REPORT

ARC WELDING

NAME
CLASS
ID

INTRODUCTION:

There are two method of welding aircraft structures and components are nonfusion and fusion. Fusion welding is the bending of compatible molten metals
into one common part or joint. Fusing of metals is accomplished by producing
sufficient heat of metals to melt, flow together and mix, on fusion welding is
joined of metals by adhesion of one metal to another. The process are brazing
and soldering.

PURPOSE:
To teach student about safety in the workshop
To introduce students about metal arc welding
To give the experience to the students

EQUIPMENT:

WELDING MACHINE:
Device that provides an electric current to perform welding. Welding usually
requires high current (over 80 amperes) and it can need above 12,000 amperes
in spot welding. Low current can also be used; welding two razor blades together
at 5 amps with gas tungsten arc welding is a good example. Therefore arc
welding, is the fusion by heat from and electric between the work and electrode.
Two types of welding machine.
CABLE:

Welding Cables are mainly defined as pair of electrical cables that supplies power
to various welding machine and functions towards the materials being welded.
Has two cables that bring electricity form welding machine to work metal and
back to welding machine and earth cable. These cables are made from small
copper wire coated with strong rubber so that you can hold it. Every cable has it
own size. Size No. 2 means that the cable will be able to withstand welding
electricity up to 200 amps.

ELCTRODE HOLDER:

Used to electricity from welding machine to work metal. It is also used to hold
the electrode during the welding process. The electrode holder connects to the
welding cable and con- ducts the welding current to the electrode. The insulated
handle is used to guide the electrode over the weld joint and feed the electrode
over the weld joint and feed the electrode into the weld puddle as it is
consumed. Electrode holders are available in different sizes and are rated on
their current carrying capacity.

EARTH HOLDER:

It is connected to the earth cable and clipped to the work metal or to work table.
It has a spring so that is can be easily clipped and unclipped. Without this
equipment, welding work will certainly cannot be done

SHIELD:

Made from fire proof material. In the middle of the shield there is a bright glass
coated with dark colour glass. Function from fire-bolt and harmful rays. There are
two types of shield, one is the helmet type and the other one is the hand held
type. It has the size of No. 10 and No. 11.

CHIPPING HAMMER:

Made from an old punch, chisel or spring metal. Shape like a chisel at one end
and has a sharpened end at the other one. Its holder is made from welded soft
metal. It is used commonly to break off slag excess stringer from the surface of
the work metal.

WIRE BRUSH:

To clean the surface of the stringer bead after the slag is chipped away and to
remove dirt from the surface of work metal before welding can be done.

GLOVE:

Use to protect your hand from fire-bolt and hot metal welding. Made from high
quality leather

TONGS:

Use to hold hot work metal after welding process.

PROCEDURE:

I.
II.
III.

IV.
V.

Connect the electrode cable and the earth cable to the Direct Current
Welding Machine
Clip the earth cable using its holder to the working table.
Put an electrode onto the holder. Make sure that the flux is not in contact
with the holder

Set the dial to 90 amps and turn on the machine.

Before you start welding, put on your gloves and shield.

SHIELD

GLOVE

VI.
VII.

VIII.

IX.
X.
XI.
XII.
XIII.

XIV.

Take a piece of scrap metal and put it on the working table.

Hole the electrode 90o above the scrap metal. Tilt the electrode 20o-25o
degrees to the right or left depending on which hand do you use from the
work metal.
Scratch the front end of the electrode onto the work metal to start the
burning after the electrode has started burning, hold it at 10mm above the
work metal. Do
Not touch the metal during the welding process because the electrode
might be stuck onto it.
Repeat the welding process for several times until you get a straight and
firm stringer bead line when you weld onto the work metal.
Get a cubic-shape metal block from your instructor.
Weld onto one side of the block to increase its thickness.
You must weld onto the block line by line. When you finish welding a line,
use chipping hammer to chipped off the slag and brush it off using a wire
brush.
Stop when you have finished welding the side in three layers.

SAFETY PRECAUTIONS:
a) Always protect your eyes from arc rays.
b) Protect your face and body from heat radiation and molten
metal.
c) Make sure that your working place is clean and tidy.
d) Move all the flammable material off the working place or cover
it up using fireproof material.
e) Make sure that all electric connection is tight, clean and dry.
f) Make sure that all line holder, earth clip and connection placed
on good place.
g) Do not ever scratch arc on top of gas cylinder.
h) Avoid welding cable from be in contact with hot metal, water,
oil and grease.
i) Avoid pulling the cable on top or near sharp things.
j) Turn off the welding machine when not in use.
k) Wear all safety clothing when welding.
l) All equipment such as hammer, chisel, brush and others must
be well taken care of.
m) A welder should not try to install or repair a welding machine.
n) Make sure that the welding machine is earthen.

