LAPORAN PRAKTIKUM PROSES MANUFAKTUR

MODUL 2
WELDING

OLEH :

KELOMPOK : 28
ANGGOTA : 1. Astrid Parama Ningrum (13406026)
2. Bona Mangkirap (13406043)
3. Irma Sofiani (13406049)
4. Nadia Fadhilah Riza (13406069)
5. Prila Sista Lilly Jane (13406080)
6. Ira Wulandari (13406094)

LABORATORIUM TEKNIK PRODUKSI

PROGRAM STUDI MESIN
INSTITUT TEKNOLOGI BANDUNG
2007
PURPOSE

1. Participants understand the variety of welding process

2. Participants understand the standard working process of Spot
Welding, Oxyacetylene Welding and Metal Arc Welding
3. Participants understand the parameter and sequences of
operations from each welding processes

BASIC THEORY

Welding Processes are divided into two major categories:

 Fusion Welding : in which coalescence is accomplished by melting two
parts to be joined, in some cases adding filler metal to the joint
 Solid State Welding : in which heat and/or pressure are used to
achieve coalescence, but no melting of the base metal occurs and no
filler metal is added

Fusion Welding is by far the more important category. It includes arc welding,
resistance welding, oxy-fuel gas welding and other fusion welding process
which cannot be classified as any of three types.

Arc Welding
A process in which coalescence of the metals is achieved by the heat from
electric arc between an electrode and the work. An electric arc is
discharge of electric current across a gap in a circuit. It is sustained by the
presence of a thermally ionized column of gas through which current
flows. To initiate the arc, the electrode is brought into contact with the work
and is then quickly separated from it by a short distance. A pool of molten
metal, consisting of base metal and filler metal is form in near the tip of
electrode. In most arc-welding process, filler metal is added during the
operation to increase the volume and strength of the weld joint. As the
electrode is moved along the joint, the molten weld pool solidifies in its
wake. Electric current was generated at current source. Current source
can produce the Alternating Current (AC) or Direct Current (DC).
Below is the figure of arc welding process:

Types of metal transfer in metal arc welding:

1. Surface tension: the melted drops of the electrode makes contact
with the puddle and is pulled in due to the surface tension of the
work piece
2. Spray arc: the melted drops of metal are sprayed from the drops of
the melted electrode, and carried by the electric arc towards the
work piece
3. Short circuit: metal is transferred from the wire to the weld pool only
when contact between the two is made, or at each short circuit

Spot Welding
It is widely used in mass production of automobiles appliances, metal
furniture and other products made of sheet metal. Resistance spot welding
is a resistance welding process in which fusion of the faying surfaces of a
lap joint is achieved a one location by opposing electrodes. The process is
used to joint sheet metal parts of thickness 3 mm or less using a series of
spot welds, in situation where an airtight assembly is not required. The
size and shape of the weld spot is determined by the electrode tip, the
most common electrode shape being round, but hexagonal, square, and
other shapes are also used. The resulting weld nugget is typically 5 to 10
mm in diameter, with an HAZ extending slightly beyond the nugget into the
base metal. If the weld is made properly, its strength will be comparable to
that of the surrounding metal. The steps in a spot welding cycle are shown
in the figure below
Oxyacetylene Welding
This type of welding process uses flame, which comes from the mixture of
oxygen and acetylenes, in order to heat the work pieces to its melting
temperature, with or without the use of filler.
The flame in this process is caused by two chemical reactions:
i. C2H2 + O2  2 CO + H2 + heat
ii. 2CO + H2 + 1.5 O2  2 CO2 + H2 + heat

Reaction (i) produces about a third of the produced heat. The product of
the reaction is capable of conducting chemical reactions, so that a second
reaction occurs.
Reaction (ii) produces about two thirds of the produced heat.

 Types of flame:
The reactions above produce a flame with a temperature of around
3200 C. The proportion of oxygen and acetylene determines the
type of flame which is created, which are:
1. Neutral flame: the mixture of oxygen and acetylene is on
equal proportion, which results an equal combination
proportion of blue and white flame.
2. Reducing/carburizing flame: acetylene is of a higher
proportion than oxygen, which results in a flame “whiter” than
the neutral flame, which makes this flame has a lower
temperature than the neutral flame.
3. Oxidizing flame: oxygen is of a higher proportion than
acetylenes. Its results the color of flame “bluer” than the
neutral flame, which makes this flame the hottest possible
one to be produced by an oxyacetylene weld.
The proportion between oxygen and acetylene must be determined
through the gas regulators.
ANALISYS

