Continental Institute of Engineering & Technology: Welding Shop

CONTINENTAL INSTITUTE OF ENGINEERING & TECHNOLOGY
JALVEHRA, NH-1, DIST:FATEHGARH SAHIB, PUNJAB
CIET
(AFFILIATED TO PUNJAB TECHNICAL UNIVERSITY, JALANDHAR)
Lab Manual
Practical Experiment Instructions Sheet
WELDING SHOP
W/S
Various Types of Welding : (a) Forge Welding: This welding is done by the black-smiths. In this two similar metal pieces are heated upto the plastic stage in the furnace. Then it is hammered so that a homogeneous mixture is formed at the joint. The surface to be joined should be cleaned and made free of any foreign particle, this is done by brushing. Gas Welding: Gas welding is the process in which a gas flame is used to raise the temperature of the metals to be joined. The metals are heated up the melting. The metal flows and on cooling it solidifies. A filter metal may be added to the flowing molten to fill up cavity made during the end preparation. Many combinations of gases are used in gas welding. But the most common of these is oxygen and acetylene. Arc Welding: The welding in which the electric arc is produced to give heat for the purpose of joining two surfaces is called electric arc welding. Principle: Power supply is given to electrode and the work. A suitable gap is kept between the work and electrode. A high current is passed through the circuit. An arc is produced around the area to be welded. The electric energy is converted into heat energy, producing a temperature of 3000C to 4000C. Resistance Welding: Resistance welding is a group of welding processes wherein coalescence is produced by the heat obtained from resistance of the work to the flow of electric current in a circuit of which is the work is a part and by the application of pressure. No filler metal is needed. Fundamentals of Electric Resistance Welding The two factors or variables mainly responsible for resistance welding are (i) The generation of Heat at the place where two pieces are to be joined. (ii) The application of pressure at the place where a weld joint is to be formed. (e) Thermit Welding: It is used on those places where there is no availability of electric supply or gas. It is a compact unit and can be moved easily upto the site. It consists of a conical shape vessel with a brick lining inside. Mixture of powdered aluminum and iron oxide is placed inside the vessel. This mixture is heated by the surface upto molten stage, due to the reaction the Aluminum is converted in Aluminum oxide.
Semester-1st/2nd
Page No. 1 of 8
(b)
(c)
(d)

CIET
Lab Manual
WELDING SHOP
W/S Semester-1st/2nd
Page No. 2 of 8 WELDING EQUIPMENTS Various equipments used for Arc welding are as under: 1. Motor Generator Set: In this a generator is driven by a suitable AC motor. The average voltage of the generator is 25 volt. The current ranges from 25 to 100 amperes, the voltage in the generator is variable. The voltage can be set to the desired value with the help of rheostat. 2. Diesel Engine Generator Set: In this set, the drive is given by a diesel engine. Rest of the system is same as in case of A.C. motor generator. Diesel engine generator sets are used in the areas where electricity is not available. 3. Transformer rectifier set: It allows the current to flow through it only in one direction. Because it has a one way valve or solid rectifier installed on the electrode side of the secondary coil. The set can supply straight polarity and reverse polarity power supply. The rectifiers are of two types: (i) Silicon diode (ii) Selenium plate 4. Welding Transformer Set: It is used to step down the voltage supply. It consists of a primary and secondary circuit. The input is given to primary winding. By electromagnetic induction the current flows through the secondary coil. The output can be controlled as per requirement. WELDING ELECTRODES Electrodes are of two types: 1 Coated electrodes 2. Bare electrodes Coated electrodes are generally applied in arc welding processes. A metallic core is coated with some suitable material. The material used for core is mild steel, nickel steel, chromium molybdenum steel etc. One end of the coated core is kept bare for holding. Bare electrodes produce the welding of poor quality. These are cheaper than coated electrodes. These are generally used in modern welding process like MIG welding. Electrode Size Electrodes are commonly made in lengths 250 mm, 300 mm, 350 mm, 450 mm and the diameters are 1.6 mm, 2 mm, 2.5 mm, 3.2 mm, 4 mm, 7 mm, 8 mm and 9 mm. Functions of Coatings 1. To prevent oxidation. 2. Forms slag with metal impurities. 3. It stabilizes the arc. 4. Increases deposition of molten metal. 5. Controls depth of penetration.

