Grade

12

TVL-IA
SHIELDED METAL ARC WELDING
NCI

QUARTER IV – Module 1-Week 1&2

WELD CARBON STEELPLATE USING SMAW

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 Set-up Welding Positioner, Jigs and Fixtures

OBJECTIVES:
1. Identify welding positioner, jigs and fixtures according to job requirements
2. Determine the location for setting up the welding positioner, jigs and fixtures
3 .Set-up welding positioner, jigs and fixtures in conformity with job requirement
4. Observe safety practices in setting up welding positioner, jigs and fixtures

PREPARED BY:

WILMER J. DIRECTO
SHS-TEACHER

INTRODUCTION

Jigs and Fixtures

JIG
A jig is a work-holding device that holds, supports, and locates the workpiece and guides the one or more
tools to perform a specific operation.
In other words, this can also be defined as, used for holding the tools and also guiding the cutting tools.
The main purpose of a jig is to provide repeatability, accuracy, and interchangeability in the
manufacturing of products.
Some important points to remember about Jigs:
1. It is used in uni-dimensional machining processes like drilling, tapping,
and reaming, etc.
2.This system is found to be light and has a complex shape.
3. Gauge blocks are not necessary and the cost of jigs is higher.
4. Jigs are not fixed to the machine table until a large operation has to be
performed.
Fixtures
Fixtures are the work holding device, which holds, supports and locates the workpiece but not guides the
cutting tool to perform a specific operation.
In other words, the fixtures are only the work holding device that holds, supports and locates the
workpiece in the desired position to perform any operation.
The main purpose of the fixtures is to hold and locate the workpiece during any machining operation and
to provide repeatability, accuracy, and interchangeability in the manufacturing of products.
Some important points about fixtures:
1. Fixtures are used in multi-dimensional machining like milling, grinding, turning, etc.
2. This system found to be heavy in weight, have simple designing.
3. Gauge blocks provided for effective handling and the cost is average.
4. Fixtures are having specific tools that use particularly in the milling machine, shapers and slotting
machines.
5. Fixtures are fixed to the machine table.
Jigs vs Fixtures:
Both the jigs and the fixtures are used to reduce the nonproductive time of any mass production process.
The jig is used for guiding the cutting tool (like a drill bit), and for doing so, jigs have components like a
bush, which comes in contact with the cutting tool.

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On the other hand, a fixture never comes into direct contact with the cutting tool.
Fixtures assure the position and alignment of the work pieces for getting the required machining operation
done.

hese are the factores should be considered before designing a jig or fixture:

1. Study of the component.

2. Study of locating elements.
3. Type and capacity of the machine
4. Loading and unloading arrangement.
5. Clamping arrangement.
6. Study of power devices for operating and clamping element and also a safety arrangement device.
7. The clearance between a jig and the component.
8. Study of tool guiding, cutter setting elements, rigidity and vibration problems.
9. Fool-proofing arrangement.
10. Study of ejecting devices, table fixing arrangement, and the indexing device.
11. Swarf removal arrangement.
Types of Jigs and Fixtures:
There are several types of Jigs and Fixtures available in the market. Also, you can create a Jig and Fixture by
yourself to do an operation easily. it is up to you. Although these are some available Jigs and Fixtures in the
market.

