Prepared By: G Sundar Raju, E Sakthivel Murugan, C Veera Ajay, S Janardhan

DEPARTMENT OF MECHANICAL ENGINEERING
SEMESTER – I
TOPIC WISE SCHEDULE FOR SEMESTER – I
Skill Set No. : SS-04

Title of the Skill Set : Welding
Semester-I Skill Set : Identify the proper welding to be used for the given material (soldering, brazing, braze weld, welding AC-DC-Forehand-
Backhand- ARC and GAS).
Outcomes:
1. Students will be able to understand the welding and allied process
2. Students will be able to practice forehand and backhand welding process
3. Students will be able to perform different weld joints using arc welding process
4. Students will be able to perform sheet metal welding using brazing process
10.25am 12.20pm 3.10pm

8.45am to 9.35am to 10.40am to 11.30am to 1.30pm to 2.20pm to 3.25pm to
Day to to to
9.35am 10.25am 11.30am 12.20pm 2.20pm 3.10pm 4.15pm
10.40am 1.30pm 3.25pm
Day 1 Introduction Exercise – 1 Exercise -2 Exercise -3
Day 2 Exercise -4 Exercise – 5 Exercise - 6 Exercise -7
1 Prepared by: G Sundar raju, E Sakthivel Murugan, C Veera Ajay, S Janardhan

SEMESTER – II
TOPIC WISE SCHEDULE FOR SEMESTER – II

Semester-II Skill Set : Identify the proper welding to be used for the given material which is having irregular geometric structure (ARC and GAS).
Outcomes:
1. Students will be able to understand the different weld parameters
2. Students will be able to perform welding on prismatic objects such as round and square pipe
3. Students will be able to fabricate window/ door frame using square pipe
4. Students will be able to weld dissimilar sheet metals such as mild steel and stainless steel using arc welding process
10.25am 12.20pm 3.10pm

Day to to to
9.35am 10.25am 11.30am 12.20pm 2.20pm 3.10pm 4.15pm
10.40am 1.30pm 3.25pm
Day 1 Introduction Exercise – 1 Exercise - 1 Exercise -2 Exercise -2
Day 2 Exercise -3 Exercise – 3 Exercise - 4 Exercise 5

SEMESTER – III
TOPIC WISE SCHEDULE FOR SEMESTER – III

Semester-III Skill Set: Identify the given material based on microstructure analysis (TIG and MIG).
Outcomes:
1. Students will be able to understand the TIG and MIG welding process
2. Students will be able to perform welding on stainless steel pipe and plate using TIG welding process
3. Students will be able to perform welding on stainless steel pipe and plate using MIG welding process
4. Students will be able to inspect welded components by visual inspection method
10.25am 12.20pm 3.10pm

Day to to to
9.35am 10.25am 11.30am 12.20pm 2.20pm 3.10pm 4.15pm
10.40am 1.30pm 3.25pm
Day 1 Introduction Exercise - 1 Exercise -2 Exercise -2
Day 2 Exercise -3 Exercise - 4 Exercise - 4 Exercise - 5 Exercise -5

SEMESTER – IV
TOPIC WISE SCHEDULE FOR SEMESTER – IV

Semester-IV Skill Set: Identification of defects on the welds and rectification exercises on leakage on welds.
Outcomes:
1. Students will be able to perform welding on MS plate and pipe using Arc/MIG welding process
2. Students will be able to inspect welded plate using LPT technique
3. Students will be able to inspect welded plate and pipe using MPT technique
4. Students will be able to inspect welded plate using UT technique
10.25am 12.20pm 3.10pm

Day to to to
9.35am 10.25am 11.30am 12.20pm 2.20pm 3.10pm 4.15pm
10.40am 1.30pm 3.25pm
Day 1 Exercise -1 Exercise – 2 Exercise -3 Exercise -4
Day 2 Exercise -5 Exercise – 6 Exercise - 7 Exercise -8

