Mapa University

Muralla St. Intramuros, Manila

Department of Mechanical and Manufacturing Engineering

SHOP PRACTICE NO. 10

Welding

ANGELES, Marison C.

ME-2

ME137L/ A3 GRADE

2015100221

Group 04

Engr. Jose V. Hernandez

Instructor
OBJECTIVES:
1. To be able to join two metals by the used of arc welding.
2. To be able to familiarize ourselves with a welding machine.

METHODS and ANALYSIS:

Spot welding is a process in which contacting metal surfaces are joined by the heat obtained
from resistance to electric current. Work-pieces are held together under pressure exerted by
electrodes.
Arc welding is the process of joining two metals, using electrodes. The low voltage and
high ampere output of the welding machine produces an arc that will melt the electrodes and serves
as a filler rod to join the metals.

MATERIALS:
4 pieces of sheet metal

2 pieces of metal to be joined

2 pieces electrode

TOOLS AND EQUIPMENTS TO BE USED:

o Arc welding machine
o Chipping Hammer
o Head shield for Arc Welding
o Spot welding machine
o Pair of leather gloves (asbestos)
o Pair of Tongs
o Pliers
o Steel Brush
o Tin Snip

PROCEDURES:
(SPOT WELDING)
1. Gather all the necessary tools and materials needed.
2. Prepare the sheet metals.
3. Cut the divided sheet metal into four strips with the help of the markers as guide, with the
use of a tin snip.
4. Form a square with the metal sheets, overlapping alternately. (See drawing)
5. Use the pliers to hold the sheet metals (two at a time) while it is being welded on the spot
welding machine.
6. Make five weld spots in each joint (where to metal sheets are joined), making a total of
20 spots or nuggets.
(ARC WELDING)
1. Place the two metals to be joined properly or hold it in a vise.
2. Place the ground to the metal, and the electrode to the holder.
3. Adjust the welder ampere rating.
4. Wear the necessary safety gadget for protection.
5. Switch on the machine and slowly approach the electrode about 1/16 to 3/16 of an inch to the
work piece.
6. Strike the electrode to the work piece to produce an arc. The angle between the electrode and
the horizontal is 60 to 80.
7. Move the electrode in straight position and maintain the 1/16 to 3/16 of an inch clearance.
8. When finished remove the slab by the chipping hammer and hold the work piece with a pair of
tongs.

QUESTIONS:
1. What is the role of thickness of plate to be weld to the electrode to be used?
- The thickness of plate to be weld plays a part in the electrode because if the setting of the
electrode to be used does not match the thickness of plate it may cause the plate to be
deformed.

2. What is a quality of a good deposited weld?

- The quality of a good deposited weld have smooth, no rough surface and no gap can be
seen between the two metals.

3. What is the right approach in striking the arc or obtaining the arc?
- In this method the striking end of the electrode is dragged across the work in manner much
the same as striking a match. When the electrode touches the work, it will create an arc.

4. What is the importance of electrode angles?

- The electrode angle is important because it determines the number of electrodes that will
be distributed to the metals. Each angle corresponds to a certain striking position.

5. How do you choose the right electrode for your welding work?
- In order to choose the right electrode for the work you must have these following
information about the project: welding speed, power supply, position of weld, type of
metal, and thickness of metal.

6. What is an arc welding?

- Arc welding is one of several fusion processes for joining metals.
 7. What is the danger of not using a face guard?
- The flash or the light from the welding will damage our eyes because of the brightness. It
is very bright that looking directly at it will hurt our eyes. Also, it produces sparks that may
bounce and damage our face.

8. How could you maintained welding arc during operation?

- It can be maintained by keeping the electrode at a consistent angle and distance from the
work piece.

9. Give another two types of joining metal?

- Brazing- a process which involves a filler metal which has a liquidus above 450C
(842F).
- Soldering- involves filler metals with a liquidus of 450C or below. The issue is further
confused by the use of such terms as silver solder.

10. What is welding?

- Welding is process of joining metals by applying heat, sometimes with pressure and
sometimes with an intermediate or filler metal having a high melting point.

MECHANICAL DRAWINGS:
(SPOT DRAWING)
FRONT VIEW (Scale: 1mm : 1mm)
 TOP VIEW (Scale: 1mm : 1mm)

RIGHT SIDE VIEW (Scale: 1mm : 1mm)

ISOMETRIC VIEW
 (ARC WELDING)

FRONT VIEW (Scale: 1mm : 1mm)

10 10

70

2.12
20

TOP VIEW (Scale: 1mm : 1mm)

10 10
RIGHT SIDE VIEW (Scale: 1mm : 1mm)
10

70

3.08
1.92

ISOMETRIC VIEW (Scale 1mm : 1mm)

DISCUSSION
(SPOT WELDING)
Spot welding is a fairly simple heat generation process: the passage of current through a
resistance generates heat. This is the same principle used in the operation of heating coils. In
addition to the bulk resistances, the contact resistances also play a major role. The contact
resistances are influenced by the surface condition (surface roughness, cleanliness, oxidation, and
platings).

Spot welding is typically used when welding particular types of sheet metal, welded wire
mesh or wire mesh. Thicker stock is more difficult to spot weld because the heat flows into the
surrounding metal more easily. Spot welding can be easily identified on many sheet metal goods,
such as metal buckets. Aluminium alloys can be spot welded, but their much higher thermal
conductivity and electrical conductivity requires higher welding currents. This requires larger,
more powerful, and more expensive welding transformers.

(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 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.

CONCLUSION
In this experiment, students were able to join two metals by the used of arc welding.
Students were also able to familiarize ourselves with a welding machine. Welding is important as
a technique of maintenance not only because of its low cost but also because of the very short
outage times of the components. Welding permits a simple design of bridges and steel
constructions. Shipbuilding would be impossible without welding. Pipelines, especially in the
range of diameters between 450 and 2000 mm, are produced exclusively by welding.
RECOMMENDATION
I would recommend to consume the time properly by having proper communication to each
teammates and divide each part simultaneously. This would result to a faster and more successful
product. Also, students would need to be more careful in every part since some tools would be
used for the first time. Also, the metal tin sheet have sharp edges, and may cause accidents, so
students would need to be more careful on handling it. And, always wear your PPE.

REFERENCES
https://en.wikipedia.org/wiki/Spot_welding

http://www.amadamiyachi.com/glossary/glossresistancespotwelding

https://ewi.org/should-you-solder-it-or-braze-it/

https://en.wikipedia.org/wiki/Oxy-fuel_welding_and_cutting

https://en.wikipedia.org/wiki/Gas_metal_arc_welding

https://en.wikipedia.org/wiki/Face_shield
 Mapa University
Muralla St. Intramuros, Manila
Department of Mechanical and Manufacturing Engineering

REPORTING
Drill Press

ANGELES, Marison C.

ME-2

ME137L/ A3 GRADE

2015100221

Group 04

Engr. Jose V. Hernandez

Instructor