COLEGIO DE SAN JUAN DE LETRAN

SCHOOL OF ENGINEERING

S.Y. 2020

ME001L- WORKSHOP THEORY AND PRACTICE

LABORATORY

RESEARCH WORK NO.2

AYSON, JONATHAN N. #2

1ME1

DATE SUBMITTED: MAY 6, 2020

ENGR. ROBERT MONTALES

INSTRUCTOR
1.What is welding?
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. Some
materials require the use of specific processes and techniques. A number are considered 'unweldable,' a
term not usually found in dictionaries but useful and descriptive in engineering. The parts that are joined
are known as a parent material. The material added to help form the join is called filler or consumable.
The form of these materials may see them referred to as parent plate or pipe, filler wire, consumable
electrode (for arc welding), etc. Consumables are usually chosen to be similar in composition to the
parent material, thus forming a homogenous weld, but there are occasions, such as when welding brittle
cast irons, when a filler with a very different composition and, therefore, properties is used. These welds
are called heterogeneous. The completed welded joint may be referred to as a weldment.

2.What is the working principle of welding?

Shielded metal arc welding (SMAW or stick welding), gas metal arc welding (more commonly
known as metal inert gas, or MIG, welding) and gas tungsten arc welding (frequently called tungsten
inert gas, or TIG, welding) all exemplify arc welding.

Arc welding uses an electrical arc to melt the work materials as well as filler material (sometimes
called the welding rod) for welding joints. Arc welding involves attaching a grounding wire to the
welding material or other metal surface. Another wire known as an electrode lead is placed on the
material to be welded. Once that lead is pulled away from the material, an electric arc is generated. It's
a little like the sparks you see when pulling jumper cables off a car battery. The arc then melts the work
pieces along with the filler material that helps to join the pieces.

Feeding the filler into the welding joint takes steady hands and an eye for detail. As the rod
melts, the welder must continuously feed the filler into the joint using small, steady, back-and-forth
motions. These motions are what gives welds their distinctive appearance. Going too fast or slow, or
holding the arc too close or far away from the material can create poor welds.
3.What are the different types of welding?

 TIG Welding

TIG welding also goes by the names of Heliarc and gas tungsten arc
welding (GTAW). With this type of welding, the electrode is non-consumable and made
of tungsten. It is one of the few types of welding that can be done with no filler metal,
using only the two metals being welded together. You can add a filler metal if you
desire, but you will have to feed it by hand. A gas tank is necessary with TIG welding to
provide the constant flow of gas needed to protect the weld. This means it’s generally
better performed indoors and away from the elements.

TIG welding is a precise form of welding that creates visually appealing welds
and doesn’t require cleanup, as there is no spatter. Due to these traits, it is a difficult
type of welding that is best reserved for experienced welders.

 Flux-Cored Arc Welding

This type of welding is similar to MIG welding. In fact, MIG welders can often
perform double duty as a FCAW welder as well. Just like in MIG welding, a wire that
serves as the electrode and the filler metal is fed through your wand. This is where
things begin to differ. For FCAW, the wire has a core of flux that creates a gas shield
around the weld. This eliminates the need for an external gas supply.

FCAW is better suited for thicker, heavier metals, since it is a high-heat welding
method. It’s often used for heavy equipment repairs for this reason. It is an efficient
process that doesn’t create much waste. Since there’s no need for external gas, it’s also
low cost. There will be a bit of slag left over, though, and it will need a bit of cleanup to
make a beautiful finished weld.

 Stick (Shielded-Metal Arc Welding)

This process of welding started in the 1930s but continues to be updated and
improved today. It has remained a popular form of welding because it is simple and easy
to learn, as well as low cost to operate. However, it doesn’t create the neatest welds,
since it splatters easily. Cleanup is usually necessary.
 A replaceable electrode “stick” also serves the role of filler metal. An arc is
created that connects from the end of the stick to the base metals, melting the
electrode into filler metal and creating the weld. The stick is coated in flux that creates a
gas cloud when heated up and protects the metal from oxidation. As it cools, the gas
settles on the metal and becomes slag.

Since it doesn’t require gas, this process can be used outdoors, even in adverse
weather such as rain and wind. It also works well on rusted, painted, and dirty surfaces,
making it great for equipment repairs. Different types of electrodes are available and
easy to swap, making it simple to weld metals of many different kinds, though it’s not
great for thin metals. Stick welding is a highly skilled process with a long learning curve.

 MIG Welding

MIG welding is a simple form of welding that can easily be performed by new
welders. MIG stands for metal inert gas, though it is sometimes called gas metal arc
welding (GMAW). It is a quick process that involves the filler metal being fed through
the wand, while gas is expelled around it to shield it from outside elements. This means
it’s not great for outdoor use. Still, it’s a versatile process and can be used to weld many
different types of metal at different thicknesses.