Skill Set No. : SS-04 Title of the Skill Set : Welding
CONTENTS
Semester-I Skill Set : To joining of Mild steel plate using Arc Welding
Sl. No. Description P. No.
Introduction of welding & Allied process 7
1. Forehand and backhand welding practice 16
2. Butt joint Edge preparation for joining process (Single-V/Double-V/Single Bevel/Double Bevel) 17
3. Butt joint welding using Arc welding 18
4. Lap /Tee Joint welding using SMAW Process. 19
5. Corner Joint welding using SMAW Process. 20
6. Welding of sheet metal using Brazing process 21
7 Demonstration of Oxy-Acetylene Gas cutting process 22
Semester-II Skill Set : To fabrication of Mild steel Pipes using Arc welding
Introduction of Arc welding process / Selection of welding Parameters / Demonstration on 24

welding generator parts
1. Welding of round pipe (Mild steel) 29
2. Welding of square pipe (Mild steel) 30
3. Fabrication of Frame using square pipe 31
4. Welding of sheet metal using resistance spot welding 32
5. Welding of dissimilar sheet metal using arc welding (Mild steel and Stainless steel) 33

Semester-III Skill Set: To fabricate plate and Pipe material using TIG & MIG welding process
Introduction of TIG & MIG welding 34
1. Welding of stainless steel plate using TIG 38
2. Welding of stainless steel Pipe using TIG 39
3. Welding of stainless steel plate using MIG 40
4. Welding of stainless steel Pipe using MIG 41
5. Visual inspection of welded components 42
Semester-IV Skill Set: To Inspect the welded components using Non Destructive Testing
1 Welding of MS Plate using Arc/MIG 48
2 Welding of MS Pipe using Arc/MIG 49
3 LPT inspection of welded plate 50
4 MPT inspection of welded plate 51
5 MPT inspection of welded pipe 52
6 UT inspection of welded plate 53

DO’S AND DON’TS
 To avoid injury, the student must take the permission of the laboratory staff before handling any machine. Careless handling of machines may result in
serious injury.
 Students must ensure that their work areas are clean and dry to avoid slipping.
 A leather apron will be issued to each student during Welding Exercise. Students not wearing the apron will not be permitted to work in the laboratory.
 Students are required to clear off all tools and materials from machine/work place.
 Always weld in a well-ventilated place. Fumes given off from the welding are unpleasant and in some case may be injurious, particularly from
galvanized or zinc coated parts.
 Do not weld around combustible or inflammable materials where sparks may be cause fire.
 Never weld containers which have been used for storing gasoline, oil or similar materials without first cleaning them thoroughly.
Introduction of welding & Allied process
 Welding is a process for joining two similar or dissimilar metals with application of heat, with or without the application of pressure and with or without
the use of filler metal.
 The heat may be generated either from combustion of gases, electric arc, electric resistance or by chemical reaction.
 Typical applications of welding the fabrication and repairing process of ships, pressure vessels, automobile bodies, off-shore platform, bridges, welded
pipes, sealing of nuclear fuel and explosives, etc.
Figure: Welding

Figure: Types of Welding process.
Weldability
The Weldability may be defined as property of a metal which indicates the ease with which it can be welded with other similar or dissimilar metals.
Welding Terminology
Figure: Welding Terminology

Welding joints
Figure: Basic weld joints
Butt joint Edge preparation for joining process
Single-Vee Butt Weld

It is used for plates up to 15.8 mm thick. The angle of the vee depends upon the technique being used, the plates being spaced approximately 3.2 mm.
Double-Vee Butt Weld

It is used for plates over 13 mm thick when the welding can be performed on both sides of the plate. The top vee angle is either 60° or 80°, while the bottom
angle is 80°, depending on the technique being used.

