DJJ1032 Mechanical Workshop Practice 1

WORKSHOP : WELDING
TITLE : ARC WELDING
DURATION : 12 HOURS
PAGE : 1 0F 6

1.0 dPractical learning outcomes

At the end of the lab session students should be able:

i) Measure finished product using appropriate measurement
Instruments. (P3,PLO5)
ii) Perform fitting, welding and machining works according to Standard Operation
Procedure (SOP). (P4,PLO 5)
iii) Demonstrate an understanding of professional ethics, responsibilities and norms of
engineering practices according to the workshop safety regulation.(A3,PLO6)

2.0 Theory

Arc Welding:
Arc welding is a liquid state welding process in which electrical energy produced by an arc
between an electrode and a workpiece is converted into heat and used for fusion welding by the
generation of intense heat, the juncture of two metal pieces is melted and mixed by an
intermediate filler metal as shown in figure 1 Upon cooling and solidification, the resulting
welded joint metallurgically bonds the former separate piece into a continuous structural
assembly.

Figure 1: Arc welding Figure 2: Welding machine

Shielded Metal Arc Welding (SMAW):

The Shielded metal Arc Welding process is one of the oldest and most widely used methods of
joining metals by welding. The process is popular because of the simplicity of equipment
 DJJ1032 Mechanical Workshop Practice 1

WORKSHOP : WELDING
TITLE : ARC WELDING
DURATION : 12 HOURS
PAGE : 2 0F 6

involved, its portability, reliability and adaptability to outdoor use. The process may be used to
weld a variety of metal types and shapes in any position. In the SMAW process, welding is done
by setting up an electrical circuit using a welding machine to produce the electricity, a welding
cable with an electrode holder to hold the electrode and a ground cable with a clamp to fasten
to the work-piece to complete the circuit as shown in figure 2. The weld is made by touching the
electrode to the work-piece closing the electrical circuit and causing the electrode to melt and
form the weld.

3.0 Apparatus / Equipments

3.1 Arc welding machine

3.2 Workpiece : Mild steel plate measuring ( 120 x 35 x 6 mm)
3.3 Electrode arc
3.4 Personal Protective Equipment(PPE) – protective head shield, hand glove, apron,
appropriate clothing, safety shoe
3.5 Welding hand tool – chipping hammer, wire brush, plier
3.6 Fume absorber

4.0 Safety Precautions

a. Give full attention when listening to a description of the rules and steps in the workshop.
b. Wear protective clothing when necessary such as gloves, goggles and aprons.
c. Do not change any of the warning notice has been placed on or next the machine by maintainer
or staff.
d. Know the main switch and an easy place to get first aid.
e. Do not play in the workshop.
f. Not too close to the machine is in operation or moving.
g. Do not try to fix a machine without telling lecturers or workshop assistants.
h. Must wear neat and appropriate to the work when you are in the workshop.
i. Give proper care to the machinery or equipment in the workshop.
j. Shall be returned to its original place after using equipment.
k. When finished using a machine, the machine should be cleaned as before.
l. Must know where is emergency switch and first aid kit
m. Ensure cleanliness the workshop on a satisfactory level.
n. Make sure the tables and chairs arranged neatly by the specified workshop layout.
o. Have a sense of responsibility to self, partner and equipment in the workshop.
p. Immediately report to the lecturer or assistant the workshop in the event of any damage or
accidents in the workshop.
 DJJ1032 Mechanical Workshop Practice 1

WORKSHOP : WELDING
TITLE : ARC WELDING
DURATION : 12 HOURS
PAGE : 3 0F 6

5.0 Procedures

Project A: Straight beads

5.1 The given M.S pieces are thoroughly cleaned of rust and scale.
5.2 The workpieces are positioned on the welding table horizontally
5.3 The electrode is fitted in the electrode holder and the welding current is set to be at
proper value.
5.4 The ground clamp is fastened to the welding table.
5.5 Wearing the apron and using the face shield, the arc is struck to start the arc.
5.6 Start welding the work piece and pay attentions to the travel speed,
5.7 In the welding process, there will be some gasses emitted so there must be a fume
absorber.
5.8 The scale formation on the welds is removed by using the chipping hammer.

Project B : Close Square Butt Joint

 DJJ1032 Mechanical Workshop Practice 1

WORKSHOP : WELDING
TITLE : ARC WELDING
DURATION : 12 HOURS
PAGE : 4 0F 6

5.1 The given M.S pieces are thoroughly cleaned of rust and scale.
5.2 Align metal to make sure the edges line up well.
5.3 The electrode is fitted in the electrode holder and the welding current is set to be at
5.4 proper value.
5.5 The ground clamp is fastened to the welding table.
5.6 Wearing the apron and using the face shield, the arc is struck and the work pieces are
tack welded at both ends of the joint.
5.7 Start welding the work piece and pay attentions to the travel speed,
5.8 In the welding process, there will be some gasses emitted so there must be a fume
absorber.
5.9 The scale formation on the welds is removed by using the chipping hammer.

Project C: Open Corner Joint

 DJJ1032 Mechanical Workshop Practice 1

WORKSHOP : WELDING
TITLE : ARC WELDING
DURATION : 12 HOURS
PAGE : 5 0F 6

5.1 The given M.S pieces are thoroughly cleaned of rust and scale.
5.2 The two pieces are positioned on the welding table with the right angle. Use magnetic
jig to make sure the metal is align with right angle.
5.3 The electrode is fitted in the electrode holder and the welding current is ser to be a
proper value.
5.4 The ground clamp is fastened to the welding table.
5.5 Wearing the apron and using the face shield, the arc is struck and the work pieces are
tack welded at both the ends and at the center of the joint.
5.6 Remove the work pieces from the magnetic jig.
5.7 Start welding the work piece and pay attentions to the travel speed,
The scale formation on the welds is removed by using the chipping hammer.

6 Discussion

6.1 What type of current is used in shielded metal arc welding?

6.2 What factors determine the size of welding cable needed for a job?
 DJJ1032 Mechanical Workshop Practice 1

WORKSHOP : WELDING
TITLE : ARC WELDING
DURATION : 12 HOURS
PAGE : 6 0F 6

6.3 When selecting an electrode holder for a specific task, you should base your selection on
what criteria?
6.4 What kind of sound does improper polarity emit?
6.5 Electrodes manufactured in the U.S must conform to what standard?

7 References

Main:

Juneja, B.L (2018). Workshop/ Manufacturing Practices,1St Edition.Cengage

Vinayaka, K.R & Manjunath, (2015).Workshop Technology For 1 Sem Diploma In Mechanical
Engineering, Sapna Book House.

Bawa, H.S (2015). Workshop Practice, Tata Mcgraw Hill Publishing Co Ltd.

Additional:

John, K.C (2011). Mechanical Workshop Practice, Prentice Hall Of India.

Juneja, B.L (2015) Workshop Practice , Cengage Learning.

Sawhney, G.S (2012) Mechanical Experiments & Workshop Practice, Ik International Pvt Ltd

Khurmi, R.S & Gupta, J.K ,( 2011) Basics of Workshop Practice, S. Chand Publishing.