Report Welding

POLYTECHNIC OF KOTA KINABALU
MECHANICAL ENGINEERING DEPARTMENT
JJ203 - MECHANICAL WORKSHOP PRACTISE 2
WELDING WORKSHOP
NAME : ___________________________________________
STUDENT ID : ___________________________________________
PROGRAMME : ___________________________________________
SESSION : ___________________________________________
LECTURER : ___________________________________________
LECTURERS REMARKS :
TABLE OF CONTENTS
TITTLE PAGES
WORK SHEET 3
INTRODUCTION 5
SAFETY PROCEDURES 6
EQUIPMENT/MACHINES/TOOLS USED 7
WORK PROCEDURES 9
FINAL PROJECT DIAGRAM 15
CONCLUSION 16
REFERENCES 18
APPENDIX 19
Page 2 of 28
WELDING DIRECTION
BEGIN FROM CENTER
ARC WELDING WORK TOP VIEW

SHEET
TITTLE : Beading WELDING DIRECTION
CONTINUE FROM CENTER
PROGRAMME :
DKM 2, DTP 2, DEM 2
MATERIAL :
Mild steel : 2 x 35 mm x 120 mm
x 6mm
OBJECTIVES :
Continue unfinished bead
TITTLE : Padding TOP VIEW FRONT
PROGRAMME : SIDE VIEW
DKM 2, DTP 2, DEM 2
MATERIAL :
x 6mm
OBJECTIVES : 120 mm
Perform padding process
TITTLE : Tee fillet TOP VIEW FRONT
PROGRAMME : SIDE VIEW
DKM 2, DTP 2, DEM 2 35 mm
MATERIAL :
Mild steel : 2 x 35 mm x 120 mm 6 mm
x 6mm
OBJECTIVES : 120 mm
Weld T fillet in a flat position
GAS WELDING WORK

SHEET 45
TITTLE : Tee fillet
60 - 70
PROGRAMME :
DKM 2, DTP 2, DEM 2
MATERIAL :
x 3mm
Welding Direction
Page 3 of 28
OBJECTIVES :
Weld T fillet and T joint in a flat
position
TITTLE : Lap joint 60 - 70
PROGRAMME :
DKM 2, DTP 2, DEM 2
MATERIAL :
30
x 3mm
Cutting direction
OBJECTIVES :
Weld lap joint and lap joint 15 - 20
using brazing process
TITTLE : Cut metal plate
PROGRAMME :
DKM 2, DTP 2, DEM 2
MATERIAL :
x 3mm
OBJECTIVES :
Cut metal plate using oxy-
acetylene process
INTRODUCTION
Page 4 of 28
Page 5 of 28
SAFETY PROCEDURES
a) Self-safety
b) Equipments/tools safety
c) Workspace safety
Page 6 of 28
Page 7 of 28
EQUIPMENTS/MACHINES/TOOLS USED
EQUIPMENTS/MACHINES/
NO USAGE DIAGRAM
TOOLS NAME
Page 8 of 28
EQUIPMENTS/MACHINES/
NO USAGE DIAGRAM
TOOLS NAME
Page 9 of 28
WORK PROCEDURES
PROJECT 1 : ____________________
NO SKECTHING/DIAGRAM PROCEDURES
Page 10 of 28
NO PROCEDURES EXPLAINATION
Page 11 of 28
Page 12 of 28
WORK PROCEDURES
PROJECT 2 : ____________________
Page 13 of 28
Page 14 of 28
WORK PROCEDURES
PROJECT 3 : ____________________
Page 15 of 28
Page 16 of 28
FINAL PROJECT DIAGRAM
Page 17 of 28
CONCLUSION
1. Arc welding machines utilize a high-amperage electric current which is extremely dangerous. Explain what
should you do to decrease the possibility of accidental electrical shock?
Page 18 of 28
2. Explain why there have AC and DC electricity supply in arc welding.
Page 19 of 28
3. Describe three (3) types of oxy-acetylene flames with appropriate sketches.
4. Explain in brief about T-fillet and Lap joint welding.
5. Do you have any suggestions for room of improvement?
Page 20 of 28
REFERENCES
Page 21 of 28
Page 22 of 28
MACHINING & WELDING WORK REPORTS RUBRIC [PLO 8]
VERY
UNSATISFACTO MARKIN
CRITERIA EXCELLENT GOO GOOD FAIR
NO RY G SCORE
D
FACTOR
(7) 5 4 3 2 1
- Overdue
- Report was submitted - Report submission
- Low quality
1 Accountability before the deadlines. on time. 4
work
- High quality work - Proper quality work
- Covers self, workplace and Cover any two of No safety
Safety
2 equipment safety. self/workplace/equip procedures 2
procedures
- Well organize ment safety stated
Equipment /
Cover any one
machinery / Complete with tools Cover any two of
of tools
3 tools used name, sketching and its tools name 2
name/sketching
(Photocopies function. /sketching/its function
/its function
are acceptable)
Explain the
- Explain the workshop
workshop
processes step by step. - Explain the workshop
processes step by
Work processes step by step.
4 step without 4
procedures - Assisted with sketching.
sketching.
- Assisted with sketching
Or
- Well organize
Sketching only
Not fulfilling the
Meet the requirement with Partially fulfilling the
5 Reports format requirement 3
excellence. requirement needed.
needed.
6 Integrity & - Report completed. - Report partially - Too much 4
Honesty completed. missing
Page 23 of 28
- Original idea - Copy totally information.
7 References > 4 references 2 References No references 1
TOTAL /100
PLO 8 : Demonstrate an understanding of professional ethics, responsibilities and norms of mechanical engineering practices
WELDING PRACTICAL TASKS RUBRIC [PLO 2]
VERY UNSATISFACTO MARKIN