TYPES OF JIGS
1. Template jig
2. Plate jig
3. Diameter jig
4. Channel jig
5. Ring jig
6. Box jig
7. Leaf jig
8. Angle plate jig
9. Indexing jig
10. Trunion jig
Types of Fixtures:
These are some Fixtures available in the market:
1. Plate fixture
2. Angle plate fixture
3. Vise-jaw fixture
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4. Indexing fixture
5. Multistation fixture
6. Profile fixture
Why should we use Jigs and Fixtures?
Let's see some advantages of Jigs and fixtures:
1. It eliminates the setting time required before machining.
2. It increases the machining accuracy and also increases production capacity.
3. Requires less skilled operation.
4. They reduce the production cost.
5. Increases machine and labor utilization.
6. They simplify the work handling.
7. Increases the quality of production in the industry.
8.They enable the quick setting of a tool and the proper positioning of the work.
Although there are so many advantages by using Jigs and Fixtures, but also there are some disadvantages
too.
Disadvantages of Jigs and Fixtures:
1. Can wear away over time.
2. Another one is the high initial set up costs (and time).
3. And can use a lot of material and be bulky.
Applications of Jigs and Fixtures:
There are various fields where we can use Jigs and Fixtures and those are:
1. Mass production of automobile parts.
2. Inspection of parts in continuous production in manufacturing industries.
3. Cutting the ingots in the steel plant.
4. In the refrigeration industry.
5. Pump assembling process
6. For drilling the flanges and drilling holes to any required angles.
7. For multi-spindle machining.
8. Jigs used for mass drilling, reaming and tapping.
9. For guiding the tools for machining contours.
10. Fixtures used for milling, mass turning, and grinding operations.
The Material used for Jigs and Fixtures:
These are the following material is used for making Jigs and Fixtures:
1. Grey cast iron
2. Hardened steel
3. Carbide
4. Plastic
5. Epoxy resins
6. Low melt alloy steels
7. Stainless steel
8. Bronze

Conclusion:
Jigs and Fixture is an essential element in Manufacturing Technology. There are several factors you should
consider to make jig and fixtures. By using these you can save a couple of production time.
Why is preheat sometimes required before welding?
Preheating the steel to be welded slows the cooling rate in the weld area. This may be necessary to avoid
cracking of the weld metal or heat affected zone.
The need for preheat increases with steel thickness, weld restraint, the carbon/alloy content of the steel,
and the diffusible hydrogen of the weld metal. Preheat is commonly applied with fuel gas torches or
electrical resistance heaters.
The purpose of preheat:
1. Reduce the risk of hydrogen cracking
2. Reduce the hardness of the weld heat affected zone
3. Reduce shrinkage stresses during cooling and improve the distribution of residual stresses.
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If preheat is locally applied it must extend to at least 75mm from the weld location and be preferably
measured on the opposite face to the one being welded.
Heat treatment of welded joints
Heat treatment is an operation that is both time consuming and costly. It can affect the strength and
toughness of a welded joint, its corrosion resistance and the level of residual stress but is also a mandatory
operation specified in many application codes and standards. In addition it is an essential variable in
welding procedure qualification specifications. Before discussing the range of heat treatments that a metal
may be subjected to, there is a need to clearly define what is meant by the various terms used to describe
the range of heat treatments that may be applied to a welded joint. Such terms are often used incorrectly,
particularly by non-specialists; for a metallurgist they have very precise meanings.
Annealing This consists of heating a metal to a high temperature, where recrystallisation and/or a phase
transformation take place, and then cooling slowly, often in the heat treatment furnace. This is often
carried out to soften the metal after it has been hardened, for example by cold working; a full anneal giving
the very softest of microstructures. It also results in a reduction in both the yield and the tensile strength
and, in the case of ferritic steels, usually a reduction in toughness.
Normalizing This is a heat treatment that is carried out only on ferritic steels. It comprises heating the steel
to some 30-50°C above the upper transformation temperature (for a 0.20% carbon steel this would be
around 910°C) and cooling in still air. This results in a reduction in grain size and improvements in both
strength and toughness.
Quenching This comprises a rapid cool from a high temperature. A ferritic steel would be heated to above
the upper transformation temperature and quenched in water, oil or air blast to produce a very high
strength, fine grained martensite. Steels are never used in the quenched condition, they are always
tempered following the quenching operation.
Tempering A heat treatment carried out on ferritic steels at a relatively low temperature, below the lower
transformation temperature; in a conventional structural carbon steel this would be in the region of 600-
650°C. It reduces hardness, lowers the tensile strength and improves ductility and toughness. Most
normalised steels are tempered before welding, all quenched steels are used in the quenched and
tempered condition.
Ageing or Precipitation hardening A low temperature heat treatment designed to produce the correct size
and distribution of precipitates, thereby increasing the yield and tensile strength. It is generally preceded
by a solution heat treatment. For steel, the temperature may be somewhere between 450-740 degree C,
an aluminium alloy would be aged at between 100-200°C. Longer times and/or higher temperatures result
in an increase in size of the precipitate and a reduction in both hardness and strength. Stress relief As the
name suggests, this is a heat treatment designed to reduce the residual stresses produced by weld
shrinkage. It relies upon the fact that, as the temperature of the metal is raised, the yield strength
decreases, allowing the residual stresses to be redistributed by creep of the weld and parent metal.
Cooling from the stress relief temperature is controlled in order that no harmful thermal gradients can
occur.
Post heat A low temperature heat treatment carried out immediately on completion of welding by
increasing the preheat by some 100°C and maintaining this temperature for 3 or 4 hours. This assists the
diffusion of any hydrogen in the weld or heat affected zones out of the joint and reduces the risk of
hydrogen induced cold cracking. It is used only on ferritic steels, where hydrogen cold cracking is a major
concern i.e. very crack sensitive steels, very thick joints etc.
Post Weld Heat Treatment (PWHT) So what does the term ‘post weld heat treatment’ mean? To some
engineers it is a rather vague term that is used to describe any heat treatment that is carried out when
welding is complete. To others however, particularly those working in accordance with the pressure vessel
codes such as BS PD 5500, EN 13445 or ASME VIII, it has a very precise meaning. When an engineer talks of
post weld heat treatment, annealing, tempering or stress relief it is therefore advisable. Heat treatment
following welding may be carried out for one or more of three fundamental reasons:
1. to achieve dimensional stability in order to maintain tolerances during machining operations or during
shake-down in service
2. to produce specific metallurgical structures in order to achieve the required mechanical properties
3. to reduce the risk of in-service problems such as stress corrosion or brittle fracture by reducing the
residual stress in the welded component

