Technical College of Engineering

Department of petrochemical

Workshop

Prepared by: Lecturer:

Waleed adnan Mr. Lazgeen

Name of Workshop : “ WELDING ”

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Introduction
Welding is a common process for joining metals using a large variety of
applications. Welding occurs in several locations, from outdoors settings on rural
farms and construction sites to inside locations, such as factories and job shops.
Welding processes are fairly simple to understand, and basic techniques can be
learned quickly. Welding is the joining of metals at a molecular level. A weld is a
homogeneous bond between two or more pieces of metal, where the strength of
the welded joint exceeds the strength of the base pieces of metal.

COMMON TERMS
There is a large vocabulary of specific welding terms. Knowing these terms is
essential to learning about welding as well as understanding how to weld.
Arc Burn: Arc burn is a metallurgical notch caused by ground clamps or striking an
arc on the base metal at any point other than the weld groove or immediate area
that will be covered with the weld cap.
Base Metal: The base metal is the metal that is to be welded or cut. It is
commonly referred to as the workpiece.
Butt Weld:A butt weld is a joint between two workpieces that are aligned on the
same plane.
Cover Pass: The cover pass finishes the welded joint. It is higher than the adjacent
surface and overlaps the groove.

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Filler Pass: The filler pass follows the hot pass and fills the weld groove flush, or
almost flush, with the surface of the workpieces.
Fillet Weld: A fillet weld is the joining of two workpieces with triangular cross-
sections at approximately 90 degrees.
Heat-Affected Zone: The heat-affected zone is the area of metal near the weld
metal that was not melted during welding, but did experience changes in its
mechanical properties and/or microstructure due to the heat applied.
Hot Pass: The hot pass is the pass immediately following the stringer pass.
Joint: The hot pass is the pass immediately following the stringer pass.
Plug Weld: Plug welding is filling a hole or gap in one piece with weld or filling a
hole and attaching the piece with the hole to the surface of another base piece.
Polarity: Polarity is the manner in which the electrode holder and workpiece
connect to the electrical supply. This can be either direct current electrode
negative, or DCEN, meaning straight polarity or direct current electrode positive,
or DCEP, meaning reverse polarity.
Spot Weld: Spot welding is the process in which the weld pieces are pressed
together with pressure, then a current is passed through them in a small spot and
the two pieces are melted together at that location. Spot welding can be
performed on metals from 0.5 to 3 mm.
Stringer or Root Bead: The stringer pass, or root bead, is the first pass in the
weld. It is typically made without any weaving motion.
Weld groove refers to a V- or U-shaped groove created by the beveling of the
workpiece edges that will be joined.
Weld Metal: The weld metal is the portion of the base metal that is melted during
the welding process.
Weld Pass: A weld pass is a single progression of welding along the joint. After a
complete pass, it is referred to as a weld bead.
Welding Electrode:In arc welding, the electrode is used to pass current through
the workpiece to fuse the two pieces together.

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OBJECTIVE
To know main function of welding.
To know the part of welding.
To know what is a true step when doing a welding.
To ensure student know the prevention of accident.
To ensure student know the skills of welding.
To ensure all student according to the instruction and safety

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 TYPES OF WELDING

Arc welding is one of several fusion processes for joining metals. By applying
intense heat, metal at the joint between two parts is caused to intermix directly,
or more commonly, with an intermediate molten filler metal. Upon cooling and
solidification, a metallurgical bond is created. Since the joining is an intermixture
of metals, the final well-meant potentially has the same strength properties as the
metal of the parts. This is in sharp contrast to non-fusion processes of joining 
(i.e. soldering, brazing etc.) in which the mechanical and physical properties of
the base of be duplicated at the joint.

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Gas welding Oxy-Acetylene welding is one of many types of welding supported by
the PRL. It is extremely versatile, and with enough skill and practice you can use
this types of welding for virtually any metal. In fact, the oxy-acetylene flame burn
at 6000 ‘F, and is the only gas flame that is hot enough to melt all commercial
metals. Oxy-acetylene welding is simple in concept two piece of metal are bought
together, and the touching edges are melted by the flame with or without the
addition of filler rod.

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 MATERIAL AND TOOLS
Arc welding

Welding machine

electrode

head sheld

wire brush

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Gloves
Clamp

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LABORATORY WORK PROCERDUR
.Prepare a piece of mild steel plate 3.0mm thick.
2.Use an electrode code MS6013 or E6013with diameter 2.5mm or 3mm.
3.Adjust the ampere around 60-100 for electrode diameter 3mm .
4.Put an electrode at the electrode holder and make sure that there are no
movement ofelectrode at the holder.
5.Hold the electrode 60’degrees work angle and 2mm- 3mm above the base
metal.
6.Hold that position over a spot just inside the left edge of the base metal until a
molten poolis established.
7.Welding then proceeds from left to right(for the right hand)
8.Stop the process at the end of the work piece.
9.The correct technique is hold an electrode at the start position for 1s or 2s and
continueuntil the end of the process. At the end, hold an electrode at the last
position for 1s or 2s before finishing the process.
10.The frequency of this action will be determined by the size of the weld being
deposited, and the correct action improve with practice.

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APPLICATIONS OF WELDING
The welding is widely used for fabrication of pressure vessels, bridges,building
structures, aircraft and space crafts, railway coaches and generalapplications
besides shipbuilding, automobile, electrical, electronic and defenseindustries,
laying of pipe lines and railway tracks and nuclear installations.Specific
components need welding for fabrication includes:
(a) Transport tankers for transporting oil, water, milk etc.
(b) Welding of tubes and pipes, chains, LPG cylinders and other items.
(c) Fabrication of Steel furniture, gates, doors and door frames, and body
(d) Manufacturing white goods such as refrigerators, washing
machines,microwave ovens and many other items of general applications.

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Conclusion
In this workshop we learned what welding, what types of welding, how to weld in
the workshop and how to prevent in the workshop before starting the welding
process At these practical, we learn about how to joining the plat iron use the Arc
and Gas Welding. Other than that we also have been teach by our lecturer how to
adjust the volume of the electric. Besides that ,Our teacher always remain us to
stay alert in safety while doing a work before and after finish the practice.
Conclusion is, I want to thanks to lecturer and my friend during learning of arc and
gas welding. How ever,these practical i will never ever forget because these talent
is bring us to learn a new thing’s in my studying at these college.

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