1.

ABSTRACT
The aim of this experiment is to produce a Butt Joint by using Arc Welding and Lap Joint by using
Gas Welding. For arc welding, the materials used are two pieces of mild steel flat of size 100 x 64 x 6
mm and the electrode is mild steel electrode 3.15 mm diameter (SWG 10) with length of 350 mm. For
gas welding, the materials used are two pieces of mild steel sheet of size 140 x 60 x 1.2 mm. After the
two experiments are done, the control parameters and welding quality are observed and tested for
leaks and imperfections.

2. INTRODUCTION
As a whole, welding is a joining process in which two (or more) parts are coalesced at their contacting
surfaces by application of heat and/or pressure. Many welding processes can be done by applying heat
alone, with no pressure applied. While others by a combination of heat and pressure. However, some
welding methods just done by applying pressure alone with no external heat. In some welding
processes a filler material is added to facilitate coalescence.
Welding is very important because it provides a permanent joint for the materials. Welded
components become a single entity with added strength. In terms of material usage and fabrication
costs, welding is one of the most economical way to join parts. When compared to welding,
mechanical fastening usually requires additional hardware components (e.g., screws and nuts) and
geometric alterations of the parts being assembled (e.g., holes). Lastly, welding is not restricted to a
factory environment and it can be done basically anywhere. There are 50 different types of welding
processes have been catalogued by the American Welding Society (AWS). Welding processes can be
divided into two major categories. One of them is fusion welding where the coalescence is
accomplished by melting the two parts to be joined, in some cases adding filler metal to the joint. For
example, arc welding, resistance spot welding and oxyfuel gas welding. Another category is solid
state welding where heat and/or pressure are used to achieve coalescence, without the melting of base
metals addition of filler metal. The examples of this type of welding are forge welding, diffusion
welding and friction welding.
Arc welding is a process that is used to join metal to metal by using electricity to create enough heat
to melt metal, and the melted metals when cool result in a binding of the metals. It is a type of
welding that uses a welding power supply to create an electric arc between an electrode and the base
material to melt the metals at the welding point. They can use either direct (DC) or alternating (AC)
current, and consumable or non-consumable electrodes. The welding region is usually protected by
some type of shielding gas, vapor, or slag. One of the most common types of arc welding is shielded
metal arc welding (SMAW). To strike an arc between the base material and a consumable electrode
rod, an electric current is used. The electrode rod is made of a material that is compatible with the
base material. It is also covered with a flux that gives off vapors that functions as a shielding gas and
provide a layer of slag to protect the weld area from atmospheric contamination. A separate filler is
unnecessary because the electrode core itself acts as filler material.

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 Figure 1: Basic configuration of an arc welding process.

Figure 2: Shielded metal arc welding.

For gas welding or Oxyacetylene welding (OAW), fusion welding performed by a high temperature
flame from combustion of acetylene and oxygen. The flame is directed by a welding torch. Filler
metal is sometimes added and the composition must be similar to base metal. To prevent oxidation,
filler rod often coated with flux. Acetylene is mostly used because it is capable of higher
temperatures‑ up to 3480°C (6300°F).
Two stage chemical reaction of acetylene and oxygen:
First stage reaction (inner cone of flame):
C2H2 + O2 → 2CO + H2 + heat
Second stage reaction (outer envelope):
2CO + H2 + 1.5O2 → 2CO2 + H2O + heat

Figure 3: A typical oxyacetylene welding operation (OAW).

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 Figure 4: The neutral flame from an oxyacetylene torch indicating temperatures achieved.

3. OBJECTIVE

i. Part 1- To make a Butt Joint by using Arc Welding.

ii. Part 2- To make a Lap Joint by using Gas Welding.

4. EXPERIMENTAL SETUP & PROCEDURE

PART 1
Tools and Equipment used: Arc welding machine with all the accessories, electrode holder, earth
lamp, try square, hacksaw, steel rule, hammer, chisel, pair of tongs, chipping hammer, face shield etc.
• Material Used: Mild Steel (MS) Flat of size 100 x 64 x 6 mm – two pieces
• Electrode: MS Electrode 3.15 mm diameter [SWG 10] length 350 mm
• Procedure:
a) The MS Flat was marked and cut.
b) The welding transformer machine was started, and the current was set to approx. 100 amps.
c) The both the sides of joints were tacked and the layer was completed by keeping the flat position of
the job.
d) Using a chipping hammer and a wire brush, the completed weld was cleaned and then the welding
layer was checked.
• Precautions:
a) Never look at the welding arc without face shield.
b) Always wear flexible gloves and leather apparels.
c) Never touch the hot job with hands.
d) Use specified current and electrodes for arc welding.

