Anand International College of Engineering Department of Mechanical Engineering

WELDING SHOP

INTRODUCTION
Welding is the process of joining similar metals by the application of heat, with or
without application of pressure or filler metal, in such a way that the joint is equivalent in
composition andcharacteristics of the metals joined. In the beginning, welding was mainly used
for repairing all kinds ofworn or damaged parts. Now, it is extensively used in manufacturing
industry, construction industry(construction of ships, tanks, locomotives and automobiles) and
maintenance work, replacing rivetingand bolting, to a greater extent.
The various welding processes are:
1. Electric arc welding,
2. Gas welding
3. Thermal welding
4. Electrical Resistance welding and
5. Friction welding
However, only electric arc welding process is discussed in the subject point of view.

Electric arc welding

Arc welding is the welding process, in which heat is generated by an electric arc struck between
an electrode and the work piece. Electric arc is luminous electrical discharge between two
electrodes
through ionized gas.

Any arc welding method is based on an electric circuit consisting of the following parts:
a. Power supply (AC or DC);
b. Welding electrode;
c. Work piece;
d. Welding leads (electric cables) connecting the electrode and work piece to the power supply.
Anand International College of Engineering Department of Mechanical Engineering

Fig:1 Arc welding set up

Fig :2 parts of an electrode

Anand International College of Engineering Department of Mechanical Engineering
Electric arc between the electrode and work piece closes the electric circuit. The arc
temperature may reach 10000°F (5500°C), which is sufficient for fusion the work piece edges
and joining them. When a long joint is required the arc is moved along the joint line. The front
edge of the weld pool melts the welded surfaces when the rear edge of the weld pool solidifies
forming the joint.
Transformers, motor generators and rectifiers’ sets are used as arc welding machines.
These machines supply high electric currents at low voltage and an electrode is used to produce
the necessary arc. The electrode serves as the filler rod and the arc melts the surface so that, the
metals to be joined are actually fixed together.
Sizes of welding machines are rated according to their approximate amperage capacity at
60% duty cycle, such as 150,200,250,300,400,500 and 600 amperes. This amperage is the rated
current output at the working terminal.
Transformers
The transformers type of welding machine produces A.C current and is considered to be theleast
expensive. It takes power directly from power supply line and transforms it to the voltage
required for welding. Transformers are available in single phase and three phases in the market.
Motor generators
These are D.C generators sets, in which electric motor and alternator are mounted on the same
shaft to produce D.C power as pert the requirement for welding. These are designed to produce
D.C current in either straight or reversed polarity. The polarity selected for welding depends
upon the kind of electrode used and the material to be welded.
Rectifiers
These are essentially transformers, containing an electrical device which changes A.C into D.C
by virtue of which the operator can use both types of power (A.C or D.C, but only one at a
time).In addition to the welding machine, certain accessories are needed for carrying out the
welding work.
Welding cables
Two welding cables are required, one from machine to the electrode holder and the other,
from the machine to the ground clamp. Flexible cables are usually preferred because of the case
of usingand coiling the cables. Cables are specified by their current carrying capacity, say 300 A,
400 A, etc.
Anand International College of Engineering Department of Mechanical Engineering
Electrodes
Filler rods are used in arc welding are called electrodes. These are made of metallic wire called
core wire, having approximately the same composition as the metal to be welded. These are
coated uniformly with a protective coating called flux. While fluxing an electrode; about 20mm
of length is left at one end for holding it with the electrode holder. It helps in transmitting full
current from electrode holder to the front end of the electrode coating. Flux acts as an insulator
of electricity. In general, electrodes are classified into five main groups; mild steel, carbon steel,
special alloy steel, cast iron and non‐ferrous. The greatest range of arc welding is done with
electrodes in the mild steel group. Various constituents like titanium oxide, potassium oxide,
cellulose, iron or manganese, Ferro silicates, carbonates, gums, clays, asbestos, etc., are used as
coatings on electrodes. While welding, the coating or flux vaporizes and provides a gaseous
shield to prevent atmospheric attack. The size of electrode is measured and designated by the
diameter of the core wire in SWG andlength, apart from the brand and code names; indicating
the purpose for which there are most suitable
Electrodes may be classified on the basis of thickness of the coated flux. As
1. Dust coated or light coated
2. Semi or medium coated and
3. Heavily coated or shielded
Electrodes are also classified on the basis of materials, as
1. Metallic and
2. Non‐metallic or carbon
Metallic arc electrodes are further sub‐divided into
1. Ferrous metal arc electrode (mild steel, low/medium/high carbon steel, cast iron, stainless
steel, etc )
2. Non‐ferrous metal arc electrodes (copper, brass, bronze, aluminum, etc).
In case of non‐metallic arc electrodes, mainly carbon and graphite are used to make the
electrodes.
Anand International College of Engineering Department of Mechanical Engineering

