“Welding”

Experiment 1

MEE 1007 Manufacturing Process Lab

Fall Semester

Submitted By:
Shashank Phansikar
20BME0703

Faculty In-charge:
Dr. Arivazhagan N
(SME, VIT University)
 Aim: to study butt joint, lap joint, T joint, corner joint.

Apparatus: Mild steel flat 100 mm X 50 mm X 5 mm.

Materials required: Transformer, Rectifier and Argon gas cylinder

Tools required.
• Rough and smooth files.
• Protractor
• Arc welding machines
• Electrodes and holder
• Tongs
• Face shields
• Chipping hammer

Procedure for butt joints

1. Test square is used to check the file on four sides of flat, mild steel, and right angles
are checked.
2. 30° taper is made in the length of the workpiece with root face 0f 2 mm.
3. For the other piece, repeat the above two steps.
4. Two pieces are kept such that the width will form for a ring V-groove.
5. At both the end of the work piece, the tags are made .
6. Welding is performed along the V-groove length by moving the electrode slowly, so as
to fill the groove with enough metal.
7. The slag is removed with the chipping hammer after the welding is completed, the
cleaning is done with the wire brush.
8. The joint thus obtained is a V-butt joint.
Procedure of lap joint

1. Prepare the surface of the given M.S. flat by filing and cleaning the surface to be
weld.
2. Cleaning is done by wire brush, and emery cloth is used to remove rust and dirt, oil,
mill scale etc.
3. Place the two pieces on the weld table parallel, the distance between them being
approximately equal to the thickness of the electrode.
4. An A.C. transformer of D.C. rectifier is used for the welding purpose. A current 250
to 300 Amps is selected depending upon the size of the electrode.
5. Connect one terminal of the transformer to the electrode by a welding cable. The
other terminal is earthed to the welding cable by another weld cable.
6. To generate the arc, the electrode is made to touch gently to the table momentarily to
complete the circuit.
7. As soon as the arc is created, the electrode is lifted to a height equal to the diameter of
the electrode. The electric arc is maintained at constant arc length.
8. Weld the two plates which are kept one over the other making a lap joint then with a
try square check the flatness and perpendicularity and if they are perfectly right then
fill the first side gap
9. The electrode is moved at uniform speed and at a constant height over the gap
between the flats
10. The electrode will melt and get fused with flat to form butt joint
11. Welding is done over the side of the joint by electrode at uniform correct height
across the junction so that the molten metal fills the gap
12. Lift the piece with a tong and using the chipping hammer remove the slag and spatter
13. Clean the weld surfaces with a wire brush and dip in water to cool the piece to room
temperatures
Procedure for corner joint

1. Prepare the surface of the given M.S. flat by filing and cleaning the surface to be weld.
2. Cleaning is done by wire brush, and emery cloth is used to remove rust and dirt, oil, mill
scale etc.
3. place the two pieces on the weld table parallel, the distance between them being
approximately equal to the thickness of the electrode
4. An arc is formed between a electrode and the metal being welded
5. Gas is fed through the torch to shield the electrode and molten weld pool
6. The filler electrode wire is continuously fed from a spool.
7. Welding is done over the other side of the joint by arc (electrode) at uniform; correct
height across the junction, so that the molten metal fills the gap.
8. Lift the piece with a tong and using the chipping hammer remove the slag and spatter.
9. Clean the weld surfaces with wire brush and dip in water to cool the piece to room
temperatures.

Procedure for T joint

1. Prepare the surface of the given M.S. flat by filing and cleaning the surface to be weld.
2. Cleaning is done by wire brush, and emery cloth is used to remove rust and dirt, oil, mill
scale etc.
3. place the two pieces on the weld table parallel, the distance between them being
approximately equal to the thickness of the electrode
4. An arc is formed between a electrode and the metal being welded
5. Gas is fed through the torch to shield the electrode and molten weld pool
6. The filler electrode wire is continuously fed from a spool.
7. Welding is done over the other side of the joint by arc (electrode) at uniform; correct
height across the junction, so that the molten metal fills the gap.
8. Lift the piece with a tong and using the chipping hammer remove the slag and spatter.
9. Clean the weld surfaces with wire brush and dip in water to cool the piece to room
temperatures.
Observations
we have created four joints in this experiment, namely butt joint, lap joint, T joint and corner
joint.
Upon a preliminary observation, the weld quality is strong. It is not easily breakable by hand.
the slag is removed and it feels smooth to touch

Safety Precautions
1. Wear the leather gloves, shoes and tight dresses.
2. Wear the welders helmet or hand shield with white and German glasses.
3. Do not look the electric arc with naked eye.
4. Set Correct rate of current.
5. When the electrode sticks to the give work piece, then switch - off the machine and rémove
the electrode, again hold it in the electric holder

Conclusion
Thus, the four joints have been prepared and studied.