INTRODUCTION Welding is a fabrication or sculptural process that joins materials,

usually metals or thermoplastics, by causing coalescence. This is often done by melting the work pieces and adding a filler material to form a pool of molten material (the weld pool) that cools to become a strong joint, with pressure sometimes used in conjunction with heat, or by itself, to produce the weld. This is in contrast with soldering and brazing, which involve melting a lower-melting-point material between the work pieces to form a bond between them, without melting the work pieces. Many different energy sources can be used for welding, including a gas flame, an electric arc, a laser, an electron beam, friction, and ultrasound. While often an industrial process, welding may be performed in many different environments, including open air, under water and in outer space. Welding is a potentially hazardous undertaking and precautions are required to avoid burns, electric shock, vision damage, inhalation of poisonous gases and fumes, and exposure to intense. The type of welding that used in industry is arc welding, gas metal or tungsten arc welding, plasma arc welding, submerged arc welding, MIG welding, TIG welding and so on. But in the class, we just learn to use the basic of welding which is arc welding. These arc welding processes use a welding power supply to create and maintain an electric arc between an electrode and the base material to melt metals at the welding point. They can use either direct (DC) or alternating (AC) current, and consumable or nonconsumable electrodes. The welding region is sometimes protected by some type of inert or semi-inert gas, known as a shielding gas, and filler material is sometimes used as well.

OBJECTIVE 1. To know all the type of welding and to study the knowledge about the welding that use in industry. 2. Learn how to use the arc welding and practice it while doing the project that were given 3. To complete the project given by the lecturer and encourage training among student.

SCOPE 1. Do a basic welding/formed notch. 2. Do a T joint welding.

SAFETY Welding can be dangerous and unhealthy if the proper precautions are not taken. However, with the use of new technology and proper protection, risks of injury and death associated with welding can be greatly reduced. Since many common welding procedures involve an open electric arc or flame, the risk of burns and fire is significant; this is why it is classified as a hot work process. To prevent injury, welders must wear personal protective equipment such as :

1. Leather gloves to avoid exposure to extreme heat and flames. 2. Welding helmets - the brightness of the weld area leads to a condition called arc eye or flash burns in which ultraviolet light causes inflammation of the cornea and can burn the retinas of the eyes. So, welding helmets with dark UV-filtering face plates are worn to prevent this exposure. 3. Welding apron This welding apron is to protect you and your clothes from hot sparks as you work with your welder.

SAFETY MEASURES 1. Always wear welding helmet during the welding process. 2. Always wear leather glove during the welding process. 3. Make sure the welding cable and earth cable is safe and in perfect condition before use to avoid electrical shock. 4. Welding far away from flammable material to avoid combustion.

METHODOLOGY

One of the most common types of arc welding is shielded metal arc welding (SMAW) it is also known as manual metal arc welding (MMA) or stick welding. Electric current is used to strike an arc between the base material and consumable electrode rod, which is made of steel and is covered with a flux that protects the weld area from oxidation and contamination by producing carbon dioxide (CO2) gas during the welding process. The electrode core itself acts as filler material, making separate filler unnecessary.

Procedure: 1. Check to make sure the welding machine is properly grounded. The welding equipment should be installed according to provision of the National Electric Code and the manufacturers recommendations. 2. A power disconnect switch should be conveniently located near each welding machine. 3. Turn the welder off and store cables before leaving the welding area. 4. The operator should keep all cable connections tight. 5. Inspect electrode holders for defective jaws and poor insulation. 6. Make adjustments in polarity and amperage only when the machine is not under load. Switching the current while the machine is under load will cause an arc to form between the contact surfaces. 7. Wear a welding helmet with a correct shade filter lens. A number 10 to 12 filter lens is usually satisfactory for general purpose welding. Most welding helmets provide a flip-up device to allow chipping or grinding to be done without removing the helmet.

8. Turn on the fumes removal system before starting to weld. 9. Do not weld in damp areas; keep hands and clothing dry at all times. Dampness on the body increases the chance of electrical shock when welding. 10. Do not weld in areas that store compressed gas cylinders. 11. Clear all combustible materials from the welding area before welding. 12. If an electrode sticks, try to twist it free. If twisting fails to free the electrode, release the electrode from the electrode holder. Turn off the switch on the welder and use pliers to break the electrode free. 13. Avoid welding directly on concrete floors. Residual moisture in the concrete may be turned to steam resulting in the concrete exploding. 14. Clean the surface of the plate before start the welding work.

RESULT AND ANALYSIS

As result of welding process that has been done by me, the plate that I weld was bit satisfactory although the welding is not perfect. This is the first time I make a welding so I lack a skill in the welding process. Even just a few days learning how to weld, I was able to make a good welding. Some of the reason why the welding is not perfect is because of the travel speed fault. If the welding is too slow, the shape of the weld is not consistent as the weld pool has built up and then collapsed into the crater. The poor control of the weld pool can result in cold joints and slag inclusions. When the welding is too fast, the ridges in the weld are elongated and triangular. Had the current been increased to compensate for the speed the ridges would still remain elongated. The perfect weld when the ridges in the weld are semi-circular. Another factors that can make the welding not perfect because of the current setting fault. When the current setting is too low, the weld will be difficult to start and the arc prone to straying towards one side of a joint in preference to the other. If the current is too high, a deep crater has formed at the end of the weld, and the slag is difficult to remove from the edges of the weld. Excessive current should not be compensated by excessive travel speed. This can result in slag inclusions due to rapid cooling of the weld. If current set correctly, the bead is a consistent rounded shape and the slag is easy to remove and give the perfect welding.

CONCLUSION

As a conclusion, there were many benefits and advantages that I got while doing this welding project and this report. From this welding class, I got many new knowledge and information about the welding. Besides that, I also got opportunity to learn how to weld. Our lecturer gives us clearly explanation before we start our project and able to do the project given quickly. There were many thing that have been guided from the first we started our project till end. At the end of this class, I have learn the welding process using the arc welding equipment, I also learn how to make a normal welding/ formed notch and T joint welding. Lastly, I can understand how to control the electrodes voltage properly.