Department of Mechanical Engineer

ing

MEFD211 MANUFACTURING PROCESSES LAB

SEMESTER 1 2015/2016
NAME & ID:

LAB ACTIVITY:

1.
Objectives
SECTION:
2.
Equipment and
GROUP: DATE:
tools Sketc
3.
4.
Safety hprecaution
Kindly please refer the MEFB 121 General Lab Report Guidelines for the details.
5.
Procedure
6.
Resul
1 Objectives
t
7.
Discussion
8.
Conclusion

To learn how to use the ARC welding machine correctly and properly. 9. Format & Overall
quality
To learn how to melt the iron as taught.

To make a straight welded line on the metal.

To make a perfect thickness welded line on the metal plate.

To learn the functions of electrode rod.

List and sketch of equipment and tools

Marks
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10
10
5
15
20
15
10
10
100

Department of Mechanical Engineer

ing

Sketch:

Safety Precautions:

Wear PPE during the welding time

For welding always wear the welding mask to prevent face from getting burn.

Do not open the mask when we are doing the welding because it get hurt our
eyes.

If the ARC welding machine occurs any problem immediately report to lab
technician.

Do not let the electrode rod get in contact with any iron because it will gives
a spark and start to weld the metal.

If one of our group mate is doing the work another member need to stand behind
the yellow line.

Always wear the welding glove before start to weld any iron.

Use the rivet blacksmith tong to move the hot welded iron to prevent the glove
from burning

Do not put the hot welded iron on the table because it can damage the table or
might hurt someone

Do not hold the hot welded iron without cooling it down by submerging it
into the water because it might be hot.

Procedure:

Firstly, wear all the safety equipments before proceeding to the welding session.

Listen carefully to the briefing of the lab technician about the use of ARC welding machine.

Observe carefully when the lab technician is doing the welding session so that it will easy for us
when we are doing it.

Once the lab technician is done with the briefing we will be given a piece of used iron plate and three
electrode rod, for us to train ourselves

Once the training session is done we can proceed to our work piece.

Each of us need to take two electrode rod for our work piece.

Insert one electrode rod into the electrode holder and test whether it is working or not by contacting it
with another metal plate.

We will be given a metal plate and are told to make three straight lines on the metal plate using the
ARC welding machine.

Once we have done making two lines on the metal plate that have been told using the ARC welding
machine, using the chipping hammer break all the hard dust so that the welded metal can be seen
clearly.

Once all the work process of welding using the ARC welding machine has done, use the rivet
blacksmith tong to carry the welded metal plate and submerge it into the water to cool it down.

Once it is fully cooled down using the vice tighten the metal plate and start to brush it.

After brushing it properly using a blacksmith hammer peel of the small piece of welded on the metal
plate.

Once it is done show the work piece to the lecturer.

Lastly, clean up the entire premises.

Result (attach the multi-view drawing)

Discussions

Arc welding 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 nonconsumable electrodes.

To supply the electrical energy necessary for arc welding processes, a number of

different power supplies can be used. The most common classification is

constant current power supplies and constant voltage power supplies. In arc welding,
the voltage is directly related to the length of the arc, and the current is related to the
amount of heat input. Constant current power supplies are most often used for manual
welding processes such as gas tungsten arc welding and shielded metal arc welding,
because they maintain a relatively constant current even as the voltage varies. This is
important because in manual welding, it can be difficult to hold the electrode perfectly
steady, and as a result, the arc length and thus voltage tend to fluctuate. Constant
voltage power supplies hold the voltage constant and vary the current, and as a result,
are most often used for automated welding processes such as gas metal arc welding,
flux cored arc welding, and submerged arc welding. In these processes, arc length is
kept constant, since any fluctuation in the distance between the wire and the base
material is quickly rectified by a large change in current. For example, if the wire and
the base material get too close, the current will rapidly increase, which in turn causes
the heat to increase and the tip of the wire to melt, returning it to its original separation
distance

10

Conclusions

Finally, I have learned how to use the ARC welding

machine properly and correctly without giving any
problem. The ARC welding machine is not difficult to
operate all we have to do to get a perfect lining and
thickness using the electrode rod carefully when we
are welding an iron or a metal plate is that we have to
keep in contact with the metal plate. We also need to
move the electrode holder slowly so that we will get a
perfect turn out.