report on welding
TRANSCRIPT
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TITLE : Welding Operation
OBJECTIVE : To demonstrate welding process to join two pieces
INTRODUCTION :
Welding is a fabrication process that joints two or more materials
together, usually metals or thermoplastics. This is often done by
melting the works pieces and adding a filter material to form a pool of
molten material that cools to become a strong joint. Many different
energy sources can be used for welding, including a gas frame, an
electric arc, a lase, an electron beam, friction, ultrasound.
Shielded metal arc welding (SMAW) is one of the most common types
of arc welding as shown in Figure B. Its electric current is used to strikean arc between the base material and consumable electrode rod,
which is made of steel and covered with flux that protects the weld
area form oxidation and contamination by producing CO2 gas during
the welding processes.
Figure A: Shielded metal arc welding (SMAW)
TOOLS REQUIRED : Welding Machine
OPERATION REQUIRED : i. Weldingii. Finishing
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APPARATUS :
1. Gloves
2. Two 4inch(10cm) Metal plates
3. Electrodes
4. Electrode holder
5. Head Shield
EXPERIMENTAL PROCEDURE :
1. Gloves and screen are worn.
2. Both of the metal plates are made same parallel to
get proper butt position. Place some metal holders
on the base of two metals , so it wont move while
welding.
3. Long sleeve jackets and gloves are worn. Welding helmets are
prepared with dark face plates and make sure its plastic screen is
clear to see through.
4. First warm the electrode by sliding on to any metal sheet, if the
electrode is hot enough then continue to welding.
5. Welding is started gently in the directional fashion from one end.
Then, Weld on another side reversely.
6. Chipped out the oxidized layer and cleaned with a wire brush after
completing the weld.
7. Tools are returned and machine is cleaned after operation.
RESULT & DISCUSSION :
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Figure C: Good welding
Figure D: Failed Welding
SAFETY AND HEALTH:
1) Wear safety equipment such as head shield, gloves and apron
before start welding.2) Do not watch the ultraviolet rays spatters when welding using
eye without a head shield.
3) Carry at a comfortable area and where the welding will be
done away from the flammable materials.
4) Do not disturb other students that are still working.
5) After finish work, use a wet towel to cover eyes.
CONCLUSION :
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In this welding operation results, we do a comparison with the
good welding and failed welding. So that, we can find out any
discrepancy and sources of error of the experiment.
Discrepancy:
1. Figure B has a good weld on a metal plate and keeps it
joined strong and Figure C has bad weld on a metal plates it
would be separated quickly with a very less force .
Sources of error:
1. Most of the welding processes involve heat. High temperature
heat is largely
responsible for welding distortion and stresses.
2. When metal is heated it expands, and it expands in all
directions.3. Welding-distortion or deformation or warping of weldmends
during welding is a natural outcome of intrinsic non-uniform
heating and cooling of the joint.
4. Distortion is the result of the action of internal stresses which
are produced while welding, and remain in the part after
heating is removed, as briefly explained in the following.
At the end of this experiment, there are problem occurs on the
welding process. To get a best result of this welding process, student
must know the angle that are used, concentration, and the movement
of the electrode and speed of moving the electrode.
REFERENCES :
i. Larry Jeffus 1983, Welding Principles and Application, 5th Edition,
Thomson Learning, Inc, USA.
ii. B. H. Amstead, Philip F. Ostwald, Myron Louis Begeman 1987,
Manufacturing Processes, 8th Edition, John Wiley & Sons Inc, USA.iii. http://www1.gantep.edu.tr/~oyilmaz/Lecture%20Notes/ME%20473/Design
%20of%20Weld%20Joints%20and%20Welding%20Errors.pdf
http://www1.gantep.edu.tr/~oyilmaz/Lecture%20Notes/ME%20473/Design%20of%20Weld%20Joints%20and%20Welding%20Errors.pdfhttp://www1.gantep.edu.tr/~oyilmaz/Lecture%20Notes/ME%20473/Design%20of%20Weld%20Joints%20and%20Welding%20Errors.pdfhttp://www1.gantep.edu.tr/~oyilmaz/Lecture%20Notes/ME%20473/Design%20of%20Weld%20Joints%20and%20Welding%20Errors.pdfhttp://www1.gantep.edu.tr/~oyilmaz/Lecture%20Notes/ME%20473/Design%20of%20Weld%20Joints%20and%20Welding%20Errors.pdf