The filler metal is a consumable wire fed from a spool, and it acts as the
electrode as well. When the arc is created from the tip of the wire to the base metal, the
wire melts, becoming filler metal and creating the weld. The wire is continuously fed
through the wand, allowing you to dial in your preferred speed. Done correctly, MIG
welding produces a smooth and tight weld that is visually appealing.

 Laser Beam Welding

` This type of welding can be used on metals or thermoplastics. As the name

implies, it involves the use of a laser as a heat source to create the welds. It can be used
on carbon steels, stainless steel, HSLA steels, titanium, and aluminum. It is easily
automated with robotics and is therefore used often in manufacturing, such as in the
automotive industry.
 Electron-Beam Welding

This is a type of welding where a high-velocity beam of electrons creates heat

through kinetic energy, welding two materials together. This is a highly sophisticated
form of welding that is performed by machine, generally in a vacuum.

 Plasma Arc Welding

Plasma arc welding is similar to GTAW, but it uses a smaller arc, increasing the
precision of the weld. It also uses a different torch, achieving much higher
temperatures. Gas is pressurized inside the wand, creating plasma. The plasma is then
ionized, making it electrically conductive. This allows the arc to be created, producing
incredibly high temperatures that can melt the base metals. This allows plasma arc
welding to be performed with no filler metal, another similarity to TIG welding.

This type of welding allows deep weld penetration with narrow welds,
producing aesthetically pleasing welds, as well as a high level of strength. On top of this,
high welding speeds are also possible.

 Atomic Hydrogen Welding

Atomic hydrogen welding is an extremely high-heat form of welding that used

to be known as arc-atom welding. This type of welding involves using hydrogen gas to
shield two electrodes made of tungsten. It can reach temperatures above those of an
acetylene torch and can be performed with or without a filler metal. This is an older
form of welding that has been replaced by MIG welding in recent years.

 Electroslag

This is an advanced process of welding that is used to join the thin edge of two
metal plates together vertically. Instead of the weld being applied to the outside of a
joint, it will take place in between the edges of the two plates. A copper electrode wire
is fed through a consumable metal guide tube that will act as filler metal. When
electricity is introduced, the arc is created, and a weld begins at the bottom of the seam
and is slowly moved up, creating the weld in place of the seam as it goes. This is an
automated process and performed by machine.
4. What do you think is the most important welding process and why?

SMAW (Shielded Metal Arc Welding) also known as MMAW (Manual Metal Arc Welding) is
undoubtedly the best and most versatile arc welding process. Reasons for my choice are as follows:

It is the most commonly used process for almost 90% of welding applications all over the world.
Ordinary street corner fabricator as well as nuclear plant manufacturer, both happily use this process for
their jobs.

It is simplest and requires only basic equipment like a welding transformer or rectifier, an
electrode holder and coated electrode at low cost. The equipment is available in all towns. It can weld in
all positions and approach difficult to weld places due to extra length of the electrode.Almost all
weldable metals can be welded by this process.

5. What are the applications of welding?

 Oil and Gas

Welding is used for the joining of pipes, during the laying of crude oil and gas
pipelines, construction of tankers for their storage and transportation. Offshore
structures, dockyards, loading, and unloading cranes are also produced by welding.

 Nuclear Industry

Spheres for the nuclear reactor, pipeline bends, joining of pipes carrying heavy
water require welding for safe and reliable operations.

 Defense Industry

Tank body fabrication, joining of turret mounting to the main body of tanks are
typical examples of applications of welding in the defense industry.

 Electronic Industry

Electronic industry uses welding to a limited extent e.g. joining leads of special
transistors but other joining processes such as brazing and soldering are widely used.
Soldering is used for joining electronic components to printed circuit boards (PCBs).
Robotic soldering is very common for the joining of parts to printed circuit boards of
computers, television, communication equipment, and other control equipment, etc.
  Electrical Industry

Components of both hydro and steam power generation system, such as

penstocks, water control gates, condensers, electrical transmission towers, and
distribution system equipment are fabricated by welding. Turbine blades and cooling
fins are also joined by welding.

 Surface transport

Railway uses welding extensively for the fabrication of coaches and wagons,
repair of a wheel, laying of new railway tracks by mobile flash butt welding machines,
and repair of cracked/damaged tracks by thermite welding.
Production of automobile components like chassis, body and its structure, fuel tanks
and joining of door hinges require welding.

 Aerospace Industry

Aircraft and Spacecraft: Similar to ships, aircraft were produced by riveting in the early
days but with the introduction of jet engines welding is widely used for aircraft structure
and for joining of skin sheet to the body.
Space vehicles that have to encounter frictional heat as well as low temperatures
require outer skin and other parts of special materials. These materials are welded with
full success for achieving safety and reliability.

