Manufacturing Laboratory-I (ME207) Report

Date of submission: 23/02/2021 Name: Ashutosh Garg

Group: G7 Entry No: 2018MEB1213

Experiment No. 7

Experiment title: Aim of the experiment is to:

Objectives:

1. Make a butt Joint by MAG welding and learn the procedures of MIG Welding and
Spot Welding.
2. Study the effect of welding currents on the weld quality.
3. Comparing the hardness of the joints by varying the welding currents and finding
the reasons behind them.
4. Comparing the different properties of the weldings with respect to different welding
currents.
Material and apparatus used:

1. Transformer
2. Control Unit
3. Argon(Inert Gas) Cylinder
4. CO2 (Active Gas) Cylinder
5. Welding Torch
6. Electrode (+ve terminal)
7. Pressure Gauge
8. Working table (-ve terminal)
9. Wire Brush
10. Tong
11. Hammer
12. Chop Saw.
13. Hardness Testing Machine
14. PPE Kit: Helmet, Thermal and electrical resistant gloves, Apron, Safety Shoes.
NOTE: PPE kit should be dry and Greese free.

Experimental procedure:

FOR MAG Welding:

1. Create a V – shaped groove in the base plate with an angle of 600 . The detailed
dimensions are given in Figure 1.
 Figure 1.

2. Now, set up the parameters for the three different weldments to be performed.
The parameters to be set are as follows:
i. CASE 1:
a. V = 22.5 V
b. I = 90 A
ii. CASE 2:
a. V = 22.5 V
b. I = 100 A
iii. CASE 3:
a. V = 22.5 V
b. I = 110 A
3. Now, for each case, perform the welding first at the corners so that the rest of
the welding is not disturbed.
4. Next step is to perform the welding process in the side where the V- shaped
groove was made.
5. Turn the Workpiece upside down and then fill the root side (Make the root pass)
of the workpiece as there may be the lack of penetration.

Figure 2.
6. After performing the welding operations for all the cases, Cut the pieces from
the welded workpieces with similar set of distances and measurements for the
hardness testing. This process is done with the help of chop saw.
7. Rockwell Hardness test is performed after the cutting of the sample materials
and then the 3 values are taken and averaged out. This may not be appropreate
as the hardness may not be uniform. This procedure is performed for all the
weldmelt cases.
FOR Spot Welding:
The two pieces of metal were held one above each other and placed between the two
copper electrodes and pressure is applied with the help of actuator after setting the heat
parameter to 60% of maximum value and time as 150 micro seconds.
Results and Discussion:

Table 1: Different cases and data given

Specimen Current (A) Hardness (HRA)

CASE 1 90 65.4
CASE 1 90 63.4
CASE 1 90 65.4
CASE 2 100 60.5
CASE 2 100 59.1
CASE 2 100 59.0
CASE 3 110 42.2
CASE 3 110 34.8
CASE 3 110 39.5

Table 2: Results obtained

CASE AVERAGE VALUES of Q (Welding Heat Input)

Hardness(HRA): in kJ/m
1 64.73 952.9411765
2 59.53 1058.823529
3 38.83 1164.705882

As we can clearly observe from the pictures of the final output, with the increase in the
current value:
a. The weld scattering is reduced.
b. The weld width increases with increase in current.
c. The cleanliness in the weld pattern is increased with increase in current.
This is due to the increase in the heat input.
Answers to Questions asked in video:
Answer 1: From the data, it can be observed that the hardness value is decreased with
the increase in the current in the weld metal. This may be due to the decrease in the
welding time of the material as the more heat is produced and filler material is filled
rapidly. Also, on the microscopic level, with the increase in heat value the structure
becomes finer.

Answer 2: Pressure in the resistance welding process plays an important role in holding
the workpiece surfaces and it also allows the current to circulate in a better way. Pressure
provides a sort of forging action. Pressure also prevents the molten metal to come out of
the welding spots.
Learning from the experiments:
1. Major learning was the methods by which the welding is done practically.
2. I also learnt about precautions to be taken during the welding.