TITLE : ARC WELDING

NAME : MUHAMMAD ALIF BIN MOHD FAUZI

MATRIK NO : 053316
SUBJECT : MANUFACTURING PROCESS
LECTURER NAME : PUAN CHE WAN NOORAKMA BINTI ABDULLAH

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Content

NO TITLE PAGE

1. INTRODUCTION 3-6

2. OBJECTIVE 7

3. MATERIAL AND EQUIPMENT 8-10

4. METHODOLOGY 11

5. RESULT 12

6. DISCUSSION 13-14

7. CONCLUSION 15

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1.Introduction to Arc Welding

Arc welding is one of several fusion processes for joining metals. Arc welding is a process
that is used to join metal to metal by using electricity to create enough heat to melt metal, and
the melted metals when cool result in a binding of the metals. Since the joining is an inter-
mixture of metals, the final weld joint 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 materials cannot be
duplicated at the joint.

In arc welding, the intense heat needed to melt metal is produced by an electric arc with the
help of a welding power supply. The arc is formed between the actual work and an electrode
(stick or wire) that is manually or mechanically guided along the joint. The electrode can
either be a rod with the purpose of simply carrying the current between the tip and the work.
Or, it may be a specially prepared rod or wire that not only conducts the current but also
melts and supplies filler metal to the joint. Most welding in the manufacture of steel products
uses the second type of electrode. The welding region is usually protected by some type of
shielding gas, vapor, or slag.

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1.1 Basic Arc Welding Circuit

The basic arc-welding circuit is illustrated in Figure 1. An alternating current (AC) or direct
current (DC) power source, fitted with whatever controls may be needed, is connected by a
work cable to the work-piece and by a “hot” cable to an electrode holder of some type, which
makes an electrical contact with the welding electrode.
An arc is created across the gap when the energized circuit and the electrode tip touches the
work-piece and is withdrawn, yet still with in close contact. The arc produces a temperature
of about 6500ºF (or 3600ºC) at the tip. This heat melts both the base metal and the electrode,
producing a pool of molten metal sometimes called a “crater.” The crater solidifies behind the
electrode as it is moved along the joint. The result is a fusion bond.

Figure 1 – Basic Arc Welding Circuit Diagram

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1.2 Arc Shielding

However, joining metals requires more than moving an electrode along a joint. Metals at high
temperatures tend to react chemically with elements in the air – oxygen and nitrogen. When
metal in the molten pool comes into contact with air, oxides and nitrides form which destroy
the strength and toughness of the weld joint. Therefore, many arc-welding processes provide
some means of covering the arc and the molten pool with a protective shield of gas, vapor, or
slag. This is called arc shielding. This shielding prevents or minimizes contact of the molten
metal with air. Shielding also may improve the weld. An example is a granular flux, which
actually adds deoxidizers to the weld. Figure 2 shows how the coating on a coated (stick)
electrode provides a gaseous shield around the arc and a slag covering on the hot weld
deposit. The slag protects the fresh weld from the air.

Figure 2 – Shielding of Welding Arc

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1.3 Basics of the Arc

The arc itself is a very complex phenomenon. In-depth understanding of the physics of the
arc is of very little value to the welder, but some knowledge of its general characteristics can
be useful.

An arc is an electric current flowing between two electrodes through an ionized column of
gas. A negatively charged cathode and a positively charged anode create the intense heat of
the welding arc. Negative and positive ions are bounced off of each other in the plasma
column at an accelerated rate.

In welding, the arc not only provides the heat needed to melt the electrode and the base metal,
but under certain conditions must also supply the means to transport the molten metal from
the tip of the electrode to the work. Several mechanisms for metal transfer exist. Two (of
many) examples include:

1.31. Surface Tension Transfer – a drop of molten metal touches the molten metal
pool and is drawn into it by surface tension.
1.32. Spray Arc – the drop is ejected from the molten metal at the electrode tip by
an electric pinch propelling it to the molten pool.

Since there must be an ionized path to conduct electricity across a gap, the mere switching on
of the welding current with an electrically cold electrode posed over it will not start the arc.
The arc must be ignited. This is caused by either supplying an initial voltage high enough to
cause a discharge or by touching the electrode to the work and then withdrawing it as the
contact area becomes heated.

Arc welding may be done with direct current (DC) with the electrode either positive or
negative or alternating current (AC). The choice of current and polarity depends on the
process, the type of electrode, the arc atmosphere, and the metal being welded.

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2.Objective :

1. To prepare a butt and Tee joint with mild steel strip using SMAW technique.

2. To gain arc welding skill.

3. To study and observe the welding techniques through demonstrations and practise

4. To differentiation between arc welding and gas welding

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3.Material and equipment :

1.Welding unit

Welding unit functions as an electric current supply to perform the arc welding process.
Welding unit can be used in AC current or DC current.

