Guided By Principal

Mr. B.L. Bagri Mrs. Kamla Agrawal

(H.O.D. of ME Dept.) (G.P.C. Satna M.P.)
Department of MECHANICAL

STUDENT’S OF FINAL YEAR

DIPLOMA IN MECHANICAL ENGINEERING

Completed there project report entiled ``RECYCLE ARC

WELDING MACHINE’’ Under our Guidance and Supervision
During the Session 2019-2022.
The project report is approved for submission towards
partial fulfillment of DIPLOMA in MECHANICAL
ENGINEERING Branch Rajiv Gandhi Proudyogiki
Vishavidalaya, Bhopal it is further certified that this work has
not been submitted elsewhere for the award of any other
certificate.

Guided By Principal
Mr. B.L. Bagri Mrs. Kamla Agrawal
(H.O.D. of ME Dept.) (G.P.C. Satna M.P.)
This is to Certify That the Project entiled as ``RECYCLE ARC
WELDING MACHINE’’
Which has been completed we submitted by
Rajdeep Nigam, Sumit Mishra ,Devansh Mishra ,Mayank
Dwivedi ,Abhay singhtiwari, Shivank urmaliya, Uddeshy
Singh Baghel
partial fulfillment of the requirement for the award of the
diploma of polytechnic engineering of MECHANICAL for the
session 2019-2022

(External Examiner) (Internal Examinar)

 ACKNOWLEDGEMENT

We Express our deep sense of gratitude of our respected and

learned Guide Mr. B.L. Bagri and Mr.Satyendra Suryavanshi
sir for their valuable help and guidance. We are thankful to
them for the encouragement they have gives us in
completing the project.
We are also grateful to respected professor
Deparment of And to our respected
Principal of
. for permiting ue to utilze all the necessary
faciities of the institution.
We are also thankful to all the other faculty and staff
members of our Department for their kind co-operation and
help.
Lastly, we would love to express our deep appreciation
towards our classmates and our indebtedness to our parents
for providing us the moral support and encouragement

Devansh Mishra Sumit Mishra

Rajdeep Nigam Mayank Dwivedi
Shivank urmaliya Abhay singhtiwari
Uddeshy Singh Baghel
This is report entailed " RECYCLE ARC WELDING MACHINE’’
submitted in partial fulfillment of DIPLOMA IN MECHANICAL
ENGINEERING during year 201-22 is an authentic record of
our project work. This is our original work and was not
submitted earilier for award of any other degree, diploma or
certificate.

PROJECT TEAM
Devansh Mishra-19047M02020
Rajdeep Nigam-19047M02046
Sumit Mishra-19047M02063
Mayank Dwivedi-19047M02035
Abhay singhtiwari-19047M02001
Shivank urmaliya-19047M02062
Uddeshy Singh Baghel- 19047M2066
Rajdeep Nigam Devansh Mishra Abhay Singhtiwari Sumit Mishra

Mayank Dwivedi Shivank Urmaliya Uddeshy Singh Baghel

 ABSTRACT

Arc-welding is the most commonly and widely used welding technique for
variety of purposes. Welded joint may not be very reliable unless the weld is of
reasonably good quality. Improving the weld quality is of prime concern. This
project work is intended to investigate the effect of magnetic field on the
structure and properties of weld in shielded metal arc welding. The objective is
to study the effect of welding parameters and to use magnetic field
advantageously to improve the weld qualities and properties (such as strength
and hardness). However there is lack of information for optimum parameters,
very little work has been reported in this direction. A magnetic field externally
applied to the welding arc, deflects the arc by electromagnetic force in the plane
normal to the field lines. The magnetic field exerts force on the electrons and
ions within the arc, which causes the arc to be deflected away from the normal
arc path. The welding arc can be deflected forward, backward, or sideways with
respect to electrode and welding direction depending upon the direction of an
external magnetic field

In this project work various mechanical properties tests as tensile strength,

harness, toughness etc. are conducted to see the effect of external magnetic field
on it. A set of weld-pieces( with magnetic field and without magnetic field) are
tested for various mechanical properties and comparable study is done to know
the change in these properties.
Project picture and components
Electric Current for Welding:

Both D.C. (direct current) and A.C. (alternating current) are used to produce an
arc in electric arc welding. Both have their own advantages and applications.