Fig :3 Electrode holder Fig :4 Ground Clamp

Fig :5Wire brush Fig :6Chipping hammer

Fig :7Hand gloves Fig :8Face shield

Fig :9Weld positions

Anand International College of Engineering Department of Mechanical Engineering
WELDING TOOLS
Electrode holder
The electrode holder is connected to the end of the welding cable and holds the electrode.
Itshould be light, strong and easy to handle and should not become hot while in operation. Figure
shows one type of electrode holder. The jaws of the holder are insulated, offering protection
from electric shock.
Ground clamp
It is connected to the end of the ground cable and is clamped to the work or welding table to
complete the electric circuit. It should be strong and durable and give a low resistance
connection.
Wire brush and chipping hammer
A wire brush is used for cleaning and preparing the work for welding. A chipping hammer is
used for removing slag formation on welds. One end of the head is sharpened like a cold chisel
and the other, to a blunt, round point. It is generally made of tool steel. Molten metal dispersed
around the welding heads, in the form of small drops, is known as spatter. When a flux coated
electrode is used in welding process, then a layer of flux material is formed over the welding
bead which contains the impurities of weld material. This layer is known as slag. Removing the
spatter and slag formed on and around the welding beads on the metal surface is known as
chipping.
Welding table and cabin
It is made of steel plate and pipes. It is used for positioning the parts to be welded properly.
Welding cabin is made‐up by any suitable thermal resistance material, which can isolate the
surrounding by the heat and light emitted during the welding process. A suitable draught should
also be provided for exhausting the gas produced during welding.
Face shield
A face shield is used to protect the eyes and face from the rays of the arc and from spatter or
flying particles of hot metal. It is available either in hand or helmet type. The hand type is
convenient to use wherever the work can be done with one hand. The helmet type though not
comfortable to wear, leaves both hands free for the work.
Shields are made of light weight non‐reflecting fiber and fitted with dark glasses to filter out the
Harmful rays of the arc. In some designs, a cover glass is fitted in front of the dark lens to protect
it from spatter.
Hand gloves
These are used to protect the hands from electric shocks and hot spatters

TECHNIQUES OF WELDING
Preparation of work
Before welding, the work pieces must be thoroughly cleaned of rust, scale and other foreign
material. The piece for metal generally welded without beveling the edges, however, thick work
pieceshould be beveled or veed out to ensure adequate penetration and fusion of all parts of the
weld. But, in either case, the parts to be welded must be separated slightly to allow better
Anand International College of Engineering Department of Mechanical Engineering
penetration of the weld. Before commencing the welding process, the following must be
considered
a) Ensure that the welding cables are connected to proper power source.
b) Set the electrode, as per the thickness of the plate to be welded.
c) Set the welding current, as per the size of the electrode to be used.

WELDING POSITIONS
Depending upon the location of the welding joints, appropriate position of the electrode and
hand movement is selected. The figure shows different welding positions.
Flat position welding
In this position, the welding is performed from the upper side of the joint, and the face of the
weld is approximately horizontal. Flat welding is the preferred term; however, the same position
is sometimes called down hand.
Horizontal position welding
In this position, welding is performed on the upper side of an approximately horizontal surface
and against an approximately vertical surface.
Vertical position welding
In this position, the axis of the weld is approximately vertical as shown in figure.
Overhead position welding
In this welding position, the welding is performed from the underside of a joint
Anand International College of Engineering Department of Mechanical Engineering
WELDING

Lap joint

EXPERIMENT No: DATE:

Aim
To make a double lap joint, using the given mild steel pieces and by arc welding.

Material used: Two mild steelpieces of 100X40X6 mm.

Tools and equipment used
1. Arc welding machine,
2. Mild steel electrodes,
3. Electrode holder,
4. Ground clamp,
5. flat nose Tong,
6. Face shield,
7. Apron,
8. Hand gloves,
9. Metallic work Table,
10. Bench vice,
11. Rough flat file,
12. Try square,
13. Steel rule,
14. Wire brush,
15. Ball peen hammer,
16. Chipping hammer.
Operations to be carried out
1. Cleaning the work pieces
2. Tack welding
3. Full welding
4. Cooling
5. Chipping
6. Finishing
Anand International College of Engineering Department of Mechanical Engineering

Fig: lap joint

Anand International College of Engineering Department of Mechanical Engineering
Procedure
1. Take the two mild steel pieces of given dimensions and clean the surfaces thoroughly from
rust, dust particles, oil and grease.
2. Remove the sharp corners and burrs by filing or grinding and prepare the work pieces.
3. The work pieces are positioned on the welding table, to form a lap joint with the required over
lapping.
4. The electrode is fitted in to the electrode holder and the welding current is set to a proper
value.
5. The ground clamp is fastened to the welding table.
6. Wearing the apron, hand gloves, using the face shield and holding the over lapped pieces the
arc is struck and the work pieces are tack‐welded at the ends of both the sides
7. The alignment of the lap joint is checked and the tack‐welded pieces are reset, if required.
8. Welding is then carried out throughout the length of the lap joint, on both the sides.
9. Remove the slag, spatters and clean the joint.

Precautions:
1. Use goggles, gloves in order to protect the human body.
2. Maintain the constant arc length.
Result The lap joint is thus made, using the tools and equipment as mentioned above.
Anand International College of Engineering Department of Mechanical Engineering
WELDING

BUTT JOINT

EXPERIMENT No: DATE:

Aim: preparation of butt joint as shown in figure using shielded metal arc welding process.

Material required: 2m.s flat pieces of given size.

Tools required:
1. welding transformer,
2. connecting cables,
3. electrode holder,
4. ground clamp,
5. electrodes,
6. hipping hammer,
7. Welding shield etc.
Anand International College of Engineering Department of Mechanical Engineering

V – butt joint
Anand International College of Engineering Department of Mechanical Engineering
Procedure:
1. The given metallic pieces filled to the desired size.
2. On both pieces beveled in order to have V groove.
3. The metallic pieces are thoroughly cleaned from rust grease, oil, etc.
4. The metallic pieces are connected to terminals of Trans former.
5. Select electrode dia based on thickness of work piece and hold it on the electrode holder.
Select suitable range of current for selected dia.
6. Switch on the power supply and initiates the arc by either striking arc method or touch and
drag method.
7. Take welding to be done before full welding.
8. In full welding process after completion one part before going to second part. Slag is removed
from the weld bed. With the metal wire brush or chipping hammer.
9. Then the above process will be repeated until to fill the groove with weld bed or weld
metal.Precautions:
1. Use goggles, gloves in order to protect the human body.
2. Maintain the constant arc length.
Result: butt joint is prepared as shown in figure by using arc-welding process.