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Department of Mechanical Engineer

ing

MEFD211 MANUFACTURING PROCESSES LAB


SEMESTER 1 2015/2016
NAME & ID:

LAB ACTIVITY:

1.
Objectives
SECTION:
2.
Equipment and
GROUP: DATE:
tools Sketc
3.
4.
Safety hprecaution
Kindly please refer the MEFB 121 General Lab Report Guidelines for the details.
5.
Procedure
6.
Resul
1 Objectives
t
7.
Discussion
8.
Conclusion

To learn how to use the MIG welding machine correctly and properly. 9. Format & Overall
quality
To learn how to melt the iron as taught.

To make a straight welded line on the metal.

To make a thin welded line on the metal

List and sketch of equipment and tools

Marks
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Department of Mechanical Engineer


ing

Sketch:

Safety Precautions:

Wear PPE during the welding time

For welding always wear the welding mask to prevent face from getting burn.

Do not open the mask when we are doing the welding because it get hurt our
eyes.

If the MIG welding machine occurs any problem immediately report to lab
technician.

Do not play around with the MIG welding machines nozzle because it might gives
a spark.

If one of our group mate is doing the work another member need to stand behind
the yellow line.

Always wear the welding glove before start to weld any iron.

Use the rivet blacksmith tong the hot welded iron to prevent the glove from
burning

Do not put the hot welded iron on the table because it can damage the table or
might hurt someone

Do not hold the hot welded iron without cooling it down by submerging it into the
water because it might be hot.

Procedure:

Firstly, wear all the safety equipments before proceeding to the welding session.

Listen carefully to the briefing of the lab technician about the use of MIG welding machine.

Observe carefully when the lab technician is doing the welding session so that it will easy for us
when we are doing it.

Once the lab technician is done with the briefing we will be given a piece of used iron plate,
for us to train ourselves.

Once the training session is done we can proceed to our work piece.

Make sure the iron that comes out from the nozzles is not too long, if it is too long than use the cutter
to cut it and make it short.

The MIG welding machine will only works when a button is pressed rapidly and the iron rod that
comes out from it needs to be in contact with the metal plate.

We will be given a rectangle metal plate and are told to make two straight lines on the metal plate
using the MIG welding machine.

Once we have done making two lines on the metal plate that have been told using the MIG welding
machine, using the rivet blacksmith tong to carry the metal plate to cool it down by submerging it into
the water.

Once it is fully cooled down using the vice tighten the metal plate and start to brush it.

After brushing it properly using a blacksmith hammer peel of the small piece of welded on the metal
plate.

Once it is done show the work piece to the lecturer.

Lastly, clean up the entire premises.

Result (attach the multi-view drawing)

Discussions

MIG welders consist of a handle with a trigger controlling a wire feed, feeding the wire from a
spool to the weld joint. The wire is similar to an endless bicycle brake cable. The wire runs
through the liner, which also has a gas feeding through the same cable to the point of arc,
which protects the weld from the air.
MIG welding is most commonly used in fabrication shops where production is high, and the
wind blowing away your gas shielding is unlikely.

MIG weld welding requires three things, electricity to produce heat, an electrode to fill the
joint, and shielding gas to protect the weld from the air. MIG welding is done using a very
small electrode that is fed continuously, while the operator controls the amount of weld being
done. In some cases when a robot takes over this process, it becomes automatic welding.

MIG welding unlike most other welding processes has one standard voltage type and polarity
type. The voltage used is D/C direct current, much like the current in a car battery. Direct
current flows in one direction, from the negative (-) to the positive (+).
The polarity used is also standard and that is D/C electrode (+) positive. This means that the
handle is the positive side of the circuit, or it may be said, the electricity flows from the metal
in to the welding handle.

When choosing the proper MIG wire or electrode you need to match the type of wire to the type of metal
being welded. Some other considerations are the type of transfer, position to be welded, and resistance to
abrasion. Most of the times when working as a welder the welding engineers specify the weld size and
electrode type to be used.
The most common wire used for welding carbon steel is ER 70S-6. In some cases you can weld two
different metals together. An example of this is welding 304 stainless steel to A36 carbon steel using an
electrode made of 309 stainless steel ER 309L.
Typical MIG welding electrodes are a solid wire ranging from a thickness of .023 to .045. Some are much
thicker for heavy industrial applications.

The most common sizes are:

.023

.030

.035

.045

10

Conclusions

Finally, I have learned how to use the MIG welding


machine properly and correctly without giving any
problem. The MIG welding machine is not difficult to
operate all we have to do to get a perfect lining and
thickness when we are welding an iron or a metal plate
is that we have to keep in contact with the metal plate
and the nozzle. We also need to move the nozzle slowly
so that we will get a perfect turn out.