MAPUA UNIVERSITY
658 MURALLA ST., INTRAMUROS, MANILA 1002, PHILIPPINES
SCHOOL OF MECHANICAL AND MANUFACTURING ENGINEERING
ME137L-2
MECHANICAL PROCESSES II
TECHNICAL REPORT # 8
SHOP PRACTICE # 8
TITLE: Arc Welding
NAME: DATE PERFORMED:
Calizar, Daniel V. September 23, 2019
STUDENT NUMBER : DATE SUBMITTED:
2016141669 September 23, 2019
II - 05
TR SP
Grade
___________________________
ENGR. SUBLIME CARVAJAL
INSTRUCTOR
1
Table of Contents
Objectives 3
Introduction 4
Discussion 5
Conclusion 12
Recommendation 13
Reference 14
2
OBJECTIVES
1. To be able to conjoin two separate metals.
2. To be able to learn how an arc welding machine function.
3. To be able to learn how to weld two metals together.
4. To be able to be knowledgeable about the arc welding and
how it works to make two metals into one.
3
INTRODUCTION
Theory:
With the negative and positive electrode both connected to
the machine and the metal table accordingly, heat is made by the
arc welding machine and the electrode is able to melt the two
different metals. When the two metals are both melted, and when
the arc welding is then taken off from the two metals, the melted
metals will then be cooled off, and thus joining into one metal.
4
DISCUSSION
Welding is the process by which two pieces of metal can be
joined together. The process of welding doesn't merely bond the
two pieces together as in brazing and soldering, but, through the
use of extreme heat and sometimes the addition of other metals
or gases, causes the metallic structures of the two pieces to join
together and become one. There are a number of different welding
methods, including spot welding, metal inert gas (MIG), and
tungsten inert gas, which are forms of gas metal arc welding, arc
welding, and gas welding, to name a few. Welding can even be
done underwater.
A weld joint must be designed to withstand the forces to which
it is expected to be subjected to during its service life. This means
that the design of the joint is determined by the type and
magnitude of the load that is expected to act on the weld. Certain
types of welding joints are designed to withstand extreme shear
loads, while others are designed to withstand extreme torsional
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loads. Types of joints used for welding are butt, lap, corner, T, and
edge.
Welding Processes
The type of joint to be created and the type of material to be
used, among other considerations, will determine the type of
welding process that will be used to complete the project. All
welding processes can be broken down into the two following
categories:
Pressure welding is a process in which external pressure is
applied to produce welded joints either at temperatures below the
melting point, which is solid state welding, or at a temperature
above the melting point, which is fusion state welding. The atoms
are moved together to a distance that is equal to or less than the
equilibrium inter atomic separation distance. This type of welding
process requires the two pieces being joined to be extremely clean
and especially free of oxides and non metallic films which must be
removed from the surfaces of the metals by wire brush, so as to
ensure the strongest welded joint possible. Pressure welding
techniques are used primarily on metals that are highly ductile or
whose ductility increases with increasing temperatures.
Fusion welding produces welded joints by localized heating of
the edges of the base metals, above their melting temperature. A
filler metal may or may not be used, and no external pressure is
required. Inert gases may or may not be used to enhance the
quality of the weld created. The welded joint is achieved after
solidification of the fused weld pool. Metals to be joined must
possess some degree of mutual solubility in solid state. Metals that
are completely soluble in the solid state, exhibit the highest degree
of weld ability, and metals with no solubility in the solid state, are
not weld able, for which an intermediate soluble metal is used.
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Arc Welding
Arc welding is used in autobody construction, especially where
stress levels are considered to be high and confidence in a suitable
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resistance spot welded joint is low. Historically, most arc welding
is performed manually. However, productivity and the operating
environment (fumes, heat generation) can be an issue and
attention has turned to the use of robot-applied arc welding. Unlike
spot welding, where there is a degree of flexibility on spot weld
position on a sheet metal flange, in arc welding the weld has to be
placed along a joint between pieces of metal. However, in a
production BIW operation there are often part-fit issues due to
component tolerances, combining to form unfavorable minimum
and maximum values or part distortion. These can mean that
accurate fixing of large sheet-metal components is impractical by
a robotic arc-welding process. Nonetheless, recent applications are
now in production, with research having focused on methods of
accurate weld seam tracking.
