Eng. Workshop Practice-MEM 460/MEK 451/ LS 6/Mohd Tolha Rev.

03-2022

UNIVERSITI TEKNOLOGI MARA

PENGAJIAN KEJURUTERAAN MEKANIKAL

Program : Bachelor of Engineering (Hons) Mechanical (CEEM 220)

Bachelor of Mechatronics Engineering Technology (Hons) (CEEM 242)
Course : Engineering Workshop Practice
Course Code : MEM460/MEK451
Course Outcome :
CO2 Demonstrate basic skills in using workshop tools and equipment [PO5, LO2,SSI] ( P5 )
CO3 Practice to the safety rules, standards and regulations when performing engineering workshop practices [PO6,
LO6] {A2}.
CO4 Work effectively in a small group of 3-5 members to collectively undertake and complete assigned project
[PO9, LO9,SS3,SS7] ( A3 )
CO5 Prepare a technical report in a structured format and professional manner. [PO10, LO4,SS2] ( A4 )

LAB SHEET NO: 6

TITLE : Welding (Shielded Metal Arc Welding)

1.0 INTRODUCTION

Shielded metal arc welding (SMAW), also known as manual metal arc (MMA) welding or informally as
stick welding. It is a manual arc welding process that uses a consumable electrode coated in flux to lay
the weld. An electric current, in the form of either alternating current or direct current from a welding
power supply, is used to form an electric arc between the electrode and the metals to be joined. As the
weld is laid, the flux coating of the electrode disintegrates, giving off vapours that serve as a shielding gas
and providing a layer of slag, both of which protect the weld area from atmospheric contamination.
 Eng. Workshop Practice-MEM 460/MEK 451/ LS 6/Mohd Tolha Rev. 03-2022

2.0 OBJECTIVE
• To demonstrate some mostly used welding process.
• To build a welded bead technique on mild steel plate.

3.0 APPARATUS
Power Supply (17-40V), Arc Welding Machine, thin plate of mild steel, DCRP, DCSP, AC (120A),
Electrode holder, leads and its terminal, Ground Clamp, leads and its terminal, Welding Electrodes.

Figure 2: Welding set-up

4.0 METHOD OF APPROACH

The students should follow the required steps during performing experiment.
1) Make sure workpiece is clean before welding
2) Clamp the workpiece as closed to the weld as possible
3) Stick an electrode to the electrode holder. A small diameter electrode requires less
current than large one.
4) Examine the weld bead to determine if the arc length is correct. Arc length for 1/16 and
3/32 in diameter electrodes should be about 1/16 in (1.6mm); arc length for 1/8 and 5/32
in electrodes should be about 1/8 in (3 mm).
5) Use a chipping hammer and wire brush to remove slag. Remove slag and check weld
bead before making another weld pass.
6) Scratch or tap an electrode on the plate ; immediately lift electrode slightly after touching
work. If arc goes out (electrode was lifted too high). If electrode sticks to workpiece, use a
quick twist to free it.

SAFETY INSTRUCTION:
Welding is a potentially hazardous process. 3 major injury cases reported are:
1) Eye damage caused by intensely bright arc
2) Molten metal burns
3) Conductive burns because of direct contact with a welded work piece

Follow the instructions and aware the hazards to minimize injury risk such as use of welding face mask
(goggles), welding and safety gloves.(PPE)
 Eng. Workshop Practice-MEM 460/MEK 451/ LS 6/Mohd Tolha Rev. 03-2022

5.0 LAB REPORT PREPARATION

The students should prepare a report based on given template (Report Form). Summarize the result and
present the data in tables or figures.

6.0 QUESTION
What are factor considerations in producing good quality of joints?
 D

A
4
4

200
9
100

3
3

BEAD ON PLATE 4-LINE

- AC 2
2

- DC+
- DC-
- WELDING SPEED
- MOVEMENT forward & backword
MEM 460

SMAW WELDING
SIZE DRAWING NUMBER REV
PERT 1 1
1

A4 X
SCALE 1:2 UNIT : MM SHEET 1/1

D A