University of Zakho

Collage of engineering
Mechanical department
`

Workshop

Welding

Name: Mohammed Amin

Stage: 2 nd

April
2019
Introduction:
Welding is the process by which two pieces of metal can be joined together. The
process of welding doesn't merely bond the two pieces together as in brazing
and soldering, but, through the use of extreme heat and sometimes the addition
of other metals or gases, causes the metallic structures of the two pieces to join
together and become one. There are a number of different welding methods,
including spot welding, metal inert gas (MIG), and tungsten inert gas, which are
forms of gas metal arc welding, arc welding, and gas welding, to name a few.
Welding can even be done underwater.
The various welding processes are:

1. Electric arc welding

2. Gas Welding
3. Thermal Welding
4. Electrical Resistance Welding
5. friction Welding
Arc Welding Processes

In arc welding process, an electric arc between an electrode and a work piece
or between two electrodes is utilized to weld base metals. The basic principle
of arc welding is shown in below Fig. 1. However, the basic elements
involved in arc welding process are shown in the below Fig. 2. Most of these
processes use some shielding gas while others use coatings or fluxes to
prevent the weld pool from the surrounding atmosphere.

Figure 1: Principle of arc welding

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Arc welding equipment:
Arc welding equipment, setup, related tools, and accessories are shown in Fig. 2.

Figure 2: Arc welding process

setup

(1) Switch box. (9) Electrode holder.

(2) Secondary terminals. (10) Hand shield.
(3) Welding machine. (11) Channel for cable protection.
(4) Current reading scale. (12) Welding cable.
(5) Current regulating hand (13) Chipping hammer.
wheel.
(14) Wire brush.
(6) Leather apron.
(15) Earth clamp.
(7) Asbestos hand gloves.
(16) Welding table (metallic).
(8) Protective glasses strap. (17) Job.
However, some common tools of arc welding are shown below in Fig. 3. Few
of the important components of arc welding setup are described as under

Figure 3: Arc welding tools and accessories

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Types of Welded Joints:
There are five different types of welded joints for bringing two parts together for
joining.
Five types of welded joints are butt joint, corner joint, lap joint, tee-joint and
edge joint.

A. Butt joint: In Butt welded type, the parts lie in the same plane and are
joined at their edges.

B. Corner joint: The parts in a corner joint form a right angle and are joined
at the center of the angle.

C. Lap joint: Lap joint consists of two overlapping parts.

butt joint, corner joint, lap joint, T joint and edge joint

D. Tee-joint: In a Tee-joint, one joint is the right angle to the other joint in the
approximate shape of the letter “T”.

E. Edge joint: The parts in edge joint are parallel with at least one of their
edges in common and the joint is made at the common edge(s).
Exercise 1: Arc Wilding

In this exercise we must weld 3 line in our square iron one of them is straight

line and another is zigzag line and another is curved line

Aim:The object of this exercise is learning how to weld

cm

*All dimensions in cm
cm

Curved line
Straight line Zigzag line

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 Tools and Accessories required :
1. Secondary terminals.
2. Welding machine.
3. Leather apron.
4. Asbestos hand gloves.
5. Protective glasses strap.
6. Electrode holder.
7. Hand shield.
8. Channel for cable protection.
9. Welding cable.
10. Chipping hammer.
11. Wire brush.
12. Earth clamp.
13.Welding table

Safety and Procedure :

All welders need to respect the job and the equipment being used. The following
is a list of safety equipment and precautions
1. Wear welding gloves
2. Wear eye protection-For arc-type welding, a much darker lens is required
than for gas welding.
3. Keep a suitable Class ABC fire extinguisher nearby while welding.
4. Keep the work area clean and free of flammables and obstructions.
Exercise 2: Lab joint

Tools and Accessories required :

14. Secondary terminals.
15. Welding machine.
16. Leather apron.
17. Asbestos hand gloves.
18. Protective glasses strap.
19. Electrode holder.
20. Hand shield.
21. Channel for cable protection.
22. Welding cable.
23. Chipping hammer.
24. Wire brush.
25. Earth clamp.
26.Welding table
Aim: to make a lab joint using a arc welding .

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Applications
Oxy-acetylene welding is particularly used for sheet metal work. All the
metals can be welded with proper filler metals. Same equipment may be used
for cutting purposes.
Advantages of Oxy-acetylene Welding
The main advantages of oxy-acetylene welding are given below:
1. Equipment is cheap as compared to other welding process.
2. It can be used for welding of all types of metals.
3. Maintenance of equipment is very less.
4. It is a portable process.
5. It can be used for cutting of metals of small thickness.
6. It is specially used for sheet metal work.

Disadvantages
7. It takes long time for heating the job as compared to the arc welding.
8. The heat affected area is more.
9. This is prone to corrosion and brittleness.
Gases are expensive and difficult to store

Discussion:
Like any other experiment in universe working in workshop have errors and
problem, so I will try to explain in this discussion where we got source of error
in our work and how we can decrease it to have a better work.

First and biggest problem in our work it was a time, we only worked in one
week and this period of time is too short to work in any work in workshop, so
we don’t take all exercises that you prepared to us, we don’t take many
knowledge in this work. Another error in our work was Tools that we used to
work with, generally quality of them wasn’t so good so that we don’t work
completely. And another error was using tools by students, many of this
equipment was new for us and it was first time to use it, so we didn’t use it right
and correctly.

It is difficult to solve these problems because this is our maximum ability, how
we can have time to study in this unsuccessful system that we go with it in our
university? And we can’t bring tools more quality than we have. This mean most
of errors wasn’t human mistakes but there is a hope to fix it.

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Reference:

 https://me-mechanicalengineering.com/arc-welding-processes-equipment/
 https://me-mechanicalengineering.com/types-of-welded-joints/
 https://www.techtransfer.com/blog/introduction-to-welding/
 https://www.hunker.com/12340946/how-to-use-a-wire-brush