Workshop Manual

B. Tech.
Mechanical Engineering

FWSMT WORKSHOP

Department of Mechanical Engineering

J.C. Bose University of Science and Technology, YMCA,
Faridabad
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 VISION of University

J.C. Bose University of Science and Technology aspires to be a nationally and internationally
acclaimed leader in technical and higher education in all spheres which transforms the life of
students through integration of teaching, research and character building.

MISSION of University

 To contribute to the development of science and technology by synthesizing teaching,

research and creative activities.
 To provide an enviable research environment and state-of-the-art technological
exposure to its scholars.
 To develop human potential to its fullest extent and make them emerge as world class
leaders in their professions and enthuse them towards their social responsibilities.

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 Department of Mechanical Engineering

VISION

To be a centre of excellence by producing high calibre, competent and self-reliant

mechanical engineers, who possess scientific temperament and would engage in activities
relevant to industries with ethical values and flair to research.

MISSION

 To provide efficient engineers for global requirements by imparting quality education.

 To explore, create and develop innovations in various aspects of engineering through
industries and institutions.
 To emphasize on practical skills and socially relevant technology.

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 DEPARTMENT OF MECHANICAL ENGINEERING

Program Educational Outcomes (PEO’S): B. Tech. Mechanical Engineering

PEO-1:

To train students with practical skills and experimental practices related to core and applied areas

of mechanical engineering to expand their knowledge horizon beyond books.

PEO-2:

To enable students to design, develop and maintain mechanical equipments which are useful for

the society.

PEO-3:

To improve team building, team working and leadership skills of the students with high regard for

ethical values and social responsibilities.

PEO- 4:

To enable students to communicate effectively and demonstrate the knowledge of project

management and independent research.

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 DEPARTMENT OF MECHANICAL ENGINEERING

PROGRAMME OUTCOMES (PO)

PO Engineering Graduates will be able to:

Engineering knowledge: Apply knowledge of mathematics, science, engineering

PO1 fundamentals, and mechanical engineering to the solution of engineering problems.
Problem analysis: Identify, formulate, review literature and analyze mechanical
PO2 engineering problems to design, conduct experiments, analyze data and interpret data.
Design /development of solutions: Design solution for mechanical engineering
PO3 problems and design system component of processes that meet the desired needs with
appropriate consideration for the public health and safety, and the cultural, societal and
the environmental considerations.
Conduct investigations of complex problems: Use research based knowledge and
PO4 research methods including design of experiments, analysis and interpretation of data, and
synthesis of the information to provide valid conclusions in mechanical engineering.
Modern tool usage: Create, select, and apply appropriate techniques, resources, and
PO5 modern engineering and IT tools including prediction and modeling to mechanical
engineering activities with an understanding of the limitations.
The engineer and society: Apply reasoning informed by the contextual knowledge to
PO6 assess societal, health, safety, legal and cultural issues and the consequent responsibilities
relevant to mechanical engineering practice.
Environment and sustainability: Understand the impact of the mechanical engineering
PO7 solutions in societal and environmental contexts, and demonstrate the knowledge and
need for sustainable development.
Ethics: Apply ethical principles and commit to professional ethics and responsibilities
PO8 and norms of the mechanical engineering practice.
Individual and team work: Function affectively as an individual, and as a member or
PO9 leader in diverse teams, and in multidisciplinary settings in mechanical engineering.
Communication: Communicate effectively on complex engineering activities with the

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PO10 engineering committee and with society at large, such as, being able to comprehend and
write affective reports and design documentation, make effective presentations in
mechanical engineering.
Project Management and finance: Demonstrate knowledge & understanding of the
PO11 mechanical engineering principles and management principles and apply these to one’s
own work, as a member and leader in a team, to manage projects and in multidisciplinary
environments in mechanical engineering.
Life- long learning: Recognize the need for, and the preparation and ability to engage in
PO12 independent research and lifelong learning in the broadest contest of technological
changes in mechanical engineering.

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 DEPARTMENT OF MECHANICAL ENGINEERING

PROGRAMME SPECIFIC OUTCOMES (PSO)

PSO Engineering Graduates will be able to:

To empower the students to apply practical skills, knowledge in major streams such as
thermal, design, manufacturing and industrial engineering.
PSO1

To enable the student to take-up career in industries or to pursue higher studies in mechanical
and interdisciplinary programs with high regard for ethical values, environmental and social
PSO2
issues.