The D.C. welding machine obtains their power from an A.C. motor or
diesel/petrol generator or from a solid state rectifier.

The capacities of D.C. machine are:

Current:

Up to 600 amperes.

Open Circuit Voltage:

50 to 90 volts, (to produce arc).

Closed Circuit Voltage:

18 to 25 volts, (to maintain arc).

The A.C. welding machine has a step down transformer which receives current
from main A.C. supply. This transformer step down the voltage from 220 V-
440V to normal open circuit voltage of 80 to 100 volts. The current range
available up to 400 amperes in the steps of 50 ampere.

The capacities of A.C. welding machine are:

Current Range:

Up to 400 ampere in steps of 50 ampere.

Input Voltage:

220V- 440V

Actual Required Voltage:

80 – 100 volts.

Frequency:

50/60 HZ.

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.

Equipments Required for Electric Arc Welding:

The various equipments required for electric arc welding are:

1. Welding Machine:

The welding machine used can be A.C. or D.C. welding machine. The A.C. welding machine
has a step-down transformer to reduce the input voltage of 220- 440V to 80-100V. The D.C.
welding machine consists of an A.C. motor-generator set or diesel/petrol engine-generator set
or a transformer-rectifier welding set.

A.C. machine usually works with 50 hertz or 60 hertz power supply. The efficiency of A.C.
welding transformer varies from 80% to 85%. The energy consumed per Kg. of deposited
metal is 3 to 4 kWh for A.C. welding while 6 to 10 kWh for D.C. welding. A.C. welding
machine usually work with low power factor of 0.3 to 0.4, while motor in D.C. welding has a
power factor of 0.6 to 0.7. The following table 7.9 shows the voltage and current used for
welding machine.

2. Electrode Holders:

The function of electrode holder is to hold the electrode at desired angle. These are available
in different sizes, according to the ampere rating from 50 to 500 amperes.
3. Cables or Leads:

The function of cables or leads is to carry the current from machine to the work. These are
flexible and made of copper or aluminum. The cables are made of 900 to 2000 very fine wires
twisted together so as to provide flexibility and greater strength.

The wires are insulated by a rubber covering, a reinforced fibre covering and further with a
heavy rubber coating.

4. Cable Connectors and Lugs:

The functions of cable connectors are to make a connection between machine switches and
welding electrode holder. Mechanical type connectors are used; as they can he assembled and
removed very easily. Connectors are designed according to the current capacity of the cables
used.

5. Chipping Hammer:

The function of chipping hammer is to remove the slag after the weld metal has solidified. It
has chisel shape and is pointed at one end.

6. Wire Brush, Power Wire Wheel:

The function of wire brush is to remove the slag particles after chipping by chipping hammer.
Sometimes, if available a power wire wheel is used in place manual wire brush.

7. Protective Clothing:

The functions of protective clothings used are to protect the hands and clothes of the welder
from the heat, spark, ultraviolet and infrared rays. Protective clothing used are leather apron,
cap, leather hand gloves, leather sleeves, etc. The high ankle leather shoes must be wear by
the welder.

9. Screen or Face Shield:

The function of screen and face shield is to protect the eyes and face of the welder from the
harmful ultraviolet and infrared radiations produced during welding. The shielding may be
achieved from head helmet or hand helmet.
 TABLE OF CONTENTS

Chapter 1: Introduction

1.1 General
…………………………………………………………………………………….1
1.2 Shielded metal arc welding
(SMAW)……………………………………………………...2
1.3 Gas Tungsten Arc Welding
(GTAW)……………………………………………………...3
1.4 Gas Metal Arc Welding
(GMAW)………………………………………………………....4
1.5 Gas
Welding………………………………………………………………………………..5

Chapter 2: Review of Literature

2.1 Summary of shielded metal arc welding

…………………………………………………...6
2.2 AC/DC Power
Sources……………………………………………………………………..7
2.3 Electrode used in
SMAW…………………………………………………………………...9
2.4 Welding
process…………………………………………………………………………...10
2.5 Objective
…………………………………………………………………………………..13

