Objectives

One of the objectives that attending the practical of welding is to know the main function
of welding. That is, to join two pieces of metal together by the use of heat, the heat melts
and liquefies the electrode, so that the metals can be joined together. In order to melt
part of a large piece of metal, you need to apply a large amount of either pressure or
heat to it.
Besides, to know what are the true steps when doing a welding. The lab assistant had
given us a short briefing about the procedures of welding before we started to practice
welding. After that, he demonstrated to us to ensure that we can understand how to weld
by using the true steps. He always made sure that we used the right tools and materials
when welding in the laboratory.
Furthermore, to ensure students know the skills of welding. After the demonstration of
the lab assistant, we were given a few hours to practice welding. The lab assistant and
lecturer took the responsibility to impart the information about the welding to us. They
were always ensured we use our skills wisely, such as adjusting the ampere when we
used different electrodes.
At the same time, to ensure all students according to the instruction and safety. During
the first week, the lab assistant had told us the proper clothing that we should wear when
welding, such as wearing the lab coat or the welding helmet. He also reminded us about
some safety precautions to ensure our safety. Before we started practising, he also
checked whether our clothing was suitable for welding.
Other than that, to ensure students know the prevention of accidents. Fire extinguisher
was provided in the laboratory to reduce the risk of fire and the students were instructed
to open all the windows in the laboratory to ensure the proper ventilation in the
laboratory. Moreover, the very thick leathered gloves are provided for the students to
prevent they were scalded by the hot metals.

Introduction
On 14 and 21 September 2015, our group of 15 persons were attended a practical of
welding in 2 days in 2 weeks. The period for each practice is 4 hours and divided to 2
parts, that is from 11am to 1pm and from 2pm to 4pm. During the practical, we learnt a
basic welding, that is, shielded metal arc welding (SMAW), which is, also known as stick
welding. It uses an electrode that has flux, the protectant for the puddle, around it.
Then, the electrode holder holds the electrode as it slowly melts away. And, the slag
protects the weld puddle from atmospheric contamination. In the laboratory, we were
advised by the lab assistant and lecturer that safety first to prevent accidents while
welding. They were taking serious about our safety while we were working at the
laboratory. For me, welding is a very important skill that students, especially mechanical
students, must learn because it is used to joining the work pieces. For examples,
welders in the area of automotive used this skill to assembly a car body.
Shielded metal arc welding (SMAW) is a manual arc welding process that uses a
consumable electrode covered with a flux to lay the weld. An electric current, in the form
of either AC or DC from a power supply is used to form an electric arc between the
electrode and the metals to be joined. The work piece and the electrode melt forming the
weld pool that cools to form a joint. As the weld is laid, the flux coating of the electrode
disintegrates, giving off vapours that serve as shielding gas and providing a layer of slag,
both of which protect the weld area from atmospheric contamination. SMAW is one of
the worlds most popular welding processes because of the versatility of the process and
the simplicity of its equipment and operation. The process is used primarily to weld iron
and steels but aluminium, nickel and copper alloy can also be welded with this method.

Safety
Welding can be dangerous and unhealthy if the proper precautions are not taken.
However, the risks of injury and death associated with welding can be greatly reduced by
using new technology and proper protection.
1. Wear personal protective equipment (heavy leather gloves and protective long
-

sleeve jackets)
Avoid exposure to extreme heat and flames

2. Wear goggles and welding helmets with dark UV-filtering face plates
- Prevent exposure to the brightness of the weld area that leads to a condition
-

called arc eye

Arc eye: ultraviolet light causes inflammation of the cornea and can burn the
retinas of the eyes

3. Ensure a proper ventilation

- Avoid the smoke containing particles of various types of oxides produced by the
-

process of SMAW
Avoid gases (carbon dioxide, ozone) and fumes containing heavy metals

4. Hold electrode with insulated handle

- Avoid electric shock from the live parts of the welding circuit or when changing
the electrode
5. Avoid welding near combustible material
- Reduce the risk of burns and fire since many of the procedures involve an open
electric arc or flame
6. Never stand in the water when welding
- Increase the skin resistance of the body and insulating properties of accessories
7. Never wear jewellery (especially rings) or metallic watch straps
- Avoid electric shock from the live parts of the welding circuit

Bad practice
1. No face protection
2. No arm protection
3. Exposed cloth
4. Exposed solvent
5. Bystander exposed to arc
6. Fire exit obstructed
7. Fire bucket unsuitable for
electrical fires - should contain sand
8. Fume extraction not effective

Hazards
arc eye, burn
burn
fire
fire/explosion, toxic vapour
arc eye
fire, burns
electric shock
inhalation of harmful fume

9. No work earth (if required)

10. Cable damaged

shock
stray arc, burns, electric shock

Procedures
1. Prepare the area that without combustible materials to be welded in.
2. Open the ventilation machine and window make sure most of the smoke sucks
3.
4.
5.
6.
7.
8.

out by the machine.

Set up the materials as Figure 1.
Prepare and clean the steel plate to be welded by using a wire brush.
Make sure all the protective gear has been wear.
Use the electrode code E6013 with diameter 2.8mm or 3.2mm.
Adjust the ampere around 80-100 for electrode diameter 3.2mm.
Put an electrode at the electrode holder and make sure there is no movement of

electrode at the holder.

