EMM3812

MECHANICAL
ENGINEERING
LABORATORY (IV)

Semester 1, 2019/2020

Title: Arc Welding

Group: 2A

No. Matric No. Name

1 192396 LUQMAN HAKIM BIN DZULKARNAIN
 [LAB EXPERIMENT: ARC WELDING] SEPTEMBER 27, 2019

TABLE OF CONTENTS

CONTENT PAGE

1.0 INTRODUCTION ………………………………………………………...…… 3

2.0 THEORETICAL BACKGROUND ………………………………………… 4

3.0 EXPERIMENTAL APPARATUS …………………………………………… 5

4.0 PROCEDURE ………………………………………………………………… 10

5.0 RESULT AND DISCUSSION ………………………………………………… 12

6.0 CONCLUSION ………………………………………………………………… 13

7.0 REFERENCES ………………………………………………………………… 13

8.0 APPENDIX …………………………………………………………………….. 14

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1.0 INTRODUCTION
Shielded Metal Arc Welding (SMAW) or stick welding is a process which melts and joins metals by
heating them with an arc between a coated metal electrode and the work piece. The electrode outer
coating, called flux assists in creating the arc and provides the shielding gas and slag covering to protect
the weld from contamination. The electrode core provides most of the weld filler metal. When the
electrode is moves along the work piece at the correct speed the metal deposits in a uniform layer called
a bead. The best welding characteristics are usually obtained using DC power sources.

The amperage needed to weld depends on electrode diameter, the size and thickness of the pieces to be
welded, and the position of the welding. Thin metals require less current than thick metals, and a small
electrode requires less amperage than a large one. It is preferable to weld on work in the flat or horizontal
position. However, when forced to weld in vertical or overhead positions, it is helpful to reduce the
amperage from that used when welding horizontally. Best welding results are achieved by maintaining
a sort arc, moving the electrode at a uniform speed, and feeding the electrode downward at a constant
speed as it melts.

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2.0 THEORETICAL BACKGROUND

Shielded metal arc welding (Stick welding, Manual metal arc welding) uses a metallic consumable
electrode of a proper composition for generating arc between itself and the parent work piece. The
molten electrode metal fills the weld gap and joins the work pieces. This is the most popular welding
process capable to produce a great variety of welds. The electrodes are coated with a shielding flux of
a suitable composition. The flux melts together with the electrode metallic core, forming a gas and a
slag, shielding the arc and the weld pool. The flux cleans the metal surface, supplies
some alloying elements to the weld, protects the molten metal from oxidation and stabilizes the arc. The
slag is removed after Solidification.

Figure 2.1 shows the how is the operation using SMAW

The welding stick (SMAW is sometimes called stick welding) is typically 225 to 450 mm long and 2.5
to 9.5 mm in diameter. The filler metal used in the rod must be compatible with the metal to be welded,
the composition usually being very close to that of the base metal. The coating consists of powdered
cellulose (i.e., cotton and wood powders) mixed with oxides, carbonates, and other ingredients, held
together by a silicate binder. Metal powders are also sometimes included in the coating to increase the
amount of filler metal and to add alloying elements. The heat of the welding process melts the coating
to provide a protective atmosphere and slag for the welding operation. It also helps to stabilize the arc
and regulate the rate at which the electrode melts. During operation the bare metal end of the welding
stick (opposite the welding tip) is clamped in an electrode holder that is connected to the power source.
The holder has an insulated handle so that it can be held and manipulated by a human welder. Currents
typically used in SMAW range between 30 and 300 A at voltages from 15 to 45 V. Selection of the
proper power parameters depends on the metals being welded, electrode type and length, and depth of
weld penetration required.

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3.0 EXPERIMENTAL APPARATUS

1.0 Mild steel flat bar

Figure 3.1 shows the mild steel flat

bar.

2.0 Electrode

Figure 3.2 shows the electrode used

for arc welding.

To conduct current through a workpiece to fuse two pieces together.

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3.0 DC Arc Welding Machine

Figure 3.3 shows the type of DC arc

welding machine used.

