POLITEKNIK NILAI, NEGERI SEMBILAN

JABATAN KEJURUTERAAN MEKANIKAL

DJJ30082-MECHANICAL WORKSHOP PRACTICE 3

WORKSHOP REPORT
(TIG WELDING/MIG WELDING)*

CLO1 Perform welding tasks according to workshop Standard Operating Procedure.(P4, PLO5)
CLO3 Demonstrate awareness of social responsibility and safety procedures in the workshop according to the workshop
safety regulations and create a secured environment in an organization while doing practical work (A3, PLO6)

NAME REGISTRATION NO CLASS

PRAVINESH A/L PARTIBAN 23DKM20F1056 DKM4C

LECTURER NAME
1. EN MOKHSEIN ABDUL MANAP
2.

CRITERIA MARK WEIGHT TOTAL

MARKS
INRODUCTION 5 1 /5
AIM/OBJECTIVE 5 1 /5
WORK MATERIAL/EQUIPMENT 5 1 /5
WORK METHOD/PROCEDURE 5 3 /15
DISCUSSION 5 2 /10
CONCLUSION/RECOMMENDATION 5 1 /5
REFERENCES 5 1 /5
TOTAL /50
TOTAL MARKS %

DATE SUBMISSION 22 MAY 2022

*POTONG YANG MANA TIDAK BERKENAAN

INRODUCTION

Originally Inert Gas Tungsten Arc Welding (Tungsten Inert Gas) is a

type of arc welding made the atmosphere control. Tungsten electrodes
were used. Electrodes only to produce an arc only. So, for the weld when
the metal Additional required to weld, trunk filler rod should be fed to the
weld area as methods done in oxy-gas welding process acetylene. During
the welding process is a shield in the form of gas inert (argon & helium) is used
to block the welded from atmospheric air. Shield works for prevent oxidation at
the electrode tip, a puddle weld and the parent metal in the vicinity of the
welded. There are two types of commonly used welding nozzle weld TIG
operation manually. For welding use per current is low (less than 200
amperes) when welding thin material, weld nozzles are usually of the type that
can cooled in air conditioning. But, for welding require more current than
200 amperes, the nozzle weld should be cooled with water so that the
electrodes do not become overheated. TIG welding is applied in all industrial
sectors but is especially suitable for high quality welding. In manual welding,
the relatively small arc is ideal for thin sheet material or controlled
penetration (in the root run of pipe welds). Because deposition rate can
be quite low (using a separate filler rod) MMA or MIG may be preferable for
thicker material and for fill passes in thick-wall pipe welds. TIG welding is also
widely applied in mechanised systems either autogenously or with filler wire.
However, several 'off the shelf' systems are available for orbital welding of
pipes, used in the manufacture of chemical plant or boilers. The systems
require no manipulative skill, but the operator must be well trained. Because
the welder has less control over arc and weld pool behaviour, careful attention
must be paid to edge preparation (machined rather than hand-prepared), joint
fit-up and control of welding parameters.

OBJECTIVE

• To gain experience and knowledge of the use of TIG arc welding and
materials safe.
• In order to improve the quality or skill in welding.
• The real way to know how to weld with inert gas welding and accurate. •
Knowing how to weld properly.
• In order to familiarize themselves in welding while making industry
training and preparation for the job when due.

WORK MATERIAL/EQUIPMENT

 TIG WELDING MACHINE

 TIG WELDING TORCH
 TORCH LINER
 ARGON GAS
 PRESSURE REGULATORS WITH FLOW METERS
 TUNGSTEN ELECTRODE
 EARTH CLAMP
 PLIERS
 WIRE BRUSH WITH CHIPPING HAMMER
 WORK PLACE TABLE
 WORKPIECE
 BENCH GRINDER MACHINE

SAFETY EQUIPMENTS

 WELDING HELMET
 WELDING GLOVES
 SAFETY BOOT
 WELDING JACKET

SAFETY PRECAUTION

• Always listen carefully to the lecturer and follow instructions.

