FACULTY OF MECHANICAL ENGINEERING

BMM 3611
MANUFACTURING PROCESSES LABORATORY

JOINING PROCESS
MIG Welding
Laboratory Date
Submission Date
Lecturer
1)
JP/PJP

2)
3)

Learning objectives
By the end of semester, students should be able to:
1. Know safe practices in manufacturing processing area.
2. Know tools, equipment and raw material for the respective lab.
3. Know standard operating procedure for the demonstrated machine.
4. Analyzed specific case study related to manufacturing process.

Members

ID

Section

Signature

1. Introduction
The objective of this laboratory is to provide hands on experience of welding operation
and quality inspection. It has been widely used to facilitate joining or assembly.
MIG welding is a permanent joining of two materials, usually metals, by coalescence. It
is induced by a combination of temperature, pressure and metallurgical conditions. This
process is adding filler metal using electrode to the joint.
2. Lab activities
Safety in lab

Know tools and processes materials

Brief on all machines

Case study

Activity
Safety

Know tools,
equipment and
materials
Intro to welding
laboratory
Case study

Task

Form

Each student gather in group

In sequence, each student read the saftety clause. If not
understand, put a note and JP/PJP will explain later.
Sign the acknowledgement forms
JP/PJP will give 10 questions about raw material, tool and
equipment application in this lab.
Student must find out the answer. (Eg. tool name & their
purpose, raw material description and the final product, etc..)
JP/PJP give brief explainaton on all machines in welding
including MIG, TIG, spot welding ( their function,
advantages & limitations)
Student must give attention. Prefer to take a note.
A case study requires student to find out an answer on the
specific problem in production.
Based on the chosen case study, JP/PJP will explain and
demonstrate process sequence (SOP) for the selected
process.
In certain cases, student will be asked to do spesific task.
Student must explain thoroughly on outcome of their
investigation

Sign the
acknowledgement
of safety
requirement form
Give your answer
in lab report

JP/PJP briefing

Describe in details
in lab report

BMM3611(1112)_Welding Lab sheet

Prepared by:
MZS@FKM,UMP(2012)

3. Case study : MIG Welding

Prepare workpiece for MIG welding

o Number and size of workpieces (8 pcs of 100 mm x 50 mm x 9 mm ).
o Cut to bevel type at one end
Do MIG welding at 1G position as shown below;

Check quality of the welded part, resetting welding parameter for better result. Record all
setting parameters used.
Inspect the welded part (visual, dye penetrant or ultrasound test)
Sketch some defects found from welding process. Suggest countermeasure to overcome the
product defect found.
Discuss in details (in lab report)
o Electrode designation based on American Welding Society Standard
o NDT test in welding process.
o For ultrsound test, include the signal output and relate to the defect found in MIG welding.

4. Lab report
For your project report, provide the following:
1. Use a cover page similar to the labsheet format.
2. Contents for the report are;
Introduction
Raw materials
Process tools
Machines and their applications
Case study Process setting / Design consideration/ Product defect & countermeasure
Conclusion/Lesson learned
References
3. Discuss the strengths and weaknesses of this laboratory. Did the laboratory help you to
learn the material better? Explain why or why not.
4. The report should be done in MS Word and an equation editor should be used for all
equations.
5. Equations should be numbered and plots should be numbered and referenced with a
descriptive caption.
6. Each group must submit a hard copy of the report.

BMM3611(1112)_Welding Lab sheet

Prepared by:
MZS@FKM,UMP(2012)

Process Sheet
(MIG Welding)
Work piece

MIG machine description

Material type/grade :___________________

Brand :______________________________

Size(L x W x T (mm):__________________

Model :______________________________
Capacity:______________________________

Electrode
Type

:_______________________________

Welding (output quality & improvement)

Type of
defects

Inspection
(Visual/NDT
Test)

Sketch of defects

Countermeasure

Process setting (for good quality welding part at 1G position)

Current

: _____________________________

Angle of electrode positioning

:_____________________________

Estimated welding speed

: _____________________________

BMM3611(1112)_Welding Lab sheet

Prepared by:
MZS@FKM,UMP(2012)