FACULTY OF MECHANICAL ENGINEERING

SME 1902
ENGINEERING WORKSHOP

WELDING

LECTURER: EN. ISKANDAR

NAMES: TAN JI SING AM090256

TEE SHI FENG AM090265
MOHAMMAD SUHAIMI AM090155

GROUP: A10
OBJECTIVE
 To learn about the welding process and tools that needed to use.
 To understand types of welding process and carry out it safely.
 To know how to perform various welding process on the workplace.

INTRODUCTION

Welding is a fabrication or sculptural process that joins materials,

usually metals or thermoplastics, by causing coalescence. This is often done
by melting the workpieces and adding a filler material to form a pool of molten material
(the weld pool) that cools to become a strong joint, withpressure sometimes used in
conjunction with heat, or by itself, to produce the weld. This is in contrast
with soldering and brazing, which involve melting a lower-melting-point material
between the workpieces to form a bond between them, without melting the workpieces.

Many different energy sources can be used for welding, including a gas flame, an electric

arc, a laser, an electron beam, friction, and ultrasound. While often an industrial process,
welding can be done in many different environments, including open air, under water and
in outer space. Regardless of location, however, welding remains dangerous, and
precautions are taken to avoid burns, electric shock, eye damage, poisonous fumes, and
overexposure to ultraviolet light.

Following the wars, several modern welding techniques were developed, including
manual methods like shielded metal arc welding, now one of the most popular welding
methods, as well as semi-automatic and automatic processes such as gas metal arc
welding, submerged arc welding, flux-cored arc welding and electroslag welding.
SAFETY MEASUREMENT
The safety must come first as we carry out any process in the workplace to ensure our life
is safe. Life is priceless. To avoid the accidents to happen, we need to obey rules and
regulation that have been set. In this module, there are 2 steps involve: cutting the metal
and the welding.
Cutting process

 Metal in a long and heavy unfabricated mode, therefore when we move it must
with cares and enough people.
 Wear safety attire before any process is being carry out.
 Do not get the metal while the cutting process is carried on.
 Do not play around in the workplace.
 Ensure the switch of the cutting machine is off after used.
Welding

 Ensure the electrode is away from the welding table as the process haven’t start
and switch is on to avoid accidents.
 Shield mask is essential as the welding process is being carried out to protect our
eyes.
 Inform your partners before any process is carried out to let them prepare.
 Use the pliers to get the sticked electrode on the metal to avoid electrode shock.
 Hand must be dry and wear hand gloves.
 Wear the shield mask ‘chipping slag’ or clear the workpiece to protect our eye
from ‘slag’ and ‘chip’.

Welders are also often exposed to dangerous gases and particulate matter. Processes

like flux-cored arc welding and shielded metal arc welding produce smoke containing
particles of various types of oxides, which will lead to medical conditions like metal
fume fever some common precautions include limiting the amount of oxygen in the
air, keeping combustible materials away from the workplace,or making use of
a positive pressure enclosure. Welding fume extractors are often used to remove the
fume from the source and filter the fumes through a HEPA filter.
TOOLS
1. CLAMP

2. CHISEL

3.WELDING GOOGLES
4. WIRE BRUSH

5. CHIPPING HAMMER

7.WELDING GLOVES
8. L-SQUARE

9. PLIERS

10. APRON
11. ELECTRODS

14. WELDING MACHINE

PROJECT 1 (RUNNING BEADS)
PROCEDURES
- a 10cm x 10 cm metal plate is produced using cutting machine
- 4 lines that act as reference lines are drawn on the metal plate using chalk
- The welding table is connected to the ground cable (negative charge), and electrode
holder is connected to the electrode cable (positive charge)
- Electrode is clamped by the electrode holder
- The 10cmx10cm metal plate is put on the welding table
- scratch the electrode on the reference line on the work piece until sparks and red flame
produced on the end of the electrode
-Using angle 60˚-75˚, move the electrode along the reference line of the the work piece
with a wave pattern
-electrode is dragged with range of 2mm – 3mm from the surface of work piece
- drag the electrode from left to right
- use the chipping hammer to knock out the slag
- clean the surface using steel brush

PROJECT 1

PROJECT 2
PROJECT 2 (PART JOINT)
PROCEDURES:
- two pieces of 10 cm long metal plates are produced using the cutting machine
- The welding table is connected to the ground cable (negative charge), and electrode
holder is connected to the electrode cable (positive charge)
- Electrode is clamped by the electrode holder
-The two metal plates are put closely together to form a 10cm x 10 cm metal plate shape
- scratch the electrode on the connection line of the two work pieces until sparks and red
flame produced on the end of the electrode
- Using angle 60˚-75˚, make a small circle on the connection line until the two metal
pieces are welded together
- Using angle 60˚-75˚, make another small circle on the connection line until the two
metal pieces are welded together
- use the chipping hammer to knock out the slag
- clean the surface using steel brush
- Flip the two metal pieces to the other side
- scratch the electrode on the connection line of the two work pieces until sparks and red
flame produced on the end of the electrode
-Using angle 60˚-75˚, move the electrode along the connection line of the two work
pieces with a wave pattern
-electrode is dragged with range of 2mm – 3mm from the surface of work piece
- drag the electrode from left to right
- use the chipping hammer to knock out the slag
- clean the surface using steel brush

CONCLUSION

Through the modules, we are able to know basic types of welding method. We also
understand the tools that we need to carry out a welding process. Safety rules also 1
element important that enforce by the instructor. Welding workplace is hazardous unless
we are keeping the rules. We are able to perform welding process safely and correctly.
Therefore we claim the module is successful.