1.

0 OBJECTIVES

 To know the main functions of welding

 To differentiate between gas welding and arc welding
 To understand the procedure of welding
2.0 ADDITIONAL THEORY
1. (Arc welding)-A metal workpiece that is grounded to the welding machine and an electrode
that is also attached to the welding machine are melted using a powerful electrical "arc" in arc
welding technology.When electric current "jumps" and moves between two conductors
through the air, electrical arcing happens. This refers to the electrode and the metal workpiece
in this instance, which are both receiving a strong electrical current from the welding
machine.The electrode and the metal it is touching are both melted by the extreme heat
produced by this arc, which leaves a pool of weld that enables the joining of the two metals.
2. (Gas welding)- Sometimes called metal inert gas (MIG) welding, gas metal arc welding is a
low-cost, high-speed process.This procedure creates filler metal for the weld by striking an
arc between the base metal and a consumable electrode that is continuously supplied. There is
no coating or core on the electrode; it is bare. An external gas, typically a mixture of carbon
dioxide, argon, or helium, provides the shielding to prevent the molten metal from reacting
with elements of the atmosphere. When welding using this method, a considerable amount of
fume may be produced. The majority of the fume produced by GMAW originates from the
electrode's consumption rather than the base metal.

3.0 OBSERVATIONS/SAFETY PRECAUTIONS

1. Wear safety boots-Safety shoes guard against fatigue and shield feet from injuries. This
primarily pertains to industrial workers who are in high-risk situations.Safety shoes are
therefore equally as vital as any other piece of personal protective equipment.Wearing safety
boots is mandatory in the workshop. This is due to the fact that it is among the most crucial
elements of safety. If we are wearing safety boots, our legs can be protected from injury in
the event that something heavy falls on our toes.
2. Wear safety goggles-Safety glasses, also known as goggles,is a types of protective eyewear
that typically enclose or shield the area around the eye to keep particles, liquids, or chemicals
out of the eyes.Wearing safety glasses is essential to prevent objects like jagged metal from
getting into our eyes.
3. Wear safety gloves-Wearing welding gloves can shield you from arc rays, hot parts, electric
shock, flames, and sharp or flying metal.The first line of protection against the hand hazards
associated with welding and cutting is proper gloves. When working, all welders and cutters
must wear protective gloves, per ANSI Standard Z49.
4. Wear welding helmet-A successful welding operation depends on the use of welding
helmets. Additionally, it will help shield the neck, eyes, and face from heat, UV light, sparks,
infrared light, and flash burns when doing some types of welding.
5. Wear protective clothing-Wearing safety gear at work is crucial because it shields wearers
from potential health and safety hazards. Also known as PPE (Personal Protective
Equipment), it guarantees a safe working environment for everyone while reducing the risk
of illness, injury, and legal problems.
6. Maintain cleanliness of workspace-Always clean the workshop after any activity done.
7. Request permission from lecturer-If feeling unsure of doing any work procedure,always
make sure to consult lecturer.
 4.0 APPARATUS

Side cutter
3. Used to cut excess wire off gmaw weld gun
 Long nose pliers
4. Used to hold workpiece in place

Wire brush
5. Used to brush off excess slag formed on the workpiece

Grinding machine
6. To grind and smooth down any imperfections on the workpiece
 Chop saw
7. Used to cut metal pieces required for welding project

Electrode
8. A necessary component for smaw welding

Clamp
9. Serves as the grounding for both gmaw and smaw welding machine
 Gmaw weld gun
10. Used to join metal pieces together

Safety goggles
11. To protect the eyes

Magnetic welding holder

12. Used to hold two metal pieces together (T joints)
 Chipping hammer
13. Used to remove slag formed on a workpiece

Safety gloves
14. Used to protect hands while doing work in the workshop

Welding helmet
15. Used to protect the wearer from bright flashes as a result of welding

Smaw machine
16. Serves as the power source that channels electricity through the electrode