1. Spot welding

 This type of welding falls in the category of solid state welding,

because the work pieces never goes through the melting phase.
Instead, the work pieces are able to be forged together, due to the
softening of the material and the pressure applied towards them,
thus causing the two work pieces to be forged be one.
 The highest temperature is between the work pieces, because in
this area, the resistance comes from the air (between the work
pieces), and the two work pieces (which naturally have higher
resistance levels than the electrodes).
2. Oxyacetylene welding

 The proportion between oxygen and acetylene must be determined

on gas regulators
 The proportions between those two gasses produce a different type
of flame, which affects the temperature of the flame. The benefits of
the different types of flames are also different, as following:
 Neutral flame: this type of flame is mostly use in the industy,
because of its adequate heat for welding most materials, and
has minimal corrosive characteristics.
 Oxidizing flame: this type of flame has the highest
temperature, but has a tendency to cause corrosion due to
its high oxygen concentration, thus it is only used to weld
materials with high melting temperature (i.e. cast iron).
 Carburizing flame: this type of flame has the lowest
temperature, produced by an oxyacetylene weld, thus it is
only used for materials with low melting temperatures (i.e.
aluminum).
3. Metal arc welding
There are 2 methods of contacts between the work piece and electrode,
which are:
a. The work piece is connected to the negative pole, and the electrode
is connected to the positive pole. This way, the width of the bond
created by the welding process, is wider with shorter penetration,
due to the force of the movement of the electrons from the negative
pole (work piece) to the positive pole (electrode), so that the
electrons would be drawn towards the electrode, and would tend to
spread on the surface of the work pieces, causing the bond to be
wider. This method is more suitable when welding thin work pieces,
in order to ensure that the bond does not exceed the depth of the
work pieces.
b. The work piece is connected to the positive pole, and the electrode
is connected to the negative pole. This way, the bond created by
the welding process, is narrower with deeper penetration, due to
the force of the movement of the electrons from the negative pole
(electrode) to the positive pole (work piece), so that the electrons
move towards the work piece, causing them to force their way in to
a deeper level in the work piece. This causes the deep penetration.
This method is more suitable when welding thicker work pieces, in
order to ensure a stronger bond.
c. During the welding process, the position of the electrode towards
the work piece may not be 90 degrees, because it would cause the
inability of the flame to be turned on. Ideally, the angle between the
electrode and the work piece is about 70 degrees.
d. The electrode in arc welding is made of the filler material covered
with a certain coating made of clay. When the electrode burned and
melted, this coating also undergoes by those processes, so that the
gas from the coating protects the flame from turning off, and
 protects the work piece from infiltration of oxygen, which may
reduce the quality of the welding material.
e. While welding, the tip of the electrode may not be attached to the
work piece. Between the two, there must be a certain distance. If
the distance is too close, electrode will stuck to the work piece, and
won’t be able to be moved. If the distance is too far, the flame will
enlarge and eventually die out. During the process, the distance
between the electrode and the work piece must be maintained by
constantly drawing the electrode nearer to the work piece, in line
with the reduction of the electrode.
f. Before welding, the work pieces should be placed in a fixed
position, so that the welding process can occur with a good result in
terms of positioning.
g. During the welding process, the ideal movement of the electrode is
in a zigzag motion, so that the filler which is produced covers the
whole area of contact between the work pieces.

Post Observation Task

Spot welding

1. Draw the work piece of welding process (put the dimension and
description which compatible with mechanical drawing), write the
material of the work piece!

*Spot welding was not completed in the observation*

:
2. Describe the procedure that has been done in the spot welding
process!
a. Check the machine condition
b. Set the electrode, copper for example
c. Nip the plate that will be joint between a pair of electrode
 d. Flow a huge electric current in a short
e. Stop the electric current
f. Leave for a while until the molten spot between the two plate to
persist and it’s temperature become normal
g. The work piece will be joined after the spot freeze.