Figure: Butt joint Edge preparation
Welding Technique
 Forehand Welding Technique

 Backhand Welding Technique

Welding defects
Electric arc welding
 Arc welding is a welding process that is used to join metal to metal by using electricity to create enough heat to melt metal, and the melted metals when
cool result in a binding of the metals.
 Arc welders can use either direct (DC) or alternating (AC) current, and consumable or non-consumable electrodes.

Significance of Polarity
When D.C. current is used for welding, the following two types of polarity are available:
(i) Straight or positive polarity.
(ii) Reverse or negative polarity.
(i) Straight or positive polarity
 When the work is made positive and electrode as negative then polarity is called straight or positive polarity.
 In straight polarity, about 67% of heat is distributed at the work (positive terminal) and 33% on the electrode (negative terminal).
 The straight polarity is used where more heat is required at the work.
 The ferrous metal such as mild steel, with faster speed and sound weld, uses this polarity.
(ii) Reverse or negative polarity.
 When the work is made negative and electrode as positive then polarity is known as reverse or negative polarity.
 In reverse polarity, about 67% of heat is liberated at the electrode (positive terminal) and 33% on the work (negative terminal).
 The reverse polarity is used where less heat is required at the work as in case of thin sheet metal weld.
 The non-ferrous metals such as aluminum, brass, and bronze nickel are welded with reverse polarity.
Arc Welding Electrodes
Arc welding electrodes can be classified into two broad categories:
1. Non-Consumable electrodes.
2. Consumable electrodes.
1. Non-Consumable Electrodes:
 These electrodes do not consumed during the welding operation, hence they named, non-consumable electrodes.
 They are generally made of carbon, graphite or tungsten. Carbon electrodes are softer while tungsten and graphite electrodes are hard and brittle.
 Carbon and graphite electrodes can be used only for D.C. welding, while tungston electrodes can be used for both D.C. and A.C. welding.
 The filler material is added separately when these types of electrodes are used.
 Since, the electrodes do not consumed, the arc obtained is stable.
2. Consumable Electrodes:
These electrodes get melted during welding operation, and supply the filler material. They are generally made with similar composition as the metal to be
welded.
The arc length can be maintained by moving the electrode towards or away from the work.

Brazing
Brazing is a metal-joining process in which two or more metal items are joined together by melting and flowing a filler metal into the joint, the filler metal
having a lower melting point than the adjoining metal

EXERCISE 1
Forehand and Backhand welding practice
Welding Electrodes
M.S electrodes 3.1 mm X350 mm
Welding Equipment
Air cooled transformer Voltage -80 to 600 V 3 phase supply, amps up to 350
Tools and Accessories required:

1. Rough and smooth files.
2. Protractor
3. Arc welding machine (transformer type)
4. Mild steel electrode and electrode holder
5. Ground clamp
6. Tongs
7. Face shield
8. Apron
9. Chipping hammer.

EXERCISE 2
Butt joint Edge preparation for joining process (Single-V/Double-V/Single Bevel/ Butt joint Edge preparation for joining process (Single-V/Double-
V/Single Bevel/Double Bevel)
AIM
To make a V- joint using the given work piece as per the drawing dimensions.
DRAWING

EXERCISE 3
Butt joint welding using Arc welding
Aim:
To make a Butt joint using the given two M.S pieces by arc welding.
Material Required:
Mild steel plate of size 100X50X5 mm – 2 No’s
Welding Electrodes
Welding Equipment

2. Protractor
5. Ground clamp
6. Tongs
7. Face shield
8. Apron
9. Chipping hammer.

EXERCISE 4
Lap /Tee Joint welding using SMAW Process
Aim:
To make a Lap/Tee joint, using the given two M.S pieces and by arc welding.
Material Supplied:
Mild steel plate of size 100X50X5 mm –2 No’s
Welding Electrodes: M.S electrodes 3.1 mm X350 mm
Welding Equipment: Air cooled transformer
Voltage-80 to 600 V,3-ɸsupply, Current up to 350Amps
LAP JOINT
TEE JOINT

