pressure is required on the job to be welded, the heat is drive to welding the pieces. The acetylene is obtained by the action of oxygen and calcium carbide. Oxy-acetylene Welding CaC2 + 2H2O = Ca(OH)2 + C2H2
(Acetylene) The gas acetylene( C2H2 )is play the most important role in Oxy-acetylene welding because it has the highest calorific value.
Neutral Flame
The neutral flame is the primary flame used by gas welders. A neutral flame has two zones: a hotter, lighter inner zone and a cooler, darker outer zone. In a neutral flame, all of the fuel
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gas is being burned in the process, resulting in a clean flame. The welder uses the tip of the inner flame zone to heat the parts to be welded, as this is the hottest part of the flame.
Carbonizing Flame
If the oxygen is reduced, a carbonizing flame is created from a neutral flame. In this case, not all of the fuel gas is being burned by the flame. A carbonizing flame has three zones, and is cooler than a neutral flame because the excess carbon acts as an insulator. Carbonizing flames deposit soot on the work piece that has to be cleaned when the part is cooled, but the addition of carbon to the metal is desirable in some iron and steel welding applications.
Oxidizing Flame
An oxidizing flame is caused by increasing the oxygen from a neutral flame. Because of the excess oxygen, this flame is hotter than the neutral or carbonizing flames. Welders generally do not use an oxidizing flame, because it can increase the oxides in the base material. However, an oxidizing flame is used for bronze and brass work.
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Advantages
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In gas welding the heating and cooling rate is slow, so it is advantage in some material welding from welding failure. The flame can be controlled easily where need low and high temperature for welding or brazing or soldering. Filler metal deposit rate can be controlled easily, because source of heat and filler metals are separate. Preheating facility is in welders hand. So where required it can be applied. In comparison of other welding process, it is low cost and low maintenance.
Complete set of gas welding
A cylinder carriage trolley. A Oxygen cylinder. A Acetylene cylinder. Oxygen regulator (regulating valve). Acetylene regulator (regulating valve). Black oxygen hose and red acetylene hose. Blowpipe and set of tips. Cylinder keys, spanners, goggles, gloves etc. Welding filler rods and welding fluxes.
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Nozzle sizes for various metal thicknessNozzle size 1 2 3 1/16 5 3/32 7 1/8 10 5/32
Plate thickness 1/32 3/64
Gas welding temperature for various common material. Aluminium - 6500C Copper 10650C Bronze 9000C Lead 3300C Zink 4250C Brass -8900C
Steel(C 0.2%) 15500C Tin
Grey cas-tiron12000C

Safety in gas welding

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Avoid the cylinder collision with sharp substance. A cap must be cover up when it is unused. Acetylene cylinder dont kept lie on the ground. Cylinders always handle on the proper trolley with tight fastened. Do not make smoke at the place where cylinders have been stored. Do not hammering on the valve for opening. Cylinders should be exposed in flame, water or sunlight. Cylinders of oxygen and acetylene should be stored separate place. Cylinder valves always kept closed after work is finished. Always use proper pressure valve regulator. Cylinders should be stored in well ventilation room. Never attempt the mixes gas in a cylinder. For leak detection in valve socket and gland nut always with water and soap mixture. During moving the cylinder the valve must be closed. Do not interchanged the regulator valve. Torch nozzle always kept in clean and all time clean the its hole. Do not use spanner for removing or attaching the nozzle tip. The screw tips tight enough for gas tight joint.
Never hang the torch with its hose on the valve regulator. Always protect the hose from circumferential damages. Fire extinguisher should be available. Before going to gas welding or gas cutting, the inflammable clothes should be removed from the body.
Wear a appropriate apron. Use goggles with non-inflammable lenses and frames. Never do chipping or grinding without wear a mask or goggles. Do not carry the hot jobs. For igniting never use matches otherwise burned the hands.
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Practical: 5 AIM: MIG WELDING

