UNIVERSITI TUN HUSSEIN ONN MALAYSIA

CENTER OF DIPLOMA STUDIES

DEPARTMENT OF MECHANICAL ENGINEERING

MANUFACTURING PROCESS

DAM23403
SEMESTER 1, SESI 2022/2023

TOPIC: GROUP PROJECT: INTERVIEW WITH COMPANY WMS WELDING

PROVIDED BY:

NAME MATRIC NUMBER

MUHAMMAD SHAH FITRI BIN ROZAIMI AA212145

SMITHCER ANAK SPENCER AA210435

WAFA NURDIANA BINTI ABDULLAH AA211225

LECTURE : MR. NORZAILAN BIN AZAHARI

SECTION :6

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CONTENT

i. Information of interview 3

ii. Information about the company 4

iii. Working system of company 6

iv. The operation of the topic chosen 7

v. The expertise required to perform the topic chosen 9

vi. Working safety and health 11

vii. Reference 14

I.

II.

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INFORMATION ABOUT THE INTERVIEW

Company name WMS Welding

Company address 4, Jalan Kebun 1d/Ks7, Bandar Putera, 4100 Klang, Selangor.

Company Mr. Wan Muhd Syuhaimi Bin Wan Mustofah

representative/
interviewee

Job position Welder

Date of interview 27 December 2022 on Tuesday

session

Time 4.00 p.m. until 5.00 p.m.

Platform Google meet

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INFORMATION ABOUT COMPANY
The address of WMS Welding is 4, Jalan Kebun 1d/Ks7, Bandar Putera, 41000, Klang,
Selangor. This company is involved in the production of products using the welding method.
Welding is the technique of attaching one substance to another using a specific material, such
as metal or thermoplastic. This welding procedure includes melting a certain type of metal to
use as a binder between two structures. Pressure is sometimes employed in addition to heat to
form the weld. This is in contrast to soldering, which only melts the joint material (solder) to
make the joint and not the structure itself. Arc welding and gas welding are the two methods
of welding. Welding can be done in a variety of ways. Welding technologies described
include flame welding, high voltage electricity, laser radiation, electron fire, and ultrasound.

Welding with an Arc welding involves the transfer of electrical energy from the
electrode to the base metal and the conversion of this electrical energy into high heat energy.
This energy is utilised to melt the electrode log, filler metal, or connecting metal, resulting in
the formation of a weld joint. Essentially, a large amount of power is required to reach a
specific temperature in order to melt the metal in a short period of time. An arc welding
machine is a step-down device that converts high voltage to low voltage while producing a
high current in order to create an arc for welding applications. It is outfitted with an electrode
holder cable as well as an earth cable to the worktop.

Gas welding is a metal joining procedure that involves heating both pieces of the metal
to be joined until they melt and fuse together. Humans discovered how to combine metals at
the beginning of the twentieth century by heating two metal rods until red hot and then
delivering a severe impact on both until they fused together. This is referred to as forge
welding. This approach has been refined with the advancement of technology till the most
recent method of gas welding is now utilised by all of us. Gas welding is a type of welding
that has long been used in industry, particularly in metal fabrication. This is due to the fact
that gas welding has been discovered to be particularly suitable for thin metal sheets. Vehicle
body repair and metal fabrication work involving thin metal sheets are two examples of work
fields that use the gas welding process.

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 Among their final products are gates, grill doors, and other items. For the final result,
the organisation employs all acceptable welding procedures. Despite the fact that this
company is not large or well-known, it employs highly skilled welders. Mr. Muhd Syuhaimi
Bin Wan Mustofah is one of the employees we had the opportunity to interview for this task.
His previous expertise as a welder in the oil and gas industry pushed us as students to thrive
in the future.

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WORKING SYSTEM OF COMPANY

The working system of the company focuses on metal-related tasks, especially welding
and fabrication. Specialised in semi-aluminium gates, awnings, and roller shutters.
Additionally, the company is also involved in bigger projects such as structure welding and
provides services to customers.

Since the company is privately owned with a small workforce, there is no clear
indication that the company has a proper working system, Therefore, we would assume the
company didn’t provide any working system for the company. Additionally, the interviewers
did not directly inquire regarding the system above.

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THE OPERATION OF THE TOPIC CHOSEN

In contrast to brazing and soldering, which do not melt the base metal, welding is a
high-heat operation that does. Typically, a filler element is included. High-temperature heat
generates a weld pool of molten material to form the connection, which can be stronger than
the parent metal. Pressure can also be employed to form a weld, either in conjunction with or
independently of heat. Shielding gas can also be used to keep the melted and filler metals
from becoming contaminated or oxidised. There are multiple types of welding that can be
utilised and each of said types has a different use case.

The first type of welding is arc welding. A variety of popular manual, semi-
automated, and automatic processes are included in this category. Metal inert gas (MIG)
welding, stick welding, tungsten inert gas (TIG) welding, also known as gas tungsten arc
welding (GTAW), gas welding, metal active gas (MAG) welding, flux cored arc welding
(FCAW), gas metal arc welding (GMAW), submerged arc welding (SAW), shielded metal
arc welding (SMAW), and plasma arc welding are examples of these.