EXERCISE 5
Corner joint welding using SMAW Process.
Aim:
To make a corner/edge joint, using the given two M.S pieces and by arc welding.
Material Required:
Mild steel plate of size 100X50X5 mm –2 No’s
Welding Electrodes: M.S electrodes 3.1 mm X350 mm
Welding Equipment: Air cooled transformer
Voltage-80 to 600 V 3 phase supply, amps up to 350
CORNER JOINT

EXERCISE 6
Welding of sheet metal using Brazing process

Aim:
To prepare a butt/tee joint with mild steel strips using brazing technique.
Equipment & materials:

1. Gas welding set
2. brazing wire
3. fluxes
4. mild steel strips (140 x 25 x 3 mm)
5. wire brush
6. Tongs etc.

EXERCISE 7
Demonstration of Oxy-Acetylene Gas cutting process

Introduction
 Oxyfuel cutting is a family of cutting processes which heats the work metal to its kindling point, causing it to burn in a stream of oxygen.
 Oxyacetylene is used more for cutting than welding, natural gas, propane and propylene are also used for cutting.
 Oxyfuel cutting is an easy process to use, cuts in all directions, is portable, and it is inexpensive to add to an existing oxy fuel welding outfit.
 Oxyfuel can cut steel from under 1/32" to over 12' thick.

Three kinds of gas flames are:
Neutral Flame:
Neutral Flame has equal quantity of Oxygen and Acetylene. It has two sharply defined Zones. One is inner white cone flame. Other is outer blue flame
envelope. This is used for welding steel, copper and aluminium. It is also used in gas cutting operation.
Oxidizing Flame:
If the gas ratio is 1.2 to 1.5 parts of oxygen to 1 part of Acetylene (i.e., excess Oxygen), Oxidizing Flame is produced. Inner white zone is smaller than
that of a neutral flame. This flame is used for welding copper, brass and bronze.
Carburizing or Reducing Flame:
If the ratio of oxygen to Acetylene is 0.9 to 1 (i.e., excess Acetylene), Carburizing Flame is produced. It has two sharply defined zones as in the case
of a neutral flame with the addition of a third zone. The third zone is white in colour, known as intermediate flame feather. It is used for welding requiring low
heat such as brazing.

SEMESTER 2
Introduction of Arc welding process / Selection of welding Parameters / Demonstration on welding generator parts
ARC WELDING PROCESSES
 The process, in which an electric arc between an electrode and a work-piece or between two electrodes is utilized to weld base metals, is called an arc
welding process.
 Most of these processes use some shielding gas while others employ coatings or fluxes to prevent the weld pool from the surrounding atmosphere
Selection of welding parameters
Power source types
Transformer
Transformer-rectifier
Inverter
Generator

1. Welding current
2. Wire electrode extension
 Long extensions result in excess weld metal being deposited with low arc heat.
 This can cause poor bead shape and low penetration.
 In addition, as the tip-to-work distance increases, the arc becomes less stable.
 For short arc welding 3/8 in. (9.6mm) tip-to-work distance is recommended.
 It is very important that the wire extension be kept as constant as possible during the welding operation

3. Welding voltage
4. Welding techniques

5. Weld penetration
 Weld penetration is the distance that the fusion line extends below the surface of the material being welded.
 Welding current is of primary importance to penetration.
 Weld penetration is directly related to welding current.
 An increase or decrease in the current will increase or decrease the weld penetration respectively.
Adjustments in Welding Parameters & Techniques

Demonstration on welding generator parts (Dismantling welding generator)

EXERCISE 1
Welding of round pipe (Mild steel)

Aim:
Material Required:
Mild steel pipe of size Dia 100 mm – 2 No’s
Welding Electrodes
Welding Equipment

2. Protractor
5. Ground clamp
6. Tongs
7. Face shield
8. Apron
9. Chipping hammer

EXERCISE 2
Welding of square pipe (Mild steel)
Aim:
To make a T joint using the given two M.S pieces by arc welding.
Material Required:
Mild steel Square pipe of size 50 mm – 2 No’s
Welding Electrodes
Welding Equipment

