Workshop Practice

Dr. Swarup Nayak

Associate Professor
School Of Mechanical Engineering
KIIT Deemed to be University
Theory on Welding

11/7/2024 School of Mechanical Engineering KIIT Deemed to be University

Introduction to Welding Section
• Definition of Welding
• Welding is a fabrication process whereby two or more parts are fused
together by means of heat, pressure or both forming a join as the parts
cool.
• Welding is usually used on metals and thermoplastics but can also be
used on wood.
• The completed welded joint may be referred to as a weldment
• The parts that are joined are known as a parent material. The
material added to help form the join is called filler or consumable

11/7/2024 School of Mechanical Engineering KIIT Deemed to be University

Introduction to Welding Section
• Advantages of Welding
• Strong and tight joining
• Cost effectiveness
• Simplicity of welded structures design
• Welding processes may be mechanized and automated
• Disadvantages of Welding
• Internal stresses, distortions and changes of micro-structure in the
weld region;
• Harmful effects: light, ultra violate radiation, fumes, high temperature.

11/7/2024 School of Mechanical Engineering KIIT Deemed to be University

Introduction to Welding Section
• Applications of Welding
• Buildings and bridges structures
• Automotive, ship and aircraft constructions
• Pipelines
• Tanks and vessels
• Railroads
• Machinery elements

11/7/2024 School of Mechanical Engineering KIIT Deemed to be University

Introduction to Welding Section
• Classification of Welding
• Welding can be broadly classified as -
• Arc welding
• Gas welding
• Resistance welding
• Solid state welding
• Thermit welding
• Electron beam welding
• Laser welding

11/7/2024 School of Mechanical Engineering KIIT Deemed to be University

Introduction to Welding Section
• Arc welding
• Arc welding is a welding process, in which heat is generated by an
electric arc struck between an electrode and the work piece.
• It involves following parts –
• Power supply (AC or DC);
• Welding electrode;
• Work piece;
• Welding leads (electric cables) connecting the electrode and work piece to the
power supply

11/7/2024 School of Mechanical Engineering KIIT Deemed to be University

Introduction to Welding Section

11/7/2024 School of Mechanical Engineering KIIT Deemed to be University

 Introduction to Welding Section
• Types of Joints
• Butt joint - A connection between the ends or edges of two parts making an
angle to one another of 135-180° inclusive in the region of the joint.

• Lap joint - A connection between two overlapping parts making an angle to one
another of 0-5° inclusive in the region of the weld or welds

• T joint – A connection between the end or edge of one part and the face of the
other part, the parts making an angle to one another of more than 5 up to and
including 90° in the region of the joint.

11/7/2024 School of Mechanical Engineering KIIT Deemed to be University

Introduction to Welding Section
• Types of Joint configurations
• Corner joint – A connection between the ends or edges of two parts making
an angle to one another of more than 30 but less than 135° in the region of the
joint.

• Edge joint - A connection between the edges of two parts making an angle to
one another of 0 to 30° inclusive in the region of the joint

11/7/2024 School of Mechanical Engineering KIIT Deemed to be University

Introduction to Welding Section
• Welding Positions

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Introduction to Welding Section
• Features of a completed Butt weld

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Introduction to Welding Section
• Features of a completed Fillet weld

11/7/2024 School of Mechanical Engineering KIIT Deemed to be University

Safety Precautions
• Safety precautions to be followed in Sheetmetal section
• Always wear gloves, to avoid injuries to hand by sharp edges and
corners of the cut piece
• Don’t touch any live electrical parts to avoid shocks or burns
• Ensure the welding cables and electrode holder are properly
insulated
• Don’t see the welding arc through naked eye to avoid UV rays
• Always use a tong for holding heated job piece

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Experiment – WELDING

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 Welding Section Experiment
• Aim of experiment: To prepare a Lap Joint (single fillet weld) by shield
metal arc welding (SMAW) process
• Raw Material Required: Two MS Flat [80x40x6 mm]
• Tools required: SMAW machine (Inverter or transformer type), Bench vice,
Flat file, Hacksaw, Steel rule, Try square, Chipping Hammer, Wire brush,
tong, Welding screen
• Welding Consumables: Flux coated electrodes [3.15 mm dia, Cellulose
coated AWS E6010]
• Operations involved
• Measuring and marking
• Filing
• Welding
• Chipping

11/7/2024 School of Mechanical Engineering KIIT Deemed to be University

Layout of the Job

Lap Joint

11/7/2024 School of Mechanical Engineering KIIT Deemed to be University

Shielded Metal Arc Welding [SMAW]
• SMAW (Stick welding, Manual metal arc welding) uses a metallic
consumable electrode of a proper composition for generating arc
between itself and the parent work piece. The molten electrode metal
fills the weld gap and joins the work pieces
• The electrodes are coated with a shielding flux of a suitable
composition. The flux melts together with the electrode metallic core,
forming a gas and a slag, shielding the arc and the weld pool.
• The flux cleans the metal surface, supplies some alloying elements to
the weld, protects the molten metal from oxidation and stabilizes the
arc.
• The slag is removed after Solidification.