Supply power to create an electric arc between a metal stick ("electrode") and the base material
to melt the metals at the point of contact.

4.0 Tools

Hammer
Face shield

Pliers Wire brush

Electrode holder
Cover Plates

Figure 3.4 shows tools for arc

welding

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Face Shield

It is made from inflammable material. In the middle of the shield there is a bright rectangular
glass coated with dark coloured glass. It is used to protect the user from fire-bolt and harmful
rays during welding work. There are two types of shield, one is the helmet type and the other
one is the hand-held type.

Gloves
It must be made from high quality leather. Use to protect your hand from fire-bolt and hot metal
welding.
Pliers

Used for holding hot workpiece

Hammer

It is used commonly to remove the slag excess stringer from the surface of the work metal.

Wire brush

Used to clean the surface of the stringer bed after the slag is chipped away and to remove dirt
from the surface of metal work before welding can be done.

Cover plate

Used to cover the table from burnt by the welding process.

Electrode holder

Hold electrode.

Apron
To protect the user from intense heat produced during welding operations.

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SAFETY PRECAUTION

▪ Please wear all the personal protective equipment recommended by OSHA.

▪ Always protect your eyes from arc rays.

▪ Protect your face and body from heat radiation and molten metal.

▪ Move all the flammable material off the working place or cover it up using fireproof material.

▪ Make sure that the welding machine is earthen.

▪ Make sure that all line holder, earth clip and connection placed on good place.

▪ Make sure that your working place is clean and tidy.

▪ Make sure that all electric connection is tight, clean and dry.

▪ Avoid pulling the cable on top or near sharp things.

▪ Do not ever scratch arc on top of gas cylinder.

▪ Turn off the welding machine when not in use.

▪ Avoid welding cable from be in contact with hot metal, water, oil and grease.

▪ Wear all safety clothing when welding.

▪ All equipment such as hammer, chisel, brush and others must be well maintained.

▪ A welder should not try to install or repair a welding machine. has distinct properties and

corresponding advantages and limitations.

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4.0 PROCEDURE
TRIAL PROCESS.
1. Clean the surface of metal plate with wire brush.

2. Place the metal plate on the working table.

3. Before welding, adjust the electric current to DC current and scratch the electrode on the scrap
metal.

4. Hold the electrode about 90o above the scrap metal. Tilt the electrode 30o to the left or right
depending on which hand do you use from the work metal.

5. Scratch the front end of the electrode onto the work metal to start the burning. After the
electrode has started burning, hold it at 3mm above the work metal.

6. Try to avoid the electrode from being in contact with the surface of work because the electrode
might be stick onto the workpiece.

7. Repeat the welding process for several times until you get a straight stringer bead line when
welding
.
8. Repeat the process of (f) for second straight stringer bead line.

9. When finish the welding process, use the chipping hammer to chip off the slag and brush it off
using a wire brush

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WORKING PROCESS

1. Clean the surface of two (2) metal plates with wire brush.

2. Place both metal plates on the working table.

3. Before welding, adjust the electric current to DC current and scratch the electrode on the scrap
metal.

Figure 4.1 shows the welding process is running

4. Hold the electrode about 90o above the scrap metal. Tilt the electrode 30o to the left or right
depending on which hand do you use from the work metal.

5. Make tack weld on both sides to prevent the metal plates from bending during the welding
process occur.

6. Scratch the front end of the electrode onto the work metal to start the burning. After the
electrode has started burning, hold it at 3mm above the work metal. Try to avoid the electrode
from being in contact with the surface of work because the electrode might be stick onto the
workpiece.

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7. When finish the welding process, use the chipping hammer to chip off the slag and brush it off
using a wire brush

Figure 4.2 shows the hammer to remove chip Figure 4.3 shows the cleaning by using wire brush

Figure 4.4 shows the finished product

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5.0 RESULT AND DISCUSSION

Elaborate the effect of the following process parameters on SMAW process:
(i) current,
(ii) voltage,
(iii) welding speed,
(iv) welding electrode

The variable of welding current primarily controls the amount of weld metal that is deposited during
welding. The welding current affects the weld penetration profile. The welding variable that has the
greatest effect on the degree of weld penetration is current (measured in amperage or amps). Therefore,
as welding current increases (i.e., more amperage), weld penetration increases and as welding current
decreases (i.e., less amperage), weld penetration decreases.