CONCLUSION:
The end of this experiment, we get to know how to do an arc welding and
how the process is occur. Besides that, there are also a few tips on
handling and welding that we have learn. We also can improve our skills in
welding.

REPORT
GAS WELDING

OBJECTIVE:
i) How to use 3 type of flame (carburizing, neutral, and oxidizing)
ii) Type of the torch that are used
iii) Thickness of the metal that involved in joining and neutral process

EQUIPMENT AND APPARATUS:

Oxygen and acetylene gas cylinder
Pressure of regulator to adjust
Gas hose to channel the gas from the cylinder to the torch
Spinder key to lock or unlock the cylinder valve
Spark light to ignite the torch

 Google
Glove

PROCEDURE:
1.) Setup the acetylene cylinder and oxygen cylinder using spinder key.
2.) Setup the regulator to control pressure from the tanks to the required pressure in the hose.
3.) Setup the torch to produce the flame starting from acetylene valve and hang to the oxygen valve
with ratio (1:1).
4.) Weld the metal with same properties rod to start joining method

Oxygen

Acetylene

RESULT:

CONCLUSION:
1. The problem that occurs on the metal in neutral weld process.
2. How to weld with correctly.
3. Three type of different flame.
4. How to start or setup the regulator valve with correctly

REPORT
GAS CUTTING

SAFETY PRECAUTIONS:
Safety is very important. Carelessness can cause accidents, so it is necessary
that at all times great care must be taken to act and work safely to prevent
harming yourself and others. You must familiarise yourselves with all safety
rules and obey and apply them.

PROTECTIVE CLOTHING:
All parts of your body must be covered when welding.
You must wear:
Overall that fasten up to the neck with long sleeves and legs that fit
properly.
Leather gloves.
Safety shoes or boots.
Dark welding glasses when using oxy-acetylene equipment.

OPENING AND CLOSING PROCEDURE GAS CUTTING

EQUIPMENT

Remove the protective cap on up right cylinder.

Instantly open cylinder valves to blow any foreign matter and wipe clean after
close.
Connect pressure regulators and tighten enough to prevent leakage.
Connect the red/maroon hose to acetylene pressure regulator and the green/black
hose to oxygen pressure regulator.
Caution: Do not force or over tighten. May damage the thread which made of
brass.

oxygen
acetylene

Open
cylinder valves to check the contents in each
cylinder while pressure regulator adjusting screw in off position. Fully open for oxygen and
to turn for acetylene.
Blows out the hoses to the torch and leak check with 20 psi shows on the oxygen working
pressure gage and 5 PSI on the acetylene pressure gage.

 Hold away the torch and open the acetylene valve about 1/6 turn and light the torch, adjust
the valve until the smoke clear and the flame yellowish color.
Open oxygen valve until bluish white, bright inner cone surrounded by outer flame
(envelope).
Heat obtain from a proper amount is 56000F

FLAME ADJUSTMENT :
1. Neutral flame

Oxygen /acetylene burn together with same volume supply

Outer cone cover the intermediate cone with rounded inner cone.

2. Oxidizing flame

Excess flame

Two cones with sharps- pointed inner cone

3. Reducing / carburizing flame

Excess acetylene.

Outer cone (envelope), intermediate (feather), inner cone.

SAFETY PRECAUTIONS WHEN USING OXY-ACETYLENE

EQUIPMENT
Keep oil and grease away from oxygen fittings.
Inspect oxygen and acetylene hoses periodically to see that it is free from cuts, cracks,
burnt or worn places.
Do not test for leaks on oxygen or acetylene fittings with a naked light or flame.
Escaping acetylene can be detected by its peculiar smell, or soapy water should be applied
with a brush to connections to test for leaks.
Do not cut or weld on tanks or other vessels, which may have contained petrol, oils, spirits,
paint or any inflammable or explosive material.
Remember sparks that are caused by welding, and particularly from oxy-acetylene cutting,
can travel a considerable distance. Such work should be carried out in a safe manner to
prevent all risk of causing fires.
When flame cutting or welding painted or galvanised plates etc., wear an approved
respirator.

Colour coding:
Hoses and accessories are colour coded as follows...

Oxygen: BLUE
Acetylene: RED

SHUTTING DOWN THE EQUIPMENT:

Close the acetylene and oxygen needle valve on torch.
Close the acetylene and oxygen cylinder valve.
Open the acetylene valve on the torch to drain the acetylene hose and regulator. This
removes pressure on the regulators working pressure gauges
Turn the acetylene-regulator adjusting screw to the left to relieve pressure on the
diaphragm and close the torch acetylene valve.
Do the same step to the oxygen torch, hose regulator and cylinder.
Hang up the torch and hose properly to prevent hose and torch damage.