2. Protractor
5. Ground clamp
6. Tongs
7. Face shield
8. Apron
9. Chipping hammer

EXERCISE 3
Fabrication of Frame using square pipe
Aim:
To fabricate a frame structure using Arc welding process
Material Required:
Mild steel square pipe of size 50 mm
Welding Electrodes
Welding Equipment

2. Protractor
5. Ground clamp
6. Tongs
7. Face shield
8. Apron
9. Chipping hammer

EXERCISE 4
Welding of sheet metal using resistance spot welding

Aim:
To prepare a lap Joint on the given work pieces using spot welding equipment.
Material Required:
Welding Equipment
Resistance spot welding Machine

EXERCISE 5
Welding of dissimilar materials (Mild steel with Stainless steel)

Aim:
To weld a dis similar materials using SMAW Process
Material Required:
Mild steel plate 100x50x 5 mm, Stainless steel plate 100x50x 5 mm
Welding Electrodes
Stainless steel Filler wire 1 mm
Welding Equipment

2. Stainless steel electrode and electrode holder
3. Ground clamp
4. Tongs
5. Face shield
6. Apron
7. Chipping hammer

SEMESTER III
Introduction of TIG & MIG welding.
Tungsten Inert Gas (TIG) Welding

 Tungsten Inert Gas (TIG) or Gas Tungsten Arc (GTA) welding is the arc welding process in which arc is generated between non consumable tungsten
electrode and work piece.
 The tungsten electrode and the weld pool are shielded by an inert gas normally argon and helium.
TIG Welding Principle

 In the Gas Tungsten Arc Welding (GTAW) metals are fused together by heating them by an electric arc established between a non-consumable (does
not melt) tungsten electrode and the work piece.
 A filler metal may not be used depending on the design of the joint.
 The molten metal, tungsten electrode and the welding zone are shielded from the atmosphere (the air around it ) by a stream of inert gas through the
welding torch.
 The resulting welds have the same chemical integrity as the original base metal.
 GTAW TIG Welding can be done in any welding position and in manual, semiautomatic and automatic modes; the method used depend on the available
equipment and the application.
 The melting temperature necessary to weld materials in the Gas Tungsten Arc Welding (GTAW) process is obtained by maintaining an arc between a
tungsten alloy electrode and the work piece.
 Weld pool temperatures can approach 2500 °C (4530 °F).
 An inert gas sustains the arc and protects the molten metal from atmospheric contamination.
 The inert gas is normally argon, helium, or a mixture of helium and argon.
Applications
The TIG Welding or GTAW process can be used to weld almost all metals and metal alloys in use today. It is a particularly effective and economic
way for welding light gauge metals (less than 3mm thickness) and for welding metals difficult to weld with the conventional welding process. Such metals
include the following:
 Aluminum and aluminum alloys
 Copper and copper alloys
 Nickel and nickel alloys
 Magnesium and magnesium alloys
 Low alloy steel and carbon steels
 Reactive materials (for example, titanium and tantalum)
 Joining carbon and alloy steels
Fig: Principle of TIG Welding. Fig: Schematic Diagram of TIG Welding System.
Metal Inert Gas (MIG) Welding

 MIG stands for metal inert gas welding or sometimes it is known as Gas Metal Arc welding.
 This welding is same as TiG welding except a non-consumable electrode replaced by consumable electrode wire.
 This process is automated or semi-automated arc welding process in which inert gases are used as shielding gas and a consumable wire electrode is
used.
 It is mostly used in sheet metal industries or in automobile industries.
MIG Welding Principle
 MIG works on same principle of TIG or arc welding.

 It works on basic principle of heat generation due to electric arc.
 This heat is further used to melt consumable electrode and base plate’s metal which solidify together and makes a strong joint. The shielded gases are
also supplied through nozzles which protect the weld zone from other reactive gases.
 This gives good surface finish and a stronger joint.