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 SEC-WS-301/21 WORKSHOP–III
B .Tech- III Semester (Mechanical Engineering)

No. of Credits: 2 Sessional: 30 Marks

L T P Total Practical: 70 Marks
0 0 4 4 Total: 100 Marks
Duration of Exam: 3 Hours

Pre-requisite: Workshop-I, Workshop- II

Successive: Workshop-IV, Workshop-V, Workshop-VI, Workshop-VII

Course Objectives: The objective of studying this course is to understand different

mechanical aspects by introduction of conventional machines, welding processes,
refrigeration& air conditioning system.
Course Outcomes (COs): After studying this course the students will be able to:

CO1- Learn and understand distinctive functions of conventional machines, arc &
gaswelding processes and MIG/MAG welding techniques.
CO 2- Perform different exercises on lathe and milling machines.
CO3- Understand the fundamental concept of refrigeration & air conditioning
equipments/ systems.
CO 4- Deposit continuous bead in flat position by different welding techniques.
List of Exercises:
Section (A): Machine shop

1. To understand and demonstrate the working principle of various

conventionalmachines namely lathe, milling, shaping & grinding machine.
2. To study elements and angles of single point cutting tools and multiple
point cuttingtools.
3. To prepare a job involving centering, facing, plain turning and step turning.
4. To prepare a job by machining on milling/ shaper machine and surface
grinding onsurface grinder.
Section (B): Welding shop
5. To prepare straight continuous bead on a mild steel plate by arc welding
usingdifferent current setting in flat position.
6. To prepare straight continuous bead on mild steel plate by MIG/MAG
welding in flatposition.
7. To set oxy-acetylene flames and fusion run without filler rod in flat
position by gaswelding process.
8. To prepare butt joint on mild steel plate in flat position by arc welding process.

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 Section (C): Refrigeration & Air conditioning shop:
9. To study various codes and tools used in refrigeration and air conditioning system.
10. To study and calculate the C.O.P of refrigeration cycle.
11. To study different refrigerants& identify various Psychometric properties
used in refrigeration & air conditioning system.
12. To perform cutting, flaring, swaging and brazing operations on ferrous and
non ferroustubes.
Note: - Total nine exercises should be performed from the above list. At least two
from each section and remaining three may either be performed from above list or
designed by the concerned institution as per the scope of the syllabus and facilities
available in the institute.

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 Welding Safety Guidelines

1. Shop staff approval is required before using any welding equipment.

2. Welders, assistants, and anyone else in the welding area shall wear glasses or shields of
recommended shades during welding operations.
3. Inspect all welding equipment to be used, prior to each use, for possible damage.
4. Avoid handling oxygen bottles with greasy hands, gloves or rags. Fatal explosions have resulted from
this cause.
5. Always strap tanks to a welding cart or a fixed object. Never allow a gas cylinder to be free standing
Replace the safety cap on all cylinders when not in use.
6. When arc welding, make sure work and/or work table is properly grounded.
7. Do not arc weld in a wet area.
8. Be alert to possible fire hazards. Move the object to be welded to a safe location, or, remove all
flammable materials from the work area.
9. Never weld in the same area where degreasing or other cleaning operations are performed.
10. Keep suitable fire extinguishing equipment nearby and know how to operate it.
11. Shut off the cylinder valves when the job is completed, release pressure from the regulators by
opening the torch valves momentarily, and back out regulator adjusting valves. Never leave the torch
unattended with pressure in the hoses.
12. Utilize all protective equipment and clothing. Do not arc weld with any part of the body uncovered,
the arc light is actinic light (excessive ultraviolet) and will cause burns similar to severe sunburn.
13. Never weld inside drums or enclosed spaces without adequate ventilation, or, the use of airline
respirators or self-contained breathing apparatus.
14. Check the ventilation system before starting to weld and periodically thereafter to insure adequate
performance. Welding fumes should not be allowed to get into the rest of the shop working
areas.
15. Never cut or weld any container that has held explosive or flammable materials. Use prescribed
methods for cleaning or flooding.
16. Never use wrenches or tools except those provided or approved by the gas cylinder manufacturer to
open valves. Never use a hammer to open or close valves.
17. Abide by any other safety measures required for each particular type of welding.
18. Allow for proper ventilation when brazing or soldering. The fluxes are acidic and toxic.
19. Do not weld on painted, galvanized or greasy, oily metals. Not only can the fumes be toxic, but the
welds will not be satisfactory and will fail in use.

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 WELDING

Introduction
Welding can be defined as the process of joining two metal parts by applying heat. In industry,
welding process is primarily used for fabricating works.
Welding is useful in making permanent joints. It can be performed by applying or not applying pressure. The
contours of the metal parts are molten to make the joint in some methods. In some types of welding
processes, filler metal is used. In some other methods, filler metal is not used.
The process of welding finds application in manufacturing automobiles, aeroplanes, rail coaches, machine
components, metal structures, boilers and ships. Generally, welding process is applied wherever metal works
are performed.

Methods of welding
There are two methods by which welding is performed
1. Plastic welding
2. Fusion welding

Plastic welding
In this method, the metal parts are heated to plastic state. At this stage, pressure is applied to make a
perfect joint. It is also known as pressure welding.

Fusion welding
The metal parts are heated unto the point of melting in this method. The joint is made at this stage and
the parts are allowed to cool. On cooling, the molten metal forms a solid joint. No pressure is applied in this
method. Hence, it is also known as pressure less welding. Arc welding and gas welding fall in this category.

