Student ______________________________

Laboratory work 1 Resistance spot welding

Technical data of the machine MT-1606
Materials to be welded and its thickness: ________________________________________
_________________________________________________________________________________
_______________________________________________________________________________
Maximum power of the machine is _______ kW, rated welding current is ________ kA.
The electric circuit of the machine -1606
PLSU ___________________________________________
TR _________________________________;
PB __________________________________;
HV _________________________________;
T1,T2 ________________________________;
FS __________________________________; WT - __________________________________;
The pneumatic system of the machine -1606
1 __________________________________;
2 __________________________________;
3 __________________________________;
4 __________________________________;
5 __________________________________;
6 __________________________________;
7 __________________________________;

The main parameters of the spot welding process are Iw - _____________________________,

tw - __________________________________, P - ______________________________________, de
- ______________________________________________________
The parameters of welded spot are:
d -____________________________________;
h - ____________________________________;
a - ____________________________________;
c - _______________________; - ________________________________________________.

Experiment number

Protocol of the samples testing

Material - ____________________________; Sheet thickness, S, mm - ______+______
Electrode contact spot diameter, mm -, dc, mm - ______
Pressure,
atm

Pressing
force, , kN

Power
Level

Welding
time, tw, sec

Distractive
force, Fd, kN

Nature of
destruction

1.
2.
3.
4.
5.
Strength diagram
, kN

t, sec
Conclusions:_______________________________________________________________________
_________________________________________________________________________________

Rating ___________
Student ______________________________

_____________________________________________________________________________
Instructors signature _______________

Laboratory work 2 Resistance butt welding and soldering

Upset (butt resistance) welding is used for ____________________________________________

The main parameters of the upset welding are ___________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
______________________________________________________________________________
Flash welding is suitable for ________________________________________________________
The main parameters of the flash welding are ___________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
______________________________________________________________________________

a) ___________________________

b) _________________________

Technical data of the machine MC-301

1. Nominal power ________ kW;

2. Supply voltage _______ V.

3. Cross-section welded: steel __________ mm2; copper alloys __________ mm2.

4. Maximum of squeezing force ______ kN.

5. Number of power level _____.

6. Secondary voltage ____________ V.

7. Welding current ______________ kA.

Electric circuit of the machine MC-301

PS1, PS2 _______________________________________;

RU _____________________; TR __________________;
AB ____________________; SB ____________________;
LS ____________________; 1 ______________________;
2 _____________________; 3 ______________________; 4
- ______________________; 5 ______________________; 6
______________________; 7 _____________________; 8
______________________; 9 _____________________;
Process of resistance brazing
a) _________________________________________________
b) _________________________________________________
c) ______________________________________________________________________________
Protocol of the sample testing
Material _______________________

Brazier _____________________

Cross-section area, mm2 - __________

Type of
Pressing
Power
process
force, kN
level
1
Welding
2
Welding
3
Welding
4
Soldering
5
Soldering

Flux - _______________________
Upset distance, Welding
Distractive
mm
time, sec force, , kN

Nature of
disruption

Conclusion: ________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
______________________________________________________________________________
Rating ___________

Instructors signature _______________

Student ______________________________
Laboratory work 3 Machine submerged welding
Process of machine submerged welding

The process uses ______________________, which is completely hidden under ____________.

The flux includes _________________________________________________________________
and other components. ________________________________________ is used as bonding agent.
Scheme of machine submerged arc welding
1 ___________________________________;
2 ___________________________________;
3 ___________________________________;
4 ___________________________________;
5 ___________________________________;
6 ___________________________________;
Output characteristic of power source
must be ___________________. Such type of
output characteristic guarantees that in case of
the arc length _______________ the welding
current

will

have

considerable

_________________, the electrode will be

fused _______________ and the arc length will
_________________________________.

The main parameters of the process are:

Uoc

1. _____________________________________________________________________________;

2. _________________________________________; 3. _________________________________;
4. ________________________________________; 5. __________________________________.

Main units of the machine A1416

1 _______________________________________;
2 _______________________________________;
3 _______________________________________;
4 _______________________________________;
5 _______________________________________;
6 _______________________________________;
7 _______________________________________;
8 _______________________________________;
9 _______________________________________;
Welding operational specification of the machine ABC
1. Speed of welding ___________ m/min.

2. Filler wire feed speed _________ m/min.

3. Diameter of filler wire ___________ mm.

4. Welding current ____________ A.

5. Welded metal thickness __________ mm.

Types of butt joints
a) _________________________________________;
b) _________________________________________;
c) _________________________________________;
d) _________________________________________;

HAZ
hardness
HR

HRBase metal hardness

Weld
hardness
HR

Flux

Vn, m/hWire feeding speed

V, m/hWelding speed

U, VVoltage

I, ACurrent

Type of
joint

Material
S, mmand thickness

Table of welding conditions and test results.

