Contents

Contents................................................................................................................................ 1 1.0 INTRODUCTION..............................................................................................................2 2.0 OBJECTIVES................................................................................................................... 3 3.0 SAFETY IN THE WORKSHOP........................................................................................3 3.1 Personal Protection.......................................................................................................3 3.2 Safety Precaution.......................................................................................................... 3 .0 !"te#$"% "n& Too%s......................................................................................................... ' (.0 TYPES OF WE)DIN* JOINT.........................................................................................10 5.1 Patent-Pending Process.............................................................................................10 5.2 Close Butt Joints......................................................................................................... 11 5.3 Corner Joints............................................................................................................... 13 +.0 SU**ESTIONS FOR I!PROVE!ENT.........................................................................1 ,.0 CONC)USION.............................................................................................................. 1(

1.0 INTRODUCTION Arc welding is a type of welding that uses a welding power supply to create an electric arc between an electrode and the base material to melt the metals at the welding point. They can use either direct (DC) or alternating (AC) current, and consumable or non-consumable electrodes. The welding region is usually protected by some type of shielding gas, vapor, or slag. Arc welding processes may be manual, semi-automatic, or fully automated. irst developed in the late part of the !"th century, arc welding became commercially important in shipbuilding during the #econd $orld $ar. Today it remains an important process for the fabrication of steel structures and vehicles. Arc welding is one of alternative for %oining process in manufacturing. Arc welding process had done by create an electric arc between electrode and the base material to melt the metal at the welding point using welding power supply. The welding region is sometimes protected by some type of inert or semi-inert gas, &nown as a shielding gas and sometime adds by an evaporating filler material. #hielded metal arc welding (#'A$), also &nown as manual metal arc (''A) welding or informally as stic& welding, is a manual arc welding process that uses a consumable electrode coated in flu( to lay the weld. They can use either direct current (DC) or alternating current (AC) from a welding power supply, used to form an electric arc between the electrode and the metal to be %oined. As the weld is laid, the flu( 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. )as metal arc welding ()'A$), sometimes referred to by its sub types metal inert gas ('*)) welding or metal active gas ('A)) welding, is a semi-automatic or automatic arc welding process in which a continuous and consumable wire electrode and a shielding gas are fed through a welding gun. A constant voltage, direct current power source is most commonly used with )'A$, but constant current systems, as well as alternating current, can be used. There are four primary methods of metal transfer in )'A$, called globular, short-circuiting, spray, and pulsed-spray, each of which

2.0 OBJECTIVES At the end of this arc welding learning, student should be able to+ ,rovide a brief introduction to engineering students about metal arc welding. -earn the basic techni.ues of welding. )ive a real life e(perience of metal arc welding to engineering students.

3.0 SAFETY IN THE WORKSHOP 3.1 Pe#son"% P#ote-t$on $ear Approved /ye ,rotection $ear lame 0esistant Clothing $ear -ong #leeves, ,oc&et laps and 1o Cuffs $ear Approved safety boot $ear Approved 2and ,rotection

3.2

S".et/ P#e-"0t$on ,lease wear all the personal protective e.uipment recommended by 3#2A. Always protect your eyes from arc rays. ,rotect your face and body from heat radiation and molten metal. 'ove all the flammable material off the wor&ing place or cover it up using fireproof material. 'a&e sure that the welding machine is earthen.

'a&e sure that all line holder, earth clip and connection placed on good place.

'a&e sure that your wor&ing place is clean and tidy. 'a&e sure that all electric connection is tight, clean and dry. Avoid pulling the cable on top or near sharp things. Do not ever scratch arc on top of gas cylinder. Turn off the welding machine when not in use. Avoid welding cable from be in contact with hot metal, water, oil and grease.

$ear all safety clothing when welding. All e.uipment such as hammer, chisel, brush and others must be well maintained.

A welder should not try to install or repair a welding machine. has distinct properties and corresponding advantages and limitations.

.0 !"te#$"% "n& Too%s 4.1 Mild steel flat bar (6 x 40 x 100 mm)

4.2

Electrode

/lectrode that use is /4!!56 /78!5 The 9/9 stands for arc welding electrode. 1e(t will be either a 4 or : digit number stamped on the electrode. The first two numbers of a 4 digit number and the first 5 digits of a : digit number indicate the minimum tensile strength (in thousands of pounds per s.uare inch) of the weld that the rod will produce, stress relieved. /78!5 electrode can be used with AC and DC currents. *t produces a medium penetrating weld with a superior weld bead appearance.

4.3

D Arc !elding Mac"ine

Current that use for mild steel arc welding are between "8 ; !58 amp. The best current use for this arc welding is !!8 amp.

4.4

#ace $"ield

*t is made from inflammable material. *n the middle of the shield there is a bright rectangular glass coated with dar& colored glass. *t is used to protect the user from fire-bolt and harmful rays during welding wor&. There are two types of shield, one is the helmet type and the other one is the hand held type.