Classification of welding processes

1. Arc welding
a. Carbon arc welding
b. Metal inert gas welding
c. Tungsten inert gas welding
d. Atomic hydrogen welding
e. Plasma arc welding
f. Submerged arc welding
g. Electro slag welding

2. Gas welding
a. Oxy-acetylene welding
b. Air-acetylene welding
c. Oxy hydrogen welding

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 3. Resistance welding
a. Butt welding
b. Spot welding
c. Seam welding
d. Projection welding
e. Percussion welding

4. Thermit welding

5. Solid state welding

a. Friction welding
b. Explosive welding
c. Ultrasonic welding
d. Diffusion welding

6. Newer welding
a. Electron beam welding
b. Laser welding

7. Welding related processes

a. Oxy-acetylene cutting
b. Arc cutting
c. Hard facing
d. Brazing
e. Soldering
Arc welding
In arc welding, the edges of two metal parts are melted by an electric arc and the joint is made. An
electrode made of a suitable metal is utilised for this purpose. The electrode is taken closer to the parts to be
joined and electric current is supplied to both the parts and the electrode. An electric arc is made between the
electrode and the metal parts.
This arc generates high temperature and melts the metal parts. The parts are joined at this molten state. The
filler metal in the form of electrode is deposited along the joint. The metal parts are joined without the
application of any pressure. Electrical energy is covered into heat energy in arc welding.
The distance between the metal parts and the electrode should be around 3mm. The heat generated during arc
welding ranges from 5000°C to 6000°C. A generator or a transformer supplies the required current to both
the electrode and the metal parts. The electrodes are flux coated to prevent the molten metal from reacting
with the atmosphere.

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 Fig. Arc welding operation

Advantages
1. Shielded Metal Arc Welding (SMAW) can be carried out in any position with highest weld quality.
2. MMAW is the simplest of all the arc welding processes.
3. This welding process finds innumerable applications, because of the availability of a wide variety of
electrodes.
4. Big range of metals and their alloys can be welded easily.
5. The process can be very well employed for hard facing and metal resistance etc.
6. Joints (e.g., between nozzles and shell in a pressure vessel) which because of their position are
difficult to be welded by automatic welding machines can be easily accomplished by flux shielded
metal arc welding.
7. The MMAW welding equipment is portable and the cost is fairly low.

Limitations
1. Due to flux coated electrodes, the chances of slag entrapment and other related defects are more as
compared to MIG and TIG welding.
2. Due to fumes and particles of slag, the arc and metal transfer is not very clear and thus welding
control in this process is a bit difficult as compared to MIG welding.
3. Due to limited length of each electrode and brittle flux coating on it, mechanization is difficult.
4. In welding long joints (e.g., in pressure vessels), as one electrode finishes, the weld is to be
progressed with the next electrode. Unless properly cared, a defect (like slag inclusion or insufficient
penetration) may occur at the place where welding is restarted with the new electrode
5. The process uses stick electrodes and thus it is slower as compared to MIG welding.

Applications
1. Today, almost all the commonly employed metals and their alloys can be welded by this process.
2. Shielded metal arc welding is used both as a fabrication process and for maintenance and repair jobs.
3. The process finds applications in
(a) Building and Bridge construction
(b) Automotive and aircraft industry, etc.

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 (c) Air receiver, tank, boiler and pressure vessel fabrication
(d) Ship building
(e) Pipes and
(f) Penstock joining
A welding arc is maintained when the welding current is forced across a gap between the electrode tip
and the base metal. A welder must be able to strike and establish the correct arc easily and quickly.

There are two general methods of striking the arc:

1. Scratching
2. Tapping
Scratching
The scratching method is easier for beginners and when using an AC machine. The electrode is
moved across the plate inclined at an angle, as you would strike a match. As the electrode scratches the plate
an arc is struck. When the arc has formed, withdraw the electrode momentarily to form an excessively long
arc, then return to normal arc length.

Tapping
In the tapping method, the electrode is moved downward to the base metal in a vertical direction. As
soon as it touches the metal it is withdrawn momentarily to form an excessively long arc, then returned to
normal arc length.

Figure. "Tapping" method of arc starting.

The principal difficulty encountered in striking the arc is "freezing," or when the electrode sticks or fuses to
the work. This is caused by the current melting the electrode tip and sticking it to the cold base metal before
it is withdrawn from contact. The extra high current drawn by the "short circuit" will soon overheat an
electrode and melt it or the flux, unless the circuit is broken. Giving the electrode holder a quick snap
backward from the direction of travel will generally free the electrode. If it does not, It will be necessary to
open the circuit by releasing the electrode from the holder.

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Warning: Never remove your face shield from your face if the electrode is frozen. Free the electrode with the
shield in front of your eyes, as it will "flash" when it comes loose.