Working:
 First, a high voltage current is change into DC current supply with high current at low voltage. This current passes though welding electrode.
 A consumable wire is used as electrode. The electrode is connected to the negative terminal and work piece from positive terminal.
 A fine intense arc will generate between electrode and work piece due to power supply. This arc used to produce heat which melts the electrode and the
base metal. Mostly electrode is made by the base metal for making uniform joint.
 This arc is well shielded by shielding gases. These gases protect the weld form other reactive gases which can damage the strength of welding joint.
 This electrode travels continuously on welding area for making proper weld joint. The angle of the direction of travel should be kept between 10-15
degree. For fillet joints the angle should be 45 degree.
Applications:
 MIG is best suited for fabrication of sheet metal.

 Generally all available metals can be weld through this process.
 It can be used for deep groove welding.

EXERCISE 1
Welding of stainless steel plate using TIG
Aim:
To make a Butt joint using the given two S.S pieces by TIG welding.
Material Required:
Stainless steel plate of size 100X50X5 mm – 2 No’s
Welding Equipment

1. TIG welding machine (Inverter type)
2. Electrode and electrode holder
3. Ground clamp
4. Tongs
5. Face shield
6. Apron

EXERCISE 2
Welding of stainless steel Pipe using TIG

Aim:
To make a joint using the given two S.S pipe pieces by TIG welding.
Material Required:
Stainless steel pipe of diameter 100 mm – 2 No’s
Welding Equipment

3. Ground clamp
4. Tongs
5. Face shield
6. Apron

EXERCISE 3
Welding of stainless steel plate using MIG
Aim:
To make a Tee/Lap joint, using the given two S.S pieces and by MIG arc welding.
Material Required:
Stainless steel plate of size 100X50X5 mm –2 No’s
Welding Equipment

3. Ground clamp
4. Tongs
5. Face shield
6. Apron

EXERCISE 4
Welding of stainless steel Pipe using MIG
Aim:
To make a joint using the given two S.S pipe pieces by MIG welding.
Material Required:
Stainless steel pipe of diameter 10 mm – 2 No’s
Welding Equipment

3. Ground clamp
4. Tongs
5. Face shield
6. Apron

EXERCISE 5
Visual inspection of welded components & Defects identifications
Visual Inspection (VT)
 Visual inspection is a non-destructive testing (NDT) weld quality testing process where a weld is examined with the eye to determine surface
discontinuities.
 It is the most common method of weld quality testing.
Advantages of nondestructive weld quality testing:
 Inexpensive (usually only labor expense)

 Low cost equipment
 No power requirement
 Quick identification of defects and downstream repair costs due to issues that weren't caught early
Disadvantages:
 Inspector training necessary

 Good eyesight required or eyesight corrected to 20/40
 Can miss internal defects
 Report must be recorded by inspector
 Open to human error
Visual Weld Quality Testing Steps
1. Practice and develop procedures for consistent application of approach

2. Inspect materials before welding
3. Weld quality testing when welding
4. Inspection when weld is complete
5. Mark problems and repair the weld

Visual Weld Equipment
 Fillet Weld Gauge is an essential weld quality testing tool.

 It is used to check fillet leg size, checking fillet throat size
Several pieces of equipment are required for visual weld quality testing:
 Weld hand held fillet gauge: measure -

- flatness of the weld
- convexity (how the weld is welded outward)
- concavity (how the weld is rounded inward)
 Protective lenses with pocket viewer and shade lens for use when observing the welding process
 Magnifying glass per the code in your area
 Flashlight
 Chisel and hammer for spatter and slag removal before the weld is inspected
 Temperature device (Tempel stick, Pyrometer) to determine the preheating, interpass and post-heating temperatures.
 Magnet to indicate the type of material being welded
 Tape measure
Visual Inspection before Welding
 Check drawings
 Look at weld position and how it corresponds to the specification. Watch the vertical direction of travel
 Check welding symbols
 Does procedure align with local codes and the weld specification
Weld Material Inspection
 Does the materials purchase match the specification for base metal size and type? Check electrode size, gas selection and grade.
 Check materials for defects. Look for contaminants such as rust, scale, mill, lamination etc.
 Are materials prepared for correct angles?
Equipment Inspection
 Check for damage (cables, ground clamps, electrode holder).