Amperage/Current controls penetration while Voltage controls the height and width of the weld deposit.
Voltage, when set in the correct range has little effect on penetration. Within this range, the higher the
voltage the lower the penetration. Higher voltage decreases penetration. Higher voltage spreads the arc
out and deposits a wider bead. Less energy density is exhibited as the voltage goes up, so penetration
drops. If the voltage is too low and you get an erratic arc you will start losing penetration.

Travel welding speed is the rate at which the welding gun is moved in the direction of welding or along
the weld joint. With low travel speeds, the filler metal deposition is high and at very low speeds the
welding arc impinges on the molten pool rather than the workpiece. With increased travel speeds, the
thermal energy per unit length of weld transmitted first increases and then decreases. At very high
speeds, there is insufficient deposition of filler metal. Hence, with all other things being the same, the
weld penetration is maximum at some moderate speeds of the weld torch.

When welding with two different diameters of the same electrode and at the same current level,
generally more penetration is achieved with the smaller diameter electrode than with the larger diameter
electrode. The higher the current density, the smaller diameter electrode will have greater weld
penetration than the larger diameter electrode. However, every electrode diameter has a maximum
current density before the welding arc becomes very unstable and erratic. So as current reaches a certain
level, it will become necessary to increase the electrode diameter.

Identify three advantages of the SMAW process for product fabrication.

SMAW has many great advantages which make it a continuing staple in most industrial settings. It can
be used in a wide range of environments including outdoors, in fabrication shops, on pipelines and
refineries, on ships and bridges, and more because it is relatively simple equipment. Next, SMAW can
be powered with gasoline or diesel in remote areas without electrical connections. Finally, it is not
sensitive to wind and draft and it is the most portable of all welding processes.

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Are there any difficulties that can be found during SMAW process? Discuss.

Yes, we can conclude that there are some problems that happened in arc welding process. The
first problem that happened in arc welding process is the electrode often stick to the workpiece,
therefore we need to give a bit distance between electrode and the welding workpiece so that
it won’t stick. The second problem is the size of arc welding is too small, therefore we need to
reduce the speed around the range of 20 to 30 second to get a good arc of weld. Third problem
is the welding line is not consistent and not straight, the instructor had given us chance to do
some trials on used mild steel plate to practice and improve our welding skills before
proceeding to the real task which is to weld two parts of mild steel bar. After we have done
some work of welding, we can know the main factor why the work in our welding is not too
good. The main factor is lack of skill from student. Then, we need to improve ourselves by do
the weld properly and use the right method in welding to get a good result of welding.

6.0 CONCLUSION

As a conclusion, to get the best result of SMAW welding are by maintaining a sort arc and moving the
electrode at a uniform speed. Besides, feeding the electrode downward at a constant speed as it melts.
Based on the result of this welding, it was not a good result due to the non-constant moving of the
electrode. Plus, a sort of arc is not maintained at the right place. The other mistake is whenever clean
the slag using a chipping hammer. There are a few precautions that always need to be concern which is
needed to wear personal protective equipment (PPE) properly such as welding helmet, boots, apron,
gloves to avoid from any hazards.

7.0 REFERENCES
[1] De Garmo, E.P., Black, J.T., Kohser, R.A. (2012). Materials and Processes in Manufacturing.
John Wiley & Sons, Inc.
[2] Groover, M.P. (2012). Fundamentals of Modern Manufacturing. John Wiley & Sons, Inc.

[3] Kalpakjian, S., Schmid, S.R. (2014). Manufacturing Processes for Engineering Materials.
Prentice Hall.

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8.0 APPENDICES

Figure 8.1 shows the welding activity Figure 8.2 shows the tools used in welding

Figure 8.3 shows the welding work Figure 8.4 shows the finished product
space

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