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Drawing:

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PART 2
• Tools & instruments: Gas welding cylinders, welding rods, pliers, spark lighter, safety goggles,
leather gloves and leather apron, scriber, welding torch, cylinder key, shearing machine, anvil,
hammer, flux powder.
• Material used: Mild Steel Sheet size 140 x 60 x 1.2 mm (02 Pieces)
• Procedure:
a) Two pieces of mild steel plate as per size and dimension (140 x 60 x 1.2 mm) were prepared.
b) Both work pieces were straightened.
c) Using wire brush or emery paper, the sides of work pieces were cleaned.
d) With help of scriber, a centre line on both pieces was marked.
e) Both strips were placed at a centre line then overlapped in a horizontal position.
f) The proper pressure of the gasses by means of pressure gauges.
g) At a correct location and alignment, the work pieces were supported on welding table.
h) The proper quantity of acetylene and oxygen gas was set for a required flame on welding
torch.
i) With help of spark lighter the acetylene gas was burned at the end of nozzle to make a neutral
flame.
j) Welding was started and the edge gapes were filled with filler metal and the same
procedure was repeated on other side and the lap joint was completed.
k) The carbon layer was chipped from weld by chipping hammer.
• Safety precautions:
a) Inspect the hose pipes connections carefully.
b) Always wear goggles, apron and gloves during the welding.
c) Don’t touch the torch tip on the job.
d) Before checking the jobs cool it.
e) Make sure the top of the bench and work piece to be welded are dry and free from
dirt, corrosion and grease.
f) To continue welding pool it is necessary to make the neutral flame.
g) Before making the flame carefully check the leakage of gases.
h) Don’t weld without flux.

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Equipment Set-Up of Gas Welding

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 5. RESULTS AND DISCUSSION

Welded plate for Part 1

Welded plate for Part 2

3 sprays used for the test

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When the welding equipment was not handled properly, a welded joint may develop various
discontinuities. The major discontinuities that affect weld quality are porosity, slag inclusions,
incomplete fusion and penetration, weld profile, high amperage and low amperage.
To overcome this, we can improve our welding skill such as preheating the weld area or increasing
the rate of heat input. Next, we can clean and prevent the contaminants from entering the weld zone
and reduced welding speed allow time for gas to escape.
Next, there are also some safety precautions that need to be obeyed. One of them is do not look at the
welding arc when you are not using any face shield and do not forget to wear flexible gloves and
leather apparels.

Question Part 1- Arc welding

a) The control parameters are current, length of arc, angle, manipulation, speed. Welding quality
is the use of technological methods and actions to test or assure the quality of welds and to
confirm the presence, location and coverage of welds.
b) Firstly, we spray the cleaner to the plate. Secondly, we spray the penetrant and finally we
spray the developer spray to detect any flaw and crack on the plate. If there is any crack we
can see at the surface of the coating or we can check it under the microscope.
c) Arc welding are much easier compare to the gas welding because we can control the current
according to our thickness of metal plate. If the plate is thin we need to set the low current to
prevent it from over weld and the metal plate will melt and form hole.

Question part 2- Gas welding

a) The control parameters are temperature of gas, amount of gas provided, filler composition.
When we are doing welding works, finished quality is vital to success of your business. So,
engineers will develop specific specifications for the product including developing the exact
welding parameters for each part of the process. Using improper parameter can lead to excess
spatter, which will need additional clean-up of welds.
b) Firstly, we spray the cleaner to the plate. Secondly, we spray the penetrant and finally we
spray the developer spray to detect any flaw and crack on the plate. If there is any crack we
can see at the surface of the coating or we can check it under the microscope.
c) Gas welding are bit difficult than the arc welding. The lab instructor set the gas according to
the thickness of the plate. We need to be extra careful when doing welding work because gas
welding is bit sensitive and It may cause explosion.

6. CONCLUSION

As a conclusion, we have learned how to join the MS Plate using the Arc and Gas welding. We have
learnt about the important parameters for both welding methods. We also been reminded to be very
careful and remember the safety precautions while doing the welding work before and after the
welding work. We also use three types of spray as a test to observe whether the plates are crack or
not. For our workpiece, there is not many imperfections on the MS plate, just some minor cracks and
it is not properly cleaned.

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7. REFERENCES

1. https://www.scribd.com/doc/23089869/Welding-Report
2. http://www.academia.edu/5198060/WELDING_REPORT
3. http://www.educationdiscussion.com/arc-welding/
4. http://www.theweldingmaster.com/welding-defects/