Chapter 3: Weld quality and weld geometry

Chapter 4: Welding with the set-up

Chapter 5: Weld tests

Chapter 6: conclusion and suggestions for further work

 INTRODUCTION

1.1 General

Welding is a process in which materials of the same fundamental type or

class are brought together and caused to join (and become one) through the
formation of primary chemical bonds under the combined action of heat and
pressure . The definition found in IS0 standard is “Welding is an operation
in which continuity is obtained between parts for assembly, by various
means”. Hence, the welding is the fusion of two or more pieces of metal
together by using the heat produced from an electric arc welding machine.
Arc welding dates back to the late 1800’s, when a man was welding with a
bare metal rod on iron, the sparks from the welding caught a stack of
newspapers on fire near him and while welding, he noticed that his welds
started looking a lot better. The reason for this was the smoke took the
oxygen out of its welding environment and decreased porosity. The arc is
struck between the electrode and the metal. It then heats the metal to a
melting point. The electrode is then removed, breaking the arc between the
electrode and the metal. This allows the molten metal to “freeze” or solidify.
The arc is like a flame of intense heat that is generated as the electrical
current passes through a highly resistant air gap.

Types of arc Welding processes: -

• SMAW (Shielded Metal Arc Welding)

• GMAW (Gas Metal Arc Welding)

• GTAW (Gas Tungsten Arc Welding)

• 1.2 SMAW (Shielded metal arc welding):

• SMAW is the most common form of welding. An arc welding machine

supplies electric current to an electrode wire. The electric current travels
through the air gap between the end of the electrode wire and the base metal.
As the electric current flows through this air gap, an electric arc is formed.
The electric arc produces heat that heats the base metal to its melting
temperature. The heat from the base metal produces a shielding gas that
protects the base metal, arc, electrode, and weld from the atmosphere during
the welding process. As the flux covering on the electrode wire melts, a
shielding gas is created. When the flux cools, it solidifies and forms a
protective slag over the weld bead. As the electrode wire melts, it becomes
the filler metal to the weld.

Fig -1.1 Shielded metal arc

GTAW (Gas Tungsten Arc Welding):

Gas Tungsten Arc Welding (GTAW), also known as tungsten inert gas
(TIG) welding is a process that produces an electric arc maintained between
a non consumable tungsten electrode and the part to be welded. The heat-
affected zone, the molten metal and the tungsten electrode are all shielded
from atmospheric contamination by a blanket of inert gas fed through the
GTAW torch. Inert gas (usually Argon) is inactive or deficient in active
chemicalproperties.

Fig 1.2 -Gas Tungsten Arc Welding

 The shielding gas serves to blanket the weld and exclude the active
properties in the surrounding air. Inert gases such as Argon and Helium do
not chemically react or combine with other gases. They pose no odor and are
transparent,
Permitting the welder maximum visibility of the arc. In some instances
Hydrogen gas may be added to enhance travel speeds. The GTAW process
can produce temperatures of up to 35,000° F (19,426° C). The torch
contributes heat only to the work-piece. If filler metal is required to make
the weld, it may be added manually in the same manner as it is added in the
oxyacetylene welding process. GTAW is used to weld stainless steel, nickel
alloys such as Monel and in conel, titanium, aluminum, magnesium, copper,
brass, bronze and gold. GTAW can also weld dissimilar metals to one
another such as copper to brass and stainless to mild steel.

1.2 GMAW (Gas Metal Arc Welding):

Gas Metal Arc Welding (GMAW) is a welding process which joins metals
by heating the metals to their melting point with an electric arc. The arc is
between a continuous, consumable electrode wire and the metal being
welded. The arc is shielded from contaminants in the atmosphere by a
shielding gas.

Fig.1.3- Gas Metal Arc Welding

 REVIEW OF LITERATURE

2.1 Summary of Shielded Metal Arc Welding:

The process produces a protective slag that will need to be removed for
cleanliness and to prevent slag inclusions in multiple pass welds. The
process also produces spatter, which is a visual defect. However, the spatter
can be easily removed with a grinder.
There are several advantages to SMAW.
 Low Start Up Costs - SMAW welding machines are relativity inexpensive
 Portability - SMAW is a very portable process because it does not require
any external shielding gas and equipment due to the ability of the electrode
to produce its own shielding gases.
 Outdoor Weld ability - SMAW welding can be done outdoors. The
shielding of the weld puddle from the coating of the electrode is not
susceptible to winds and draft, and therefore, is an excellent choice for
outdoor welding.
 All Position Welding - SMAW can be done in all welding positions, which
eliminates the need for expensive fixture or manipulation of the part being
welded.
 Variety of Materials - Many base materials and alloys can be welded with
the SMAW process.

