Safety and Cleanliness Regulations in Welding Workshop

Always wear PPE

Ask practice safety measure in the workshop
Ask permission to use any equipment
Report any damage or loss that occurs to the supervisor
Cleaning work areas
Keeping designated walking areas clear of debris
Restoring equipment and tools after job is complete
Course : JJ103 Mechanical Workshop Practice
Synopsis : Mechanical Workshop Practice 1 exposes the students to welding,
machining and fitting which involve the use of arc and gas welding machine, lathe machine,
drilling machine, grinding, hand tools, marking out tools, measuring and testing tools.
Students are taught to emphasize on safety procedures and cleaness in the workshop.
Course Learning Outcomes :
Upon completion of this course, student should able to:
Explain safety procedure in the workshops according to the workshop safety regulation.
Perform fitting, machining and welding work according to Standard Operation
Procedure\(SOP)
Practice correct safety procedures and working techniques in the workshop.
Title: Straight Weld, Square butt joint weld, Open corner
joint welding
Theories on arc welding :
Arc welding is one of several fusion processes for joining metals. By applying intense heat,
metal at the joint between two parts is melted and caused to intermix directly, or more
commonly, with an intermediate molten filler metal. Upon cooling and solidification, a
metallurgical bond is created. Since the joining is an intermixture of metals, the finals, the final
weldment potentially has the same strength properties as the metal of the parts. This is in sharp
contrast to non-fusion processes of joining (i.e. soldering, brazing etc.) in which the mechanical
and physical properties of the base materials cannot be duplicated at the joint.


Apparatus :
Arc welding machine. Welding ampere AC 90-130amp.
PPE ( gloves, goggle, safety boot, protective shield )
Electrode size 12 or 10, E6013
Wire brush
Mild steel plate, dimension 5 x 75 x 120 mm 2 piece

Procedures :
Students need to prepare 3 projects namely 3 straight line bead weld,
square butt joint weld and open corner joint weld.
Wear all the safety PPE. (Glove, welding shield, apron etc.)
Prepare the workpiece.
Clip the earth plat onto the working table and put the electrode holder
on working table.
ON the switch at the miller arc welding machine.
Adjust the welding ampere between 90-130 ampere.
Place the workpiece as showed in figures.
By using the recommendation electrodes, make a small weld joint on
the edges of the two sides
Make a clean joint by moving electrode holder simultaneously.
By using the chipper hammer, remove slug. See that the piece are
iniformly joint.
Repeat the above step for square butt joint and open corner joint as in
Figure.
Clean and sweep the work place after finish the welding work.

Question :
1. What is the pupose of welding?
common way of joining two or more pieces of metal. It is used to melt metal
together by heating it using an arc of electricity between two electrodes or an
electrode and the metal being worked on.

2. Explain the priciples of arc welding.
Arc welding is a welding process, in which heat is generated by an electric arc
struck between an electrode and the work piece.

3. Name the components and tools that make up the schematic representation of the
shielded metal arc welding.