Conclusions: ____________________________________________________________
_________________________________________________________________________________
_______________________________________________________________________________
Rating ___________

Instructors signature _______________

Student ______________________________
Laboratory work 4 Manual arc welding with AC transformers
For manual arc welding open circuit voltage on the safety side shall be maximum _______ V
for alternative current and _______ V for direct current. The slope shall be __________________.
Performances of the transformer TD-500
1. Power consumed - _______ kW. 2. Supply voltage of power
source - ________ or __________.
3. Open circuit voltage: at high currents range - ________ V; at
low currents range - ________ V.
4. Rated current - _______ A. 5. Range of current regulation _________________ A.
Scheme of the welding transformer TD-500
1 __________________________________________
2 __________________________________________
3 __________________________________________
4 __________________________________________
5 __________________________________________
6 __________________________________________
The bobbins of secondary winding are _______________________.
Electrical circuit of the transformer TD-500
The secondary winding consists of ________ coils and the
primary winding consists of _________ coils, two of which are
the

____________________

and

the

others

are

_________________________.
1
2
1
2
1
2
1
2

____________________ connection of bobbins gives low inductive resistance and the range of high
currents and the ____________________ connection gives high inductive resistance and the range of
low current.
If __________________________ connection of coils the additional sections of primary winding are
_________________________________________

Number

Protocol of the test of transformer TD-500

1
2
3
4
5
6

Measurement
Current on
the scale

Open circuit,
U, V

Short circuit,
I, A

Operating mode
Current,
Voltage,
I, A
U, V

90
150
240
240
300
350
Graf of the TD-500`s external characteristics

Conclusions: _____________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
______________________________________________________________________________

Rating ___________

Instructors signature _______________

Student ______________________________
Laboratory work 5 Analysis of electric arc characteristics and
equipment for TIG welding
Argon is an _____________, ______________ gas; it does not _______________ with metals and
does not ______________________ in them;
There are two types of argon arc welding: ________________________________________
and ________________________________________________.
____________________ is usually used as the material of non-consumable electrode. The
electrode can resist high _________________________, and has _____________ thermal emission.
Arc remains stable even when the current _____________________________________________.
Only _____________ output characteristic can guarantee steady-state arc under TIG welding.
Scheme of TIG welding:
1 ____________________________,
2 ____________________________,
3 ____________________________,
4 ____________________________,
5 ____________________________,
6 _____________________________
Schematic circuit of the IST-125 inverter

________________________ current which comes to input terminal of thyristor rectifier, is

transformed to _____________________ current, then to the _____________________________
current in thyristor converter, later the current is again rectified by the outlet rectifier to
____________________current and comes to output terminal of inverter.

Measured results to plot the output characteristic slope of IST-125

Arc length, L, mm

Arc voltage, U, V
Current I, A
Current, I, A

10

20

30

40

50

Voltage, U, V (L=2mm)
Voltage, U, V (L=5mm)

Sum of anode voltage drop and cathode voltage drop, U+U, = _________
Voltage drop per arc length unit, U = _______________
Conclusions: ___________________________________________________________________
_______________________________________________________________________________
Rating ___________

Instructors signature _______________

Student ______________________________
Laboratory work 6 Microplasma arc welding
The _________________________ arc can be used at the plasmatrones, when the work metal is
one of the arc electrode, and the ____________________________ arc is used, when this metal isn't
included in the current circuit.
An pilot arc is struck between the
electrode and the _____________. Into
the nozzle ____________ gas is fed.
The outer layers of the gas flow
passing through the outlet have a
______________________________.
Those results in plasma concentrating,
the temperature ___________ in the
_______________________________.
The important characteristics of the heat source are H (______________________________)
and q (______________________________________________).

Protocol
Number of the experiment
Parameters of the mode. Results.

Grade of a material
Sheet thickness, mm
Type of joint
Polarity
Welding current for nontransferred arc, A
Welding current for transferred arc, A
Arc voltage ,V
Open circuit voltage, V
Impulse duration of arc current, s
Pause between the welding current impulses, s
Plasma gas consumption, l/min
Shielding gas consumption, l/min
Tungsten electrode diameter, mm
Heat-flow rate, W/mm2
Conclusions

Rating ___________

Instructors signature _______________

Student ______________________________
Laboratory work 8 Cold welding of plastic material
The main points of the pressure cold welding process.

Schemes of cold welding

)
b)
c)
d)
Scheme of the machine -5-3
1
2
3
4
5
6
7
8
9

1. Technical characteristics of the machine MCXC-5-3

2. Protocol of the samples tests

Material
Wire cross-section area F, mm2

Stick-out distance

Force of fracture, ,

mode of

kN

fracture

1
2
3
4

3. Conclusions

Rating ___________

Instructors signature _______________

Note