There are certain disadvantages of SMAW:

 Low Efficiency - The efficiency of a SMAW electrode can be defined as the

percentage of the electrode that is consumed and becomes part of the weld.
SMAW electrodes are 60%-65% efficient. The primary reason for this low
 efficiency is stub loss, or the portion of the electrode that is unused and
discarded. .
 Operating Factor - Operating factor can be defined as the amount of arc on
time in a shift of work, labeled as a percentage. SMAW welding has an
operating factor of approximately 25% - 30%--workday is spent arc welding.
 Restarts - SMAW electrodes are only 9”-18” in length. When the electrode
is consumed in the arc, it needs to be replaced with a new one. This means
that welding stops, and time is taken to replace each electrode.
 Operator Skill - SMAW welding requires a high level of operator skill. This
process is one of the hardest arc welding processes to learn.
 Slag & Spatter.

2.2 AC/DC power sources:

 AC (Alternating Current)-- Current direction alternates, between positive &
negative.
 DC (Direct Current) -- Current flows in one direction
a. DC Positive (STRAIGHT)
Electrode negative, work positive
b. DC Negative (REVERSE)
Electrode positive, work negative
 AC/DC Rectifiers

Fig.2.1- AC Power source

Fig.2.2 - DC Power source
2.3 Electrode used in SMAW:
The American Welding Society or AWS sets guidelines for SMAW electrodes
with which manufacturers have to comply. These guidelines include chemistry
and mechanical properties, and usability tests. Each letter and digit stands for
something very specific. The E stands for electrode. AWS defines an electrode
as the current carrying device, not necessarily the consumable that becomes the
weld-ment. In the case of SMAW, the electrode core is consumed as well as any
metallic elements in the coating to become the weld deposit. 70 stand for
minimum tensile strength in 10,000 psi. The weld deposit made by this SMAW
electrode must consistently meet a minimum tensile strength requirement of
70,000 pounds per square inch (psi). The next digit is either a 1 or a 2 and
indicates welding position. A “1” indicates that the electrode is an all position
electrode-- (flat, horizontal, vertical up, vertical down, and overhead). While the
2 stands for welds that can only be made in the flat/horizontal position. The 3rd
and 4th digit combined indicates the type of current the electrode operates on
and the type of coating.
 Fig.2.3- Designation of welding electrode
2.4 Welding process of SMAW :

Shielded metal arc welding (SMAW), also known as manual metal arc
(MMA) welding, flux shielded arc welding or informally as stick welding, is
a manual arc welding process that uses a consumable electrode coated with
flux to lay the weld. An electric current, in the form of either alternating
current or direct current from a welding power supply, is used to form an
electric arc between the electrode and the metals to be joined. As the weld is
laid, the flux coating of the electrode disintegrates, giving off vapors that
serve as a shielding gas and providing a layer of slag, both of which protect
the weld area from atmospheric contamination.
 Fig.2.4- Welding process with end view

2.5 Objective: -

The objective of this project work is to study effect of magnetic field on the
weld quality and geometry when the field is applied longitudinal to the
electrode travel i.e. the field lines are perpendicular to the electrode travel.
The material of the weld-piece taken is mild steel and the welding process is
shielded metal arc welding. The weld quality of the pieces will be checked
by conducting different weld test as hardness, tensile strength and impact
test. The tensile test will be conducted on the UTM and hardness test is on
hardness tester with steel ball penetrator. The impact test will be conducted
 on the impact testing machine. Charpy test will be conducted to check the
toughness of the weld-piece. The weld geometries will be checked through
the visual inspection and penetration depth, reinforcement height and weld
bead width will be considered.

Objective of the project work at a glance :-

 To study the effect of magnetic-field on weld-quality and weld geometry

when the field is applied-longitudinal to electrode.