 Check arc voltage
 Check amperage meter for range against specification
Visual Inspection during Welding
 Check electrodes for size, type and storage (low hydrogen electrodes are kept in a stabilizing oven)
 Watch root pass for susceptibility to cracking
 Inspect each weld pass. Look for undercut and required contour. Ensure the weld is cleaned properly between each pass.
 Check for craters that need to be filled
 Check welds sequence and size. Gauges are used to check size.
Inspection after Welding
 Check weld against code and standards

 Check size with gauges and prints
 Check finish and contour
 Check for cracks against standards
 Look for overlap
 Check undercut
 Determine if spatter is at acceptable levels

Welding inspection using weld Gauges
Welding Defects
UNDERCUT WELD CRACK POROSITY
INCOMPLETE FUSION SPATTERS
OVERLAP INCOMPLETE PENETRATION EXCESS CONCAVITY

SEMESTER IV
EXERCISE 1
Welding of MS Plate using Arc/MIG

Aim:
Material Required:
Welding Electrodes
Welding Equipment

2. Protractor
5. Ground clamp
6. Tongs

EXERCISE 2
Welding of MS Pipe using Arc/MIG
Aim:
Material Required:
Mild steel pipe of size Dia 100 mm – 2 No’s
Welding Electrodes
Welding Equipment

2. Protractor
5. Ground clamp
6. Tongs
7. Face shield
8. Apron
9. Chipping hammer

EXERCISE 3
LPT inspection of welded plate
Aim:
To inspect a welded plate and pipe using Liquid penetrant Test.
Material Required:
1. Cleaner
2. Penetrant
3. Developer
Procedure

EXERCISE 4
MPT inspection of welded plate
Aim:
To inspect a welded plate using Magnetic particle Test.
Material Required:
1. Yoke
2. Dry or Wet particles
3. Sprayer
Procedure
 A ferromagnetic test specimen is magnetized with a strong magnetic field created by a magnet or special equipment.
 If the specimen has a discontinuity, the discontinuity will interrupt the magnetic field flowing through the specimen and a leakage field will occur

EXERCISE 5
MPT inspection of welded pipe
Aim:
To inspect a welded pipe using Magnetic particle Test.
Material Required:
1. Yoke
2. Dry or Wet particles
3. Sprayer
Procedure
 A ferromagnetic test specimen is magnetized with a strong magnetic field created by a magnet or special equipment.
 If the specimen has a discontinuity, the discontinuity will interrupt the magnetic field flowing through the specimen and a leakage field will occur

EXERCISE 6
UT inspection of welded plate
Aim:
To inspect a welded pipe using Magnetic particle Test.
Material Required:
1. Pulsar/Receiver
2. Transducer
3. Display unit
Procedure
 UT inspection system consists of several functional units, such as the pulser/receiver, transducer, and display devices.
 A pulser /receiver is an electronic device that can produce high voltage electrical pulses.
 Driven by the pulser, the transducer generates high frequency ultrasonic energy.
 The sound energy is introduced and propagates through the materials in the form of waves.
 When there is a discontinuity (such as a crack) in the wave path, part of the energy will be reflected back from the flaw surface.
 The reflected wave signal is transformed into an electrical signal by the transducer and is displayed on a screen.
 In the applet below, the reflected signal strength is displayed versus the time from signal generation to when an echo was received.
 Signal travel time can be directly related to the distance that the signal traveled.
 From the signal, information about the reflector location, size, orientation and other features can sometimes be gained.