These procedures, which typically employ a filler material, are generally used to join
metals such as stainless steel, aluminium, nickel and copper alloys, cobalt, and titanium. Arc
welding procedures are widely employed in a variety of industries, including oil and gas,
power, aerospace, and automotive.

Our next type of welding is friction welding. Mechanical friction is used to fuse
materials in friction welding procedures. This can be done in a variety of methods on various
welding materials such as steel, aluminium, and even wood.

Mechanical friction generates heat, which softens the materials, allowing them to
combine and form a bond as they cool. The particular procedure employed, such as friction
stir welding (FSW), friction stir spot welding (FSSW), linear friction welding (LFW), and
rotary friction welding, determines how the joining happens (RFW). Friction welding does
not use filler metals, flux, or shielding gas. Friction is commonly utilised in aerospace
applications because it is perfect for connecting otherwise "non-weldable" lightweight
aluminium alloys. Friction procedures are utilised in many industries and are being
investigated as a means of bonding wood without the use of adhesives or nails.

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 To join materials, a beam of high-velocity electrons is used in this fusion joining
technique. When the electrons collide with the workpieces, their kinetic energy is converted
into heat, causing the materials to melt together. This process is known as electron beam
welding. Electron beam welding (EBW) is done in a vacuum (through a vacuum chamber) to
keep the beam from dispersing. EBW has numerous frequent applications, including joining
thick sections. This implies it can be used in a variety of industries, including aerospace,
nuclear power, automotive, and rail.

The laser weld is used to join thermoplastics or metal parts for our final weld. This
procedure uses a laser to create a concentrated heat suitable for fast, deep welds, and high
joining rates. Because this procedure is easily automated, the high welding speed at which it
can be performed makes it ideal for big-volume applications, such as those in the automotive
industry. Laser beam welding, unlike electron beam joining, may be done in the air rather
than in a vacuum.

Last but not least is the resistance weld. This is a quick method that is often utilised in
the automotive sector. Resistance spot welding and resistance seam welding are the two
variants of this procedure. Spot welding employs heat delivered between two electrodes and
applied to a tiny region as the workpieces are fastened together. Seam welding is identical to
spot welding, except that the electrodes are replaced with rotating wheels to provide a
continuous leak-free weld.

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THE EXPERTISE REQUIRED TO PERFORM THE TOPIC CHOSEN

Based on the interview, the interviewee classifies the requirements needed to perform
welding, which is one for the Oil and Gas industry and a typical workshop. As mentioned
during the interview, Oil and Gas industry have strict requirements for an employee to be
able to take the position of a welder.

The oil and gas sector relies on a wide range of very complex infrastructure, including
rigs, pipelines, platforms, plants, and facilities. Welding methods are used to build most of
these infrastructures. Welding is essential in oil and gas operations, both for new project
development and for maintaining existing facilities. There are multiple requirements for
welders to be hired into the oil and gas industry. First and foremost is the employee’s general
knowledge regarding the process and operation of welding. This refers to the types of
welding, their operation, and the uses of each weld.

The welder must be qualified to take the position as a welder, as the interviewee had
mentioned, the minimum education requirement for welders is an SPM certificate, though a
diploma certificate and degree are preferable. Next, the welders are required to obtain a
welding certificate. Certification can help you become a certified welder, giving you an
advantage while looking for work. After completing the certification, you will be issued a
certified welder card. Qualification is still required once you apply for a job.

These are some of the organisations discussed throughout the interview:

 The American Welding Society (AWS) is a non-profit organisation that offers

professional qualifications and possibilities for collaboration in the welding
business. Get cutting-edge industry knowledge, resources, and skills for a
successful career.
 American Society of Mechanical Engineers (ASME) - The ASME offers a
welding technology virtual classroom certification course. It covers codes and
standards that apply, techniques, principles, symbols, material selection, and
preheat.
 American Petroleum Institute (API) - The API 577 certification allows
specialised inspectors, metallurgists, and welding experts to demonstrate their
industry knowledge. This certification is valid for a period of three years.

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 These organisations and institutions do give out multiple types of certifications. Just
to list a couple of these:

1. Certified Welder (CW)

You can use practical examinations to obtain transferrable certifications and
become a certified welder. Welding skills evaluations could be conducted in
industries such as petroleum pipelines, chemical refineries, structural steel,
and sheet metal.

2. Welding Inspector Certification (CWI)

The accreditation of a certified welding inspectors displays a high degree of
skill and leadership in the welding business. A certified welding inspector
collaborates with other project managers and helps other professionals obtain
certification. To be qualified for a welder inspector certification, you must
have at least one year of work experience. The exam is made up of three
computer-based assessments: one on fundamental welding and two inspection-
based, open-book tests.

3. Welding Supervisor Certification (CWS)

Those who have advanced to managerial positions in the field are eligible to
apply for the CWS certification. It is intended for industry executives with
experience in quality assurance and problem-solving. Supervisors must
understand what factors influence productivity, weld quality, material waste,
and safety. They improve communication, review materials and manpower,
and meet objectives while adhering to safety regulations.

