DIPLOMA IN MECHANICAL ENGINEERING

(DJJ10022) MECHANICAL WORKSHOP PRACTICE 1

NAME : DUVENTHIREN LAXMA YOGENDRAN

REG.NO : 01DKM20F1065

CLASS : DKM1B

LECTURER’S : EN. SIVASAN

NAME

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BI TOPIC PG
L
1.0 INTRODUCTION 3

2.0 OBJECTIVE 4

3.0 SAFETY PROCEDURE IN WORKSHOP 5

4.0 MATERIALS , TOOLS & EQUIPMENTS 6

5.0 WORKING PROCEDURES 10

6.0 CONCLUSION 11

7.0 REFERENCES 12

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 1.0 - INTRODUCTION

Gas welding is a welding process that melts and joins metals by heating them with a flame
caused by a reaction of fuel gas and oxygen. The most commonly used method is
Oxyacetylene welding, due to its high flame temperature. The flux may be used to deoxidize
and cleanse the weld metal. The flux melts, solidifies and forms a slag skin on the resultant
weld metal.

2.0 – OBJECTIVES
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 To perform on of the welding techniques and understand important of gas welding.
 
 Define the problem that occurs on the gas welding.
 
 Recognize the type of metal, filler rod, and tools that are used in gas welding.
 
 Recognize types of gas welding and steps to create the gas welding.
 
 To know safety measure along the welding process.

3.0 – SAFETY PROCEDURE IN WORKSHOP

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 EACH USER MUST USE THE APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT (PPE)
WHEN USING THE MACHINE / EQUIPMENT such as : ( Safety Boots , Goggle , Gloves ,
Apron and other equipment )

 OBTAIN PERMISSION FROM A TECHNICAL LECTURER BEFORE USING THE MANIFOLD

SYSTEM / EQUIPMENT

 ENSURE ALL THE THE MANIFOLD SYSTEM / EQUIPMENT ARE IN A GOOD CONDITION
AND SAFE BEFORE USE

 USE ALL THE THE MANIFOLD SYSTEM / EQUIPMENT PROPERLY , SECURELY AND IN
ACCORDANCE WITH THE STANDARD OPERATING PROCEDURE (SOP) AND TURN OFF
THE TORCH AND PRESSURE REGULATOR AFTER USE

 CLEAN THE THE MANIFOLD SYSTEM / EQUIPMENTFROM ALL THE IMPURITIES AFTER
USE

 REPORT ANY DAMAGE OF THE THE MANIFOLD SYSTEM / EQUIPMENT TO THE

LECTURER / TECHNICIAN IMMEDIATELY

 IF HAD AN ACCIDENT , QUICKLY TURN OFF THE TORCH AND REPORT TO THE
LECTURER / TECHNICIAN

 ARRANGE ALL THE EQUIPMENTS IN A NEAT AND ORDERLY PLACE

 MAKE SURE THE WORKSHOP IS FREE OF ALL THE IMPURITIES AND FREE OF ALL
OBSTACLES

 USE A FIRE EXTINGUISHER IF THERE WAS A MINOR FIRE

 LEAVING THE LAB / WORKSHOP AS SOON AS POSSIBLE TO THE GATHERING PLACE IF

THE EMERGENCY OR FIRE ALARM WARNING IS RINGING

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4.0 – MATERIALS , TOOLS & EQUIPMENTS

MATERIALS ,TOOLS AND FUNCTION

EQUIPMENT

GOGGLE
 To protect the eye from excessive
light

HOSE
 Red hose is used to channel
acetylene gas
 Green hose is used to channel
oxygen gas

TORCH
 To adjust the rate of oxygen and
acetylene

NON-RETURNING VALVE
 Acetylene gas and oxygen allow
only one direction

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PRESSURE REGULATOR
 To regulate the amount of gas to
pass through the hose

WIRE BRUSH
 To clean and clear the metals chips
after welding in the metal surfaces

PLIER
 Used to carry hot metal plate and
adjust the metal plate

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 SPARKER
 To create a flame at the torch

FILLER ROD
 Bridge the root gap and thus form a
penetration bead without sacrificing
full fusion of the root faces

SAFETY GLOVES
 To cover hands from burn. These
gloves allow digit articulation while
protecting the operator from
electrical shock,extreme heat and
ultraviolet and infrared radiation and
also provide abrasion resistance and
enhanced grip.

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SAFETY APRON
 Protects you and your clothing from
hot metal and slag that is generated
while welding,grinding or using a
cutting torch.

SAFETY BOOTS
 To protect your feets from
injuries.It’s also protect your feet
from burn or scalded and avoid your
feets from metal sparks

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 5.0 – WORKING PROCEDURES
o Make sure pressure regulator screws are backed out

o Make sure torch valves are closed

o Open the acetylene valves

o Ignite flame with striker

o Than slowly open the oxygen valve until flame leaves end of tip and no smoke is
present than the flame goes back to tip till it become neutral flame

o Keep the metal plate side by side to make a butt join

o If the torch is held in the correct position, a small puddle of molten metal forms.
o The puddle should be centered in the joint and composed of equal parts of those
pieces being welded.
o After the puddle appears, the tip should be moved in a semicircular arc or circular
motion equally between the pieces to ensure an even distribution of heat.
o As the metal melts and the puddle forms, filler rod is needed to replace the metal that
flows out from around the joint.

o The rod is added to the puddle in the amount that provides for the completed fillet to
weld the metal plate perfectly.

o Once done the welding process , have to turn off all the valves on the torch and also
on the pressure regulator.

6.0 – CONCLUSION
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As conclusion, the objective can achievable to do the practical welding. The student must
have skill to do the welding, used the knowledge and understanding of the theories, and also
welding techniques are applied in the practical welding to join two metal plates by heating
them with high temperature flame. The practical task have been complete and the report will
accomplished to prove the student can be done the practical task of Gas Welding.

7.0 – REFERENCES

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 https://www.harrisproductsgroup.com/en/blog/2019/may/working-with-
torches.aspx
 https://en.wikipedia.org/wiki/Gas_metal_arc_welding
 https://www.flight-mechanic.com/gas-welding-procedures-and-techniques/

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