CIET
Lab Manual
WELDING SHOP
W/S
6. 7.
Semester-1st/2nd
Controls the cooling rate. Adds alloy elements to the joint.
Page No. 3 of 8
Specifications of electrodes: An electrode is specified by six digits with profile letter M. These six digits indicate the following matter: M: It indicates that it is suitable for metal are welding. First Digit: First digit may be from 1 to 8, which indicate the type of coating on the electrode. Second Digit: It denotes the welding position for which electrode is manufactured. It varies from 1 to 6. Third Digit: It denotes the current to be used for an electrode. It is taken from 0 to 7. Fourth Digit: Fourth digit is from 1 to 8. Each digit represents the tensile strength of welded joint. Fifth Digit: It carries any number from 1 to 5. This digit denotes a specific elongation in percentage of the metal deposited. Sixth Digit: It carries any number from 1 to 5 denotes impact strength of the joint. WELDING JOINTS 1. Butt Joint: In this type of joint, the edges are welded in the same plane with each other. V or U shape is given to the edges to make the joints strong. 2. Lap Joint: This type of joint is used in joining two overlapping plates so that the corner of each plate is joined with the surface of other plate. Common types of lap joints are single lap, double lap or offset lap joint. 3. T-Joint: When two surfaces are to be welded at right angles, the joint is called TJoint. The angle between the surfaces is kept 90. 4. Corner Joint: In this joint the edges of two sheets are joined and their surfaces are kept at right angle to each other. Such joints are made in frames, steel boxes etc. 5. Plug Joint: Plug Joints are used in holes instead of rivets and bolts.

CIET
Lab Manual
WELDING SHOP
Page No. 4 of 8
WELDING DEFECTS
S.No. 1. 2. 3. Defects Reasons Low penetration of metals into (a) Incorrect current each other (b) Fast speed or welding Cracks in welded metal (a) Wrong selection of electrode (b) Metal contains too much carbon Poor appearance (a) Faulty electrodes (b) Irregular welding (c) Wrong arc length (d) Overheating due to high current Inclusions (a) Dirty base metals (b) Higher sulphur content in metals to be welded (c) Improper removal of slag Poor Fusion (a) Wrong current setting (b) Wrong clearance between the electrode and work piece (c) Fast speed of welding Blow Holes (a) Wrong arc length (b) Old electrode (c) Impurities in base metal Warping (a) Uneven heating (b) Over heating due to high current (c) Thin cross-section of metals (d) Slow speed of welding Scattering of welding (a) High current (b) Long arc (c) Faulty electrodes
4. 5.
6. 7.
8.

CIET
Lab Manual
WELDING SHOP
Page No. 5 of 8
Objective: Beading practice with arc welding Tools and Equipment: Arc welding machine with all the accessories, try square, hacksaw, steel rule, hammer, chisel, pair of tongs, chipping hammer, face shield etc. Material Used: MS-Flat of size 100*64*6 mm one piece Electrode: M.S Electrode 3.15 mm dia [SWG 10], length 350 mm. Drawing: See diagram Procedure: 1. Marking and cutting the MS Flat 2. Start the welding transformer machine, and then set the current to approx. 100 amps. 3. Hold the Electrode at an angle as shown in diagram. Keeping the Flat in position complete the layer. 4. Clean with a chipping hammer and a wire brush. Precaution: 1. Never look at the welding arc without face shield. 2. Always wear flexible gloves and leather apparels. 3. Never touch the hot job with hands. 4. Use specified current and electrodes for arc welding.

CIET
Lab Manual
WELDING SHOP
Page No. 6 of 8
Beading practice with Arc welding

CIET
Lab Manual
WELDING SHOP
Page No. 7 of 8 Objective: To make a butt joint by arc welding. Tools and Equipment used: Arc welding machine with all the accessories, electrode holder, earth lamp, try square, hacksaw, steel rule, hammer, chisel, pair of tongs, chipping hammer, face shield etc. Material Used: MS Flat of size 100*64*6 mm two pieces Electrode: MS Electrode 3.15 mm dia [SWG 10] length 350 mm Drawing: See diagram Procedure: 1. Marking and cutting the MS Flat 2. Start the welding transformer machine, and then set the current to approx. 100 amps. 3. Tack both the sides of joints. Keeping the flat position of the job, complete the layer. 4. Clean with a chipping hammer and a wire brush and then check the welding layer. Precaution: 1. Never look at the welding arc without face shield. 2. Always wear flexible gloves and leather apparels. 3. Never touch the hot job with hands. 4. Use specified current and electrodes for arc welding.

CIET
Lab Manual
WELDING SHOP
Page No. 8 of 8
To make butt joint by Arc welding
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Continental Institute of Engineering & Technology: Welding Shop

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CONTINENTAL INSTITUTE OF ENGINEERING & TECHNOLOGY

JALVEHRA, NH-1, DIST:FATEHGARH SAHIB, PUNJAB

(AFFILIATED TO PUNJAB TECHNICAL UNIVERSITY, JALANDHAR)

Practical Experiment Instructions Sheet