Welding Electrodes
An electrode is a piece of wire or a rod of a metal or alloy, with or without coatings. An arc is set up
between electrode and workpiece. Welding electrodes are classified into following types-
(1) Consumable Electrodes
(a) Bare Electrodes
(b) Coated Electrodes
(2) Non-consumable Electrodes
(a) Carbon or Graphite Electrodes
(b) Tungsten Electrodes

Consumable electrode is made of different metals and their alloys. The end of this electrode starts
melting when arc is struck between the electrode and workpiece. Thus consumable electrode itself acts as a
filler metal. Bare electrodes consist of a metal or alloy wire without any flux coating on them. Coated
electrodes have flux coating which starts melting as soon as an electric arc is struck. This coating on melting
performs many functions like prevention of joint from atmospheric contamination, arc stabilizers etc.

Non-consumable electrodes are made up of high melting point materials like carbon, pure tungsten or
alloy tungsten etc. These electrodes do not melt away during welding. But practically, the electrode length
goes on decreasing with the passage of time, because of oxidation and vaporization of the electrode material
during welding. The materials of non-consumable electrodes are usually copper coated carbon or graphite,
pure tungsten, thoriated or zirconiated tungsten.

Electrodes may be classified on the basis of thickness of the coated flux. As

1. Dust coated or light coated
2. Semi or medium coated and
3. Heavily coated or shielded

Electrodes are also classified on the basis of materials, as

1. Metallic and
2. Non‐metallic or carbon

Metallic arc electrodes are further sub‐divided into

1. Ferrous metal arc electrode (mild steel, low/medium/high carbon steel, cast iron, stainless steel,
etc)
2. Non‐ferrous metal arc electrodes (copper, brass, bronze, aluminum, etc).
In case of non‐metallic arc electrodes, mainly carbon and graphite are used to make the electrodes.

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Functions of Electrode Coating Ingredients
The covering coating on the core wire consists of many materials which perform a number of functions
as listed below:

1. Welding electrodes are used to join various similar and dissimilar metals as plain carbon steels, cast
iron, copper, aluminum, magnesium and their alloys, stainless steels and other alloy steels.
2. Slag forming ingredients, like silicates of magnesium, aluminum, sodium, potassium, iron oxide,
china clay, mica etc., produce a slag which because of its light weight forms a layer on the molten
metal and protects the same from atmospheric contamination.
3. Arc stabilizing constituents like calcium carbonate, potassium silicate, titanates, magnesium silicates,
etc.; add to arc stability and ease of striking the same.
4. Gas shielding ingredients, like cellulose, wood, wood flour, starch, calcium carbonate etc. form a
protective gas shield around the electrode end, arc and weld pool.
5. Deoxidizing elements like ferro-manganese, and ferro-silicon, refine the molten metal.
6. It limits spatter, produces a quiet arc and easily removable slag.
7. Alloying elements like ferro alloys of manganese, molybdenum etc., may be added to impart suitable
properties and strength to the weld metal and to make good the loss of some of the elements, which
vaporize while welding.
8. Iron powder in the coating improves arc behavior, bead appearance helps increase metal deposition
rate and arc travel speed.
9. The covering improves penetration and surface finish.
10. Core wire melts faster than the covering, thus forming a sleeve of the coating which constricts and
produces an arc with high concentrated heat.
11. Coating saves the welder from the radiations otherwise emitted from a bare electrode while the
current flows through it during welding.
12. Proper coating ingredients produce weld metals resistant to hot and cold cracking. Suitable coating
will improve metal deposition rates.

Fig : parts of an electrode

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 Plate Thickness (mm) Electrode Size (mm) Current Range (Amp.)
1.5-2mm 2.5mm 60-90Amp
2-6mm 3.15mm 90-130Amp
6-8mm 4mm 140-180Amp
>8mm 5mm 180-220Amp

Arc Welding Equipment

1. Arc welding power source

Both direct current (DC) and alternating current (AC) are used for electric arc welding, each having
its particular applications. DC welding supply is usually obtained from generators driven by electric motor or
if no electricity is available by internal combustion engines. For AC welding supply, transformers are
predominantly used for almost all arc welding where mains electricity supply is available. They have to step
down the usual supply voltage (200-400 volts) to the normal open circuit welding voltage (50-90 volts). The
following factors influence the selection of a power source:

1. Type of electrodes to be used and metals to be welded

2. Available power source (AC or DC)
3. Required output
4. Duty cycle
5. Efficiency
6. Initial costs and running costs
7. Available floor space
8. Versatility of equipment

2. Welding cables
Welding cables are required for conduction of current from the power source through the electrode
holder, the arc, the workpiece and back to the welding power source. These are insulated copper or
aluminium cables.

3. Electrode holder
Electrode holder is used for holding the electrode manually and conducting current to it. These are
usually matched to the size of the lead, which in turn matched to the amperage output of the arc welder.
Electrode holders are available in sizes that range from 150 to 500 Amps.

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 Fig: - Electrode holder
4. Earth Clamp
The earth clamp is a tool that, via the earth cable, ensures the electrical circuit to be closed between
the welding power source and the piece to be welded. The choice of cable section and length should be based
on the maximum welding current in amps.

Fig: - Earth Clamp

4. Hand Screen
Hand screen used for protection of eyes and supervision of weld bead.

Fig: - Hand Screen

5. Chipping hammer
Chipping Hammer is used to remove the slag by striking.

Fig. Chipping hammer

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6. Wire brush
Wire brush is used to clean the surface to be weld.