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The range of heat treatments to achieve one or more of these three objectives in the range of ferrous and
non-ferrous metals and alloys that may be welded is obviously far too extensive to cover in great detail
within these brief Job Knowledge articles. The emphasis in the following section will be on the PWHT of
carbon and low alloy steels as required by the application standards although brief mention will be made
of other forms of heat treatment that the welding engineer may encounter in the ferrous alloys. There are
two basic mechanisms that are involved, firstly stress relief and secondly micro-structural modifications or
tempering.
Stress Relief Why is it necessary to perform stress relief? It is an expensive operation requiring part or
all of the welded item to be heated to a high temperature and it may cause undesirable metallurgical
changes in some alloys. As mentioned above there may be one or more reasons. The high residual stresses
locked into a welded joint may cause deformation outside acceptable dimensions to occur when the item
is machined or when it enters service. High residual stresses in carbon and low alloy steels can increase the
risk of brittle fracture by providing a driving force for crack propagation. Residual stresses will cause stress
corrosion cracking to occur in the correct environment carbon and low alloy steels in caustic service or
stainless steel exposed to chlorides. What causes these high residual stresses? Welding involves the
deposition of molten metal between two essentially cold parent metal faces.
As the joint cools the weld metal contracts but is restrained by the cold metal on either side; the residual
stress in the joint therefore increases as the temperature falls. When the stress has reached a sufficiently
high value (the yield point or proof strength at that temperature) the metal plastically deforms by means of
a creep mechanism so that the stress in the joint matches the yield strength. As the temperature continues
to fall the yield strength increases, impeding deformation, so that at ambient temperature the residual
stress is often equal to the proof strength (Fig 1). To reduce this high level of residual stress, the
component is reheated to a sufficiently high temperature.
As the temperature is increased the proof strength falls, allowing deformation to occur and residual stress
to decrease until an acceptable level is reached. The component would be held at this temperature
(soaked) for a period of time until a stable condition is reached and then cooled back to room temperature.
The residual stress remaining in the joint is equal to the proof strength at the soak temperature. Figure 1
shows that residual stress in a carbon manganese steel falls reasonably steadily from ambient to around
600 degree C but that the high strength creep resistant steels need to be above 400 degree C before the
residual stress begins to fall. Stainless steel is hardly affected until the temperature exceeds 500 degree C.
There is therefore a range of soak temperatures for the various alloys to achieve an acceptable reduction in
residual stress without adversely affecting the mechanical properties of the joint. In carbon manganese
steels this temperature will be between 550-620 degree C, in creep resistant steels somewhere between
650-750 degree C and for stainless steels between 800-850 degree C.