4.%

&eat"er 'and (lo)es

*t must be made from high .uality leather. <se to protect your hand from firebolt and hot metal welding.

4.6

*lier

<sed for hold hot wor&piece

4.+

"i,,ing 'ammer

*t is made from an old punch, chisel or spring metal. #hape li&e a chisel at one end and has a sharpened end at the other one. *ts holder is made from welded soft metal. *t is used commonly to remove the slag e(cess stringer from the surface of the wor& metal.

4.-

!ire .r/s"

<sed to clean the surface of the stringer bed after the slag is chipped away and to remove dirt from the surface of metal wor& before welding can be done.

4.0

&eat"er 1ac2et

4.10

-eather %ac&et is used to protect the user from the intense heat produced during welding operations. *t is made of high .uality leather to provide greater comfort for the user. Ang/lar Mild $teel .ar

<sed for hold two pieces of metal during corner %oint weld.

(.0 TYPES OF WE)DIN* JOINT (.1 P"tent1Pen&$n2 P#o-ess !or2ing *roced/re a) Clean the surface of metal plate with wire brush. b) ,lace the metal plate on the wor&ing table. c) =efore welding, ad%ust the electric current to DC current and scratch the electrode on the scrap metal. d) 2old the electrode about "8o above the scrap metal. Tilt the electrode 58o to the left or right depending on which hand do you use from the wor& metal. e) #cratch the front end of the electrode onto the wor& metal to start the burning. After the electrode has started burning, hold it at 5mm above the wor& metal. Try to avoid the electrode from being in contact with the surface of wor& because the electrode might be stic& onto the wor&piece.

10

f) 0epeat the welding process for several times until you get a straight stringer bead line when welding. g) 0epeat the process of (f) for second straight stringer bead line.

h) $hen finish the welding process, use the chipping hammer to chipped off the slag and brush it off using a wire brush

(.2

C%ose B0tt Jo$nts !or2ing *roced/re a) Clean the surface of two (>) metal plates with wire brush. b) ,lace both metal plates on the wor&ing table. c) =efore welding, ad%ust the electric current to DC current and scratch the electrode on the scrap metal. d) 2old the electrode about "8o above the scrap metal. Tilt the electrode 58o to the left or right depending on which hand do you use from the wor& metal. e) 'a&e tac& weld on both side to prevent the metal plates from bending during the welding process occur.

11

f) #cratch the front end of the electrode onto the wor& metal to start the burning. After the electrode has started burning, hold it at 5mm above the wor& metal. Try to avoid the electrode from being in contact with the surface of wor& because the electrode might be stic& onto the wor&piece.

g) $hen finish the welding process, use the chipping hammer to chipped off the slag and brush it off using a wire brush

12

(.3

Co#ne# Jo$nts !or2ing *roced/re a) Clean the surface of two (>) metal plates with wire brush. b) ,lace the angular of mild steel on the wor&ing table to support two (>) metal plates. c) =efore welding, ad%ust the electric current to DC current and scratch the electrode on the scrap metal. d) 2old the electrode about "8o above the scrap metal. Tilt the electrode 58o to the left or right depending on which hand do you use from the wor& metal. e) 'a&e tac& weld on both inside the metal plates to prevent the metal plates from not parallel during the welding process occur. f) #cratch the front end of the electrode onto the wor& metal to start the burning. After the electrode has started burning, hold it at 5mm above the wor& metal. Try to avoid the electrode from being in contact with the surface of wor& because the electrode might be stic& onto the wor&piece

g) $hen finish the welding process, use the chipping hammer to chipped off the slag and brush it off using a wire brush

13

+.0 SU**ESTIONS FOR I!PROVE!ENT Changes all leather gloves which not in good condition. <se a suitable e(haust fan during welding

Change the cable that connected to the earth holder and electrode holder which not in good condition 'a&e sure the mirror of the face shield clearly.

14

,.0 CONC)USION *n conclusion, we can conclude that there are some problems that happened in arc welding process. The first problem that happened in arc welding process is the thic&nesses of arc line on metal plate. $e can overcome it such as we can improve our s&ill with we can reduce the movement of speed when doing arc welding. #econd problem is combination of the metal plate is not too strong. *t may cause the wor& be crac& or don?t have enough .uality. To overcome this problem is we need to add more electrodes at the wor&. Third problem is the wor& of arc welding not good enough. *t may cause from the wrong angle and wrong position on plate when doing welding. This problem can solve if we use 58@ in angle and at least 5mm between electrode and plate when welding. After we ma&e some wor& of welding, we can &now the main factor why the wor& in our welding is not too good. The main factor is lac& of s&ill from student. #o that we need to improve ourselves by do the weld properly and use the right method in welding.

15