Fig. Wire brush

7. Protective clothing
Operator wears the protective clothing such as apron to keep away the exposure of direct heat to the
body.

Fig. Leather Apron Fig. Leather Hand Gloves

8. Chisel
Chisels are used for removing surplus metal or for cutting thin sheets. These tools are made from
0.9% to 1.0% carbon steel of octagonal or hexagonal section. Chisels are annealed, hardened and tempered to
produce a tough shank and hard cutting edge. Annealing relieves the internal stresses in a metal. The cutting
angle of the chisel for general purpose is about 60°.

Fig:.Chisel

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10. Punches
These are used for making indentations on the scribed lines, to make them visible clearly. These are
made of high carbon steel. A punch is specified by its length and diameter (say as 150’ 12.5mm). It consists
of a cylindrical knurled body, which is plain for some length at the top of it. At the other end, it is ground to
a point. The tapered point of the punch is hardened over a length of 20 to 30mm.

(a) Dot Punch is used to lightly indent along the layout lines, to locate center of holes and to provide a
small center mark for divider point, etc. for this purpose, the punch is ground to a conical point
having 60° included angle.

Fig. Dot Punch

(b) Center Punch is similar to the dot punch, except that it is ground to a conical point having 90°
included angle. It is used to mark the location of the holes to be drilled.

Fig. Center Punch

11. Try Square

It is measuring and marking tool for 90 angle .In practice, it is used for checking the squareness of
many types of small works when extreme accuracy is not required .The blade of the Try square is made of
hardened steel and the stock of cast Iron or steel. The size of the Try square is specified by the length of the
blade.

Fig: Try Square

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12. Scriber
A Scriber is a slender steel tool, used to scribe or mark lines on metal work pieces. It is made of
hardened and tempered High Carbon Steel. The Tip of the scriber is generally ground at 12 o to 15o . It is
generally available in lengths, ranging from 125mm to 250mm .It has two pointed ends the bent end is used
for marking lines where the straight end cannot real.

Fig: Scriber
13. Files
Filing is one of the methods of removing small amounts of material from the surface of a metal part.
A file is hardened steel too, having small parallel rows of cutting edges or teeth on its surfaces. On the faces,
the teeth are usually diagonal to the edge. One end of the file is shaped to fit into a wooden handle. The
figure shows various parts of a hand file. The hand file is parallel in width and tapering slightly in thickness,
towards the tip. It is provided with double cut teeth. On the faces, single cut on one edge and no teeth on the
other edge, which is known as a safe edge. Files are classified according to their shape, cutting teeth and
pitch or grade of the teeth. The figure shows the various types of files based on their shape.

Fig: Parts of a Hand File

14. Mallet:
It is generally made of wood or plastic. It is used whenever slight blows are required. Wooden
hammer (mallet) is most commonly used because it does not damage the work surface.

Fig: Mallet

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15. Marking and Measuring Tools:
Accurate marking and measurement is very essential in carpentry work, to produce parts to exact size.
To transfer dimensions onto the work; the following are the marking and measuring tools that are required in
a carpentry shop.

16. Steel Rule and Steel Tape

Steel rule is a simple measuring instrument consisting of a long, thin metal strip with a marked scale
of unit divisions. It is an important tool for linear measurement.
Steel tape is used for large measurements, such as marking on boards and checking the overall
dimensions of the work.

Fig: Steel Rule

Fig: Steel Tape

17. BENCH VICE:

It is firmly fixed to the bench with the help of nuts and bolts. It consists of a cast Iron body and cast
iron jaws. Two jaw plates are fitted on both the jaws. The holding surface of the jaw plates is knurled in
order to increase the gipping. Jaw plates are made up of carbon steel and are wear resistant. One jaw is fixed
to the body and the second slides on a square threaded screw with the help of a handle. The jaws are opened
upto required length; job is placed in the two jaws and is fully tightened with the help of handle. Handle is
used to move the movable jaw

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 SAFETY RECOMMENDATIONS FOR ARC WELDING
The beginner in the field of arc welding must go through and become familiar with these general
safety recommendations which are given as under.

1. The body or the frame of the welding machine shall be efficiently earthed. Pipe lines containing gases or
inflammable liquids or conduits carrying electrical conductors shall not be used for a ground return circuit
All earth connections shall be mechanically strong and electrically adequate for the required current.
2. Welding arc in addition to being very is a source of infra-red and ultra-violet light also; consequently the
operator must use either helmet or a hand-shield fitted with a special filter glass to protect eyes
3. Excess ultra-violet light can cause an effect similar to sunburn on the skin of the welder
4. The welder’s body and clothing are protected from radiation and burns caused by sparks and flying
globules of molten metal with the help of the following:
5. Gloves protect the hands of a welder.
6. Leather or asbestos apron is very useful to protect welder’s clothes and his trunk and thighs while seated
he is doing welding.
7. For overhead welding, some form of protection for the head is required
8. Leather skull cap or peaked cap will do the needful.
9. Leather jackets and 1ather leggings are also available as clothes for body protection.
10. Welding equipment shall be inspected periodically and maintained in safe working order at all times.
11. Arc welding machines should be of suitable quality.
12. All parts of welding set shall be suitably enclosed and protected to meet the usual service conditions.