 To compare the process of arc-welding with magnetic-field and without

magnetic-field.

WELD QUALITY AND WELD GEOMETRY

 Weld quality: -

To ensure the satisfactory performance of a welded structure, the quality of

the welds must be as per acceptance standards. The quality of the welds
must be determined by adequate testing procedures. These tests includes
measure of various defects occur in a weld. The acceptance standards are the
minimum weld quality which must be achieve for satisfactory performance
of welds.

Defects in weld-pieces-

The defects which occur in the weld-pieces due to the imperfect welding
conditions and their causes are as follows:
1. Undercutting:-

Undercutting is the burning away of the base metal at the toe of the weld.

Causes:
 Current adjustment that is too high.
 Arc gap that is too long.
 Failure to fill up the crater completely with weld metal.

2. Incomplete penetration:- This term is used to describe the failure of the filler

and base metal to fuse together at the root of the joint.

Causes:
 The rate of travel is too high.
 The welding current is too low

3. Lack of fusion:-

Lack of fusion is the failure of a welding process to fuse together layers of

weld metal or weld metal and base metal.

Causes:
 Failure to raise to the melting point the temperature of the base metal or the
previously deposited weld metal.
 Dirty plate surfaces.
 Improper electrode size or type.
 Wrong current adjustment.
4. Slag inclusion:-

Slag inclusions are elongated or globular pockets of metallic oxides and

other solid compounds. They produce porosity in the weld metal.
Causes: Failure to remove the slag between the layers causes slag
inclusions

5. Porosity:

Porosity is the presence of pockets which do not contain any solid material.
They differ from slag inclusions in that the pockets contain gas rather than a
solid.

Gases are derived from:

 Gas released by cooling weld
 Gases formed by the chemical reactions in the weld.

Fig.4.1- Welding defects

 WELDING WITH THE SET-UP

 Preparation of Specimens:

The mild steel pieces of the dimension 150 mm X 50 mm X 6 mm are used

as a work-piece for the welding. Each metal piece first cleaned for dust and
rust. Before the actual welding process the space between the specimens is
fixed with a support. The space between the specimens for the butt welding
is depends upon the thickness of the work-piece. For a 6 mm thickness there
is no requirement of making groove, so a 3 mm gap is maintained during the
whole process of welding. The quality and geometry of weld is much
depends on correct and same gap throughout length of the specimen.
 Grouping and cutting of weld-pieces:
 WELD TESTS

 Hardness test:

Hardness may be defined as the ability of a substance to resist indentation of

localized displacement. A hardness test is used to determine the hardness of
weld metal. In the Rockwell hardness test, the specimen is mounted on the
anvil of the machine and a load is applied against a hardened steel ball
which is in contact with the surface of the specimen being tested.

The load is allowed to remain 1/2 minute and is then released, and the depth
of the depression made by the ball on the specimen is measured. The
resultant Rockwell hardness number is obtained from the dial.

Rockwell hardness tester:

The principle of the Rockwell tester is essentially the same as the Brinell
tester. It differs from the Brinell tester in that a lesser load is impressed on a
smaller ball or cone shaped diamond. The depth of the indentation is
measured and indicated on a dial attached to the machine. The hardness is
expressed in arbitrary figures called "Rockwell numbers." These are prefixed
with a letter notation such as "B" or "C" to indicate the size of the ball used
the impressed load, and the scale used in the test.

 Tensile strength test:

This test is used to measure the tensile strength of a welded joint. The tensile
strength, which is defined as stress in kgf per square meter. It is calculated
by dividing the breaking load of the test piece by the original cross section
area of the specimen. The test result which is conducted on universal testing
machine ( UTM) is given in the table. The gripping and rupture points
located in the figures. This test is used to measure the strength of a welded joint.
A portion of the welded plate is locate the weld midway between the jaws of the testing
machine. The width thickness of the test specimen are measured before testing, and

the area in square inches is calculated by multiplying these before testing ,

and the area in square inches is calculated by multiplying these two figures.

Fig.7.2- Tensile Testing Process

The tensile test specimen is then mounted in a machine that will exert
enough pull on the piece to break the specimen. The testing machining may
be either a stationary or a portable type. A machine of the portable type,
operating on the hydraulic principle and capable of pulling as well as
bending test specimens.