9. Hold the electrode at 60 degrees work angle and 2mm 3mm above the base
metal.
10. Strike a welding arc by tapping the metal and quickly pulling up or striking it like
a match.
11. Hold that position over a spot just inside the left edge of the base metal until a
molten pool is established.
12. Move the weld pool across the metal with making sure your travel speed and arc
length are steady.
13. Stop the process at the end of the work piece.
14. Clean the slag by using the chipping hammer.
15. Clean the weld by using the wire brush.

Observation
During my practising time, I noticed that as a beginner, I will commonly have too long an
arc length and too great a lead angle. Actually, the arc length will also increase by an
excessive rod lead angle. Although arc welding is a constant current process, the arc
length has an effect on voltage. For example, reducing the arc length will decrease the
voltage and this reduces the heat in the weld. If the arc length is too short, the surface of
the weld is uneven where it has been dragged along by the rod and the weld will contain
slag inclusions. On the other hand, a flat and wide weld with a great deal of spatter will
be produced if the arc length is too long. This is because of the distance between the rod
and the work is too great and increasing the voltage. This results to an unstable arc and
the slag is difficult to remove from the edges of the weld.

At the same time, as a beginner welder, I tend to move the rod too quickly. As a result, a
thin, weak bead was produced. The ridges in the weld were elongated and triangular. On
the other side, when my travel speed is too slow, it results in a wide tall build-up of weld.
The shape of the weld is not consistent because the weld pool has collapsed into the
crater. Cold joints and slag inclusions were resulted by the poor control of the weld pool.

Other than that, I noticed that using incorrect current when welding is also a common
fault for beginners. That is, when the current is too low, a tall, narrow bead that lack in
penetration was produced. The weld will be difficult to start as it will stick to the base
metal easily and the arc prone to straying towards one side of a joint in preference to the
other. On the other hand, when the current is too high, the bead is wide, flat and
irregular. Besides, a deep crater has formed at the end of the weld and the slag is
difficult to remove from the edges of the weld. For information, excessive current should
not be compensated by excessive travel speed. This can result in slag inclusions due to
rapid cooling of the weld.

Results
On 21 September, an assessment was carried out to the students to value the results of
this practical. We are asked to make an arc welding by using two techniques that is
maintaining straight line and moving around with small circles during welding.
** Photo 1
This is the welding straight (tegak) that I had done in the assessment. I had get 35
marks out of 40 marks for this part.
** Photo 2
I had also done a welding webbing (anyaman) during the assessment as shown in the
photo. I get 30 marks out of 40 marks for this part.
** Photo 3
Photo above shows the jointing part that I did in the assessment. Due to that was the
first time I did it and the time to practice is not enough for me, it is not so good-looking
and I get 8 marks out of 20 marks for this part.

Conclusion
The project that I had done was not satisfied by my lecturer. This is because there are
some quality problems. For example, weld spatter that damages its appearance. It was
caused by excessively high current, a long arc or arc blow. Arc blow can also cause
porosity in the weld, as can joint contamination, high welding speed and a long welding
arc, especially when low-hydrogen electrodes are used. Besides, porosity and poor
fusion that can potentially weaken the weld were done by me. They are caused by low
current, contaminated joint surfaces. Moreover, shallow penetration can make the weld
prone to cracking. It can be addressed by decreasing welding speed, increasing the
current or using a smaller electrode. Furthermore, I am just a first timer and lack of
experiences. Thus, all of these quality problems can actually be eliminated by more
practices.
As a conclusion, all of the objectives have been achieved successfully. During these
practical, I learnt about a new skill, which is arc welding. This skill is about how to joining
the steel plate by using SMAW. The true steps of welding were imparted to us to ensure
that we understand the procedures of welding. For instance, our lecturer taught us to
hold the electrode 2mm 3mm above the base metal to avoid the electrode stick to the
base metal. At the same time, I learnt about the skills of welding. For example, we have
been taught by our lecturer how to adjust the ampere for different electrodes. Other than
that, our lecturer always stays alert in our safety during the period of practical. He will
make sure we wear the proper clothing when welding. As conclusion, I want to thanks
my lecturer for teaching me so much knowledge and my friends for their helping hands
during the practical time. However, this practical will always etched in my heart because
this is a new and exciting experience for me and this skill is very useful for me and as a
preparation when I work outside later.

Appendices

Shielded Metal Arc Welding (SMAW)

References
1.
2.
3.
4.

Haynes, Tom (1987) Basic Welding, Toronto: McGraw-Hill

Hoffman, David (2012) Welding, Boston: Prentice Hall
Pender, James A. (1986) Welding 3rd edition, Toronto: McGraw-Hill
http://me.rrc.mb.ca/Catalogue/ProgramInfo.aspx?ProgCode=WELDF-

5.
6.
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8.

CT&DescriptionType=10&RegionCode=WPG
http://www.academia.edu/5198060/WELDING_REPORT
http://www.wikihow.com/Weld
https://en.wikipedia.org/wiki/Welding
http://www.iat.uni-bremen.de/sixcms/media.php/81/070905AWS_Welding
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%20flicker.pdf