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 EXERCISE-1
AIM:- To prepare straight cont. bead on a mild steel plate by arc welding using different current
setting in flat position.
TOOL + EQUIPMENTS:-welding m/c with accessories, chipping hammer, tong, wire brush, leather apron,
leather hand-gloves, scriber, scale etc.
MATERIAL REQUIRED: - ( i ) M.S. plate 130x50x6mm = 1no.
(ii) M.S. electrode: - ∅ 3.15 x 350mm
PROCEDURE: -To be written by students as per job.
Note: - All dimensions are in mm.

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 GAS METAL ARC WELDING (GMAW) OR METAL INERT GAS WELDING (MIG)

Metal inert gas arc welding (MIG) or more appropriately called as gas metal arc welding (GMAW)
utilizes a consumable electrode and hence, the term metal appears in the title. There are other gas shielded
arc welding processes utilizing the consumable electrodes, such as flux cored arc welding (FCAW) all of
which can be termed under MIG. Though gas tungsten arc welding (GTAW) can be used to weld all types of
metals, it is more suitable for thin sheets. When thicker sheets are to be welded, the filler metal requirement
makes GTAW difficult to use. In this situation, the GMAW comes handy. The typical setup for GMAW or
MIG welding process is shown in Fig. The consumable electrode is in the form of a wire reel which is fed at
a constant rate, through the feed rollers. The welding torch is connected to the gas supply cylinder which
provides the necessary inert gas. The electrode and the work-piece are connected to the welding power
supply. The power supplies are always of the constant voltage type only. The current from the welding
machine is changed by the rate of feeding of the electrode wire. Normally DC arc welding machines are used
for GMAW with electrode positive (DCRP). The DCRP increases the metal deposition rate and also provides
for a stable arc and smooth electrode metal transfer. With DCSP, the arc becomes highly unstable and also
results in a large spatter. But special electrodes having calcium and titanium oxide mixtures as coatings are
found to be good for welding steel with DCSP. In the GMAW process, the filler metal is transferred from the
electrode to the joint. Depending on the current and voltage used for a given electrode, the metal transfer is
done in different ways.

Fig. Gas metal arc welding (GMAW) set up

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 EXERCISE-2
AIM: - To prepare straight continuous bead on mild steel plate by Mig / Mag welding in flat
position.
2. TOOL + EQUIPMENTS:- Mig / Mag welding m/c with accessories, chipping hammer, tong, wire brush,
leather apron, leather hand- gloves, scriber, scale, no of punch set etc.
3. MATERIAL REQUIRED: - (i) M.S. plate 130x50x6mm = 1no.
(ii) M.S. consumable electrode: - ∅ 0.8mm
(iii) Working pressure of co2 gas: - 10 to 15 lit/ min. or 20 to 30 cft (cubic
feet per hour)
4. PROCEDURE: -To be written by students as per job.
Note: - All dimensions are in mm.

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 GAS WELDING
It is a metal joining process in which the ends of pieces to be joined are heated at their interface by
producing coalescence with one or more gas flames (such as oxygen and acetylene), with or without the use
of a filler metal.

Oxy-Acetylene gas Welding

Oxyacetylene welding, commonly referred to as gas welding, is a process which relies on combustion
of oxygen and acetylene. When mixed together in correct proportions within a hand-held torch or blowpipe, a
relatively hot flame is produced with a temperature of about 3,200˚C. The chemical action of the
oxyacetylene flame can be adjusted by changing the ratio of the volume of oxygen to acetylene. Three
distinct flame settings are used, neutral, oxidising and carburizing. Welding is generally carried out using the
neutral flame setting which has equal quantities of oxygen and acetylene. The oxidizing flame is obtained by
increasing just the oxygen flow rate while the carburising flame is achieved by increasing acetylene flow in
relation to oxygen flow. Because steel melts at a temperature above 1,500˚C, the mixture of oxygen and
acetylene is used as it is the only gas combination with enough heat to weld steel. However, other gases such
as propane, hydrogen and coal gas can be used for joining lower melting point non-ferrous metals, and for
brazing and silver soldering.

Equipment
Oxyacetylene equipment is portable and easy to use. It comprises oxygen and acetylene gases stored
under pressure in steel cylinders. The cylinders are fitted with regulators and flexible hoses which lead to the
blowpipe. Specially designed safety devices such as flame traps are fitted between the hoses and the cylinder
regulators. The flame trap prevents flames generated by a 'flashback' from reaching the cylinders; principal
causes of flashbacks are the failure to purge the hoses and overheating of the blowpipe nozzle. When
welding, the operator must wear protective clothing and tinted coloured goggles. As the flame is less intense
than an arc and very little UV is emitted, general-purpose tinted goggles provide sufficient protection.