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Shielded Metal Arc Welding [SMAW]

11/7/2024 School of Mechanical Engineering KIIT Deemed to be University

Arc Welding
• Arc Length - It is the straight distance between the electrode tip and
the job surface when an arc is formed
• Types of Arc length –
• Normal Arc Length - The correct arc length or normal arc length is
approximately equal to the diameter of the core wire of the electrode.
• Long Arc Length – If the distance between the tip of the electrode and the
base metal is more than the diameter of the core wire, it is called ‘Long arc’.
• Short Arc Length – If the distance between the tip of the electrode and the
base metal is less than the dia. of the core wire, it is called a ‘short arc’.

11/7/2024 School of Mechanical Engineering KIIT Deemed to be University

 Measuring and Marking Operations
• The measuring and the marking operations are the basic operations to
prepare the prime workpieces as per required dimension by the help of
different tools
• Tools used are:
• Steel rule
• Try square
• Hacksaw
• Flat file

11/7/2024 School of Mechanical Engineering KIIT Deemed to be University

Measuring and Marking Operations
Hacksaw

Flat file

Try Square

Steel rule

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 Procedure
• Step by step procedure
• Mark and cut two pieces of MS Flat as per the required dimensions [i.e. 80x40x6
mm].
• Remove any contaminations from the surfaces to be weld by Filing operation
• After filing the final dimension of the pieces should be 79x39x5.5 mm
• Set the welding machine with suitable parameter and the electrodes should be fixed in
the holder
• For the given thickness, the Current value would be 90 to 110 amps. and the voltage
value would be 40 to 60 volts.
• Select the right polarity to achieve better weld quality. [DC output with constant
voltage and electrode as negative is called Direct Current Straight Polarity (DCSP);
when polarity is negative and electrode is positive, it’s called as Direct current Reverse
Polarity (DCRP)]
• Then, the workpieces can be placed in the welding booth

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 Procedure (Cont..)
• Step by step procedure
• The operator must equip with all Personal Protective Equipment (PPE) such as
Safety shoes, Apron, welding screen and leather gloves before starting the welding
process
• First, tack the job at it’s two extreme ends
• Start the welding with suitable welding speed and position. For the given thickness,
single pass welding will be enough
• After finishing the welding, take out the job from the booth using a tong and let it
cool down at room temperature
• Then, do the chipping operation using a chipping hammer to remove any spatter, slag
and any other contaminations
• Finally, clean the weldment using a wire brush

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Cutting Operation
• The required raw materials [Two MS flats of 80mm length] should be
cut from a given long flat
• Initially, the long flat must be marked and then fixed in the bench vice
• After fixing, using the hacksaw the flat has to be cut into two required
pieces
• Tools used
• Bench vice
• Hacksaw

Hacksaw Bench vice

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Filing Operation
• After the cutting operation, the cut pieces will be filed to smooth the
surfaces and to remove any unwanted rust from the surfaces
• For this operation, the pieces will be fixed in the bench vice and filed
using the flat file
• After, filing the try square can be used to check the perpendicularity
of two adjacent sides of the workpieces
• Tools used
• Flat file
• Try Square

Try Square
Filing Operation using Flat file
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Welding Operation
• The welding operation (arc welding) will be carried out to prepare the
required lap joint using arc welding machine (SMAW)

• Tools used:
• SMAW machine
• Electrode holder
• Flat tong
• Hand screen

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Welding Operation

Electrode Holder

Hand Screen

SMAW machine Flat Tong

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Cooling Operation
• After the completion of welding operation, the weldment temperature
is very high and therefore, its cooled down to room temperature by
dipping inside a sand bucket
• Tools used:
• Flat tong
• Sand bucket

11/7/2024 School of Mechanical Engineering KIIT Deemed to be University

Chipping Operation
• A method of removing surface defects with a chipping hammer, so that
the defects will not be worked into the finished product
• Chipping is used to remove scale, rust, or other foreign materials from
the workpiece.
• It can also be used between beads to remove slag, and after welding to
ensure a neatly finished weld.
• Chipping is often used in combination with wire brushing to prepare
surfaces
• Tools used
• Chipping hammer
• Tong
• Wire brush
Chipping hammer Wire brush

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Concluding Remarks
• Write your own conclusion.

Safety Measures
• Write on your own, what measures you have taken during the welding
experiment.

11/7/2024 School of Mechanical Engineering KIIT Deemed to be University