ARC WELDING REPORT

NAME: BONG FOO LEONG

REGISTRATION NO: 01DKP20F1021
CLASS: DKP2
LECTURER’S NAME: MR. MIZANUR RAHMAN BIN
MOHD ALI

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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. First developed in the late part of
the 19th century, arc welding became commercially important in
shipbuilding during the Second World War. Today it remains an
important process for the fabrication of steel structures and vehicles.

 Arc welding is one of alternative for joining 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, known as a
shielding gas and sometime adds by an evaporating filler material.
Shielded metal arc welding (SMAW), also known as manual metal arc
(MMA) welding or informally as stick welding, is a manual arc welding
process that uses a consumable electrode coated in flux 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 joined. As the weld is laid,
the flux 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. Gas metal arc
welding (GMAW), sometimes referred to by its sub types metal inert
gas (MIG) welding or metal active gas (MAG) 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 GMAW, but constant current systems, as well as
alternating current, can be used.

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Objectives

At the end of this arc welding learning, student should be able to:

 Provide a brief introduction to engineering students about metal arc

welding.

 Learn the basic techniques of welding.

 Give a real life experience of metal arc welding to engineering

student.

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Safety Procedure in Workshop

1. Personal Protection
 Wear Approved Eye Protection
 Wear Flame Resistant Clothing
 Wear Long Sleeves, Pocket Flaps and No Cuffs
 Wear Approved safety boot
 Wear Approved Hand Protection

2. Safety Precaution
 Always protect your eyes from arc rays.
 Protect your face and body from heat radiation and molten
metal.
 Make sure that the welding machine is earthen.
 Make sure that your working place is clean and tidy.
 Make sure that all electric connection is tight, clean and dry.
 Avoid pulling the cable on top or near sharp things.
 Turn off the welding machine when not in use.
 Wear all safety clothing when welding.
 All equipment 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.

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Safety During Arc Welding
Arc welding can be a hazardous activity, even for the most experienced
worker. Whether you’re responsible for a crew’s safety or are an
independent fabricator, these tips will help you to keep yourself and others
safe.

 Avoid electric shock

- Arc welders typically operate at a range of 80v to 120v. The shock
can be life threatening, particularly if there are pre-existing health
conditions, and it can cause workers to fall or stumble into other
equipment. Do not touch the electrode or the work circuit, and do not
access the internal circuits while the unit is live.

 Shield eyes and skin from UV light

- Always wear gloves without holes and a proper welding mask. Don’t
wear shorts or short sleeves and cover exposed areas of the skin.

 Avoid burns
- Avoid handling hot equipment or metal that has recently been
welded. If handling it is necessary, use plier.

 Maintain your equipment

- Don’t overuse your equipment as this can cause it to overheat. Allow
time for cooling and reduce the current if this occurs. Replace any
damaged equipment immediately. Keep cables free of oil and dirt and
ensure that electric cables are not frayed.

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 Avoid breathing fumes
- Ventilate confined spaces or use a respirator. If an area isn’t naturally
ventilated, use a fan or other artificial ventilation. Avoid welding on
coated materials such as galvanized or cadmium plated steel as
these will produce toxic fumes. Do not weld near chemicals. The heat
and UV rays can cause them to release fumes.

 Protect your eyes and ears

- After removing the welding helmet, wear goggles or safety glasses to
prevent slag from entering the eyes. The welding process and some
types of equipment can create a lot of noise, so it’s important to wear
hearing protection equipment.

 Maintain a safe work environment

- Keep your work environment free of clutter to avoid falls or other
accidents. Do not work in wet areas or areas which are too cramped.
Ensure that all workers know the safety rules and are following them.

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Material, Tools and Equipments

 Electrode

- The prefix "E" designates an arc welding electrode. The first two

digits of a 4-digit number and the first three digits of 5-digit number
indicate minimum tensile strength. For example, E6010 is a 60,000
psi tensile strength electrode while E10018 designates a 100,000
psi tensile strength electrode.

 Arc Welding Machine

- Current use for this arc welding are between 90 – 115 amp.

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 Face Shield

- In the middle of the shield there is a bright rectangular glass coated

with dark colored glass. It is used to protect the user from fire-bolt
and harmful rays during welding work.

 Leather Hand Glove

- It must be made from high quality leather. Use to protect your hand
from fire bolt and hot metal welding.

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 Plier

- Used for hold hot workpiece.

 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.

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 Wire Brush

- 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.

 Apron

- Leather jacket is used to protect the user from the intense heat
produced during welding operations.

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 Weld Fume Exhaust Fan

- Is a system that utilizes a fan using negative draft to pull fumes and
dust particles in to a contained filtration system. This process
removes hazardous particles from the air.

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Working Procedure
a) Clean the surface of metal plate with wire brush.

b) Place the metal plate on the working table.

c) Before welding, adjust the electric current to DC current and

scratch the electrode on the scrap metal.

d) Hold the electrode about 70° above the scrap metal. Tilt the
electrode to the left or right depending on which hand do you use
from the work metal.

e) Scratch the front end of the electrode onto the work metal to start
the burning. After the electrode has started burning, hold it at 3mm
above the work metal.

f) Try to avoid the electrode from being in contact with the surface of
work because the electrode might be stick onto the workpiece.

g) Repeat the welding process for several times until you get a
straight stringer bead line when welding.

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h) Repeat the process of (f) for second straight stringer bead line.

i) When finish the welding process, switch off the welding machine
switch and use the chipping hammer to chipped off the slag and
brush it off the metal plate using a wire brush.

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Principle of Arc Welding

 Arc welding is a welding process, in which heat is generated by an

electric arc struck between an electrode and the work piece.

 Electric arc is luminous electrical discharge between two electrodes

through ionized gas.

 Any arc welding method is based on an electric circuit consisting of

the following parts:
- Power supply (AD / DC)
- Welding electrode
- Work piece
- Welding leads (electric cables) connecting the electrode and work
piece to the power supply.

1. Electric arc between the electrode and work piece closes the electric
circuit. The arc temperature may reach 10000°F (5500°C), which is
sufficient for fusion the work piece edges and joining them.

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Starting Arc Welding Method
2. Scratching

3. Knocking

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Types of Welding Joint

1. Close Butt Joint

2. Lap Joint

3. Tee Joint

4. Edge Joint

5. Corner Joint

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1.

2.

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3.

5.

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Welding Techniques
1. Stringer

2. Crescent

3. Zig-zag

4. Box weaver

5. Circles

6. Double J

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Welding Symbols

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Conclusion

In 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 thicknesses
of arc line on metal plate. We can overcome it such as we can improve our
skill with we can reduce the movement of speed when doing arc welding.

Second problem is combination of the metal plate is not too strong. It may
cause the work be crack or don’t have enough quality. To overcome this
problem is we need to add more electrodes at the work.

Third problem is the work of arc welding not good enough. It may cause
from the wrong angle and wrong position on plate when doing welding. This
problem can solve if we use 30º in angle and at least 3mm between
electrode and plate when welding.

After we make some work of welding, we can know the main factor why the
work in our welding is not too good. The main factor is lack of skill from
student. So that we need to improve ourselves by do the weld properly and
use the right method in welding.

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