5.0 PROCEDURES
 (SMAW WELDING)
 Prepare a piece of mild steel plate 3.0mm thick
 Use an electrode code E4113 or E6013 with diameter 2.6mm or 3.2mm
 Adjust the ampere around 60 – 100 for electrode diameter 3.2mm
 Place an electrode at the electrode holder and make sure that there is no movement of the
electrode
 Hold the electrode 45 degrees(work angle) and 2mm – 3mm above the base metal.
 Maintain the position over a spot just inside the left edge of the base metal until a molten pool
is formed.
 Proceed welding from left to right(for the right hand)
 Halt the process at the end of the work piece.
 The correct technique is to hold an electrode at the starting position for 1s or 2s and continue
until the end of the process. At the end, hold the electrode at the last position for 1s or 2s
before finishing the process.
 The frequency of this action will be determined by the size of the weld being deposited, and
the correct action will improve with practice.

(GMAW WELDING)
 Using a clean piece of mild steel sheet, set up the TIG machine, adjust the current to a
suitable flame, and then drive a molten pool in a straight line down the sheet.
 Starting at one end, angle the torch 45 degrees toward the direction of the weld.
 A tiny spark indicates that there is enough melted pool to move the torch and put in the filler
rod.
 The filler rod should be dipped into the melting pool for four to five seconds.
 Proceed down the sheet in a circular pattern with the terminal facing the other end.
 Continue doing this exercise until the molten pool's width is uniform and the direction of
travel is straight.
 After the welding process is finished, turn off the welding equipment. Remove any leftover
slag from the moldings.
6.0 DRAWING OF WORKPIECE
7.0 DISCUSSIONS
To create a SMAW and GMAW welding, we must learn new skills related to welding. In the process,
we learn how to work at a welding workshop with the proper equipment and supplies.
Additionally,SMAW and GMAW welding improves our readiness and skill set for later outdoor
work. When welding, there are a few types types of iron joints that we can learn about,and one of
them is butt joints. It is important to avoid welding metal pieces together in the same spot for an
extended period of time as this may result in holes in the metal pieces. Excessive movement speed of
the tip will impact plate penetration, resulting in a perforated appearance.We express our gratitude to
our lecturer for providing us with a timely deadline, especially when we see the results of our
collaborative work.Our lecturer gave us the ability to learn new welding techniques and provide us
with additional welding knowledge. I faced a number of difficulties working on this project. I had to
learn how to operate the welding machine first. With the help of my lecturer, I was able to learn even
though it was challenging at first. The mild steel piece was difficult for me to see because of the less
clear welding helmet that we wear for protection.
CONCLUSION
In summary, this workshop has equipped me with the skills necessary to perform SMAW and GMAW
welding operations. I am also able to maintain the workshop's safety and cleanliness. In addition, I am
able to show that I understand social responsibility and the workshop's safety protocols as outlined in
the safety regulations.Next, I am able to perform welding work with the proper electrode and
amperage selection in a secured environment within an organization. I can also weld using the proper
technique as well as welding a flat butt joint. In addition, our lecturer always reminded us to exercise
caution and stay alert when working on assignments before and after practice. Not to mention,I was
capable of producing beads and perform welding work.
REFERENCES
https://www.sciencedirect.com/topics/materials-science/shielded-metal-arc-
welding#:~:text=Shielded%20metal%20arc%20welding%20(SMAW)%20is%20a%20welding
%20process%20in,in%20the%20joint%20being%20welded.
https://www.sciencedirect.com/topics/engineering/gas-metal-arc-welding#:~:text=Gas%20metal
%20arc%20welding%20(GMAW)%20is%20a%20high%2Dspeed,for%20the%20weld%20(2).
Shielded metal arc welding,John R. Walker,W. Richard Polanin
Welding skills,processes and practices,Larry Jeefus,Lawrence Bower,Hugh M. Philips
Gas Metal Arc Welding Handbook,William H.Winnick