6.Are there applications of physics and chemistry in welding process? Why did you say so for Physics?
Why did you say so for Chemistry?

 Physics

When choosing your welder you will have to choose one of two polarity
settings. These are:

Straight Polarity (DC electrode negative)

Reverse Polarity (DC electrode positive) – used for MIG/GMAW Welding.

 The electricity flows from the power source, through the electrode and across
the arc, through the base material to the work lead and back to the power sourc

The importance of polarity related to the direction that the electrons are
flowing. For DC electrode positive (MIG) the electrons are flowing from the base metal
to the electrode. You will need to switch this over when doing flux cored welding.

The electron flow you just learned about is what creates the arc in arc welding.
This is a form of electrical energy. The arc created by the electric current is converted
into heat Thermal because of the resistance of electron flow. The heat melts the metal
to fuse it together.

 Chemistry

During the welding process the metal changes states or forms. Initially the metal
is a solid. When the arc starts the solid is converted into a liquid. Some of the liquid is
converted into a gas vapor. When the arc stops the liquid cools to form a solid again –
this is the newly formed weld joint.

During the welding process certain chemical reactions take place. Hydrogen,
Oxygen, and Nitrogen can react in the weld puddle and cause changes in the structure
of the weld weakening the weld.

7.Of the many safety precautions in welding, what would you consider as the top three most important?
Justify your answer

 Protect Eyes, Skin and Ears

It is one of the important safety precautions because it can cause burns, eye
damage, cuts, and crushed toes and fingers are ever-present when welding. With the
appropriate Personal Protective Equipment (PPE), you can protect your workers against
physical hazards. In order to avoid these hazards, we need to wear appropriate PPE like
welding helmet and goggles to protect workers’ eyes and head from hot slag, sparks,
intense light, and chemical burns.
 Fire and electricity resistant clothing, hand shields, welding gloves, aprons, and
boots can be worn to protect workers from heat, fires, electrocution, and burns. Take
note that flame retardant treatments become less effective with repeated laundering.
Pant legs must not have cuffs and must cover the tops of the boots. Cuffs can collect
sparks. Earmuffs and earplugs can also protect workers against noise.

 Protect against Fumes and Gases

It is important because Overexposure to welding fumes and gases can cause

severe health problems like respiratory illnesses, cancer, and impaired speech and
movement. Exposure to fumes and gases can be controlled by following these safety
precautions:

1. Provide adequate ventilation and local exhaust to keep fumes and gases from
the breathing zone and the general area.
2. Welding operators should always wear an approved respirator unless exposure
assessments are below applicable exposure limits.
3. Report concerns to a supervisor so your exposure to substances of the welding
fumes can be checked.
 Protect against Electric Shock

It is important because Electrocution is the most immediate and serious risk for
a welder. The sudden discharge of electricity to the human body can cause serious
injury and even death. However, electrocution risk from welding can be minimized by
following these basic precautions:

1. Inspect welding equipment and electrode holder before proceeding to work.

2. Perform lockout and tag out procedures when performing repairs. Only
qualified repair technicians should service or repair welding equipment.
3. Do not touch the metal parts of the electrode holder with skin or wet clothing.

8. As a mechanical engineering student, why is it important for you to learn about welding?

When we think about welding, we often don't realize how this industry impacts the world
around us. Welding is an essential component of many industries such as the automotive industry, the
construction industry, the aviation industry, and more. Without this form of metal work, so many things,
including many buildings, gates, small kitchen appliances, vehicles - and even space travel - would not
exist. It is important for me to learn about welding because welding is essential to industries. Without
welding, many designs of mechanical engineers would not be possible in reality. So I need to learn the
concept of welding because it is one of the essential thing to make a machine. Without welding, how
can we join two metals to form different products like our vehicles, machineries and many more. When I
learned about welding, it is not difficult for me to design our projects because I know how to turn it into
reality with the help of welding. In other words, it plays an important role in advancing and improving
our quality of life. Every industry depends on it.

9. Do you think you need the technical skills in welding in your life? Why?

Yes, because there are so many applications of welding in our life. It is not only applicable in the
industry but it can be useful also in our house and in daily life. From the kitchen appliances we use each
day, the buildings we live in, to the cars we drive. Most of what we use is welded or made with
equipment that has been welded. If I have the skills in welding, I can repair whatever is broken in our
house. I can also create different things that are useful in our life with the help of welding. The example
of it is making a simple table or chair and even other furnitures that are essential in the house.

10. What project would you do and why?

I will make a drawing table. It is simple but it is useful for me as an engineering student. There
are so many projects in the school that requires drawing so it will be useful for me as I can comfortably
make my drawings and with the drawing table, I can make use of all of my drawing materials. It is not
just for drawings, but I can also use this table for finishing my assignments and research works.

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