The specimen is ruptured under tensile load, and the maximum load in
pounds is determined. The shearing strength of the weld in pounds per linear
inch is determined by dividing the maximum load by the length of fillet weld
that ruptured. The shearing strength in pounds per square inch is obtained by
dividing the shearing strength in pounds per linear inch by the average throat
dimension of the weld in inches. The test specimens are made wider than
required and machined down to size.

Fig 7.6 :FRACTURE OF TEST PIEC

7.3 Impact Test:

The two kinds of specimens used for impact testing are known
as Charpy and Izod. Both test pieces are broken in an impact testing
machine. The only difference is in the manner that they are anchored. The
Charpy piece is supported horizontally between two anvils and the
pendulum strikes opposite the notch. The Izod piece is supported as a
vertical cantilever beam and is struck on the free end projecting over the
holding vise

A Charpy test measures the welds ability to withstand an Impact force. Low
Charpy test readings indicate brittle weld metal Higher Charpy readings
indicate the samples toughness.

- Weld-pieces for Charpy test

 Spatter on weld metal:

It has appeared that the welding with magnetic field has less spattering
action on the weld metal than the without magnetic field. fig shows it below.

Fig .8.2

 Effect on weld properties:

The effect of magnetic field on the weld quality is checked through the
various tests for mechanical properties. The weld properties which we have
considered here are hardness, tensile strength and toughness. The specimens
for each welding test are prepared and the tests are conducted on them. Test
results for various mechanical properties are tabulated above.
 Tensile test:

The effect of magnetic field on the tensile strength is to increase it. The weld
test conducted on the pieces shows the increase of tensile strength. The
change in the properties is calculated in terms of percentage and there is an
increase of 6.6% on an average. This shows that a magnetic field applied
longitudinal to weld bead, deflected the arc such that the tensile properties of
the weld-pieces increases.

 Hardness test:

The hardness of the material and weld section both are checked and result is
found which shows the decrease in the hardness of weld metal. When we are
comparing the weld-pieces which are welded without magnetic field the
hardness is decreases. The hardness value of the materials are taken in terms of
RHN ( Rockwell hardness number ). When the RHN increases it shows the
increase in hardness of the material. All the hardness reading in our work is
taken at the B scale of the Rockwell hardness tester.

 Toughness:

Toughness test is used to check the ability of a weld to absorb energy under
impact without fracturing. This is a dynamic test in which a test specimen is
broken by a single blow, and the energy used in breaking the piece is measured
in foot-pounds. This test compares the toughness of the weld metal with the base
metal. It is useful in finding if any of the mechanical properties of the base metal
were destroyed by the welding process.
 CONCLUSIONS AND SUGGESTIONS

 Conclusions :

On the basis of different experiments, automation of welding process and

effect of magnetic field the following conclusions are derived:

1. The welding set-up on lathe provides automatic motion to the work-piece

and welder has to provide only the feed to electrode. This provides the
smoothness in welding process.
2. Effect of magnetic field applied transverse to welding direction affects the
bead width of joint and increases it.
3. Undercuts, spatter etc. welding defects are reduced.
4. The tensile strength of the weld joint is on improvement side due the
refinement of grains.
5. Hardness of the weld decreases as compared with the weld-pieces which are
welded without magnetic field.
6. Reinforcement height of weld reduces as the weld bead width is increasing.
7. Toughness of the weld metal increases.

Hence, we can say that the use of external magnetic field transverse to the
welding direction is helping in improvement of weld quality and weld
geometry. Here we can say that the transverse magnetic field can also affect
the weld quality .
 Suggestions For Further Work:

In this project we have constrained our work by testing the effect of

magnetic field in longitudinal direction only. Further this can be study for
 Magnetic field in transverse direction of weld bead
 Magnetic field applied axial to the electrode

Further the study can be extended by conducting the following mechanical

properties test

 Bend test
 Non destructive tests

In this project work the weld geometry tests are not conducted only the
visual inspection is done and the results based on that are considered.
Further the study can be extended by performing the macro structure study
of the weld metal. This can be done on polishing and grinding machines.
This could be result in perfect testing of weld bead width and penetration
depth.