Figure 3 – welding unit

2.Consumable mild steel wire

Consumable Mild steel wire is used to connect a section. It works when it is connected with
welding unit wires and it will work.

Figure 4 – consumble mild steel wire

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3.Mild steel flat. (100 x 80 x 5mm , 100 x 60 x 5mm)

Mild Steel flat is used to make the arc work welding on it.

Figure 5- mildsteel flat (100 x 80 x 5mm , 100 x 60 x 5mm)

4.Protecting gas

The function of protecting gas is to protect the eyes and face of the welder from the harmful
ultraviolet and infrared radiations produced during welding. The shielding may be achieved
from use the protecting gas.

Figure 6 – Protecting gas

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5.Wire brush

The function of wire brush is to remove the slag particles after chipping by chipping
hammer. 

Figure 7- wire brush

6.Tongs

Tongs is a tool used for the grip and lifting of objects instead of holding them directly with
hands. In the work of welding, tongs is used to lift the hot object after doing arc welding
process.

Figure 8 – tongs

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4.Methodology :

1. The mild steel has been cleaned plats and joined by wire brush.
2. The plat pieces has been arranged properly to provide the gab for full penetration for
bult joint. (gab ½ thicknesses of flats)
3. Striking of arc , speed and arc length control has been practiced.
4. The welding current had been set , voltage according to the type of metal to be joined.
5. The arc had been striked and tacks at the both ends had been made to hold the metal
pieces together during the welding process.
6. Beads had been layed along the joint to maintain the proper speed and arc length.
7. The welded zone had been cleaned and submitted.

Figure 9- Arc welding method

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5.Result :

Figure 10 -Straight line arc welding

Figure 11 - Tee joint arc welding

Figure 12 , 13 , 14 -Combined tee joint , angle plate and

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6.Discussion :

6.1 Precaution to be taken during various arc welding processes.

One of the safety precautions when doing arc welding is we mush always wear the safely
shoes,so that our feet are protected from hot object embedded our feed. After that, we also
must keep the surrounding clean. Then we will not be exposed to danger. Next, we must
always wear gas protecting while performing the arc welding. This is because, gas protecting
can ensure our eyes are not exposed to sparks that is generated during the arc welding run.

In addition, we must use the tongs to lift the Mild steel flat after doing the arc welding. This
is because the steel Mild is very hot after the weld process is done. This can avoid our hands
burns when it is hit by hot material. Next, we must ensure that welding units are adjusted at
the appropriate voltage value according to the material to welding. If the voltage is not set
correctly, it will harm ourselves.

6.2 Advantages of SMAW over GTAW.

- Versatility ready applied to a variety of application and a wide choice of electrodes.

- Relative simplicity and portability of equipment
- Low cost
- Adaptable to confined space and remote location.
- Suitable for out of position welding.
- Quick change from one material to another material
- Deposition rates faster than GTAW manual.

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 6.2 Difference between consumable and non-consumable arc welding.

There are two type of electrodes are used normally during a welding process. This can be a
consumable electrode or a non-consumable electrode.

Consumble electrodes are ones that would have significant changes in their structure when
they are used. This is to say that these electrodes would be consumed in their use. Non-
consumable electrodes are the ones that are not consumed during the process of arc welding.

Some welding processes require a flux coated electrode. These electrodes when used would
create a smoke around the weld. This would help to stop the air around the weld. Also a
consumable electrodes can melt and mix with the weld creating a stronger bond.

Therefore the choice between using a consumable and non-consumable electrode lied
between the type of metal that is set up for welding. A consumable electrode can aid in the
process of better elimination of impurities.

6.4 Limitations of arc welding.

 Not very portable.

 Process may be limited to flat or horizontal fillet welding positions.
 Limited to steel and some nickel based alloys.
 Best for long straight seams or rotated pipes or vessels.
 Requires flux handling systems.

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7.Conclusion :

After this experiment, I can to prepare a butt ang tee-joint with mild steel strip using SMAW
technique. After learning the arc welding, I can combine the a butt and tee joint with mild
steel without the help of others. I also can gain my skill in welding process. Welding skills
are very important to me for my future. I'll use this skill in my future in doing welding work.
After doing this lab, I realized that welding work is very important for my future. Next, I can
differentiate between SMAW and GTAW. If I can't differentiate between these types of
welding, I would probably be making a welding process using the wrong material. Therefore,
I will harm myself and my environment. I also can to study and observe the welding
techniques though demonstrations and practise.

Through this Lab I can learn a lot of techniques in welding and it's a valuable experience for
me. This experience I will use in my work one day later.

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