Objectives: Understanding about MIG welding process why MIG welding is used its application and advantages
Principle operation This welding process is said for semi-automated MIG welding. Check the electrical supply, water supply and gas flow in before going to ignition started. Then set the feed of electrode and proper current also. The electrode should be projected about 12-16 mm from the torch tip before going to start arc. The arc length should be maintaining about 2-4mm and the torch tip should be 10-12mm from the work piece. To produce the arc the shielding gas and proper current supply is to be on and scratch the electrode against the job, then moved forward to carry out MIG welding. Always take in mind that the electrical supply, gas flow and water supply should be on. The torch is moved along the joint for carrying out the welding process and the torch angle is about 700with the horizontal. Application MIG welding has large used in automobile industry, aircraft parts welding, pressure vessel manufacturing and many other places.For welding tool steels, carbon, silicon and low allow steels, stainless steel, aluminium and its alloy, magnesium, nickel and its alloy, copper and its alloy, titanium and so many metals.It is used for refrigerator parts manufacturing . Advantages:

There are many advantages of MIG welding mention bellow: Joints can produce with deep penetration. The metals thickness can not be vary with this MIG welding process. Thick and thin metals are welded very effectively.
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This welding process is very suitable for large scale production unit because, it can be performed much faster than other types of welding process like TIG etc.
Large amount of metal can be deposited on the work piece. TheMIG welding process can reduces the welding cost, because it produces neat and clean metal deposit on the work piece. Spatter free and smooth welding surface is produced, so it is no need to extra cleaning
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Practical: 6
AIM: SPOT WELDING
Objectives: Understanding about Spot welding process, Machine component of spot welding and its application in engineering field where it is essential. Introduction:
Spot welding joint is one type of electric resistance welding. Generally joining the sheet to sheet, sheet to rolled sections, wire to wire etc. by this spot weld process. The spot welding is very effectively, which can replace the rivet joints and is very speedy process, this spot welding machine does not need skilled operator, it can be operated by semi-skilled labour. The principle of spot welding is shown in the bellow diagram. In this machine basically having a transformer core (T) which is having a primary winding (PW). This primary winding tapped at a number of points. The secondary winding (SW) has the two ends of a circuit (C) which is connected two arms made of copper or bronze. Each side has a copper electrode, this electrode of spot welding produce the sufficient heat to fuse the joining metal. The lower arm is generally stationary and upper arm is movable (upward and downward). The technical terms are rocker arms or electrode arms. The electrodes of spot welding is cooled by water, the water is passing through the inter looped water line.
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The essential factor of spot welding
The welding current. The time of current application. The pressure of electrodes. The shape or area of electrodes. The surface condition of welded material.
Advantages of spot welding
In this welding process is free from fumes and spatter. Generally it has nothing maintenance or no skilled persons are required for maintenance. No skilled persons are need to operate the spot welding. Welding cost is minimum.
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Practical: 7 AIM: EDGE PREPARATION

Objectives: Learn about how to prepare various edges of components with various shape and learn about how to joint the various material with proper selection of Operation and types of welding with various welding machines.
Introduction:
The edge preparation is very essential for good quality welding. In this consists of cutting the edges of the places to be joint by welded in suitable shapes and proper cleanness must required. Which is free from dust, soil, oil, grease and other external harmful particle. According to the method of cutting the edges are face to face, single V, double V, single U, double U, single bevel, double bevel, single J, double J. When face to face or plain face to be welded which is allow only up-to 5mm thickness of plate Preparation or edge shaping may be applied to each piece (joint member) in the same way, or combinations of the joint preparations may be used. The edge preparation for welding these joints depends on the strength requirements and other design considerations. The Welder needs to be aware of the most common edge preparations as shown below with the help of grinder m/c ,shaper m/c ,milling m/c