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Types of Welding Flames
In oxy-acetylene welding, flame is the most important means to control the welding joint and the
welding process. The correct type of flame is essential for the production of satisfactory welds. The flame
must be of the proper size, shape and condition in order to operate with maximum efficiency. There are three
basic types of oxy-acetylene flames.
1. Neutral welding flame (Acetylene and oxygen in equal proportions).
2. Carburizing welding flame or reducing (excess of acetylene).
3. Oxidizing welding flame (excess of oxygen).

The gas welding flames are shown in Fig

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Neutral Welding Flame
A neutral flame results when approximately equal volumes of oxygen and acetylene are mixed in the
welding torch and burnt at the torch tip. The temperature of the neutral flame is of the order of about 5900°F
(3260°C). It has a clear, well defined inner cone, indicating that the combustion is complete. The inner cone
is light blue in color. It is surrounded by an outer flame envelope, produced by the combination of oxygen in
the air and superheated carbon
monoxide and hydrogen gases from the inner cone. This envelope is Usually a much darker blue than the
inner cone. A neutral flame is named so because it affects no chemical change on the molten metal and,
therefore will not oxidize or carburize the metal. The neutral flame is commonly used for the welding of mild
steel, stainless steel, cast Iron, copper, and aluminum.

Carburizing or Reducing Welding Flame

The carburizing or reducing flame has excess of acetylene and can be recognized by acetylene
feather, which exists between the inner cone and the outer envelope. The outer flame envelope is longer than
that of the neutral flame and is usually much brighter in color. With iron and steel, carburizing flame
produces very hard, brittle substance known as iron carbide. A reducing flame may be distinguished from
carburizing flame by the fact that a carburizing flame contains more acetylene than a reducing flame. A
reducing flame has an approximate temperature of 3038°C. A carburizing-flame is used in the welding of
lead and for carburizing (surface hardening) purpose. A reducing flame, on the other hand, does not carburize
the metal; rather it ensures the absence of the oxidizing condition. It is used for welding with low alloy steel
rods and for welding those metals, (e.g., non-ferrous) that do not tend to absorb carbon. This flame is very
well used for welding high carbon steel.

Oxidizing Welding flame

The oxidizing flame has an excess of oxygen over the acetylene. An oxidizing flame can be
recognized by the small cone, which is shorter, much bluer in color and more pointed than that of the neutral
flame. The outer flame envelope is much shorter and tends to fan out at the end. Such a flame makes a loud
roaring sound. It is the hottest flame (temperature as high as 6300°F) produced by any oxy-fuel gas source.
But the excess oxygen especially at high temperatures tends to combine with many metals to form hard,
brittle, low strength oxides. Moreover, an excess of oxygen causes the weld bead and the surrounding area to
have a scummy or dirty appearance. For these reasons, an oxidizing flame is of limited use in welding. It is
not used in the welding of steel. A slightly oxidizing flame is helpful when welding (i) Copper-base metals
(ii) Zinc-base metals and (iii) A few types of ferrous metals such as manganese steel and cast iron. The
oxidizing atmosphere in these cases, create a basemetal oxide that protects the base metal.

Welding torch
Fig. shows the construction of the welding torch. It is a tool for mixing oxygen and acetylene in
correct proportion and burning the mixture at the end of a tip. Gas flow to the torch is controlled with the
help of two needle valves in the handle of the torch. There are two basic types of gas welding torches:
(1) Positive pressure (also known as medium or equal pressure), and
(2) Low pressure or injector type
The positive pressure type welding torch is the more common of the two types of oxyacetylene torches.

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 Fig. Welding torch
Torch tips
It is the portion of the welding apparatus through which the gases pass just prior to their ignition and
burning. A great variety of interchangeable welding tips differing in size, shape and construction are
available commercially. The tip sizes are identified by the diameter of the opening. The diameter of the tip
opening used for welding depends upon the type of metal to be welded.
Hose pipes
The hose pipes are used for the supply of gases from the pressure regulators. The most common
method of hose pipe fitting both oxygen and acetylene gas is the reinforced rubber hose pipe. Green is the
standard color for oxygen hose, red for acetylene, and black hose for other industrially available welding
gases.
Goggles
These are fitted with colored lenses and are used to protect the eyes from harmful heat and ultraviolet
and infrared rays.
Gloves
These are required to protect the hands from any injury due to the heat of welding process.
Spark-lighter
It is used for frequent igniting the welding torch.
Filler rods
Gas welding can be done with or without using filler rod. When welding with the filler rod, it should
be held at approximately 900 to the welding tip. Filler rods have the same or nearly the same chemical
composition as the base metal. Metallurgical properties of the weld deposit can be controlled by the optimum
choice of filler rod. Most of the filler rods for gas welding also contain deoxidizers to control the oxygen
content of weld pool.
Fluxes
Fluxes are used in gas welding to remove the oxide film and to maintain a clean surface. These are
usually employed for gas welding of aluminium, stainless steel, cast iron, brass and silicon bronze. They are
available in the market in the form of dry powder, paste, or thick solutions.

