NAME: OGUNKANMBI SAMUEL OLANREWAJU

PROGRAMME: CHEMICAL ENGINEERING

LEVEL: 200
MATRIC. NO. : 13CF015155
COURSE: GEC 218

ARC WELDING
OBJECTIVES

To know main function of welding.

To know the procedure of arc welding.
To ensure student know the skills of welding.
To ensure all student according to the instruction and safety

INTRODUCTION

What is Welding?

Welding is often done by melting the work pieces and adding a filler material to
form a pool of molten material (the weld pool) that cools to become a strong
joint, with pressure sometimes used in conjunction with heat, or by itself, to
produce the weld. This is in contrast with soldering and brazing, which involve
melting a lower-melting-point material between the work pieces to form a bond
between them, without melting the work pieces. Welders can be found in lots of
places and in lots of companies these include the making of
aeroplanes assembling cars and other vehicles constructing buildings and
bridges working on oil rigs in the middle of the ocean and under the sea.
TYPES OF WELDING

Some of the best known welding methods include:

Shielded metal arc welding (SMAW) - also known as "stick welding", uses an
electrode that has flux, the protectant for the puddle, around it. The electrode
holder holds the electrode as it slowly melts away. Slag protects the weld
puddle from the outside world.

Gas Tungsten-Arc Welding- Gas Tungsten-Arc Welding is considered to be one

of the most difficult and time consuming of welding processes used today
(along with Plasma Arc Welding). This is because it requires a great amount of
focus and skill due to the small area of space between the arc of the flame and
the material being welded. Usually, small strips of metal that do not contain
much iron are welded with this process.

Electro-slag welding (ESW) - a highly productive, single pass welding process

for thicker materials between 1 inch (25 mm) and 12 inches (300 mm) in a
vertical or close to vertical position.

MIG (Metal Inert Gas) Welding- Metal Inert Gas Welding is a process of
welding that uses a gas to shield the weld metal. The gas keeps the metal being
welded from being effected from natural elements in the environment, such as
oxygen. This allows the welder to operate at a continuous rate, making the
process fairly quick

Flux-Cored Welding- Flux-cored welding was created and put into use in the
early years of the 1950s. Its purpose was to give another option to the popular
use of stick welding. The Flux-Cored process is mostly used for projects that
require fast speed as it is an automatic form of welding. Many construction
workers use this process on the job because of the speed and the ability to use
flux-cored welding in multiple situations on various materials.

Submerged arc welding (SAW) - uses an automatically fed consumable

electrode and a blanket of granular fusible flux. The molten weld and the arc
zone are protected from atmospheric contamination by being "submerged"
under the flux blanket.
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.
Arc welding processes may be manual, semi-automatic, or fully automated.
First developed in the late part of the 19th century, arc welding became
commercially important in shipbuilding during the Second World War. Today it
remains an important process for the fabrication of steel structures and vehicles.

In arc welding, the intense heat needed to melt metal is produced by an electric
arc. The arc is formed between the actual work and an electrode (stick or wire)
that is manually or mechanically guided along the joint. The electrode can either
be a rod with the purpose of simply carrying the current between the tip and the
work. Or, it may be a specially prepared rod or wire that not only conducts the
current but also melts and supplies filler metal to the joint. Most welding in the
manufacture of steel products uses the second type of electrode.

MATERIALS/ TOOLS

1. Arc Machine
2. Leather Gloves
3. Electrode
4. 2 mild steel rods 150mm
5. Hack Saw
6. Vice
7. Safety Goggles
8. Laboratory coat/ Overall
9. Bucket of Water
WORK PROCEDURE

Prepare two mild steel rods of 150 (15cm) length by cutting with a hack
saw.
Use an electrode code MS6013 or E6013with diameter 2.6mm or 3.2mm.
Adjust the ampere around 60 100 for electrode diameter 3.2mm
Put an electrode at the electrode holder (LIVE) and make sure that there
are no movement of electrode at the holder.
Place the 2 rods on a vice and tighten to prevent them from shaking
Hold the electrode at an angle and at a distance above the 2 rods placed
together.
Strike the electrode on the EARTH or on the work piece touching the
EARTH in order to get a spark
Welding then proceeds from top to bottom in the middle of the 2 rods.
Stop the process at the end of the rods
Untighten the vice and use gloves to transfer the welded rods to a bucket
of water for it to cool.
Welding is done.

DIAGRAM OF ARC WELDING

PRECAUTIONS

Protect skin and eyes from UV light, and shield your welding area from
the eyes of onlookers.
Work in a well-ventilated area (extraction fans should be used when
welding inside a workshop) A vapour mask or an air fed helmet are
required for special materials.
Be careful not to leave anything flammable nearby. Welding spatter and
grinding sparks can travel a long distance.
Slag can ping off a hot weld and burn into your eyes. Use safety glasses
or goggles.
Be sure the work cable is connected to the work as close to the welding
area as practical Work cables connected to the building framework or
other locations some distance from the welding area increase the
possibility of the welding current passing through lifting chains crane
cables or other alternate circuits.

CONCLUSIONS

At this practical, we learn about how to joining the mild steel rods using the Arc
Welding method. Our lecturer always reminds us to stay alert in safety while
doing a work before and after finish the practice.