Most applications of arc welding in the automotive industry
are metal inert gas welding (MIG) with a consumable wire
electrode. The arc is struck between the electrode and the
workpiece and is shrouded by a layer of inert gas. The main
advantages of the process are the good strength of the welded
joints and the need for access from only one side. However, these
benefits are offset by concerns over cycle times and, in the case of
aluminum, potential thermal distortion, shrinkage stresses and, in
some instances, the need for surface pretreatment. An alternative
for thin sheets (approximately < 1.0 mm) is tungsten inert gas
(TIG) welding. The arc welding of thin-walled aluminum extrusions
(in relation to aluminum spaceframe construction) has its own
unique problems.
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Arc welding produces large quantities of light, from the
ultraviolet (UV) to infrared radiation. UV radiation from a welding
arc is intense – for example a metal inert gas (MIG) weld using
helium gas running at 300 A typically produces 5Wm− 2 in the UVB
and UVC at a distance of one metre. This is many times the
intensity of the sun at noon. The visible radiation is also intense.
Oxyacetylene welding produces less UV light, but still produces
substantial quantities of visible and infrared radiation.
The lasers used in welding are typically carbon dioxide, at a
wavelength of 10.6 mm, Nd/YAG at 1.06 mm and excimer lasers
which operate in the UV region. The radiation from lasers is intense
and the beams have very small divergence, so that they travel long
distances with very little reduction in power density.
Procedure:
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1. The students first equipped themselves with the safety
materials that is provided, and the resources that are going
to be used is given.
2. The students then turned on the arc welding machine and first
tried to the table if it is able to melt the metals that are
already melted with it.
3. Then the students melted the two different metals together
to conjoin it into one metal.
Safety
All welders need to respect the job and the equipment being
used. The following is a list of safety equipment and precautions:
• Wear welding gloves
• Wear eye protection-For arc-type welding, a much darker lens is
required than for gas welding.
• Keep a suitable Class ABC fire extinguisher nearby while
welding.
• Keep the work area clean and free of flammables and
obstructions.
Safety Precautions:
• Always operate in an open well-ventilated area or vent the
engine exhaust directly outdoors.
• Never fuel the engine while running or in the presence of an
open flame.
• Wipe up spilled fuel immediately and wait for fumes to disperse
before starting the engine. *Never remove the radiator pressure
cap from liquid cooled engines while they are hot to prevent
scalding yourself.
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• Stop the engine before performing any maintenance or trouble
shooting. The ignition system should be disabled to prevent
accidental start of the engine.
• Keep all guards and shields in place.
• Keep hands, hair, and clothing away from moving parts.
Key points to remember:
• Be sure the welder is properly installed and grounded.
• Never weld without adequate ventilation.
• Take proper precautions to prevent fires.
• Protect your entire body with fire retardant clothing, shoes, and
gloves.
• Wear eye protection at all times.
• Weld only in a firesafe area.
• Never do any welding, cutting, or hot work on used drums,
barrels, tanks, or other containers.
• Mark metal "HOT" with a soapstone.
• Keep a well stocked first aid kit handy.
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CONCLUSION
The shop practice done by the students were successful. The
students were able to conjoin the two separate metals into one
using the arc welding. The students were also been able to be
knowledgeable and learn how an arc welding machine function. The
reason why on how the arc welding works on how it heats the
metals to be joined into one and other information were also
experienced by the students.
12
RECOMMENDATION
The students strictly recommend to not touch the metal where
the negative electrode is attached and also the two different metals
that were joined into one using the arc welding. Those current
metals after being used upon with the arc welding is surely to be
hot, and even with the proper equipment such as the glove, the
hand is possible to be burned. The students also recommend that
the other individuals that are going to do this shop practice should
be careful and be aware of the safety instructions before and after
doing the practice.
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REFERENCE
Aguilar, M. (2018, November 12). What is Welding? - Types of
Welding Processes. Retrieved from
[Link]
technology/30578-types-of-welding-processes/
Arc Welding Safety. (n.d.). Retrieved from
[Link]
Electric Arc Welding. (n.d.). Retrieved from
[Link]
welding
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