CRITERIA EXCELLENT GOOD FAIR
GOOD RY G SCORE
(9) 5 4 3 2 1 FACTOR
ARC WELDING
All of the following safety No welding
Two or more of the following
practices were followed: helmet worn.
safety practices violated:
Proper welding gloves No safety glasses
No welding gloves worn.
worn. worn.
Safety Practices Incorrect shoes worn. 2
Proper shoes worn. Student will not
Incorrect clothing worn.
Proper clothing worn. be allowed to
Hot metal carried in gloved
Pliers, etc. used to carry continue the
hand(s).
hot metal. assignment.
Bead width equals the The majority of the bead is Bead
Bead Width width of two electrodes equal to the width of two unsuccessfully 3
used. electrodes used. made.
Bead
Bead has an acceptable Proper bead shape is not
Bead Shape unsuccessfully 2
shape for the entire weld. consistent for the entire length
made.
of the bead.
Bead has neither of the
Bead has one of the following
following problems:
problems: Bead
Bead is rough, narrow
Weld Start & Finish Bead is rough, narrow and unsuccessfully 1
and high.
high. made.
Weld crater is not filled
Weld crater is not filled in.
in.
Weld Defects No weld defects are Bead 2
Page 24 of 28
1 of the following defects are
present:
Excess spatter is present.
unsuccessfully
present. Bead is not uniform.
made.
Weld ripples are long and
pointed.
MARKI
GAS WELDING NG SCORE
FACTOR
Properly prepared weld Did not prepare

metal. weld metal.
Tacked weld metal in Missed one or two of the Did not tack
Metal Inspection 1
proper position. criteria. metal.
Showed to instructor Did not show to
before welding. instructor before
welding.
Less than the

Bead Width 1/8" to 3/16" wide 1/16" to 1/8" wide thickness of the 3
material
1/16" high and smooth 3/32" height and varied Less than 3/32"
Bead Height 3
bead consistence and inconsistent
Penetration of less than Penetration of less than 1/2 Penetration of

Penetration 3
3/4 of the base the base less than 1/4 the
base
Page 25 of 28
TOTAL /100
PLO 2 : Demonstrate practical skills which includes the ability to troubleshoot, repair and do maintenance work for mechanical equipment.
Page 26 of 28
Name : ______________________________________________
Student ID : ______________________________________________
Practical Task Report

PLO Marks PLO Marks
PLO 2 PLO 8
TOTAL ( /100)*70 = TOTAL ( /100)*30 =
Your Total mark is :
Lecturer signature,
.......................................
Date :
Page 27 of 28
-THE END-
Page 28 of 28

Report Welding

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Report Welding

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POLYTECHNIC OF KOTA KINABALU

MECHANICAL ENGINEERING DEPARTMENT

JJ203 - MECHANICAL WORKSHOP PRACTISE 2

FINAL PROJECT DIAGRAM 15

ARC WELDING WORK TOP VIEW

GAS WELDING WORK

4. Explain in brief about T-fillet and Lap joint welding.

5. Do you have any suggestions for room of improvement?

VERY UNSATISFACTO MARKIN

Properly prepared weld Did not prepare

Less than the

Penetration of less than Penetration of less than 1/2 Penetration of

Practical Task Report

Your Total mark is :

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