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 SAFETY RECOMMENDATIONS FOR GAS WELDING

Welding and cutting of metals involve the application of intense heat to the objects being welded or
cut. This intense heat in welding is obtained from the use of inflammable gases, (e.g. acetylene, hydrogen,
etc.) or electricity. The intense welding heat and the sources employed to produce it can be potentially
hazardous. Therefore, to protect persons from injury and to protect building and equipment against fire, etc.,
a set of recommendations concerning safety and health measures for the welders and those concerned with
the safety of the equipments etc., have been published by BIS and many other similar but International
organizations. By keeping in mind these recommendations or precautions, the risks associated with welding
can be largely reduced. Therefore, it is suggested that the beginner in the field of gas welding must go
through and become familiar with these general safety recommendations, which are given below.
1. Never hang a torch with its hose on regulators or cylinder valves.
2. During working, if the welding tip becomes overheated it may be cooled by plunging the torch into
water; close the acetylene valve but leave a little oxygen flowing.
3. Always use the correct pressure regulators for a gas. Acetylene pressure regulator should never be
used with any other gas.
4. Do not move the cylinder by holding the pressure regulator and also handle pressure regulators
carefully.
5. Use pressure regulator only at pressures for which it is intended.
6. Open cylinder valves slowly to avoid straining the mechanism of pressure regulator.
7. Never use oil, grease or lubricant of any kind on regulator connections.
8. For repairs, calibrations and adjustments purposes, the pressure regulators should be sent to the
supplier.
9. Do cracking before connecting pressure regulator to the gas cylinder.
10. Inspect union nuts and connections on regulators before use to detect faulty seats which may cause
leakage of gas when the regulators are attached to the cylinder valves.
11. Hose connections shall be well fittings and clamped properly otherwise securely fastened to these
connections in such a manner as to withstand without leakage a pressure twice as great as the
maximum delivery pressure of the pressure regulators provided on the system.
12. Protect the hose from flying sparks, hot slag, hot workpiece and open flame. If dirt goes into hose,
blow through (with oxygen, not acetylene) before coupling to torch or regulator.
13. Store hose on a reel (an automobile wheel) when not in use.
14. Never allow the hose to come into contact with oil or grease; these deteriorate the rubber and
constitute a hazard with oxygen.
15. Use the correct color hose for oxygen (green/black) and acetylene (red) and never use oxygen hose
for acetylene or vice versa.
16. Always protect hose from being trampled on or run over. Avoid tangle and kinks. Never leave the
hose so that it can be tripped over. Hazards of fumes, gases and dusts can be minimized by (i)
improving general ventilation of the place where welding is carried out (ii) using local exhaust
units, and (iii) wearing individual respiratory protective equipment.

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 EXERCISE-3
AIM: - To set oxy-acetylene flames and fusion run without filler rod in flat position by
gas welding process.

TOOL + EQUIPMENTS: -High pressure oxy-acetylene gas plant with accessories, tong, wire brush, gas
welding goggles , spark lighter, scale, mallet, scriber, Leather hand gloves, Leather apron, tip cleaner etc.
MATERIAL REQUIRED: - ( i ) M.S. sheet 130x50x1.2mm = 1no.
Torch flame: - Neutral or balancing (1:1:1½)
Working pressure of oxygen + acetylene cylinder 0.140kg/cm²
PROCEDURE: -To be written by students as per job.
Note: - All dimensions are in mm.

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Types of Joints
The joints used in welding are
1. Butt joint 2. Lap joint 3. T – joint
4. Corner joint 5. Edge joint

1. Butt joint
It is used to join the ends or edges of plates lying in the same plane. Plates having thickness less than
5mm do not require edge preparation but plates having thickness more than 5mm require edge
preparation on both sides.

2. Lap joint
It is used to join two over lapping pieces so that the edges of each piece are welded to the surface of
the other. It is used on plates less than 3mm thickness. Common types are single lap and double lap
joint. Edge preparation is not required for these joints.

3. T – joint
It is used to weld two perpendicular plates. This is economical for joining thin plates up to 3mm. This
joint is often used in structures.

4. Corner joint
It is used to join the edges of two pieces whose surfaces are approximately at right angles to each
other. It is common in the construction of boxes, tanks, frames and other similar items. Edge
preparation is not necessary for these joints.

5. Edge joint
It is used to weld two parallel plates. This is economical for joining thin plates up to 6mm. This joint
is often used in sheet metal work. It is suitable for severe loading.

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 EXERCISE-4
AIM: - To prepare butt joint on mild steel plate in flat position by arc welding process.

TOOL + EQUIPMENTS: - Welding m/c with accessories, chipping hammer, tong, wire brush, leather
apron, leather hand- gloves, scriber, scale etc.
MATERIAL REQUIRED: - (I) M.S. plate 130x40x6mm = 2nos.
(II) M.S. electrode: - ∅ 3.15 X 350MM
PROCEDURE: -To be written by students as per job.
Note: - All dimensions are in mm.

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