• Do not run / rush in the workshop.
• Know where the emergency stop buttons are positioned in the workshop.
• Always wear a face shield and welding glove before the welding is started.
• Wear good strong shoes or safety boot. Training shoes are not suitable.
• When attempting practical work, all stools should be put away.
• Bags should be stored away, during practical sessions in the workshop.
• When learning how to use a machine, listen very carefully to all the
instructions given by the lecturer. Ask questions, especially if you do not fully
understand.
• Do not use a machine, if you have not been shown how to operate it safely
by your lecturer.
• Always be patient, never rush to do the practical work.
• Always use guards, when operating machines.
• Keep hands / hair and clothing away from moving / rotating parts of
machinery.
• Use hand tools carefully, and stored it to their place properly after use.
• Report any damage / faults to machines / equipment. Damage or a faulty
part, could cause an accident.
• Keep your workbench tidy. When you have finished with a tool /
piece of equipment, return it to its storage cupboard / rack.
• Never distract another pupil, when they are working on a machine or using
tools /equipment.

WORK METHOD/PROCEDURE

1)First, the workpiece is placed on the

work table.

2) Second, the earth clamp is placed

at the foot of the work table to ensure
the current is connected.

3) Third the main switch is turned on

and also the argon gas is opened and
make sure the pressure for the
workpiece.

4) Next, the power button of the

machine is also turned on.
5) Then the voltage, current and also
resistance is adjusted according to
suitability in order to get a good
quality of welding.
6) The TIG welding torch is held at an
own convenience.

7) After that, start a slightly welding

at the end part of the workpiece as a
mark before starting re-welding on
the workpiece according to the
instructions given to complete the
task.

8) In case the tungsten electrode is

blunt, open the back of the torch and
take the tungsten electrode out then
sharpen the electrode using a bench
grinding machine.
9)Afterwards, the workpiece is re-
welded in a straight line from the right
side to the end of the left side with a
suitable speed by pressing the trigger
to obtain the lap joint.

10) Finally, the wire brush is used to

make the workpiece shine and free
from dust. Ready to submit the task.

DISCUSSION

In TIG welding, a non-consumable tungsten electrode is used to establish an

arc on the base metal. The heat of the arc produced melts the base metal and
produces a weld pool. In contrast to normal stick welding, when TIG welding,
an inert gas shields the weld area in order to prevent air from contaminating
the weld. This shielding gas prevents oxidation of the tungsten electrode,
the molten weld puddle, and the heat-affected zone adjacent to the weld bead.
In a typical TIG setup, an AC/DC welding machine is used with a flow of
shielding gas. The shielding gas goes through a regulator and flow meter and
on to the torch. The torch has a collet body combination that holds the
electrode. A heat-resistant cup or ceramic nozzle surrounds the electrode and
controls the gas shield. In addition, water-cooled TIG machines are available
for high-amperage welding applications. Tungsten inert gas (TIG) welding
became an overnight success in the 1940s for joining magnesium and
aluminium. Using an inert gas shield instead of a slag to protect the weld pool,
the process was a highly attractive replacement for gas and manual metal arc
welding. TIG has played a major role in the acceptance of aluminium for high
quality welding and structural applications. Process characteristics: In the TIG
welding process the arc is formed between a pointed tungsten electrode and
the workpiece in an inert atmosphere of argon or helium. The small intense arc
provided by the pointed electrode is ideal for high quality and precision
welding. Because the electrode is not consumed during welding, the TIG
welder does not have to balance the heat input from the arc as the metal is
deposited from the melting electrode. When filler metal is required, it must be
added separately to the weld pool.

CONCLUSION

The conclusion is, I have learned many things during this project, especially in
dealing with TIG machine. This is because there are several steps that
must be followed before conducting proper welding. We need to be
comfortable with the welding equipment. Practice welding on scrap metal. This
is a good way to become familiar with the equipment you are using, allowing
for more confidence when doing the actual welding. Besides, reducing
amperage to prevent overheating plus slightly increase travel speed or shorten
the arc length.

REFERENCES

 https://www.studocu.com/my/document/politeknik-sultan-azlan-shah/
mechanical-practical/tig-welding-practical-report/21118517
 https://en.wikipedia.org/wiki/Gas_tungsten_arc_welding
 https://www.academia.edu/5198060/WELDING_REPORT