WEEK 1
POST -TEST
Multiple Choice
Directions: Read and analyze the statement carefully. Choose the best answer and write the letter only in
your answer sheet.
1. A work-holding device that holds, supports, and locates the workpiece
and guides the one or more tools to perform a specific operation.
a. Jig b. Fixtures c. Jigs and Fixtures d. Plate Jig
2. The work holding device, which holds, supports and locates the
workpiece but not guides the cutting tool to perform a specific operation.
a. Jig b. Fixtures c. Jigs and Fixtures d. Plate Jig
3. Are used to reduce the nonproductive time of any mass production
process.
a. Jig b. Fixtures c. Jigs and Fixtures d. Plate Jig
4. Is commonly applied with fuel gas torches or electrical resistance
heaters.
a. Pre heating b. Heat treatment c. Jigs and Fixtures d. Plate Jig
5. Is an operation that is both time consuming and costly.
a. Pre heating b. Heat treatment c. Jigs and Fixtures d. Plate Jig
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6. This consists of heating a metal to a high temperature, where
recrystallization and/or a phase transformation take place, and then
cooling slowly, often in the heat treatment furnace.
a. Pre heating b. Heat treatment c. Annealing d. Normalizing
7. This is a heat treatment that is carried out only on ferritic steels.
a. Pre heating b. Heat treatment c. Annealing d. Normalizing
8. This comprises a rapid cool from a high temperature.
a. Quenching b. Tempering c. Annealing d. Normalizing
9. A heat treatment carried out on ferritic steels at a relatively low temperature, below the lower
transformation temperature; in a conventional structural carbon steel this would be in the region of 600-
650°C.
a. Quenching b. Tempering c. Annealing d. Normalizing
10. A low temperature heat treatment designed to produce the correct size and distribution of
precipitates, thereby increasing the yield and tensile strength.
a. Ageing or Precipitation hardening
b. Tempering
c. Annealing
d. Normalizing
a. Ageing or Precipitation hardening b. Tempering c. Annealing d. Normalizing
TEST II
Fill in the blank.
Direction: Write the correct words in the Applications of Jigs and Fixtures.
1. Mass production of __________________parts.
2. ___________ of parts in continuous production in manufacturing industries.
3. Cutting the ingots in the _____________.
4. In the refrigeration ____________.
5. ______________assembling process
6. For drilling the ____________________ holes to any required angles.
7. For multi-spindle ___________________.
8_____________ used for mass drilling, reaming and tapping.
9. For guiding the tools for _____________________.
10. _______________used for milling, mass turning, and grinding operations.

TEST III
PERFORMANCE TASK

1. What is the main purpose of a Jig?

2. What is a Jig & Fixture and what is it used for?

Reference:

1.https://link.springer.com/article/10.1023/A:1008978319436
2. https://en.wikipedia.org/wiki/Fixture_(tool)
3. https://en.wikipedia.org/wiki/Jig_(tool)
4.CBLM, TESDA
5.Welding Technology, Second Edition by Gower A. Kennedy
6. Welding Inspection Technology, Education Department, American welding Society

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7.Welding Principles and Application by Larry Jeffus and Harold V. Johnson