3. Write the full name and function of the component of spot welding
machine which used in the practicum!
a. Upper horn
b. Rocker arm
c. Air cylinder
d. Tap switch
e. Secondary flexible conductor
f. Electrode holder : to hold the electrode in static position
g. Lower horn
h. Transformer secondary
i. Foot control
j. Air valve
k. Electrodes (to flow the electric current)

Oxyacetylene welding

1. Draw the work piece of oxyacetylene process (put the dimension and
description which compatible with mechanical drawing), write the
material of the work piece!
 Material of the work piece: ST 37

2. Describe the procedure that has been done in the oxyacetylene

welding process!
a. Check the appliances’ condition
b. Connect the torch with the oxygen’s and acetylene’s tube
c. Set the flow of gas
d. Set the composition of oxygen and acetylene to get a proper
flame
e. Use the safety goggle
f. Prepare the work piece that will be weld
g. Light the torch by using the lighter
h. Hold the well controller in right hand and filler in the left hand
i. Light the filler until it is melted then direct it to the gaps between
the work pieces.
j. Do the process until both of the work pieces are joined
 3. Write the full name and function of the component of oxyacetylene
welding machine which used in the practicum

 Controller lid: The lid of the gas tube to control the flow of the
gas
 Flammable gas: So that the gas could quickly produced flame
 Oxygen : To accommodate oxidation
 Rubber-tube: where the gas flow
 Manual controller lid: manually adjustable lid to control the flow
of the gas running from the rubber-tube.
 Welding flame and fusion unit: where the gases are fused and
produces flame
 Burner edge: the boundary part of the welding tool that is
pointed directly to the work piece
 Flame: produced from the blend of the gases used to be
contacted directly to weld the work piece.

Metal Arc Welding

 1. Describe the operation procedure of electric welding with electrodes
(give the scheme of the tools)!

Electric arc welding procedure:

 Turn on the transformation
 Place the work piece on the work table
 Connect the negative pole to the work piece and the positive
pole to the electrode
 Check the electric arc flame before welding
 Do the welding process concerning the capability of the
electrode to fill the welding part
 Use safety goggle and gloves if needed.

Electric arc welding process scheme :

electroda
holder
electroda

arc
AC or DC
power
source

solidified
weld metal

2. Describe the form of metal transferring at electric welding (globular,

spray, and short-circuit), how the metal transfer occurs in this
experiment?
 Globular
Material transfer forms bigger lumps
  Spray
The form of material transfer looks like the globular ones but
smaller
 Short Circuit
The material transfer is like flowing because of the small gap
between materials.
From the experiment, the material transfer occurs was the short-circuit
transfer because of the small gap between electrode and the work
piece

3. What is the effect of discontinued welding to the welding result, what is

the cause and how to overcome the problem?
 The holder must be set by keeping the consistent distance to
overcome the irregular gap between electrode and the work piece
so that the arc does not scatter
 The effect of the dazzling flame could be overcame by using safety
goggle

Common Welding Process

Which one is the best welding process in this practicum and how do you
compare the other types of welding process (not practiced in this practicum)
that you have learned?

The best process is the oxyacetylene welding because it is easier to do and

the flame is not too dazzling to your eyes so that you can directly see the
result on your work piece and control the movement of the filler.

CONCLUSION
The Welding Process consists of spot welding, oxyacetylene welding, and
metal arc welding.

The operation principle of each welding process is:

1. Spot Welding, without filler metal and the work piece will be forged
because of centered heat
2. Oxyacetylene Welding, using filler metal with combustions reaction
between oxygen and acetylene for heating the work piece
3. Metal Arc Welding, using filler metal which is combined with electrode.
Electrode is given by electric current and welding is starting

The process procedures:

 In spot welding, first of all, we have to check the machine condition. Fit
the welding parameter, and then welding process is starting (squeeze
time, weld time, hold time, off time).
 In oxyacetylene welding, oxygen and acetylene gas are flowing to the
torch by hoses. In torch, each gas composition is regulated with gas
control valve. Both of the gas will be mixed and producing the fire in
welding tip, then work pieces are closed and heated until reach the
melting point of filler metal. While the work piece is becoming hot, the
filler metal is put in filling gap until the filler metal is melted.
 In metal arc welding, the transformation is turned on and then the
electrode is forged in the electrode clamp. Do the welding process with
make the electrode closer with work pieces so that the filler metal in
the electrode will be melted and finally will be forged with other work
piece.
Daily applications of three welding process are vary. But in real life, metal arc
welding is commonly used because it is more effective and efficient than
others.

Spot welding is less efficient because the work piece have to be moved
continuously so it’s need more power and longer time.

In oxyacetylene welding, filler metal is melted with the work piece which is
heated before (left hand grasp the filler metal, right hand grasp the welding
torch). While the metal arc welding is only putting the electrode to work pieces
so the filler metal can immediately fill the gap.

The make the welding process optimal, it can be done with several ways. For
the example, in metal arc welding, the welding is started with the end of the
work piece so that the work pieces cannot move. Other example is clamping
the work pieces in the edge so that it cannot be moved.
ENCLOSURE

Welding Simulation Oxygen and Acetylene tubes

Electrode Classification
The electrode classification