Prepared By: G Sundar Raju, E Sakthivel Murugan, C Veera Ajay, S Janardhan

Transféré par

Informations du document

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

Prepared By: G Sundar Raju, E Sakthivel Murugan, C Veera Ajay, S Janardhan

Transféré par

Droits d'auteur :

Formats disponibles

DEPARTMENT OF MECHANICAL ENGINEERING

TOPIC WISE SCHEDULE FOR SEMESTER – I

Skill Set No. : SS-04

10.25am 12.20pm 3.10pm

1 Prepared by: G Sundar raju, E Sakthivel Murugan, C Veera Ajay, S Janardhan

TOPIC WISE SCHEDULE FOR SEMESTER – II

Skill Set No. : SS-04

10.25am 12.20pm 3.10pm

2 Prepared by: G Sundar raju, E Sakthivel Murugan, C Veera Ajay, S Janardhan

TOPIC WISE SCHEDULE FOR SEMESTER – III

10.25am 12.20pm 3.10pm

3 Prepared by: G Sundar raju, E Sakthivel Murugan, C Veera Ajay, S Janardhan

TOPIC WISE SCHEDULE FOR SEMESTER – IV

Skill Set No. : SS-04

10.25am 12.20pm 3.10pm

4 Prepared by: G Sundar raju, E Sakthivel Murugan, C Veera Ajay, S Janardhan

Sl. No. Description P. No.

Introduction of welding & Allied process 7

1. Forehand and backhand welding practice 16

3. Butt joint welding using Arc welding 18

4. Lap /Tee Joint welding using SMAW Process. 19

5. Corner Joint welding using SMAW Process. 20

6. Welding of sheet metal using Brazing process 21

7 Demonstration of Oxy-Acetylene Gas cutting process 22

Sl. No. Description P. No.

Introduction of Arc welding process / Selection of welding Parameters / Demonstration on 24

2. Welding of square pipe (Mild steel) 30

3. Fabrication of Frame using square pipe 31

4. Welding of sheet metal using resistance spot welding 32

5 Prepared by: G Sundar raju, E Sakthivel Murugan, C Veera Ajay, S Janardhan

Sl. No. Description P. No.

Introduction of TIG & MIG welding 34

1. Welding of stainless steel plate using TIG 38

2. Welding of stainless steel Pipe using TIG 39

3. Welding of stainless steel plate using MIG 40

4. Welding of stainless steel Pipe using MIG 41

5. Visual inspection of welded components 42

Sl. No. Description P. No.

1 Welding of MS Plate using Arc/MIG 48

2 Welding of MS Pipe using Arc/MIG 49

3 LPT inspection of welded plate 50

4 MPT inspection of welded plate 51

5 MPT inspection of welded pipe 52

6 UT inspection of welded plate 53

6 Prepared by: G Sundar raju, E Sakthivel Murugan, C Veera Ajay, S Janardhan

Introduction of welding & Allied process

7 Prepared by: G Sundar raju, E Sakthivel Murugan, C Veera Ajay, S Janardhan

Figure: Welding Terminology

8 Prepared by: G Sundar raju, E Sakthivel Murugan, C Veera Ajay, S Janardhan

Figure: Basic weld joints

Butt joint Edge preparation for joining process

Single-Vee Butt Weld

Double-Vee Butt Weld

9 Prepared by: G Sundar raju, E Sakthivel Murugan, C Veera Ajay, S Janardhan

 Forehand Welding Technique

10 Prepared by: G Sundar raju, E Sakthivel Murugan, C Veera Ajay, S Janardhan

Electric arc welding

12 Prepared by: G Sundar raju, E Sakthivel Murugan, C Veera Ajay, S Janardhan

(i) Straight or positive polarity.

(ii) Reverse or negative polarity.

(i) Straight or positive polarity

(ii) Reverse or negative polarity.

Arc Welding Electrodes