As for the requirement for a typical workshop are, welders must know the basics of
welding and able to do measurements. This is due to the lower skills required to work in a
workshop. Although higher skills are preferable to the lack of regulation to filter better-
skilled welders, lower-skill welders are more prominent in workshops.

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WORKING SAFETY AND HEALTH

There are various hazards to employees and environmental effects during the welding
process. Classification is one of the potentially hazardous occupational activities. As a result,
welding safety procedures that are meant to safeguard welding employees from welding
hazards are required. To increase worker safety, thorough training, inspection of
classification equipment, and ensuring that workers understand safety concerns before
performing classification activities are required. This is done to reduce the possibility of
injury and other accidents.

Exposure to smoke and gas is one of the effects of welding activities and how to avoid
them. Excessive exposure to smoke and gases can result in serious health problems such as
respiratory diseases, cancer, and impaired vision and smell. Exposure to smoke and gas can
be reduced by taking safety precautions such as providing adequate ventilation to keep smoke
and gas out of public areas and practising private breathing. Furthermore, exposure to smoke
and gas can be controlled by following safety precautions, such as the classification operator
always wearing a respirator according to its specifications, unless the exposure level is below
the applicable exposure limit. If you have already been exposed to smoke and are
experiencing unpleasant symptoms, consult your doctor immediately.

Furthermore, workers are exposed to Physical dangers are those that can cause physical
harm from welding, such as burns, eye damage, scratches, and finger injuries. You can
protect yourself from physical risks by using the proper Personal Protective Equipment
(PPE). PPE is protective equipment worn in the workplace to reduce exposure to risks that
can result in significant damage or sickness. Contact with chemical, radioactive, physical,
electrical, mechanical, or other workplace risks can result in these injuries and diseases. Wear
adequate personal protective equipment (PPE) such as a welding helmet and welding goggles
to protect the worker's head and eyes from heat, sparks, harsh light, and chemical burns. In
addition, wear welding clothing that is resistant to fire and electricity, as well as welding
gloves, aprons, and safety shoes. This personal protective equipment cannot be overlooked
because it protects employees from heat, fire, electric shock, and burns. It should also be
noted that the amount of re-washing frequencies can cause fire resistant equipment to lose
effectiveness. Pay attention to the long jeans used to cover the tops of the shoes so that the
feet are not exposed to sparks, as well as the use of ear muffs to protect your hearing from
noise during the welding process.

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 In addition, workers are exposed to electric shock. Electric shock is one of the most
dangerous hazards for welders. During the welding process, an electric current might be
released suddenly, causing significant harm and even death. The risk of electric shock during
welding can be reduced by taking simple precautions like as Always inspect welding
equipment and electrode holders before beginning work. Use Lockout Tag out protocols
when performing maintenance, especially in industrial environments. To repair the welding
equipment, use a professional expert. Do not touch the metal section of the electrode holder,
especially when wet or rainy, and keep a safe distance.

Besides, during the welding process, a gas such as Cesium is formed in the electrode
radioactive strontium Tontium is a radioactive element, although tungsten argon arc welding
has a tiny dosage of radiation, and the damage is not dangerous within the authorised range. It
is possible for your health to be harmed if radioactive gas or particles enter the body as a
source of internal radiation. This gas cannot be freely discharged straight into the
environment since it has a greenhouse impact. Ventilation actions are among those that must
be taken. To eliminate harmful gases and pollutants, the argon arc welding workplace must
have adequate ventilation. In addition to industrial ventilation, multiple axial fans can be
installed to ventilate outside air where there is a high concentration of welding workloads and
welding machines. Local ventilation methods, such as open bow exhaust hoods, exhaust
torches, and tiny portable fans, can also be utilised to eliminate harmful gases around the
bow.

Last but not least, there is a potentially hazardous egress during the welding process.
ozone and nitrogen oxides, the temperature of the arc column is high during argon arc
welding. Because the intensity of ultraviolet radiation is significantly higher than that of
normal arc welding, a large amount of ozone and nitride oxide is created during the welding
process; particularly, the ozone concentration far exceeds the standard sanitation criteria. If
proper ventilation procedures are not implemented, these gases have a significant influence
on human health and are the most dangerous factor for argon arc categorization. High-
frequency argon arc welding safety precautions.

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The following steps have been made to prevent and reduce the impact of high-frequency
electromagnetic fields:

1) The work piece is correctly grounded, and the torch cable and ground wire are
protected with braided metal wire.
2) Frequencies are accurately lowered.
3) Avoid using a high frequency oscillator as a stabilising arc device to shorten the
length of high frequency electrical action.
4) Additional personal safeguards Because of the intense activity of ozone and
ultraviolet radiation during argon arc welding, it is advisable to use non-cotton gloves.
Personal protective measures such as blow helmets, blow covers, or respirators can be
used when the container is welded and local ventilation cannot be used.

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REFERENCE

 Screen shot of permission of interview for the company

 Screen shot of interview session :

 Link Google Drive for interview session :

https://drive.google.com/folderview?id=18YFTiufHjvXKlbIypjTyRIF9tpPCZ4MK

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