JOINT ARRANGEMENTS AND WELDS
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The edge preparations are arranged to make the weld joint. The pieces to be welded may be connected or a gap between the pieces to ensure penetration may be used. On most joints the gap is at the bottom of the joint and is referred to as the root of the joint. The term root opening or open root is used to describe this condition. For example; Open root V groove, or V groove with an open root. When the joint design allows, a backing strip or insert may be used for easier welding. Some joints may have a backing weld, or back weld applied. A back weld is applied after the groove is filled. A backing weld is applied before the groove is filled.
See examples below:
THE FIVE BASIC JOINTS
There are five basic joints in common use for assembling metal.
1. BUTT JOINTS 2. T JOINTS 3. LAP JOINTS 4. CORNER JOINTS 5. EDGE JOINTS
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1. BUTT JOINTS A butt joint is formed when the pieces to be welded are laid side by side and it is one of the most widely used types of joint.
KEY POINT: In other words, the pieces are butted together.
The names in the examples above are from the type of weld applied to the joint. Often the type of weld is used to fully describe the joint. For example; this joint is a single bevel butt joint.
The V groove and bevel grooves are easier to prepare and are used more than the J or U groves.
KEY POINT: If two imaginary lines are drawn parallel to the horizontal line in the above symbols they show the joint shape, this is true for most of the symbols. This can be helpful to remember since symbols on a blueprint do not show the actual joint shape or edge preparation.

2. T JOINTS
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A T joint is formed when one piece of metal to be welded is placed vertically on another piece lying horizontally, to form the shape of an inverted T.
KEY POINT: The T shape resembles an overhead position T joint.
The vertical member is usually placed at 90 deg to the horizontal member. One of the most widely used types of weld applied to a T joint is the fillet weld. When a single pass or multiple passes are made against the joint, the weld resembles a Triangle when viewed from the side.
KEY POINT: Pronounce the T in fillet FILL-ET; not as FILL-AY a fish
The T joint and fillet weld are the most frequently used joint and type of weld. In the same way the edges of the butt joint may be prepared for welding, the tee joints vertical piece may be prepared using a Bevel, or J shape. The preparation allows the Welder to penetrate into the root of the joint. See examples below:

3. LAP JOINTS
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A Lap joint is formed when one piece to be welded is laid down and another piece is overlapped to form an edge for fillet welding or an area to allow plug or slot welding.
Lap joints are often used when plug or slot welding thinner sections.
A plug weld is made by welding holes evenly spaced across the length of one or both sides of the joint. A slot weld is similar except slots are made instead of holes.
Other welds may be applied to laps such as projection, or seam welding. See examples below:
LAP JOINTS
4. CORNER JOINTS
A corner joint is formed by placing one piece to be welded on the other so that a corner is formed. The corner may be Flush; Half Open; or Fully Open.
An edge preparation may be applied to one, or both of the pieces of the joint for penetration and strength.
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KEY POINT: The weld applied to the inside of many of the above is a fillet weld.
5. EDGE JOINT
An Edge joint is formed when the two edges of the pieces to be welded come together. This joint may be formed as a result of another structural shape and is not as widely used as some of the other joints. See examples below.
SUMMARY
Welders need to know the basic joint shapes and the type of welds most commonly applied to them. The five basic joints are: Butt; T; Lap: Corner; and Edge. The edge preparation may be: Square edge; Bevel edge; Double Bevel edge; Chamfer edge; J groove edge; and Double J groove edge.
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J and U grooves are more labor intensive to prepare and may not be seen as often in
Butt joints may be open root, have a backing, or be welded both sides. The weld applied to a T joint is a called a Fillet weld. Fillet welds are the most commonly used welds. Corner joints may be: Flush; Half open; or Full open. Corner joints may be simple or have edge preparation to increase penetration. Lap joints are more likely to be used when welding thinner sections, or when plug and slot welding is called for. Edge joints are usually seen as a result of an overall joint configuration.

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MERCHANT POLYTECHNIC COLLEGE

This is certify that

Has satisfactorily completed the course in

Within four walls of merchant Polytechnic College,Basna.

/20 Head of Department